U.S. patent application number 11/049269 was filed with the patent office on 2005-11-17 for fiber reinforced metal construct for reduced fatigue and metal embrittlement in susceptible structural applications.
Invention is credited to Hubbell, David A., Hubbell, Mary C..
Application Number | 20050252165 11/049269 |
Document ID | / |
Family ID | 35308079 |
Filed Date | 2005-11-17 |
United States Patent
Application |
20050252165 |
Kind Code |
A1 |
Hubbell, David A. ; et
al. |
November 17, 2005 |
Fiber reinforced metal construct for reduced fatigue and metal
embrittlement in susceptible structural applications
Abstract
An assembly of structural elements, having significant
asymmetric engineering properties, such as iron and glass,
providing fatigue resistant structural composites.
Inventors: |
Hubbell, David A.;
(Pensacola, FL) ; Hubbell, Mary C.; (Pensacola,
FL) |
Correspondence
Address: |
David A. Hubbell
Apt # 128
1600 Governors Dr.
Pensacola
FL
32514
US
|
Family ID: |
35308079 |
Appl. No.: |
11/049269 |
Filed: |
February 2, 2005 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60540993 |
Feb 2, 2004 |
|
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Current U.S.
Class: |
52/745.19 |
Current CPC
Class: |
E04C 3/29 20130101; E04C
3/06 20130101; E04C 5/073 20130101; E04C 3/10 20130101 |
Class at
Publication: |
052/745.19 |
International
Class: |
E04B 001/00 |
Claims
We claim:
1. The means and methods of making a structural member of
reinforced ferrous material comprising using an amount of
non-metallic fiber reinforcement structurally attached to said
ferrous material.
2. An assembly as in claim 1, wherein the said ferrous material
surface and near-surface is metallurgically alloyed with another
metal before attachment of said non-metallic fiber
reinforcement.
3. An assembly as in claim 2, wherein said ferrous-alloy surface is
partly removed before attachment of said non-metallic fiber
reinforcement.
4. An assembly as in claim 3, wherein attachment of non-metallic
fiber reinforcement is with a resin.
5. An assembly as in claim 4, wherein said resin is
catalyst-sensitive to the alloying metal.
6. An assembly as in claim 2, wherein the said ferrous material
surface and near-surface is metallurgically alloyed via the hot-dip
galvanizing process before attachment of said non-metallic fiber
reinforcement.
7. An assembly as in claim 6, where in said ferrous-zinc alloy
surfaces are partly exposed by removal of some of the galvanized
ferrous material's external zinc surface before attachment of said
non-metallic fiber reinforcement.
8. An assembly as in claim 1, wherein said non-metallic fiber
reinforcement is substantially in excess of that warranted, said
ferrous material is compressed before being structurally attached
to said non-metallic fiber reinforcement and after affecting said
structural attachment, releasing said ferrous material to tension
the said non-metallic fiber reinforcement throughout its structural
attachment with said ferrous material.
9. An assembly as in claim 2, wherein said non-metallic fiber
reinforcement is substantially in excess of that warranted, said
ferrous material is compressed before being structurally attached
to said non-metallic fiber reinforcement and after affecting said
structural attachment, releasing said ferrous material to tension
the said non-metallic fiber reinforcement throughout its structural
attachment with said ferrous material.
10. An assembly as in claim 3, wherein said non-metallic fiber
reinforcement is substantially in excess of that warranted, said
ferrous material is compressed before being structurally attached
to said non-metallic fiber reinforcement and after affecting said
structural attachment, releasing said ferrous material to tension
the said non-metallic fiber reinforcement throughout its structural
attachment with said ferrous material.
11. An assembly as in claim 4, wherein said non-metallic fiber
reinforcement is substantially in excess of that warranted, said
ferrous material is compressed before being structurally attached
to said non-metallic fiber reinforcement and after affecting said
structural attachment, releasing said ferrous material to tension
the said non-metallic fiber reinforcement throughout its structural
attachment with said ferrous material.
12. An assembly as in claim 5, wherein said non-metallic fiber
reinforcement is substantially in excess of that warranted, said
ferrous material is compressed before being structurally attached
to said non-metallic fiber reinforcement and after affecting said
structural attachment, releasing said ferrous material to tension
the said non-metallic fiber reinforcement throughout its structural
attachment with said ferrous material.
13. An assembly as in claim 6, wherein said non-metallic fiber
reinforcement is substantially in excess of that warranted, said
ferrous material is compressed before being structurally attached
to said non-metallic fiber reinforcement and after affecting said
structural attachment, releasing said ferrous material to tension
the said non-metallic fiber reinforcement throughout its structural
attachment with said ferrous material.
14. An assembly as in claim 7, wherein said non-metallic fiber
reinforcement is substantially in excess of that warranted, said
ferrous material is compressed before being structurally attached
to said non-metallic fiber reinforcement and after affecting said
structural attachment, releasing said ferrous material to tension
the said non-metallic fiber reinforcement throughout its structural
attachment with said ferrous material.
15. An assembly as in claim 4, wherein said compression of said
ferrous material is achieved by reducing its temperature below its
intended ambient temperature range use.
16. An assembly as in claim 15, wherein temperature reduction of
ferrous material is achieved with the aid of thermoacoustical means
and methods.
17. An assembly as in claim 14, wherein voids are present within
the ferrous material for the purpose of using cabling to apply a
compressive force on said ferrous material.
18. An assembly as in claim 1, wherein said non-metallic fiber
reinforcement element is structurally attached to more than one
ferrous material element.
19. An assembly as in claim 1, wherein said ferrous material
element is structurally attached to more than one non-metallic
fiber reinforcement element.
20. An assembly as in claim 1, wherein said non-metallic fiber
reinforcement electrically insulates said ferrous material.
Description
RELATED APPLICATIONS
[0001] This application claims the benefit of Provisional
application Ser. No. 60/540,993 filed Feb. 2, 2004
U.S. PATENT DOCUMENTS
[0002]
1 510 December 1837 Sorel 826 July 1838 Johnson 869 August 1838
Alger 1,374 October 1839 Sumner & Naylor 10,106 October 1853
Goodyear 11,815 October 1854 Thomin & Stumer 19,866 April 1858
Morewood & Rogers 22,864 February 1859 Gardiner 51,724 December
1865 Jenkins 59,787 November 1866 Whitling 95,017 September 1869
Grey 139,902 June 1873 Lummus 178,460 June 1876 Pauly 199,973
February 1878 Hadfield 213,015 March 1879 Wahl & Eltonhead
214,085 April 1879 Beck 222,655 December 1879 Breeding 232,122
September 1880 Hammesfahr 354,788 December 1886 Hickley 390,969
October 1888 Hooper & Clark 537,463 April 1895 Hunter 851,118
April 1907 Chadwick 893,792 July 1908 Gabriel 903,909 November 1908
Steiner 1,269,926 June 1918 Gesell 1,409,017 March 1922 Ortiz
1,684,663 February 1925 Dill 1,731,346 October 1929 Meehan
1,781,699 November 1930 Parmley 1,844,994 February 1932 van Boyen
2,035,977 March 1936 Nichols 2,078,910 April 1937 Merrill 2,111,826
March 1938 Waltman & Dillon 2,133,238 October 1938 Slayter et
al. 2,155,121 April 1939 Finsterwalder 2,172,933 September 1939
Daesen & Bradley 2,255,022 September 1941 Emperger 2,303,394
December 1942 Schorer 2,319,105 May 1943 Billner 2,407,881
September 1946 Hoover & Hayes 2,435,998 February 1948 Cueni
2,453,079 November 1948 Rossmann 2,660,049 November 1953 Maney
2,758,321 August 1956 Westfall 2,781,658 February 1957 Dobell
2,796,373 June 1957 Overum 2,797,179 June 1957 Reynolds 2,824,021
February 1958 Cook & Norteman 2,857,755 October 1958 Werth
2,869,214 January 1959 Van Buren 2,940,870 June 1960 Baldwin
3,078,555 February 1963 McFarland 3,255,875 June 1966 Tierney
3,257,266 June 1966 Sapper 3,493,550 February 1970 Schmitt
3,627,466 December 1971 Steingiser, Phillips & Cass 3,627,571
December 1971 Cass & Steingiser 3,930,639 January 1976
Steinberg, et al. 3,936,341 February 1976 Nanoux 3,950,905 April
1976 Jeter 3,951,697 April 1976 Sherby et al. 3,998,602 December
1976 Horowitz, et al. 4,049,874 September 1977 Aoyama 4,105,811
August 1978 Horowitz, et al. 4,107,228 August 1978 Horowitz, et al.
