WO2017091904A1 - Procédés et composition de renfort structurel - Google Patents

Procédés et composition de renfort structurel Download PDF

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Publication number
WO2017091904A1
WO2017091904A1 PCT/CA2016/051418 CA2016051418W WO2017091904A1 WO 2017091904 A1 WO2017091904 A1 WO 2017091904A1 CA 2016051418 W CA2016051418 W CA 2016051418W WO 2017091904 A1 WO2017091904 A1 WO 2017091904A1
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WO
WIPO (PCT)
Prior art keywords
epoxy
layer
saturated
mesh
film
Prior art date
Application number
PCT/CA2016/051418
Other languages
English (en)
Inventor
Marty Rouse
Mike Orr
Kalid Hussein
Cory Ravenscroft
Greg Buozalezcki
Russell Holtby
Original Assignee
Tci Carbon Fiber Technologies Inc.
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
Application filed by Tci Carbon Fiber Technologies Inc. filed Critical Tci Carbon Fiber Technologies Inc.
Publication of WO2017091904A1 publication Critical patent/WO2017091904A1/fr

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Classifications

    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L63/00—Compositions of epoxy resins; Compositions of derivatives of epoxy resins
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J5/00—Manufacture of articles or shaped materials containing macromolecular substances
    • C08J5/24—Impregnating materials with prepolymers which can be polymerised in situ, e.g. manufacture of prepregs
    • C08J5/241—Impregnating materials with prepolymers which can be polymerised in situ, e.g. manufacture of prepregs using inorganic fibres
    • C08J5/244—Impregnating materials with prepolymers which can be polymerised in situ, e.g. manufacture of prepregs using inorganic fibres using glass fibres
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J5/00—Manufacture of articles or shaped materials containing macromolecular substances
    • C08J5/24—Impregnating materials with prepolymers which can be polymerised in situ, e.g. manufacture of prepregs
    • C08J5/241—Impregnating materials with prepolymers which can be polymerised in situ, e.g. manufacture of prepregs using inorganic fibres
    • C08J5/243—Impregnating materials with prepolymers which can be polymerised in situ, e.g. manufacture of prepregs using inorganic fibres using carbon fibres
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J2363/00—Characterised by the use of epoxy resins; Derivatives of epoxy resins

