WO2009059361A1 - A structural element - Google Patents

A structural element Download PDF

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Publication number
WO2009059361A1
WO2009059361A1 PCT/AU2008/001640 AU2008001640W WO2009059361A1 WO 2009059361 A1 WO2009059361 A1 WO 2009059361A1 AU 2008001640 W AU2008001640 W AU 2008001640W WO 2009059361 A1 WO2009059361 A1 WO 2009059361A1
Authority
WO
WIPO (PCT)
Prior art keywords
fibre composite
structural element
fibre
sandwich panels
structural
Prior art date
Application number
PCT/AU2008/001640
Other languages
French (fr)
Inventor
Gerardus Maria Van Erp
Original Assignee
Loc Composites Pty Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from AU2007906122A external-priority patent/AU2007906122A0/en
Application filed by Loc Composites Pty Ltd filed Critical Loc Composites Pty Ltd
Publication of WO2009059361A1 publication Critical patent/WO2009059361A1/en

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Classifications

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    • B32B3/02—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by features of form at particular places, e.g. in edge regions
    • B32B3/08—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by features of form at particular places, e.g. in edge regions characterised by added members at particular parts
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    • E—FIXED CONSTRUCTIONS
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    • E01B3/46—Transverse or longitudinal sleepers; Other means resting directly on the ballastway for supporting rails made from different materials
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
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    • E04C2/246—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products laminated and composed of materials covered by two or more of groups E04C2/12, E04C2/16, E04C2/20 combinations of materials fully covered by E04C2/16 and E04C2/20
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    • E04C2/38—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure with attached ribs, flanges, or the like, e.g. framed panels
    • E04C2/388—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure with attached ribs, flanges, or the like, e.g. framed panels with a frame of other materials, e.g. fibres, plastics
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Definitions

  • This invention relates to a structural element.
  • the invention relates to a shelving structural element for use as a load bearing beam.
  • Fibre composites with greatly improved corrosion resistance and durability, low weight and high strength, ease of transportation and lower energy consumption during manufacture, are increasingly being considered for civil engineering applications.
  • the key advantages of these new materials are often lost in the high materials and manufacturing costs. The latter can generally be attributed to inappropriate usage of these materials in this new environment.
  • Pultrusion is a manufacturing process rather analogous to the production of steel and aluminium.
  • the pultrusion process is ideal for the continuous production of elements of constant cross-sectional geometry and moderate complexity.
  • the advantages are relatively low labour cost, minimal material wastage, consistent quality and high production rates.
  • the invention resides in a structural element comprising: a plurality of fibre composite sandwich panels, each sandwich panel having a pair of fibre composite skins with structural core material located there between; the plurality of fibre composite sandwich panels being adhered together; two planar, fibre composite joiners; each of the joiners having a width that is longer than the width of the fibre composite sandwich panels; the fibre composite joiners being adhered to different composite fibre skins of different composite sandwich panels; and at least one end member located adjacent at least one end of the plurality of fibre composite sandwich panels; the at least one end member being adhered to the fibre composite sandwich panels and the two planar fibre composite joiners.
  • the structural core material of the sandwich panel is typically made from a polymer.
  • the structural core material may include microspheres made from polymeric materials, such epoxy resin, unsaturated polyester resin, silicone resin, phenolics, polyvinyl alcohol, polyvinyl chloride, polypropylene, and polystyrene or from inorganic materials, such as glass, silica-alumina ceramics or Cenospheres (hollow fly ash particles).
  • structural core material may include a foamed phenolic resin product.
  • the skins of the sandwich panels may be made from fibre reinforced polymers.
  • the fibres may be made from glass, carbon, Kevlar, thermoplastics or combinations thereof.
  • the polymer may be made of polyester, vinylester, phenolic, epoxy, polyurethane, thermoplastics or combination thereof.
  • the polymer used in the skins is the same as that used in the structural core material. More preferably, the sandwich panel is produced in single manufacturing process. In this way a strong primary bond can be created between the skins and the foam core.
  • the fibre for the fibre composite joiners may be made from glass, carbon, Kevlar, thermoplastic or combinations thereof whilst the polymer may be made of polyester, vinylester, phenolic, epoxy, polyurethane, thermoplastic resins or combinations thereof.
  • the end member may be formed entirely from fibre composite.
  • the fibre may be made from glass, carbon, Kevlar, thermoplastic or combinations thereof whilst the polymer may be made of polyester, vinylester, phenolic, epoxy, polyurethane, thermoplastic resins or combinations thereof.