4,158,082 June 1979 Belousofsky 4,272,211 June 1981 Sabel 4,327,536
May 1982 Ascher 4,789,586 December 1988 Morimura, et al. 4,842,923
June 1989 Hartman 5,219,629 June 1993 Sobolev 5,324,563 June 1994
Rogers, Crane & Rai 5,613,334 March 1997 Petrina 5,641,543 June
1997 Brooks 5,695,867 December 1997 Saitoh, et al. 6,170,209
January 2001 Dagher, et al. 6,367,208 April 2002 Campbell, et al.
6,409,433 June 2002 Hubbell, et al. 6,454,488 September 2002 Lewis,
Sr., et al. 6,502,805 January 2003 Lewis, et al. 6,616,976
September 2003 Montano et al. 6,685,154 February 2004 Blyth, et
al.
OTHER REFERENCES
[0003] Design of Concrete Structures, by Urquhart & O'Rourke,
McGraw-Hill Book Company, .COPYRGT.1940.
[0004] Standard Specifications for Structural Supports for Highway
Signs, Luminaires and Traffic Signals, 4.sup.th Edition, 2001,
American Association of State Highway and Transportation
Officials.
BACKGROUND OF THE INVENTION
[0005] The present invention provides the means and methods for
construction of fatigue resistant structural composites assembled
from structural elements having significant asymmetric engineering
properties. Examples of asymmetric engineering materials are iron
and glass. In the case of iron, very high compressive strengths are
available, relative to other commonly encountered engineering
materials. Iron's high available compressive strengths are offset
by tensile strengths usually in the range of commonly encountered
mild-steels. As identified in the referenced present art below,
iron compressive strengths in excess of 250,000 psi are
commercially available. At such high compressive strength iron
usually exhibits tensile strengths in the low 20,000 psi range with
elongation of a few percent. As such, iron provides an example of a
material having asymmetric engineering properties. In contrast,
typical mid-range-strength steels usually exhibit near-symmetric
tensile and compressive properties. Non-metallic structural fibers,
such as fiberglass and carbon fiber are other examples of
asymmetric engineering materials. In the case of fiberglass and
carbon fiber, when properly aligned, bonded and anchored, provide
very high tensile strengths with some configurations offering
tensile strengths in excess of iron's high compressive strengths.
As identified in the referenced present art below, non-metallic
fiber tensile strengths in significant excess of 300,000 psi are
commercially available. The present invention provides the means
and methods of constructing structural composites of iron and
non-metallic fiber whereby the iron is reinforced in design-driven
tensile regions with high tensile strength non-metallic fiber such
as fiberglass. Such iron-and-glass structural composites offer
economic advantages over the present art. For example, reinforced
concrete (RC) design is usually limited to concrete compressive
strengths of 5,000 psi (+/-) and reinforcing steel tensile
strengths of 50,000 psi (+/-). Such RC design is achieved by
assuming zero elongation of the concrete element and a few percent
elongation of the reinforcing steel. The present invention's design
is achieved by assuming a few percent contraction or negative
elongation of its compressive element, the iron, and zero
elongation of it's tensile element, the fiberglass. Such a
reinforced iron or reinforced ferrous structural composite allows
designers to move from a composite design, such as RC, balancing
composite compressive/tensile strengths of 5,000 psi/50,000 psi
(+/-) to 250,000 psi/300,000 psi (+/-). Further, the present
invention allows the use of very high strength steels which
presently have limited use due in part to concerns about
brittleness and limited resistance to physical shock. Structural
application combinations of non-metallic fiber and steel or
aluminum are well-known in the present art. The present invention
advances the present art by first providing means and methods of
utilizing iron's very high compressive strengths and by applying
the general concept of prestressed RC design whereby the
compressive element, iron and/or very high strength steel, is
pre-contracted before attachment of the non-metallic fiber tensile
element. In contrast, prestressed RC design provides for elongation
of the steel tensile element before attachment (casting) of the
compressive concrete element. The very high shear-transfer
requirements to gain structural composite action between iron and
fiber is another achievement of the present invention. I have
termed this result "reinforced ferrous composite".
[0006] The present invention is the result of numerous experiments
merging Letters Patent issued to one co-inventor and prior art
devices of our design with existing government requirements of the
construction, performance and use of commonly encountered
structural steel and iron elements with present art knowledge
providing new, economic, structural composite materials
configurations.
[0007] An explanation of some general structural-composite
principles of the present invention may be by way of paraphrasing
specific present art U.S. patents: U.S. Pat. No. 5,613,334 to
Petrina (Petrina '334). Petrina '334 states (col. 1, line 24)
"Concrete is strong under compression, but relatively low in
strength under tension."
[0008] The present invention (paraphrasing Petrina '334 and
substituting cast iron etc. for concrete) utilizes the fact that
cast iron and high-strength steels (due to both these inherent
engineering properties and existing engineering design code
prohibitions) are strong under compression, but relatively low in
strength under (allowable) tension. Examples of aforementioned
engineering design code prohibitions include Urquhart &
O'Rourke's observations that (page 42-44) "(s)ome authorities
prefer that bars of the structural steel grade only be used but the
modern tendency is to use the intermediate grade. The brittleness
of the hard or high-carbon steel is to be feared especially in
light members subject to sudden impact stresses. High-carbon steel
when used should be thoroughly inspected and tested in order to
prevent brittle or cracked material from being used in the
completed structure."
[0009] Petrina '334 continues "When a structural member such as a
beam is made of concrete, it is under both compressive stress at
the top of the beam and tension at the bottom of the beam. Thus a
concrete beam would tend to fail by being cracking and pulling
apart at the bottom, where the stress is tensile. The same is true
of . . . any other application where tensile forces will be applied
to concrete."
[0010] The present invention (paraphrasing Petrina '334) utilizes
the fact that when a structural member such as a beam is made of
cast iron and/or high-strength steels, it is under both compressive
stress at the top of the beam and tension at the bottom of the
beam. Thus a cast iron and/or high-strength steel beam (assuming a
symmetrical cross-section centered on the neutral-axis and ignoring
structural shape failure, as taught by U.S. Pat. No. 139,902 to
Lummus, such as localized-buckling) would tend to fail by pulling
apart at the bottom, where the stress is tensile. The same is true
of any other application where tensile forces will be applied to
cast iron and/or high-strength steels.
[0011] Petrina '334 states (col. 1, line 32) "This can be overcome
by placing reinforcement where it is necessary for structural
members to resist tensile forces. The result is called `reinforced
concrete.`"
[0012] In the present invention (paraphrasing Petrina '334) this
can be overcome by placing reinforcement where it is necessary for
the structural members to resist tensile forces.
[0013] Petrina '334 continues, "The reinforcement is typically in
the form of steel bars . . . or welded wire fabric (in the case of
flat areas such as roads, floors, or other concrete slabs)."
[0014] In the present invention (paraphrasing Petrina '334 and
substituting fiberglass etc. for steel bars) the reinforcement is
in the form of non-metallic fiber (such as fiberglass, carbon
fiber) bars and/or fabric sheet and/or plate.
[0015] Petrina '334 states (col. 1, line 39) "In a concrete beam,
the steel rebar is placed in the lower part of the beam, so that
the tensile forces are countered by the reinforcement. The steel
reinforcement is bonded to the surrounding concrete so that stress
is transferred between the two materials."
[0016] In an embodiment of the present invention (paraphrasing
Petrina '334) such as a cast iron and/or high-strength steel beam
the non-metallic fiber reinforcement is placed in the lower part of
the beam, so that the tensile forces are countered by the
reinforcement. The non-metallic fiber reinforcement is bonded to
the surrounding cast iron and/or high-strength steel so that stress
is transferred between the two materials.