Definitions

  • the present invention relates generally to the field of structural reinforcement. More specifically, the present invention relates to the use of composite materials, such as fiber- re info reed polymers, to form a layer on the interior or exterior of a physical object to be reinforced.
  • composite materials such as fiber- re info reed polymers
  • Fiber- re info reed polymers are composite materials comprising a polymer reinforced with fibers.
  • the fibers are usually a glass, carbon, or aramid matrix, although other fibers such as paper or wood are sometimes used.
  • the polymer is a thermoset cured resin.
  • Fiber- re info reed polymers have a number of uses, including the reinforcement of the interior or exterior surfaces of structures. Surface reinforcement can be particularly useful when retrofitting or refurbishing structures, to avoid or delay the replacement of costly components.
  • CFRPs carbon fiber reinforced polymers
  • GFRPs glass fiber reinforced polymers
  • CFRPs carbon fiber reinforced polymers
  • GFRPs glass fiber reinforced polymers
  • Some examples include: reservoirs, cisterns, storage tanks, pipes, silos, bridges, dams, manholes, sewer lines, culverts, parapets, beams, slabs, walls, columns, floors, decks, vaults, and various other structural elements.
  • CFRPs and/or GFRPs including concrete, steel, stone, and brickwork.
  • a conventional approach for CFRP / GFRP reinforcement particularly when dealing with interior surfaces, is the 'wet layup' technique. In the wet layup technique, alternating layers of epoxy and saturated fiber mesh are built up on the surface of the structure to be reinforced, with each layer at least partially curing before the next layer is applied, often using a roller.
  • winding which is particularly useful for the exterior surfaces of elongate structures.
  • the surface is first coated with a partially cured epoxy layer and then one or more layers of glass or carbon fiber mesh is then wound over the surface of the object, often in long strips.
  • Forming one aspect of the invention is a method of structural
  • freezing permits the fiber mesh layers to be saturated off site in larger batches and transported to the work site in refrigerated carriers, to permit greater quality control. In some cases, this may involve a period of storage. Freezing may also allow the epoxy to be maintained at or near a desired level of curing and/or increase the overall tackiness of the epoxy, either of which may increase the adherence of the fiber mesh to an underlying surface or layer, thereby reducing delamination.
  • the invention extends to methods of preparing, storing, and using the frozen saturated mesh as well as the frozen saturated mesh itself.
  • Forming another aspect of the invention is a saturated fiber mesh having at least one removable film layer to contain the epoxy within the saturated fiber mesh during storage or transport.
  • the saturated fiber mesh may be wound into rolls, preferably with the film layer facing outward.
  • the saturated fiber is sandwiched between opposing film layers, to permit easier winding of the rolls and provide greater control over exposure of the saturated mesh to the working environment.
  • freezing in accordance with the present invention may permit storage of the wound rolls for later use and to control the rate at which the epoxy in the mesh is permitted to cure.
  • Film layers are then removed as required during the application of the saturated mesh to the object or structure to be reinforced.
  • Forming another aspect of the invention is a product comprising : a web; an epoxy impregnated in the web, the epoxy being in a temperature condition at which curing is inhibited or arrested; and a layer of film applied to one of the sides of the web.
  • the epoxy can be partially cured.
  • the product can further comprise a layer of film applied to the other of the sides of the web.
  • This product can be used in a method for reinforcing a surface of a structure that forms another aspect of the invention, this method comprising: removing the temperature condition which inhibited or arrested curing of the epoxy; pressing the web against the surface of the structure; and allowing the epoxy to cure; and removing the layer of film.
  • Forming another aspect of the invention is a method for use with a pair of prestressed concrete cylinder pipes, each pipe having an inner tube, an intermediate tube surrounding the inner tube and an outer tube surrounding the intermediate tube, the inner tube being prestressed concrete, the intermediate tube being steel and the outer tube being prestressed concrete, one of the ends of the pipe being a spigot end wherein the intermediate tube and inner tube are coterminous and extend beyond the outer tube, the other of the ends having a bell end wherein the outer tube and the intermediate tube are coterminous and extend beyond the inner tube, the ends being such that, when a pair of the pipes are brought together, with the bell end of one of the pair being disposed towards the spigot end of the other, the spigot end is received by the bell end, leaving a first gap between the adjacent outer tubes and a second gap between the inner tubes.
  • the first filler can be epoxy reinforced with chopped glass fibre; and/or the first fibre layer can be glass fibre reinforced polymer; and/or the second filler can be epoxy reinforced with chopped glass fibre; and/or the second fibre layer can be carbon fibre reinforced polymer.
  • FIG 1A is a perspective view of a saturated fiber mesh according to one embodiment of the present invention.