  • the end member may be a hybrid reinforcing module.
  • the hybrid reinforcing module may include a tubular fibre composite member, a filled resin system located within said tubular fibre composite member, and at least one elongated steel member located within the filled resin system such that the filled resin system binds the steel member and tubular member together.
  • the tubular fibre composite member is a pultruded member.
  • the pultruded member may be substantially square or slightly rectangular in transverse cross-section.
  • the internal void of the tubular member may be square, rectangular or circular.
  • the tubular fibre composite member may have the majority of its fibres orientated in a longitudinal direction.
  • the polymer in the filled resin system may be a polyester, vinylester, polyurethane or epoxy resin.
  • the filled resin system is a filled epoxy system.
  • the filled resin system has high adherence to both the steel and the tubular fibre composite member.
  • the steel member may be a round or deformed bar, threaded rod or tendon (cable).
  • the steel member may be made of plain carbon steel, galvanised steel or stainless steel. There may be a single steel member or multiple steel members located within the beam. If there are multiple steel members, they may be spaced substantially an equal distance away from each other.
  • the steel member may be prestressed prior to the hybrid member being formed.
  • the steel member may be slighter shorter than the length of the tubular fibre composite member so that the steel is located fully within the tubular member. These ends of the tubular member may be completely filled with the filled resin system in order to create a solid 'block' of corrosion protection for the steel member at both ends of the tubular member.
  • the structural element may further include an external fibre composite laminate which is wrapped around the structural element to assist in preventing delamination.
  • the fibres may be made from glass, carbon, Kevlar, thermoplastics or combinations thereof.
  • the polymer may be made of polyester, vinylester, phenolic, epoxy, polyurethane, thermoplastics or combination thereof.
  • the structural element may also include a protective coating which is placed around the structural element.
  • the coating is a provided to increase UV, fire resistance and robustness of the structural unit. Normally, the coating is a non structural protective polymer coating.
  • the invention resides in the method of manufacturing a structural element, the method comprising the steps of: adhering a plurality of fibre composite sandwich panels together, each sandwich panel having a pair of fibre composite skins with structural core material located there between; and adhering two planar, fibre composite joiners, each of the joiners having a length that is longer than the length of the fibre composite sandwich panels, to different composite fibre skins of different composite sandwich panels; and adhering at least one end member to at least one end of the plurality of fibre composite sandwich panels and to the two planar fibre composite joiners.
  • the method may further include one or more of the following steps: adhering an external fibre composite laminate around the structural element; and placing a protective coating around the structural element.
  • FIG. 1 shows a sectional view of a sandwich panel according to an embodiment of the invention
  • FIG. 2 shows a sectional view of a planar, fibre composite joiner according to an embodiment of the invention
  • FIG. 3 shows a sectional view of an end member according to an embodiment of the invention
  • FIG. 4 shows a sectional view an alternate end member according to an embodiment of the invention
  • FIG. 5A shows a first structural unit according to an embodiment of the invention
  • FIG. 5B shows a second structural unit according to an embodiment of the invention
  • FIG. 6 shows a first example of a structural element according to an embodiment of the invention
  • FIG. 7 shows a second example of a structural element according to an embodiment of the invention
  • FIG. 8 shows a third example of a structural element according to an embodiment of the invention
  • FIG. 9 shows a fourth example of a structural element according to a fourth embodiment of the invention.
  • FIG. 10 shows a fifth example of a structural element according to a fourth embodiment of the invention.
  • FIGS. 1 to 5B show components that are used to produce various structural elements shown in FIGS. 6 to 9.
  • FIG. 1 shows a fibre composite sandwich panel 10 used to produce structural elements shown in FIGS. 6 to 9.
  • the sandwich panel 10 has a structural core material 11 and two fibre composite skins 12.
  • the structural core material 11 in this embodiment is made from epoxy resin with
  • the materials used to produce the structural core material 11 may be varied to specified needs of a structural element.
  • the fibre composite skins 12 are made from glass fibre and epoxy resin. It should be appreciated that the fibre composite skins 12 may be also made from other materials depending on the structural requirements of the structural element.
  • the skins 12 of the sandwich panel 10 provide the structural element with shear strength, while the core material provides the structural element with a material that can hold screws and bolts.
  • a wide range of fibre architectures can be used for the skins 12 but generally they will contain at least some fibres at plus and minus forty five degree angles to the length of the laminate.
  • FIG. 2 shows a planar, fibre composite joiner 20.