[0017] U.S. Pat. No. 893,792 to Gabriel (Gabriel '792). Gabriel
'792 teaches that (page 1, line 59) "(i) n making the beam, a
sufficient number of shear members required for with-standing the
intended load, are formed . . . and are distributed along the
member at distances proportioned to the load or shear distribution.
They are tilted so that the planes of the arms are oblique to the
rod axis and thus transverse to the shear strains." The present
invention utilizes Gabriel '792's teachings, where needed, by
providing in the cast-iron or high-strength steel, geometry
shear-connectors running from the tensile element(s) into the
ferrous material toward the neutral-axis, such transmission
extending beyond the neutral-axis into the tensile zone if
necessary or desired.
[0018] Petrina '334 states (col. 1, line 44) "In a further
development the steel is stretched before the development of bond
between it and the surrounding concrete. When the force that
produces the stretch is released, the concrete becomes
precompressed in the part of the structural member that is normally
the tensile zone under load. The application of loads when the
structure is in service reduces the precompression, but generally
tensile cracking is avoided. Such concrete is known as `prestressed
concrete`."
[0019] In the present invention (paraphrasing Petrina '334 and
substituting prestressing the tensile member for pre-compressing
the compressive member) in a further development, the cast iron
and/or high-strength steel is compressed before the development of
bond between it and the non-metallic fiber reinforcement. When the
force that produces the compression is released, the non-metallic
fiber reinforcement becomes pre-tensioned in the part of the
structural member that is normally the tensile zone under load. The
application of loads when the structure is in service reduces
tensile stress in the cast iron and/or high-strength steel. I have
termed such pre-compressed (before application of dead-loads,
service-loads, etc.) reinforced ferrous composite "pre-loaded
reinforced ferrous composite".
[0020] Petrina '334's (col. 3, line 23) "FIG. 2 shows a side view
of a concrete beam using the reinforcing rod of the invention, with
a cut-away to show the rods." (col. 5, line 7) "FIGS. 2 and 3 show
side and end views, respectively, of a concrete beam (11). . . . "
Without addressing other aspects of the present invention, it can
be simplistically stated that I substitute ferrous metal for
Petrina '334's " . . . concrete beam (11) . . . " element in the
Petrina '334 composite structure of concrete and fiber reinforcing
bar. That said, given the disparity of engineering properties
between concrete and steel rebar or Petrina '334's fiber bar vs the
near balance in engineering properties between say cast-iron and
fiberglass or carbon fiber, while the engineering design principles
of composite structural design remain unaffected, the present
invention's physical manifestations are significant, unanticipated,
enhancements over Petrina '334 by magnitudes. For example,
substitution of 200,000 psi cast-iron for a Petrina '334 device's
5,000 psi concrete radically alters structural, architectural,
manufacturing and erection requirements.
[0021] Specific engineering material properties used herein (where
noted, full text quoted below) are:
[0022] For the present art, Petrina '334-type devices, typically
encountered concrete compressive strengths are in the 4,000 to
8,000 psi. range and typically encountered steel rebar tensile
strengths are in the 60,000 to 80,000 psi. range.
[0023] The present invention allows use of structural-composite
compressive-element(s), for example cast-iron, ranging from (where
noted, full text quoted below) 300,000 psi (U.S. Pat. No. 4,272,211
to Sabel)[Brinell 650 to 700 see FIG. 1], 190,000 psi (U.S. Pat.
No. 3,951,697 to Sherby et al.), 140,000 psi (U.S. Pat. No.
1,731,346 to Meehan)[Brinell 320 to 360 see FIG. 1], and 175,000
psi (U.S. Pat. No. 1,731,346 to Meehan)[Brinell 402 see FIG. 1]
When the present invention utilizes Petrina '334 teachings of
pre-loading the structural-composite via stretching the steel
tensile-element, the present invention pre-loads it's
structural-composite by compressing the compressive-element(s)
before shear-connecting the tensile-element(s). U.S. Pat. No.
1,731,346, dated Oct. 15, 1929, to Meehan (Meehan '346) Meehan '346
teaches of cast-iron composition having elongations ranging from
(see full text quoted below) 1% to 7% and some present art
ductile-iron having elongation properties in excess of 10%. The
present invention contemplates use of conventional means of
pre-compression and/or use of thermo-contraction to "prestress" the
present invention's structural-composite.
[0024] The present invention allows use of structural-composite
non-metallic fiber tensile-element(s), ranging from (where noted,
full text quoted below) 250,000 psi (U.S. Pat. No. 5,324,56 to
Rogers, Crane & Rai), 500,000 psi (U.S. Pat. No. 4,842,923 to
Hartman), 282,000 psi (U.S. Pat. No. 3,627,571 to Cass &
Steingiser), 200,000 psi (U.S. Pat. No. 3,627,466 to Steingiser et
al.), 119,000 psi (U.S. Pat. No. 3,255,875 to Tierney).
[0025] Critical to structural composite design is Petrina '334's
observation that for steel reinforced concrete to achieve a
structural composite state (col. 1, line 40) "The steel
reinforcement is bonded to the surrounding concrete so that stress
is transferred between the two materials." The present invention
achieves a structural composite state between ferrous structural
elements and non-metallic fiber structural elements via present art
means of enhanced surface adhesion and use of present art
resins.
[0026] The present invention improves on U.S. Pat. No. 537,463 to
Hunter (Hunter '463), which teaches of cast-iron and steel
structural composite construction. Hunter '463 teaches of (page 1,
line 8) " . . . having a hard resisting surface, and a softer and
more yielding backing . . . "
[0027] An explanation of some additional general principles and
addressing specifically the shear-transfer or structural bonding
between the structural compressive and tensile main elements of the
present invention may be by way of paraphrasing U.S. Pat. No.
5,641,543 to Brooks (Brooks '543).
[0028] Brooks '543 teaches that (col. 1, line 62) "Broadly the
invention comprises a method for preparing galvanized steel stock
for the application of a top coating. As is understood in the art,
for galvanized steel there are typically four layers in the zinc
coating. A first eta . . . layer which interfaces with the steel
surface, a zeta . . . layer, a delta . . . layer and then finally a
gamma . . . layer." (col. 1, line 37) " . . . fabricators pre-treat
the zinc coating, typically by sandblasting, before application . .
. . This serves to `roughen` the surface. The roughened surface has
an increased surface area to enhance the bonding . . . "
[0029] The present invention's method includes, when configured
with hot-dip galvanized ferrous metal element(s), (paraphrasing
Brooks '543), roughing the hot-dip galvanized zinc surface to
achieve a roughened surface which has an increased surface area to
enhance the bonding of the aforementioned resin(s) between the
structural metal element(s) and the structural non-metallic fiber
element(s) of the present invention's structural composite.
[0030] Brooks '543 teaches that (col. 1, line 56) "The process of
the invention treats the surface of the zinc layer to `roughen` the
surface without embedding impurities into the zinc."
[0031] In the present invention, when configured with hot-dip
galvanized ferrous metal element(s), unlike Brooks '543, the method
includes partial or complete removal of surface zinc, uncovering
some of the zinc-iron alloy layers (zeta, delta, gamma) preferably
via scarfing and/or scarifying and/or abrading. Removal of the soft
zinc outer surface exposes zinc-iron alloys of high shear strength.
U.S. Pat. No. 2,111,826 to Waltman & Dillon (Waltman '826)
teaches that (col. 1, line 11) "An examination of a regular one dip
. . . " iron article " . . . will generally reveal a first thin
layer of very fine grain structure close to the steel or iron body
. . . consisting probably of FeZn.sub.3, a second, heavier layer of
long needle-like crystals protruding more or less perpendicularly
to the . . . " iron article " . . . and consisting probably of
FeZn.sub.7, . . ." The American Galvanizers Association provides
the following Diamond Pyramid Number (DPN) hardness ratings for a)
zinc DPN of 70, b) typical steel DPN of 159, c) zeta zinc-iron
alloy DPN of 179 and d) delta zinc-iron alloy DPN of 244. Not only
are the typically out-of-sight, below the "pure" zinc eta layer,
zinc-iron alloy layers "harder" than the underlying steel and as
such stress-concentrating due to their "relative-stiffness"
vis--vis the underlying steel, but in frequently occurring
structural engineering applications the zinc-iron alloy layers are
in the "extreme-fiber" condition of structural service loads.