  • FIG IB is a perspective view of a saturated fiber mesh according to another embodiment of the present invention.
  • FIG 2A is a perspective view of a saturated fiber mesh roll according to an embodiment of the present invention.
  • FIG 2B is a perspective view of saturated fiber mesh sheets
  • FIG 3A is a perspective view of a saturated fiber mesh according to the present invention being applied to an elongate structure using a winding technique
  • FIG 3B is a perspective view of a saturated fiber mesh according to the present invention being applied to a concave structure using a wet layup technique
  • FIG. 4 shows a prior art pipe coupling
  • FIG. 5 shows the structure of FIG. 4 following application of the method at the bell end
  • FIG. 6 shows the structure of FIG. 4 following application of the method at the spigot end
  • FIG. 7 is a cross-sectional view of a pressure chamber.
  • manufacture begins by saturating a fiber layer 120 with an epoxy resin.
  • the fiber layer 120 can, by way of example, comprise glass or carbon fiber fabrics, the glass fiber fabrics being woven from HYBON ® 2022 direct roving fiber glass (PPG Industries, Inc.) having a weight of between 200 g/m 2 and 1600 g/m 2 and the carbon fiber fabrics being woven from UTS50TM F24 24K 1600tex D continuous carbon fiber (Toho Tenax America, Inc.) having a weight between 300 g/m 2 and 8500 g/m 2 .
  • Other carbon fiber and glass fiber fabrics may also be used, as can hybrid materials that combine different types of fiber in a single layer.
  • Other suitable forms of fiber known in the art are also contemplated, such as a ram id fibers.
  • the fiber layer 120 is saturated with an epoxy that forms a polymer matrix when cured.
  • the epoxy can, for example, be TCI-300-B (Cridel
  • Thermoset Resins, Inc. a two-component room temperature cured thermoset resin, mixed at a ratio of 100% resin to 33% hardener.
  • Various other suitable epoxies are known in the art and so the choice of epoxy depends on the specific application in question.
  • the epoxy resin which saturates the fiber layer 120 is allowed to partially cure, preferably until the epoxy becomes tacky and adherent, but still pliable.
  • the precise curing depends at least in part on the epoxy used and the conditions under which the curing takes place. It has been found that a curing time of 2-4 hours at room temperature is sometimes adequate, and normally no more than 7 hours is required.
  • FIG 1A shows a saturated fiber mesh 100 according to one embodiment in which a layer of film 110, 130 is applied to two opposing surfaces of the fiber layer 120.
  • FIG IB shows an alternative embodiment in which film 110 is applied to only one side of the fiber layer 120.
  • the film 110, 130 may be made of various materials, which may in some cases depend on the epoxy used. In the context of the fibres and epoxy specifically described above, a low density polyethylene film has been identified to be useful, but persons of skill in the art may identify other suitable films depending on the application in question.
  • the resulting saturated mesh 100 can, for example, be either formed into sheets 150 or wound into rolls 140. Examples are depicted in FIGS 2A and 2B.
  • sheets 150 may be formed by using pre-cut fiber layers 120 or by cutting the saturated mesh 100 into defined shapes. In either case, the formation of sheets 150 or rolls 140 may in some circumstances provide for easier storage and/or transportation of the saturated fiber mesh 100.
  • the saturated fiber mesh 100 is then frozen to substantia lly arrest the curing process.
  • a room-temperature epoxy was used and temperatures of between -5°C and -34°C, preferably - 18°C were used to freeze the saturated fiber mesh 100.
  • the exact temperature used during freezing may depend on the curing temperature and freezing point of the epoxy used .
  • intended mea ning of "frozen” is "held at a low temperature in order to preserve it", not "turned into ice as a result of extreme cold", although the mesh may well at least substantia lly solidify when frozen.
  • the fiber mesh 100 may be stored in a frozen state for future use and/or transported to the work site in refrigerated carriers. In some
  • the frozen fiber mesh 100 may be stored at temperatures of between -5°C and -34°C for 3-5 days, and sometimes for longer than 10 days.
  • the maximum shelf life of the saturated fiber mesh 100 will depend on storage conditions and the epoxy used .
  • the ability to store or transport the fiber mesh 100 in a frozen state can ease the timing requirements otherwise imposed by the curing of the epoxy resin. Further, the ability to manufacture saturated fiber mesh 100 in large batches in a controlled environment off-site may perm it greater quality control and consistency during the saturation process. This may in turn result in greater quality control for the final cured fiber-reinforced polymer, by reducing
  • the frozen fiber mesh 100 may be allowed to partially thaw to improve the tackiness and adherence of the partially cured epoxy. In some embodiments, the frozen fiber mesh 100 may be allowed to partially thaw at room temperature for 15-30 mins. Where sheets 150 or rolls 140 are used, thawing may be done before or after separating the sheets 150 or unrolling the rolls 140, as appropriate for the application.
  • the saturated fiber mesh 100 Once the saturated fiber mesh 100 has reached a working temperature, it can be applied to the surface of a structure to be reinforced. A working temperature between around 4°C to 40°C is contemplated.