  • the fibre composite joiner 20 is made from glass fibre with the polymer used being epoxy.
  • the fibre composite joiner 20 is a pultruded member and has a length and a depth similar to the sandwich panel 10 but a width that is longer than the sandwich panel 10.
  • FIG. 3 shows an end member 30 made from glass fibre with the polymer used being epoxy.
  • the end member 30 provides the structural element with bending strength and stiffness. It also provides a strong layer on the top and bottom of a structural member to carry localised forces.
  • FIG. 4 shows an alternative end member in the form of a hybrid structural module 50 formed from a tubular fibre reinforced composite member 51 , a filled resin system 52 and a steel reinforcement bar 53.
  • the hybrid structural module 50 shown is disclosed in International Patent
  • the tubular fibre reinforced composite member 51 is a pultruded member that is substantially square in transverse cross-section.
  • the resin in the filled resin system 52 is a filled epoxy system with the filler consists of centre-spheres with a nominal particle size range between 20- 300 microns.
  • the steel bar 53 is a high strength steel bar.
  • the filled resin system 52 fills the void between the steel bar 53 and tubular fibre composite member 51 and adheres to both the steel bar 53 and inside of the tubular fibre composite member 51 to make the steel bar 53 and tubular fibre composite member 51 work together as single structural unit.
  • FIG. 5A shows a first structural unit 60 that is created from sandwich panel 10 shown in FIG. 1 , the fibre composite joiner 20 shown in FIG. 2 and the end member 30 shown in FIG. 3.
  • sandwich panel 10 shown in FIG. 1
  • the fibre composite joiner 20 shown in FIG. 2
  • the end member 30 shown in FIG. 3.
  • two sandwich panels 10 are adhered together using an epoxy adhesive. It should be appreciated that any number of sandwich panels 10 can be combined (i.e. glued together) depending on the desired width of the structural unit 60.
  • Fibre composite joiners 20 are then adhered to the skins 12 of outer sandwich panels 10. As the fibre composite joiners 20 are longer than the sandwich panels 10, the fibre composite joiners 20 extend past the sandwich panels 10 to form gap between adjacent fibre composite joiners 20. The end members 30 are located within these gaps and adhered to the fibre composite joiners 20 and the sandwich panels 10.
  • FIG. 5B shows a second structural unit 70.
  • the structural unit shown in this example is the same as the structural unit shown in FIG. 5A except that the end member 30 shown in FIG. 3 has been replaced with the end member 50 shown in FIG. 4.
  • the combination of the sandwich panels 10, the fibre composite joiners 20 and the end members 30, 40 are typically used as "building blocks" in larger structural elements.
  • the combination of the sandwich panels 10, the fibre composite joiners 20 and the end members 30 be used on their own as a structural element due to shaped and structural properties having a lot in common with a steel l-girder.
  • FIG. 6 shows a first example of a structural element 100 which includes three first structural units 60 and an external fibre composite laminate 80.
  • the three first structural units 60 are adhered together using epoxy adhesive. It should be noted that the number of end members may be varied depending on design requirements.
  • the external fibre composite laminate 80 is then wrapped around and adhered to the three first structural element units 60 to assist in preventing delamination. Further, the external fibre composite laminate 80 provides additional bending and shear strength.
  • FIG. 7 shows how three first structural units 70 can be combined with four sandwich panels 10 and an external fibre composite laminate 80 to create a second example of a structural unit 200.
  • the three first structural units 60 are adhered to adjacent sandwich panels 10.
  • the external fibre composite laminate 80 is then wrapped around and adhered to the three first structural unit 60 and four sandwich panels 10 to assist in preventing delamination.
  • the sandwich panels 10 may be shaped adjacent the corners to allow for a more efficient and effective process of adhering the external fibre composite laminate 80.
  • FIG. 8 shows how flat fibre composite reinforcements 90, in the form of carbon-epoxy fibre composite, can be included in between the first structural unit 60 and the sandwich panels 10 to increase the shear capacity of a third structural element 300 without significantly increasing the width of the structural element 300.
  • FIG. 9 shows a fourth example of a structural element 400.
  • the fourth structural element is the same as the structural element shown in FIG. 7 with the addition of an applied protective coating 85 preferably made of a filled methacrylates or phenolic coating. By providing a protective coating 85, this improves the UV and fire resistance of the structural element.
  • FIG. 10 shows a fifth example of a structural element 500.