[0032] Exposure of zinc-iron alloy layers allows the use of resins
with zinc-catalytic "set", on the exposed zinc-iron alloy materials
which maximizes the shear developed, said resins, of course, being
compatible with the non-metallic fiber's support matrix.
[0033] Example applications of the present invention in addressing
specific engineering-problem-statements include the wide
governmental acceptance of the Standard Specifications for
Structural Supports for Highway Signs, Luminaires and Traffic
Signals, 4.sup.th Edition, 2001, as the structural design code and
guideline for flexible civil structures having low resonant
frequencies relative to their service design loadings' frequencies
and exhibiting low damping structural characteristics, replacing
"Strength Loads Design" with "Structural Fatigue Design". This
change in structural design approach, from one of "strength-driven"
to one of "fatigue-driven" has resulted in " . . . increased
material costs . . . " to governmental agencies of " . . . as much
as 250%".
[0034] The present invention provides means and methods of
neutralizing structural fatigue loadings and thereby allowing a
return to a "strength-driven" structural design and its associated
significant reduction in materials costs. The present invention
allows both design of "strength-driven" structures and retrofit for
existing fatigue susceptible structures. Use of such
"strength-driven" structural design allows application of
prestressing forces when incorporating composite elements having
asymmetric strength engineering materials properties such as but
not limited to iron, and/or when composite elements include the use
of fatigue susceptible metal(s) such as weldments.
[0035] Fatigue cracks in aluminum and steel initiate mostly from
discontinuities within these engineering materials in regions of
high stresses. Repeated load cycling in regions of high stress
results in progressive damage of a localized nature. Common
fracture modes are intergamular and/or transgranular cleavage. This
type of fatigue crack propagation is encouraged via liquid metal
embrittlement which may result from welding and/or other
metallurgic processes such as hot-dip galvanizing.
[0036] Due in large part to economic cost advantages, steel is
frequently the engineering material of choice for structural
engineering tensile and bending moment applications.
[0037] Even where economics encourage the use of concrete in
structural engineering compressive strength applications, steel is
used as the tensile and shear-transfer engineering material of
choice. Use of steel in civil and structural engineering
applications, where corrosion is expected, such as highway bridges,
necessitates that the steel components are frequently protected
from corrosion via the hot-dip galvanizing process. Hot-dip
galvanizing results in a metallurgical formation of zinc and iron
alloy layers surrounding and encapsulating the structural steel
element.
[0038] The typically encountered welding operation of jointing
structural metal members creates discontinuities within these
engineering materials. These discontinuities are manifested in
intergamular and/or transgarnular illregularities in the weldment
and nearby base-metal. In the case of steel, the hot-dip
galvanizing process "liquefies" and "grows" zinc-iron alloy
crystalline structures of widely differing "hardnesses" within
these intergarnular and/or transgarnular discontinuities.
[0039] The present invention addresses and provides relief from
problems with vibration and fatigue associated with stress
fluctuations and corresponding cycles of significantly below
service-load levels. Just as abovementioned, "The assessment of
stress fluctuations and the corresponding number of cycles for all
. . . " load " . . . events (lifetime loading histogram) is
practically impossible. With this uncertainty, the design . . . for
a finite fatigue life becomes impractical." The same is true for
the assessment of service-load stress fluctuations over the
service-life of structures and their individual structural
elements. The present invention replaces the hot-dip galvanized
surface as the "extreme-fiber" in the areas of known
stress-concentrating regions such as weldments and their localized
neighborhoods by addition of resin-fiberglass layer(s)
[0040] In cases where the structural composite may be subjected to
loadings orthoclastically or significant force vectors resulting in
bearing on fiberglass and/or resin elements of said structural
composite which might lead to "crushing" of said elements, this
inventor's previous U.S. Pat. No. 6,561,492's FIGS. 10, 13, &
14 illustrate the nature of allowing metallic elements of the
structural composite to have partial surface to surface contact (in
U.S. Pat. No. 6,561,492 said surface to surface interface being
preferably wood-to-galvanized steel) and/or contact via only the
resin element(s) with the overall geometry of the composite
structure to provide "channels" and/or "non-bearing" spaces and/or
"traces" for the fiber elements so as to allow said fiber elements
to provide tensile, and/or compressive and/or shear while
experiencing minimal "crushing" loads. Said "channels" or "traces"
are depicted below as items #66, 70, 72, 74, etc. in U.S. Pat. No.
6,561,492's FIG. 10 and in U.S. Pat. No. 6,561,492's FIGS. 13 &
14 (including items #86, 88, etc. Other examples of said "channels"
or "traces" include this inventor's (as a co-inventor) U.S. Pat.
No. 6,502,805 FIG. 10 (item 58) and U.S. Pat. No. 6,502,805 FIG.
11's Item #66's and #67's formed void, shown below and (not shown)
U.S. Pat. No. 6,502,805 FIG. 15B's Item #126's formed void.
[0041] In conjunction with placement of the multi-part,
zinc-catalyst, resin in contact with the zinc/zinc-iron surface,
the hot-dipped galvanized steel element may be heated, relative to
the resin, to encourage formation of "bridging-chains" at or near
the surface exposure of the intergamular and/or transgarnular
discontinuities present.
[0042] The above was discovered, by research and experiments, means
and methods of structural compositions allowing for the
construction of metal, preferably ferrous, reinforced with
non-metallic fiber, such as fiberglass, which are structurally
prestress-able, providing, for a given load-case, lighter, less
expensive, greater structural-fatigue-resistance- , and greater
physical-shock-resistance than the present art. My discoveries are
founded, in part, on Letters Patent issued to me, specifically:
[0043] U.S. Pat. No. 6,367,208, Campbell, et al. ('208), issued to
me, which teaches of a structural composite (col. 2, line 67) " . .
. formed of a polymer matrix and a reinforcement material extending
through a tensile region." (col. 3, line 9) "The reinforcement can
be, for example, sheet steel, or fiber (cloth or strands), such as
fiberglass or carbon fiber. The sheet steel is preferably in the
form of one or more thin, galvanized, perforated U-channel steel
sheet(s). In further preferred embodiments, the post is formed by
casting the polymer in a mold with the reinforcement positioned in
the mold." Multiple full-scale testing at E-TECH Testing
(Sacramento, Calif.) and Case-Western Reserve University (and
published: STRUCTURES Magazine, July/August 2001, page 11) show
that '208 devices provide structurally efficient and economically
effective means and methods of (col. 4, line 33) " . . .
establishing a bond between the tensile face and the compressive
face via shear transfer from the tensile face material and the
polymer matrix of the pile's or post's material. Gluing is an
option when the polymer is of sufficient shear strength and both
the tensile face material and the polymer are compatible for
gluing. If the polymer is not of sufficient shear strength and/or
if a chemical bond, such as that formed by gluing, is not
practical, and/or if there is incompatibility of materials for
chemical bonding between the reinforcement and the polymer, the
physical shear connection is provided either by extending the
reinforcement into the polymer to a depth compatible with shear
transfer requirements or by extending the polymer into and/or
encapsulating all or part of the reinforcement. Alternatively, the
fibers can be applied to a preform tensile face, which is then put
in an injection mold where another polymer layer is molded on top
of the fibers." '208 devices address the need for a (col. 5, line
20) " . . . polymer . . . to resist shear stress in the . . . "
structural composite " . . . and to prevent delamination at the
interface of the sheet steel . . . and the polymer . . . when a
lateral load is applied." The present invention incorporates these
and other teachings of '208.
[0044] U.S. Pat. No. 6,409,433, Hubbell, et al. ('433), issued to
me, which teaches to (col. 7, line 15) " . . . place composite
material(s) on the structural element's core allows for application
other than providing "hoop" strengthening of core compressive
materials. This allows for, but not limited to, structural beams."