  • the layers of film 110,130 can be useful to ensure that the mesh 100 does not adhere to itself in storage and can also be useful where it is desirable to minimize mess and/or exposure of the environment or personnel to the partially cured epoxy. This in turn may reduce the need for special suits or other protective equipment. It will be evident that, in order to apply the mesh 100 to a structure, at least one of the layers of film must be removed.
  • FIGS 3A and 3B illustrate the application of saturated fiber meshes 100 according to embodiments of the present invention to exemplary structures 10.
  • FIG 3A depicts a winding technique
  • FIG 3B depicts a wet layup technique.
  • Other techniques are also known in the art.
  • the saturated fiber mesh 100 is applied to the surface of the structure 10 and the epoxy is allowed to at least partially cure.
  • the saturated mesh 100 is applied to the surface of the structure 10 using tension (e.g. for the winding technique) and/or pressure from a trowel or roller (e.g. for the wet layup technique).
  • tension e.g. for the winding technique
  • pressure from a trowel or roller (e.g. for the wet layup technique).
  • the presence of the first layer of film 110 aids the application process by providing a clean surface upon which to apply pressure.
  • the first layer of film 110 is removed to expose the opposing surface of the saturated mesh 100 to permit any additional layers to be added to the fiber-reinforced polymer.
  • the film 110 is removed after the epoxy is allowed to partially cure, thereby, inter alia, improving adhesion.
  • a partial curing time of 12-96 hours, preferably 72 hours may be used.
  • first film layer 110 provides a clean surface upon which an installer can apply force during the application process using a roller, trowel, or the like.
  • the first film layer 110 also provides a barrier between the epoxy and the worker or environment that can remain in place while the epoxy is partially cured.
  • the surface of the structure 10 may be any shape.
  • saturated fiber mesh 100 sandblasted and/or primed with an epoxy primer before the saturated fiber mesh 100 is applied.
  • multiple layers e.g. 2-20
  • Changing the orientation of the fiber mesh 100 in successive layers and/or using different types of fiber in the various layers may also be used to create a fiber- reinforced polymer having certain desired characteristics for the particular application.
  • thickened epoxy may be applied between layers as appropriate for the application.
  • a top coat of epoxy may be applied if a finished surface is desired.
  • HYBON ® 2022 direct roving fiber glass was saturated with TCI-300-B resin [100 parts resin to 33 parts hardener, room temperature] and allowed to cure at 20C for 4 hours. Thereafter, the product was stored in a freezer at -20C for 10 days and then placed in ambient conditions [20C] for a period of 30 minutes. One of the plastic layers was removed, and the side of the product thus exposed was then applied to a surface that had been previously primed in a conventional manner. After 72 hours, the remaining layer of plastic was removed, and the joint was tested according to AWWA ASTM standards, resulting in a pull strength in excess of the 300 psi minimum.
  • a method which forms another exemplary embodiment of the invention is hereinafter described and will be understood to be suitable for use with a pipe joint of the general type shown in FIG. 4.
  • the pipe joint of FIG. 4 will be seen to be defined by a pair of prestressed concrete cylinder pipes 200, each pipe having an inner tube 202, an intermediate tube 204 surrounding the inner tube and an outer tube 206 surrounding the intermediate tube, the inner tube being prestressed concrete, the intermediate tube being steel and the outer tube being prestressed concrete, one of the ends of the pipe being a spigot end 208 wherein the intermediate tube and inner tube are coterminous and extend beyond the outer tube, the other of the ends having a bell end 210 wherein the outer tube and the intermediate tube are coterminous and extend beyond the inner tube, the ends being such that, when a pair of the pipes are brought together, with the bell end of one of the pair being disposed towards the spigot end of the other, the spigot end is received by the bell end, leaving a first gap 212 between the adjacent outer
  • thermoset epoxy in the form of thickened thermoset epoxy reinforced with glass fibre chopped to a maximum 1/4" length, in the first gap [100 g epoxy: 1 g fibre]
  • thermoset epoxy • providing a second filler, in the form of thickened thermoset epoxy
  • the CFRP is applied in a wet lay up with a required number of plies and
  • FIG. 5 A joint constructed according to the method is shown in FIG. 5, wherein :
  • FIG.6 A further version of the joint is shown in FIG.6; this joint is substantially similar to the joint of FIG. 5, but whereas in FIG. 5 the second fibre layer overlaps the bell end, in FIG. 6, the second fibre layer overlaps the spigot end.
  • a test cell 300 is shown in FIG. 7 and has been found to be useful for testing joint strength.
  • the test cell includes a cylindrical steel vessel 302 terminating in an aperture surrounded by a flange 304.
  • a steel lid 306 having a central port 308 is secured to the flange 304 by bolts 310 and sealed by a rubber gasket 312.
  • the materials of the contemplated first fibre layer, second filler layer and second fibre layer are applied to the lid in the manner indicated above, i.e. :
  • the material of the second fibre layer is applied to the second filler as 318 the layers 314, 316, 318 being sized smaller than the aperture and layers 314,316 being provided with through-holes communicating with port 308.