  • This structural element 500 includes three first structural units 60, two second structural units 70, four flat fibre composite reinforcements 90, an external fibre composite laminate 80 and a protective coating 85.
  • the three first structural units 60 and two second structural units 70 are adhered together in the sequence shown in FIG. 10.
  • the external fibre composite laminate 80 is then wrapped around and adhered to the three first structural units 60, two second structural units 70 and four flat fibre composite reinforcements 90.
  • the protective coating 85 is then applied to the external fibre composite laminate 80 to complete the fifth structural element 500.
  • the fifth structural element 500 can be used as transom which provides a number of distinct advantages.
  • the hybrid modules 50 By locating the hybrid modules 50 on the outside of the structural element 500 (within 60mm of the edge), they do not interfere with the fastening of a rail plate to the sandwich panels 10.
  • Fasteners of the rail plate are located within the central all-composite section, i.e. the three first structural units 60 and four flat fibre composite reinforcements 90, of the structural element 500.
  • the steel bars 53 of the hybrid structural module 50 in the corner of the structural element 500 will provide significant impact resistance to the structural element 500.
  • any number and type of structural elements can be made using the above components.
  • the resultant structural element can therefore be designed and created with varying dimensions and load carrying capacities.
  • Each individual component can be mass produced and prefabricated using quality controlled manufacturing procedures to reduce costs. Before assembly of the structural element, the quality of each individual element can be easily inspected which greatly assist in the production of a high quality structural element.

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Abstract

The invention resides in a structural element comprising a plurality of fibre composite sandwich panels, each sandwich panel having a pair of fibre composite skins with structural core material located there between; the plurality of fibre composite sandwich panels being adhered together; two planar, fibre composite joiners; each of the joiners having a width that is longer than the width of the fibre composite sandwich panels; the fibre composite joiners being adhered to different composite fibre skins of different composite sandwich panels; and at least one end member located adjacent at least one end of the plurality of fibre composite sandwich panels; the at least one end member being adhered to the fibre composite sandwich panels and the two planar fibre composite joiners.

Description

"A STRUCTURAL ELEMENT" FIELD OF THE INVENTION
This invention relates to a structural element. In particular, the invention relates to a shelving structural element for use as a load bearing beam.
BACKGROUND OF THE INVENTION
For many decades, steel, concrete and timber have been the dominant construction materials in civil and structural engineering. These materials have a number of advantages, not the least of which is their relatively low cost. However, it is clear from experience of the last thirty years in Europe, Japan and particularly the USA that existing materials and construction technology have not delivered the reliability needed.
Conventional materials and technologies, although suitable in many cases, lack in longevity in certain environments, are very heavy and, in the case of hardwood timber, are increasingly difficult to obtain.
In order to address these problems, a range of new advanced materials have recently been introduced into the construction market. Fibre composites, with greatly improved corrosion resistance and durability, low weight and high strength, ease of transportation and lower energy consumption during manufacture, are increasingly being considered for civil engineering applications. However, the key advantages of these new materials are often lost in the high materials and manufacturing costs. The latter can generally be attributed to inappropriate usage of these materials in this new environment.
Most civil engineering applications of fibre composites are currently based around the pultrusion process. Pultrusion is a manufacturing process rather analogous to the production of steel and aluminium. The pultrusion process is ideal for the continuous production of elements of constant cross-sectional geometry and moderate complexity. The advantages are relatively low labour cost, minimal material wastage, consistent quality and high production rates.
However, the pultrusion process also has some serious disadvantages. The initial costs of setting up for a production run are very high and are directly proportional to the size and complexity of the component to be manufactured. Consequently, most pultruders offer a limited range of standard structural sections similar to those available in steel. Experience has shown that the great majority of these sections have limited load carrying capacity and they are generally not recommended for primary load carrying functions.
Specialised pultruded members for civil engineering applications have been developed and their structural performance has been quite satisfactory. However, the high cost involved in these types of development makes them economically unviable. For fibre composites to become viable in civil and structural engineering, a cheaper, more flexible design and manufacturing approach is required.
OBJECT OF THE INVENTION
It is an object of the invention to overcome or alleviate one or more of the disadvantages of the above disadvantages or provide the consumer with a useful or commercial choice.
It is a preferred object of this invention to enable structural elements made from fibre composites to be produced that have improved load-carrying characteristics.
It is a further preferred object of the invention to allow structural elements made of fibre composite materials to be produced cost effectively.
It is a still further preferred object of the invention to provide structural elements made of fibre composites that can be easily varied in size, strength and stiffness.