Multiple full-scale testing at North Carolina State University
shows that a '433 device provides a structurally efficient and
economically effective (col. 6, line 5) " . . . structural tubular
element . . . . The structural tubular element . . . can be
composed of various materials, . . . concrete, plastic, rubber,
structural foam, etc. A friction coating can be applied on the
tubular wall of the hollow conduit to provide an improved
connection between the wall of the hollow conduit and the
structural tubular element." (col. 10, line 14) " . . . to oxidize
metal-components which could be intentionally placed between the
composite-materials-shell . . . . Oxidation would cause the
metal-oxide to "expand" pushing the "friction" coat components
into, and thus increasing friction resistance . . . . " The present
invention incorporates these and other teachings of '433.
[0045] U.S. Pat. No. 6,454,488, Lewis, Sr., et al. ('488), issued
to me, which teaches (col. 2, line 38) " . . . to attenuate and
dissipate the energy . . . . " via " . . . a monolithic synthetic
resin (plastic) composition . . . . " providing an (col. 3, line
17) " . . . incremental force reduction . . . . " Full-scale
testing conducted by the present inventor has demonstrated the
workability of '488 devices. The present invention incorporates
these and other teachings of '488.
[0046] U.S. Pat. No. 6,502,805, Lewis, et al. ('805), issued to me,
which teaches of a (col. 5, line 56) " . . . tube . . . made from .
. . sheet metal . . . joined at overlapping portions with sheet
metal plate . . . . " Said (col. 5, line 60) " . . . tube . . . can
be rectangular, trapezoidal, trapezium or regular polygon. Further,
the individual sides of the tube may be curved, convex or concave.
The cross-sectional dimensions may change along the length of tube
50. (col. 6, line 24) " . . . a structural foam, or similar
material, is enclosed in the tube . . . and thereby pressurize the
tube for greater strength." Multiple full-scale testing at E-TECH
Testing (Sacramento, Calif.), Texas Transportation Institute (TTI),
North Carolina State University and testing conducted privately by
the present inventor has demonstrated the workability of '805
devices. The present invention incorporates these and other
teachings of '805.
[0047] U.S. Pat. No. 6,685,154, Blyth, et al. ('154), issued to me,
which states that (col. 1, line 15) "The prior art for providing
the transfer of moment forces . . . " within a structure system " .
. . is through the use of weldments . . . by means of welded flange
plates and/or welded splice plates and/or connection plates. These
jointed structures are usually designed so as to be intentionally
stronger than the individually attached structural members. They
are designed to carry dead load and moment forces, and load shears
and torsion loads . . . " (col. 1, line 27) "Weldments are subject
to fatigue stresses. Recent structural failures and the resulting
research has identified weldment fatigue failure as the primary
cause of these structural failures." Multiple full-scale testing at
Case-Western Reserve University and North Carolina State University
show that '154 devices provide structurally efficient and
economically effective (col. 1, line 40) "means and methods for
joining two or more structural members without the use of weldments
. . . without suffering the fatigue-load weakness of the prior art
joint designs while still able to transfer intended design loads."
The present invention incorporates these and other teachings of
'154.
[0048] The following Present Art background and review is separated
into:
[0049] Hot-Dip Galvanizing Present Art
[0050] Metal Vibration and Bonding of Dissimilar Material(s)
Present Art
[0051] Structural Iron and Steel Present Art
[0052] Structural Fiber Present Art
[0053] Structural Composite Present Art
[0054] Prestressed Structural Composite Present Art
[0055] The following Hot-Dip Galvanizing Present Art background and
review focus on:
[0056] U.S. Pat. No. 510, dated Dec. 7, 1837, to Sorel (Sorel
'510)
[0057] U.S. Pat. No. 1,374, dated Oct. 18, 1839, to Sumner &
Naylor (Sumner '374)
[0058] U.S. Pat. No. 10,106, dated Oct. 11, 1853, to Goodyear
(Goodyear '106)
[0059] U.S. Pat. No. 19,866, dated Apr. 6, 1858, to Morewood &
Rogers (Morewood '866)
[0060] U.S. Pat. No. 59,787, dated Nov. 20, 1866, to Whitling
(Whitling '787)
[0061] U.S. Pat. No. 95,017, dated Sep. 21, 1869, to Grey (Grey
'017)
[0062] U.S. Pat. No. 213,015, dated Mar. 4, 1879, to Wahl &
Eltonhead (Wahl '015)
[0063] U.S. Pat. No. 222,655, dated Dec. 16, 1879, to Breeding
(Breeding '655)
[0064] U.S. Pat. No. 1,409,017, dated Mar. 7, 1922, to Ortiz (Ortiz
'017)
[0065] U.S. Pat. No. 2,111,826, dated Mar. 22, 1938, to Waltman
& Dillon (Waltman '826)
[0066] U.S. Pat. No. 2,172,933, dated Sep. 12, 1939, to Daesen
& Bradley (Daesen '933)
[0067] U.S. Pat. No. 2,407,881, dated Sep. 17, 1946, to Hoover
& Hayes (Hoover '881)
[0068] U.S. Pat. No. 2,824,021, dated Feb. 18, 1958, to Cook &
Norteman (Cook '021)
[0069] U.S. Pat. No. 2,940,870, dated Jun. 14, 1960, to Baldwin
(Baldwin '870)
[0070] U.S. Pat. No. 3,078,555, dated Feb. 26, 1963, to McFarland
(McFarland '555)
[0071] The present invention utilizes the teachings of Sorel '510.
Sorel '510 teaches that (page 1, paragraph 2) "It is well known to
chemists and to all persons versed in the physical sciences that a
galvanic-action is produced by the contact of two metals different
in their natures, and that the most oxidizable of these two metals
so brought into contact becomes positively electrified, while that
which is least oxidizable becomes negatively electrified; and also
that when brought into this sate the most oxidizable or positively
electrified metal has a tendency to become oxidized and will
abstract oxygen from compounds containing this agent, while the
least oxidizable of the two metals will be protected from oxidation
although exposed to agents which would oxidize it but for the
contact of the negative metal." (page 1, paragraph 3) "In the scale
of the oxidability of the different metals, commencing with those
which are the most oxidable, it has been found that zinc stands
before iron, and it follows, therefore, that when these two metals
are brought into contact a protecting influence will be exerted
upon the iron by the zinc, and that the rusting of the former metal
will be thereby prevented." (page 1, paragraph 5) " . . . the
application of which my process is dependent for its efficacy . . .
and the various modes which I have devised for carrying the same
into operation. These modes which I have essayed are five in
number, and are as follows: first, applying the zinc to the iron or
steel in the manner in which tin is applied in the process of
tinning . . . " (page 1, paragraph 6) "The first process--that of
coating the articles to be protected with metallic zinc . . . the
articles to be coated must be rendered clean and free from oxide by
processes analogous to those followed in preparing them for
ordinary tinning, such as immersing them in diluted sulphuric . . .
acid . . . The zinc in like manner must be poured in proper
crucibles or other convenient vessels adapted to the nature and
size of the articles to be operated upon . . . The articles to be
coated, after being dipped into the melted zinc, are to be
withdrawn slowly, that too much of the metal may not adhere to
them. They are then to be thrown into cold water, . . . and dried
as quickly as possible, as otherwise they may be injured by the
appearance of dark spots, which it is desirable to avoid. When
chains for cables or for other purposes are being withdrawn from
the zinc they must be shaken until sufficiently cooled to prevent
the links from being soldered together by the melted metal. . . .
The melted zinc being ready and covered with sal-ammoniac, the
chains are to be put into it and suffered to remain there about a
minute. . . . In all cases the purest zinc should be employed."
(page 3, paragraph 1) "I do not claim to be the discover of the
principle of the protection of metals from oxidation by galvanic
action; nor do I claim to be the first to have proposed the
employment of zinc for the preserving of iron therefrom, masses of
zinc having been applied, or it having been proposed to apply it in
masses to steam-engine boilers and probably to other articles with
this intention; but from this my plan or mode of procedure differs
as obviously as it surpasses it in efficiency and in its
applicability to numerous purposes in the arts where application in
masses would be impossible or altogether unavailable." The present
invention incorporates these and other teachings of Sorel '510 in
general and specially Sorel '510's "first-mode".
[0072] The present invention utilizes the teachings of Sumner '374.