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  • Chemical & Material Sciences (AREA)
  • Materials Engineering (AREA)
  • Engineering & Computer Science (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Health & Medical Sciences (AREA)
  • Medicinal Chemistry (AREA)
  • Polymers & Plastics (AREA)
  • Organic Chemistry (AREA)
  • Manufacturing & Machinery (AREA)
  • Inorganic Chemistry (AREA)
  • Laminated Bodies (AREA)
  • Reinforced Plastic Materials (AREA)
  • Moulding By Coating Moulds (AREA)

Abstract

L'invention concerne un produit comprenant une bande imprégnée de résine époxy dans une condition de température à laquelle le durcissement est inhibé ou arrêté, et pouvant comprendre en outre, sur un ou deux côtés de la bande, une couche de film. La résine époxy peut être partiellement durcie. Le produit peut être utilisé dans un procédé selon lequel la condition de température ayant inhibé ou arrêté le durcissement est retirée, la bande est placée contre la surface d'une structure et la résine époxy peut durcir. Un certain temps peut être nécessaire pour que la résine époxy soit réactivée avant de presser la bande contre la surface. Si le produit présente deux couches de film, l'une doit être retirée pour permettre à la bande d'être pressée contre la surface. Une couche de film peut être laissée sur la bande, lorsque la bande est pressée contre la surface, et retirée de la bande après que la résine époxy a été amenée à durcir au moins partiellement.
PCT/CA2016/051418 2015-12-03 2016-12-02 Procédés et composition de renfort structurel WO2017091904A1 (fr)

Applications Claiming Priority (6)

Application Number Priority Date Filing Date Title
CA2913839 2015-12-03
CA2913839A CA2913839A1 (fr) 2015-12-03 2015-12-03 Methode et composition de renfort structurel
US201662327667P 2016-04-26 2016-04-26
US201662327657P 2016-04-26 2016-04-26
US62/327,667 2016-04-26
US62/327,657 2016-04-26

Publications (1)

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WO2017091904A1 true WO2017091904A1 (fr) 2017-06-08

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Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP3502202A1 (fr) * 2017-12-20 2019-06-26 Palo Alto Research Center Incorporated Nouveaux matériaux et procédé d'assemblage d'un pipeline renforcé de fibres
WO2023064552A1 (fr) * 2021-10-15 2023-04-20 Pipeline Coatings System Llc Composites époxy de réparation de pipeline, procédés et applications
US11976763B2 (en) 2018-07-04 2024-05-07 Hitachi Energy Ltd Fibre reinforced polymer tube

Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE102011082192A1 (de) * 2011-09-06 2013-03-07 Bayerische Motoren Werke Aktiengesellschaft Verfahren und Vorrichtung zum Herstellen von Prepregs aus Wickelverfahren
CA2921904A1 (fr) * 2013-08-22 2015-02-26 Cytec Industries Inc. Liaison de materiaux composites

Patent Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE102011082192A1 (de) * 2011-09-06 2013-03-07 Bayerische Motoren Werke Aktiengesellschaft Verfahren und Vorrichtung zum Herstellen von Prepregs aus Wickelverfahren
CA2921904A1 (fr) * 2013-08-22 2015-02-26 Cytec Industries Inc. Liaison de materiaux composites

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP3502202A1 (fr) * 2017-12-20 2019-06-26 Palo Alto Research Center Incorporated Nouveaux matériaux et procédé d'assemblage d'un pipeline renforcé de fibres
US11014327B2 (en) 2017-12-20 2021-05-25 Palo Alto Research Center Incorporated Materials and method for joining fiber reinforced pipeline
US11976763B2 (en) 2018-07-04 2024-05-07 Hitachi Energy Ltd Fibre reinforced polymer tube
WO2023064552A1 (fr) * 2021-10-15 2023-04-20 Pipeline Coatings System Llc Composites époxy de réparation de pipeline, procédés et applications

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