It is a still further preferred object of the invention to allow structural elements to be produced that have excellent durability and are able to resist biological and chemical attack.
It is a still further preferred object of the invention to allow structural elements to be produced that have no environmental restrictions that affect storage, handling and eventually disposal. SUMMARY OF THE INVENTION
In one form, although not necessarily the only or broadest form, the invention resides in a structural element comprising: a plurality of fibre composite sandwich panels, each sandwich panel having a pair of fibre composite skins with structural core material located there between; the plurality of fibre composite sandwich panels being adhered together; two planar, fibre composite joiners; each of the joiners having a width that is longer than the width of the fibre composite sandwich panels; the fibre composite joiners being adhered to different composite fibre skins of different composite sandwich panels; and at least one end member located adjacent at least one end of the plurality of fibre composite sandwich panels; the at least one end member being adhered to the fibre composite sandwich panels and the two planar fibre composite joiners. The structural core material of the sandwich panel is typically made from a polymer. The structural core material may include microspheres made from polymeric materials, such epoxy resin, unsaturated polyester resin, silicone resin, phenolics, polyvinyl alcohol, polyvinyl chloride, polypropylene, and polystyrene or from inorganic materials, such as glass, silica-alumina ceramics or Cenospheres (hollow fly ash particles). Alternatively, structural core material may include a foamed phenolic resin product.
The skins of the sandwich panels may be made from fibre reinforced polymers. The fibres may be made from glass, carbon, Kevlar, thermoplastics or combinations thereof. The polymer may be made of polyester, vinylester, phenolic, epoxy, polyurethane, thermoplastics or combination thereof.
Preferably, the polymer used in the skins is the same as that used in the structural core material. More preferably, the sandwich panel is produced in single manufacturing process. In this way a strong primary bond can be created between the skins and the foam core.
The fibre for the fibre composite joiners may be made from glass, carbon, Kevlar, thermoplastic or combinations thereof whilst the polymer may be made of polyester, vinylester, phenolic, epoxy, polyurethane, thermoplastic resins or combinations thereof.
The end member may be formed entirely from fibre composite.
The fibre may be made from glass, carbon, Kevlar, thermoplastic or combinations thereof whilst the polymer may be made of polyester, vinylester, phenolic, epoxy, polyurethane, thermoplastic resins or combinations thereof.
Alternatively, the end member may be a hybrid reinforcing module. The hybrid reinforcing module may include a tubular fibre composite member, a filled resin system located within said tubular fibre composite member, and at least one elongated steel member located within the filled resin system such that the filled resin system binds the steel member and tubular member together.
Preferably, the tubular fibre composite member is a pultruded member. The pultruded member may be substantially square or slightly rectangular in transverse cross-section. The internal void of the tubular member may be square, rectangular or circular. The tubular fibre composite member may have the majority of its fibres orientated in a longitudinal direction.
The polymer in the filled resin system may be a polyester, vinylester, polyurethane or epoxy resin. Preferably, the filled resin system is a filled epoxy system. Preferably, the filled resin system has high adherence to both the steel and the tubular fibre composite member.
The steel member may be a round or deformed bar, threaded rod or tendon (cable). The steel member may be made of plain carbon steel, galvanised steel or stainless steel. There may be a single steel member or multiple steel members located within the beam. If there are multiple steel members, they may be spaced substantially an equal distance away from each other. The steel member may be prestressed prior to the hybrid member being formed. The steel member may be slighter shorter than the length of the tubular fibre composite member so that the steel is located fully within the tubular member. These ends of the tubular member may be completely filled with the filled resin system in order to create a solid 'block' of corrosion protection for the steel member at both ends of the tubular member.
The structural element may further include an external fibre composite laminate which is wrapped around the structural element to assist in preventing delamination. The fibres may be made from glass, carbon, Kevlar, thermoplastics or combinations thereof. The polymer may be made of polyester, vinylester, phenolic, epoxy, polyurethane, thermoplastics or combination thereof. The structural element may also include a protective coating which is placed around the structural element. Typically, the coating is a provided to increase UV, fire resistance and robustness of the structural unit. Normally, the coating is a non structural protective polymer coating.
In another form, the invention resides in the method of manufacturing a structural element, the method comprising the steps of: adhering a plurality of fibre composite sandwich panels together, each sandwich panel having a pair of fibre composite skins with structural core material located there between; and adhering two planar, fibre composite joiners, each of the joiners having a length that is longer than the length of the fibre composite sandwich panels, to different composite fibre skins of different composite sandwich panels; and adhering at least one end member to at least one end of the plurality of fibre composite sandwich panels and to the two planar fibre composite joiners.