Sumner '374 teaches of (page 1, paragraph 1) " . . . an improvement
in the process, method, or methods by which various articles of
iron or steel may be preserved from oxidation or rusting by the
galvanic action produced by zinc (for which process Letters Patent
were granted to M. Sorel . . . ) . . . " (page 1, paragraph 3) "We
take sheets of iron and cover them with tin . . . After having
completed this operation we submit the sheets or plates so prepared
to a like process, with the substitution of zinc for tin . . . When
thus treated the plates or sheets of iron preserve their
malleability unimpaired, and may be bent and otherwise worked as
easily as before they had received such coating--a result which
appears to be due to the interposition of the coating of tin
between the zinc and the iron, by which interposition the chemical
combination of the iron and zinc is prevented." The present
invention incorporates these and other teachings of Sumner '374 in
general and specifically the bending moment resistance provided by
zinc/iron alloy surface layers resulting from use of the Sorel '510
discoveries.
[0073] The present invention utilizes the teachings of Goodyear
'106. Goodyear '106 teaches to (page 1, paragraph 3) " . . . take
any article of metal--say of iron, for instance--which it is
desired to cover in this way and generally roughen its surface, so
that the caoutchouc or gutta-percha will, when vulcanized, adhere
to it more firmly." The present invention incorporates these and
other teachings of Goodyear '106.
[0074] The present invention utilizes the teachings of Morewood
'866. Morewood '866 teaches (page 1, paragraph 4) " . . . to form a
new metallic surface upon sheets of iron or other metal which forms
the basis of the manufacture by depositing the metal which is to
form the surface from its chemical solutions by the galvanic
process; . . . then finish the article by coating the sheets with a
non-metallic material, composition, or varnish which is repellent
of moisture, which may be used at so low a temperature as to leave
the sheet metal as nearly as possible with its original form and
toughness, and which protects the surfaces of the sheets from
oxidation . . . we prefer for this purpose a resinous or such
material . . . " The present invention incorporates these and other
teachings of Morewood '866.
[0075] The present invention utilizes the teachings of Whitling
'787. Whitling '787 teaches that (page 1, paragraph 2) "The plate
of iron to be coated is first . . . immers(ed) . . . in a bath . .
. of . . . acid . . . A second bath . . . zinc . . . " (page 1,
paragraph 3) "The plate is then dipped in the second bath, and,
while wet, is immersed in a third bath of melted tin . . . and
thoroughly coating the same." The present invention incorporates
these and other teachings of Whitling '787.
[0076] The present invention utilizes the teachings of Grey '017.
Grey '017 teaches how (page 1, paragraph 2) " . . . to provide
galvanized iron of more improved quality . . . " (page 1, paragraph
3) "The invention consists in preparing the iron previous to
galvanizing it, in a way calculated to provide a better article in
point of toughness and appearance when finished, the zinc covering
being disposed much more evenly and in large spangles over the
entire surface of the sheet." The iron (page 1, paragraph 7) " . .
. sheets are trimmed to the desired size, and are . . . ready for
pickling in a bath prepared of water and sulphuric acid . . . "
(page 1, paragraph 8) "The object in pickling the iron is to remove
the scale formed on the surface of the iron in the process of
rolling it into sheets, it being absolutely necessary that all the
scale shall be removed, and the surface of the iron perfectly
clean, as when any scale remains it will not be covered in the
process of galvanizing." (page 1, paragraph 9) "After the iron has
remained in the pickle long enough to have removed the scale . . .
the sheets are dipped . . . into the zinc . . . " (page 1,
paragraph 10) "There is a positive injury done the iron by this
process of removing the scale (which is entirely obviated by my
method,) which is produced by acid penetrating the pores of the
iron, when it is exposed too long in the bath, making it brittle or
short in the grain, so that it is easily broken when bent." (page
1, paragraph 11) " . . . the acid is attaching that portion of the
sheet from which the thin scale was removed in the early part of
the process, and eating small holes therein, and wasting away the
iron." (page 1, paragraph 12) "The surface of the iron, as a
natural consequence, is rough, and when it is galvanized, the zinc
will not flow freely or smoothly upon it, which, in my opinion,
prevents the formation of the large spangles, which are desirable."
The present invention incorporates these and other teachings of
Grey '017.
[0077] The present invention utilizes the teachings of Wahl '015.
Wahl '015 teaches that (page 1, paragraph 3) "In coating iron with
zinc . . . the usual process is to first subject the objects of
cast or wrought iron or steel to the process of pickling--that is,
immersing in a bath of dilute sulphuric acid, then in water, then
in a bath of muriatic acid, and, after drying the objects, to
immerse them in the bath of molten zinc . . . The objections to
this process are, first, injury to the iron, and especially if it
be in the form of thin plates; by the corrosive action of the acid
treatment; second, the formation of what is known as `dross` in the
zinc . . . bath, . . . This dross is due to the formation of a
zinc-iron . . . alloy in the bath by the intimate contact of the
iron with the zinc . . . and the formation of this alloy is
promoted by the spongy condition to which the surface of the iron
has been reduced by the acid treatment--a condition which has the
twofold disadvantage of promoting the zinc-iron . . . alloy and of
rendering the adhesion of a proper coating of zinc . . . tedious,
and, in many cases, imperfect." (page 1, paragraph 4) "In carrying
out our invention we entirely discard the acid treatment above
referred to, and adopt any process of mechanical cleansing . . . "
The present invention incorporates these and other teachings of
Wahl '015.
[0078] The present invention utilizes the teachings of Breeding
'655. Breeding '655 teaches that (page 1, paragraph 4) "For some
arts and industries it is essential that a pipe or tube galvanized
on its exterior has its interior surface uncoated or
non-galvanized, to accomplish which is the object of my invention."
(page 1, paragraph 6) "In order to accomplish this result of
galvanized and non-galvanized surfaces, the iron pipe, as it comes
from the mill, and as is well known, has its outer and inner
surfaces covered with scale, grease, &c., is closed at both
ends by stoppers or caps B, and thus immersed in the acid bath, the
effect whereof is to remove the scale, &c., from the exterior
surface only. The pipe is now withdrawn from the bath, and the
stoppers or caps are removed from the pipe, which latter is then
subjected to the action of the coating metal." (page 1, paragraph
7) "It will be seen that the inner surface of the pipe will not
galvanize, owing to the existing or unremoved scale and impurities,
while the outer surface will be galvanized, as usual . . . " The
present invention incorporates these and other teachings of
Breeding '655.
[0079] The present invention utilizes the teachings Ortiz '017.
Ortiz '017 teaches (page 1, line 21) "Many attempts have been made
to provide a ferrous metal with a uniform continuous coating of
aluminum, but these attempts have been unsuccessful. In one
proposed process for the purpose, the ferrous metal has been dipped
in a bath of molten aluminum at a temperature several hundred
degrees above the melting point of aluminum, such process being
based upon a supposed lack of affinity between the ferrous metal
and the aluminum at temperatures nearer the melting point of
aluminum. Other attempts have been made by providing the ferrous
metal with a preliminary film or wash coating of a metal other than
the coating metal. Both these methods have been unsuccessful, the
first method causing the metal to attach the iron and produce
irregular coatings of widely varying form and composition and
partly destroying the outline of the article; while the latter one
produces a coating, not of aluminum, but of an alloy of aluminum
and the wash metal. In the latter case, a coating of pure aluminum
could only be obtained by successive dippings in a series of baths,
making the process commercially impracticable. Salts of heavy
metals have also been used for coating the ferrous metals before
dipping in molten aluminum, but in such case salts are brought into
the molten aluminum which practically prevent the contact between
the metals and thus a complete and continuous coating is not
obtained. The salts of the heavy metals used also react with the
aluminum, the result being a coating not of aluminum, but of an
alloy." (page 1, line 58) "I have discovered a method by which
ferrous articles can be given an aluminum coating in the form of a
dense, poreless layer united to the ferrous metal by an
intermediate layer of iron aluminum alloy, the aluminum being also
uniform, continuous and of a constant characteristic form and
composition." (page 1, line 66) "My process is based upon the
discovery that if a cleaned ferrous article is lowered into a bath
of molten aluminum at such a rate and under such conditions that
the successive portions of the ferrous article are successively
wetted by the molten aluminum, as evidenced by the presence of an
upwardly projecting meniscus at the juncture between the ferrous
article and the bath, a uniform, continuous aluminum coating is
obtained of a constant characteristic form and composition. The
same process may be employed for coating ferrous metals with other
non-ferrous metals or alloys, and the meniscus must be constantly
maintained by so regulating the speed of feeding the article in the
molten bath that the meniscus will not be destroyed or inverted.