The method may further include one or more of the following steps: adhering an external fibre composite laminate around the structural element; and placing a protective coating around the structural element.
BRIEF DESCRIPTION OF THE DRAWINGS Embodiments of the invention will be described within reference to the accompanying drawings in which:
FIG. 1 shows a sectional view of a sandwich panel according to an embodiment of the invention;
FIG. 2 shows a sectional view of a planar, fibre composite joiner according to an embodiment of the invention;
FIG. 3 shows a sectional view of an end member according to an embodiment of the invention; FIG. 4 shows a sectional view an alternate end member according to an embodiment of the invention;
FIG. 5A shows a first structural unit according to an embodiment of the invention;
FIG. 5B shows a second structural unit according to an embodiment of the invention;
FIG. 6 shows a first example of a structural element according to an embodiment of the invention;
FIG. 7 shows a second example of a structural element according to an embodiment of the invention; FIG. 8 shows a third example of a structural element according to an embodiment of the invention;
FIG. 9 shows a fourth example of a structural element according to a fourth embodiment of the invention; and
FIG. 10 shows a fifth example of a structural element according to a fourth embodiment of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIGS. 1 to 5B show components that are used to produce various structural elements shown in FIGS. 6 to 9.
FIG. 1 shows a fibre composite sandwich panel 10 used to produce structural elements shown in FIGS. 6 to 9. The sandwich panel 10 has a structural core material 11 and two fibre composite skins 12. The structural core material 11 in this embodiment is made from epoxy resin with
Cenospheres and expanded polystyrene bead fillers. It should be appreciated that the materials used to produce the structural core material 11 may be varied to specified needs of a structural element. The fibre composite skins 12 are made from glass fibre and epoxy resin. It should be appreciated that the fibre composite skins 12 may be also made from other materials depending on the structural requirements of the structural element.
The skins 12 of the sandwich panel 10 provide the structural element with shear strength, while the core material provides the structural element with a material that can hold screws and bolts. A wide range of fibre architectures can be used for the skins 12 but generally they will contain at least some fibres at plus and minus forty five degree angles to the length of the laminate. FIG. 2 shows a planar, fibre composite joiner 20. The fibre composite joiner 20 is made from glass fibre with the polymer used being epoxy. The fibre composite joiner 20 is a pultruded member and has a length and a depth similar to the sandwich panel 10 but a width that is longer than the sandwich panel 10. FIG. 3 shows an end member 30 made from glass fibre with the polymer used being epoxy. The end member 30 provides the structural element with bending strength and stiffness. It also provides a strong layer on the top and bottom of a structural member to carry localised forces.
FIG. 4 shows an alternative end member in the form of a hybrid structural module 50 formed from a tubular fibre reinforced composite member 51 , a filled resin system 52 and a steel reinforcement bar 53. The hybrid structural module 50 shown is disclosed in International Patent
Application No. PCT/AU2003/001519.
The tubular fibre reinforced composite member 51 is a pultruded member that is substantially square in transverse cross-section. The resin in the filled resin system 52 is a filled epoxy system with the filler consists of centre-spheres with a nominal particle size range between 20- 300 microns. The steel bar 53 is a high strength steel bar.
The filled resin system 52 fills the void between the steel bar 53 and tubular fibre composite member 51 and adheres to both the steel bar 53 and inside of the tubular fibre composite member 51 to make the steel bar 53 and tubular fibre composite member 51 work together as single structural unit.
When using a hybrid structural module 50 in a structural element, generally a large proportion of the load is carried by the steel reinforcement. Steel is a well understood material with good fatigue behaviour and hence, the use of the hybrid module in a structural element provides a lot of confidence in the load carrying capacity of a structural element. FIG. 5A shows a first structural unit 60 that is created from sandwich panel 10 shown in FIG. 1 , the fibre composite joiner 20 shown in FIG. 2 and the end member 30 shown in FIG. 3. In order to create the first structural unit 60, two sandwich panels 10 are adhered together using an epoxy adhesive. It should be appreciated that any number of sandwich panels 10 can be combined (i.e. glued together) depending on the desired width of the structural unit 60.
Fibre composite joiners 20 are then adhered to the skins 12 of outer sandwich panels 10. As the fibre composite joiners 20 are longer than the sandwich panels 10, the fibre composite joiners 20 extend past the sandwich panels 10 to form gap between adjacent fibre composite joiners 20. The end members 30 are located within these gaps and adhered to the fibre composite joiners 20 and the sandwich panels 10.