The presence of this meniscus will cause oxides or foreign
compounds at the juncture to be washed away from the contacting
surfaces, in such a way that an actual `diffusion joint` is
obtained. By the term `diffusion joint` in this specification, I
mean the joint which occurs when two metals are brought into
contact and interpenetration of one into the other taken place, or
when mutual interpenetration occurs. Neither material need be at or
above its melting point, though either or both may be." (page 1,
line 98) "First, the ferrous article should be cleaned as
thoroughly as practicable from oxides or other impurities on the
surface . . . " (page 2, line 3) "The aluminum is melted,
preferably in either an inert or reducing atmosphere . . . " (page
2, line 14) "The surface of the aluminum bath being as clean as
practicable, the ferrous article is lowered gradually in the molten
aluminum bath, at such a rate that its successive portions are
wetted by the molten metal." (page 2, line 80) " . . . the iron and
molten aluminum unite with a diffusion joint, consisting of a
constant and definite aluminum alloy of characteristic structure
and composition. This alloy forms a continuous homogeneous coating
on the surface of the ferrous metal, uniting the ferrous metal to a
surface layer of pure aluminum, which lies upon the alloy. This
aluminum coating is continuous, compact, dense and bright." (page
2, line 90) "The character of the coating and the joint may be
varied somewhat by varying the temperatures and the period during
which the ferrous metal is held in the bath." (page 2, line 122) "I
have found that by continued high temperature heating of the
article produced by my process, the alloy coating or diffusion
joint will be increased in thickness . . . " (page 3, line 4) "Even
under the wide range of temperatures above described and with wide
variations in time of treatment, the same alloy is formed at the
juncture joint, this alloy being a chemical compound having the
formula FeAL.sub.3." The present invention incorporates these and
other teachings of Ortiz '017.
[0080] The present invention utilizes the teachings of Waltman
'826. Waltman '826 teaches that (col. 1, line 11) "An examination
of a regular one dip . . . " iron article " . . . will generally
reveal a first thin layer of very fine grain structure close to the
steel or iron body . . . consisting probably of FeZn.sub.3, a
second, heavier layer of long needle-like crystals protruding more
or less perpendicularly to the . . . " iron article " . . . and
consisting probably of FeZn.sub.7, and an outside layer or coating
consisting mainly of zinc, with some iron in solution." The present
invention incorporates these and other teachings of Waltman
'826.
[0081] The present invention utilizes the teachings of Daesen '933.
Daesen '933 teaches that (col. 1, line 10) "When a ferrous metal
article . . . is dipped in molten zinc baths at galvanizing
temperatures between 850.degree. to 900.degree. F., the zinc will
alloy with the ferrous metal to form a ferro-zinc alloy coating on
the article. This alloy coating contains iron and zinc in varying
proportions such as FeZn; FeZn.sub.3; and FeZn.sub.7. The iron
content in the alloy decreases with the increase in distance from
the . . . " ferrous article. Thus the inner zone of the coating
adjacent the article may be FeZn; the middle zone may be FeZn.sub.3
and the outer zone FeZn.sub.7 to pure Zn." The present invention
incorporates these and other teachings of Daesen '933.
[0082] The present invention utilizes the teachings of Hoover '881.
Hoover '881 teaches of (col. 1, line 1) " . . . the preparation of
ferrous sheets to receive resinous coatings . . . " (col. 1, line
19) " . . . recently . . . there has been a shift to enamels which
consist of resins of thermo-setting type, or contain large
quantities of such resins . . . " (col. 2, line 1) "Without
desiring to be bound by theory we believe that blistering is caused
by moisture and hydrogen coming from the sheet surface and falling
to escape through the enamel." (col. 2, line 17) "In the newer
types of enamel a thermo-setting resin is used which, with the
vehicle, not only makes the enamel more viscous as applied, thereby
yielding a heavier coating, but in itself undergoes a chemical
change so that it hardens and becomes permanently infusible. This
type of enamel has the advantage of setting much more quickly and
attaining the maximum hardness after a shorter baking operation."
(col. 2, line 40) "In the formation of our improved sheets, the
ferrous sheet metal is galvanized in any suitable way by being
cleaned and treated with molten zinc . . . " (col. 2, line 46) "The
galvanized sheets are then passed through a solution containing
phosphoric acid, zinc phosphate and an oxidizing agent such as
sodium nitrate. This bath applies a coating of zinc phosphate to
the sheet surface." The present invention incorporates these and
other teachings of Hoover '881.
[0083] The present invention utilizes the teachings of Cook '021.
Cook '021 teaches that (col. 1, line 34) "Tight coat hot dip
galvanizing involves the admixture with zinc in the molten coating
bath of another metal or metals whose function is to inhibit the
formation of brittle zinc-iron alloy, which inhibition is a
prerequisite to the production of a tightly adherent coating. . . .
The metal most commonly used is aluminum . . . The added metal is
in very small percentage in relation to the zinc, normally
constituting not over one or two percent by weight of the total
content of the bath." The present invention incorporates these and
other teachings of Cook '021.
[0084] The present invention utilizes the teachings of Baldwin
'870. Baldwin '870 teaches that (col. 1, line 26) "Hot dip
galvanizing of iron and steel to protect the ferrous metal from
corrosion has been practiced on a large scale for more than a
century." The present invention incorporates these and other
teachings of Baldwin '870.
[0085] The present invention utilizes the teachings of McFarland
'555. McFarland '555 teaches that (col. 1, line 16) "It has been
recognized that a zinc-iron alloy surface on steel sheets presently
produced by the heat treatment of galvanized steel sheets is an
excellent base for paint, lacquer, and other high luster paint-type
finishes. However, the intermetallic compounds forming the
zinc-iron alloy, like most intermetallic compounds, are very
brittle, particularly in compression, and can be pressed into many
desired forms only with considerable difficulty and not without
impairing the integrity of the alloy coating." The present
invention incorporates these and other teachings of McFarland
'555.
[0086] The following Metal Vibration and Bonding of Dissimilar
Material(s) Present Art background and review focus on:
[0087] U.S. Pat. No. 11,815, dated Oct. 17, 1854, to Thomin &
Stumer (Thomin '815)
[0088] U.S. Pat. No. 1,269,926, dated Jun. 18, 1918, to Gesell
(Gesell '926)
[0089] U.S. Pat. No. 2,078,910, dated Apr. 27, 1937, to Merrill
(Merrill '910)
[0090] U.S. Pat. No. 2,758,321, dated Aug. 14, 1956, to Westfall
(Westfall '321)
[0091] U.S. Pat. No. 2,797,179, dated Jun. 25, 1957, to Reynolds
(Reynolds '179)
[0092] U.S. Pat. No. 3,257,266, dated Jun. 21, 1966, to Sapper
(Sapper '266)
[0093] U.S. Pat. No. 3,493,550 dated Feb. 3, 1970, to Schmitt
(Schmitt '550)
[0094] U.S. Pat. No. 3,930,639 dated Jan. 6, 1976, to Steinberg, et
al. (Steinberg, et al. '639)
[0095] U.S. Pat. No. 3,936,341 dated Feb. 3, 1976, to Nanoux
(Nanoux '341)
[0096] U.S. Pat. No. 3,998,602 dated Dec. 21, 1976, to Horowitz, et
al. (Horowitz, et al. '602)
[0097] U.S. Pat. No. 4,049,874 dated Sep. 20, 1977, to Aoyama
(Aoyama '874)
[0098] U.S. Pat. No. 4,105,811 dated Aug. 8, 1978, to Horowitz, et
al. (Horowitz, et al. '811)
[0099] U.S. Pat. No. 4,107,228 dated Aug. 15, 1978, to Horowitz, et
al. (Horowitz, et al. '228)
[0100] U.S. Pat. No. 4,158,082 dated Jun. 12, 1979 to Belousofsky
(Belousofsky '082)
[0101] U.S. Pat. No. 4,327,536 dated May 4, 1982, to Ascher (Ascher
'536)
[0102] U.S. Pat. No. 4,789,586 dated Dec. 6, 1988, to Morimura, et
al. (Morimura, et al. '586)
[0103] U.S. Pat. No. 5,219,629 dated Jun. 15, 1993, to Sobolev
(Sobolev '629)
[0104] U.S. Pat. No. 5,641,543, dated Jun. 24, 1997, to Brooks
(Brooks '543)
[0105] U.S. Pat. No. 5,695,867 dated Dec. 9, 1997, to Saitoh, et
al. (Saitoh, et al. '867)
[0106] U.S. Pat. No. 6,543,191 dated Apr. 8, 2003, to Kress (Kress
'191)
[0107] U.S. Pat. No. 6,616,976, dated Sep. 9, 2003, to Montano et
al. (Montano et al. '976)
[0108] The present invention utilizes the teachings of Thomin '815.