FIG. 5B shows a second structural unit 70. The structural unit shown in this example is the same as the structural unit shown in FIG. 5A except that the end member 30 shown in FIG. 3 has been replaced with the end member 50 shown in FIG. 4.
The combination of the sandwich panels 10, the fibre composite joiners 20 and the end members 30, 40 (i.e. structural units 60, 70) are typically used as "building blocks" in larger structural elements. However, it should be appreciated that the combination of the sandwich panels 10, the fibre composite joiners 20 and the end members 30 be used on their own as a structural element due to shaped and structural properties having a lot in common with a steel l-girder.
FIG. 6 shows a first example of a structural element 100 which includes three first structural units 60 and an external fibre composite laminate 80. In order to create the first structural element 100, the three first structural units 60 are adhered together using epoxy adhesive. It should be noted that the number of end members may be varied depending on design requirements. The external fibre composite laminate 80 is then wrapped around and adhered to the three first structural element units 60 to assist in preventing delamination. Further, the external fibre composite laminate 80 provides additional bending and shear strength.
FIG. 7 shows how three first structural units 70 can be combined with four sandwich panels 10 and an external fibre composite laminate 80 to create a second example of a structural unit 200. The three first structural units 60 are adhered to adjacent sandwich panels 10. The external fibre composite laminate 80 is then wrapped around and adhered to the three first structural unit 60 and four sandwich panels 10 to assist in preventing delamination. It should be appreciated that the sandwich panels 10 may be shaped adjacent the corners to allow for a more efficient and effective process of adhering the external fibre composite laminate 80.
FIG. 8 shows how flat fibre composite reinforcements 90, in the form of carbon-epoxy fibre composite, can be included in between the first structural unit 60 and the sandwich panels 10 to increase the shear capacity of a third structural element 300 without significantly increasing the width of the structural element 300.
FIG. 9 shows a fourth example of a structural element 400. The fourth structural element is the same as the structural element shown in FIG. 7 with the addition of an applied protective coating 85 preferably made of a filled methacrylates or phenolic coating. By providing a protective coating 85, this improves the UV and fire resistance of the structural element.
FIG. 10 shows a fifth example of a structural element 500. This structural element 500 includes three first structural units 60, two second structural units 70, four flat fibre composite reinforcements 90, an external fibre composite laminate 80 and a protective coating 85.
In order to produce the fifth structural element 500, the three first structural units 60 and two second structural units 70 are adhered together in the sequence shown in FIG. 10. The external fibre composite laminate 80 is then wrapped around and adhered to the three first structural units 60, two second structural units 70 and four flat fibre composite reinforcements 90. The protective coating 85 is then applied to the external fibre composite laminate 80 to complete the fifth structural element 500.
The above structural elements may be used for various purposes, such as beams, transoms, sleepers or the like elements. For example, the fifth structural element 500 can be used as transom which provides a number of distinct advantages. By locating the hybrid modules 50 on the outside of the structural element 500 (within 60mm of the edge), they do not interfere with the fastening of a rail plate to the sandwich panels 10. Fasteners of the rail plate are located within the central all-composite section, i.e. the three first structural units 60 and four flat fibre composite reinforcements 90, of the structural element 500. In the case of a derailment, the steel bars 53 of the hybrid structural module 50 in the corner of the structural element 500 will provide significant impact resistance to the structural element 500.
It should be appreciated that any number and type of structural elements can be made using the above components. The resultant structural element can therefore be designed and created with varying dimensions and load carrying capacities. Each individual component can be mass produced and prefabricated using quality controlled manufacturing procedures to reduce costs. Before assembly of the structural element, the quality of each individual element can be easily inspected which greatly assist in the production of a high quality structural element.
It should be appreciated that various other changes and modifications may be made to the embodiment described without departing from the spirit or scope of the invention.

Claims

CLAIMS:
1. A structural element comprising: a plurality of fibre composite sandwich panels, each sandwich panel having a pair of fibre composite skins with structural core material located there between; the plurality of fibre composite sandwich panels being adhered together; two planar, fibre composite joiners; each of the joiners having a width that is longer than the width of the fibre composite sandwich panels; the fibre composite joiners being adhered to different composite fibre skins of different composite sandwich panels; and at least one end member located adjacent at least one end of the plurality of fibre composite sandwich panels; the at least one end member being adhered to the fibre composite sandwich panels and the two planar fibre composite joiners.
2. The structural element of claim 1 wherein the structural core material of the sandwich panel is made from a polymer.
3. The structural element of claim 1 or claim 2 wherein the structural core material includes one or more of following materials: microspheres, glass, silica-alumina ceramics, cenospheres and/or a foamed phenolic resin product.
4. The structural element of any one of the preceding claims wherein the skins of the sandwich panels is made from fibre reinforced polymers
5. The structural element of claim 4 wherein the fibres are made from glass, carbon, Kevlar, thermoplastics or combinations thereof and the polymer is made of polyester, vinylester, phenolic, epoxy, polyurethane, thermoplastics or combination thereof.
6. The structural element of any one of the preceding claims wherein a polymer used to produce the skins is the same as that used to produce the structural core material.
7. The structural element of any one of the preceding claims wherein the fibre for the fibre composite joiners is made from glass, carbon, Kevlar, thermoplastic or combinations thereof whilst the polymer is made of polyester, vinylester, phenolic, epoxy, polyurethane, thermoplastic resins or combinations thereof.
8. The structural element of any one of the preceding claims wherein the end member is formed entirely from fibre composite.
9. The structural element of claim 9 wherein the fibre is made from glass, carbon, Kevlar, thermoplastic or combinations thereof whilst the polymer may be made of polyester, vinylester, phenolic, epoxy, polyurethane, thermoplastic resins or combinations thereof.
10. The structural element of and one of claim 1 to 7 wherein the end member is a hybrid reinforcing module.
11. The structural element of claim 10 wherein the hybrid reinforcing module includes a tubular fibre composite member, a filled resin system located within said tubular fibre composite member, and at least one elongated steel member located within the filled resin system such that the filled resin system binds the steel member and tubular member together.
12. The structural module of claim 11 wherein the tubular fibre composite member is a pultruded member.
13. The structural element of claim 11 or claim 12 wherein the tubular fibre composite member may have the majority of its fibres orientated in a longitudinal direction.
14. The structural element of claim any one of claims 11 to 13 wherein the polymer in the filled resin system is a polyester, vinylester, polyurethane or epoxy resin.
15. The structural element of any one of claims 11 to 14 wherein the steel member is prestressed prior to the hybrid member being formed.
16. The structural element of any one of claims 11 to 15 wherein the steel member is slighter shorter than the length of the tubular fibre composite member.
17. The structural element of any one of the preceding claims further including an external fibre composite laminate which is wrapped around the sandwich panels, the joiners and end member.
18. The structural element of claim 8 wherein external fibre composite laminate is made from glass, carbon, Kevlar, thermoplastics or combinations thereof and the polymer may be made of polyester, vinylester, phenolic, epoxy, polyurethane, thermoplastics or combination thereof.
19. The structural element of any one of the preceding claims further including a protective coating which is wrapped around the sandwich panels, the joiners and end member.
20. A method of manufacturing a structural element, the method comprising the steps of: adhering a plurality of fibre composite sandwich panels together, each sandwich panel having a pair of fibre composite skins with structural core material located there between; and adhering two planar, fibre composite joiners, each of the joiners having a length that is longer than the length of the fibre composite sandwich panels, to different composite fibre skins of different composite sandwich panels; and adhering at least one end member to at least one end of the plurality of fibre composite sandwich panels and to the two planar fibre composite joiners.
21. The method of claim 11 further including the step of: adhering an external fibre composite laminate around the structural element.
22. The method of claim 11 or claim 12 further including the step of: placing a protective coating around the structural element.
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US20100212710A1 (en) * 2009-02-25 2010-08-26 Roeder Hts High Tech Structures Kg Supporting Profile and Connecting Profile with Reinforcing Insert as well as Method for Producing a Fiber-Reinforced Metal Profile
WO2014094057A1 (en) * 2012-12-19 2014-06-26 Carbonloc Pty Ltd A railway sleeper
EP2935697A4 (en) * 2012-12-19 2016-08-17 Carbonloc Pty Ltd A railway sleeper
CN110654088A (en) * 2019-10-29 2020-01-07 天津爱思达新材料科技有限公司 Thermoplastic composite material sandwich plate structure and welding forming method
WO2023070174A1 (en) * 2021-11-01 2023-05-04 New Building Solutions Pty Ltd Building material
WO2024095023A1 (en) * 2022-11-04 2024-05-10 Jonathan Gunn Construction system

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