Thomin '815 teaches that (page 1, paragraph 2) "A difficulty occurs
in enameling surfaces liable to contract and expand unequally by
heat, or such as expand to an extent which throws them out of
shape, owing to the enamel becoming detached from its intimate
connection with the surface of the metal; . . . " (page 1,
paragraph 3) "It is usual in enameling cast-iron to mix the several
materials of which the enamel is to be composed, fuse them, and
when cooled pulverize and grind them into a thin paste with water.
This is flooded or spread over the metallic surface and treated in
a muffler to a temperature sufficient to vitrify the frit." (page
1, paragraph 4) "Sheet-iron does not maintain its shape, but
becomes cockled by the heat necessary to the process, and hence a
difficulty arises. As the enamel attains a certain degree of
rigidity by the evaporation of the water or other medium of
flotation, the metal wrinkles and the enamel does not adhere with
sufficient tenacity to follow it." (page 1, paragraph 6) "We do not
claim applying the powdered frit to a previous coating of
enamel-paste while the latter is moist, such a process having been
long in use . . . . " The present invention incorporates these and
other teachings of Thomin '815.
[0109] The present invention utilizes the teachings of Gesell '926.
Gesell '926 teaches a (page 1, line 10) " . . . method for
preventing the rusting of iron or steel objects . . . It utilizes
to this effect the protective agent which an electro-positive metal
to iron creates under certain conditions on the said iron or steel
object by means of a galvanic current. Another object of the
present invention is to prepare the iron or steel parts in such a
way that only a very slight galvanic current will be required to
prevent them from rusting." (page 1, line 35) " . . . I make use of
the phenomena of electrolysis which generates when two different
metals are in contact with each other and submerged in a saline
solution, and which creates a protective agent on the
electro-negative metal, while the electro-positive metal is eaten
away. I have found by experiment that when iron is in metallic
contact with zinc, both submerged in the ocean, the iron does not
rust, while the zinc is slowly consumed." (page 1, line 49) "The
rate of consumption of the electro-positive metal is proportional
to the rate with which the water absorbs the protective agent on
the electro-negative metal. The rate of this absorption varies with
the quality of the water and is more rapid when the water is in
motion than when it is quiet." (page 1, line 57) "I explain the
rusting of a painted iron plate submerged in water by the theory
that the paints at present in use are not absolutely waterproof,
thus giving opportunity for minute particles of water to pass
through minute pores or fissures and act upon the metal, causing it
to rust . . . . When the first little spots have begun to rust,
they spread out under the paint and peel it off." (page 1, line 69)
"If such a painted iron plate is in metallic contact with a mass of
zinc, both contacting with a saline water solution, a rusting will
be prevented on the well paint covered parts by the action of the
paint, and on the uncovered parts by the action of the zinc. As
thus the rusting process cannot take a start, the paint is
prevented from peeling off, and the consumption of zinc is slow
because its electrolytic action is confined only to the minute
uncovered spots." The present invention incorporates these and
other teachings of Gesell '926.
[0110] The present invention utilizes the teachings of Merrill
'910. Merrill '910 teaches of a (page 1, col. 2, line 38) " . . .
method of bonding rubber to metal . . . " The present invention
incorporates these and other teachings of Merrill '910.
[0111] The present invention utilizes the teachings of Westfall
'321. Westfall '321 teaches of (page 3, col. 1, line 15) " . . .
molding structural members into a plastic shell so that the members
so molded in become an integral part of the shell." The present
invention incorporates these and other teachings of Westfall
'321
[0112] The present invention utilizes the teachings of Reynolds
'179. Reynolds '179 teaches of (page 3, col. 1, line 12) " . . . a
body of reinforced plastic materials which are laminated so as to
provide a decorative outer layer, which will be reasonable proof
against wear and against damage by different materials which might
come in contact therewith and an inner layer which will impart the
desired mechanical strength to the body as a whole." As such the
Reynolds Device is not intended to be a structural-composite. That
is, the " . . . outer layer . . . " does not provide or enhance the
overall structural capacity of the finished composite. The present
invention incorporates these and other teachings of Reynolds
'179
[0113] The present invention utilizes the teachings of Sapper '266.
Sapper '266 teaches that (page 2, col. 1, line 12) "(b)ecause of
their comparatively low cost and high strength-to-weight ratio,
reinforced plastics, particularly those based on glass
fiber-reinforced polyester systems are rapidly replacing other
materials of construction in the manufacture of many shaped
structures . . . . " (page 2, col. 1, line 39) "A serious
deficiency of glass fiber-reinforced polyester structures . . . is
their poor resistance to the ravages of weathering. This deficiency
manifests itself in the form of surface erosion of the structure
causing a loosening and raising of the reinforcing fibers near the
surface . . . the raised fibers provide multiple paths for the
ingress of water into the body of the structure thus accelerating
hydrolytic degradation. Attempts to correct this deficiency have
included the use . . . of pure resin or resin-rich outer layers of
polyester called gel coats and/or veils . . . " (page 2, col. 1,
line 60) "While these methods . . . somewhat . . . lessen . . . .
the problem . . . they . . . merely postpone rather than eliminate
the trouble inasmuch as the inherently unweatherable and
hydrolytically unstable polyester is still exposed outermost in the
structure." The present invention incorporates these and other
teachings of Sapper '266
[0114] The present invention utilizes the teachings of Schmitt
'550. Schmitt '550 teaches of (page 1, col. 1, line 13) " . . .
thermoplastic polyvalent metal-bridged polymers based on major
amounts of methyl methacrylate . . . . " Schmitt establishes terms
and nomenclatures as relating (page 1, col. 1, line 56) " . . . to
an improved process for effecting such bridging without loss of
thermoplasticity which comprises interfacially contacting a
solution or dispersion of a metal compound with a solution of a
suitable polymer such that the desired bridging is effected. The
term "bridging" as employed herein denotes an extrinsic association
between adjacent linear polymer chains. The association has the
effect of reversibly crosslinking the polymer chains even though
the bridging is accomplished through ionic bonding of the two
chains with a single polyvalent metal ion forming a mutual salt
therebetween. In the classical meaning of the term "crosslinking,"
the union of the two polymer chains is the result of covalent bonds
which lead to thermset polymers. In the present case, the ionic
bonds provide the strengthening effects of cross-links below the
shaping temperature of the polymer but do not interfere with the
mobility of the polymer chains at or above the shaping
temperature." The present invention incorporates these and other
teachings of Schmitt '550.
[0115] The present invention utilizes the teachings of Steinberg,
et al. '639. Steinberg, et al. '639 points out that (page 5, col.
6, line 68) Methyl Ethyl Ketone Peroxide is in fact " . . . fire
resistant . . . . " The present invention incorporates these and
other teachings of Steinberg, et al. '639.
[0116] The present invention utilizes the teachings of Nanoux '341.
Nanoux '341 teaches that (page 3, col. 1, line 18) " . . . it has
not been possible hitherto to produce this combination
satisfactorily because the various methods proposed for producing
adhesion do not succeed in imparting sufficient resistance to
delamination to this combination. Thus, for example, it has been
proposed, in British Pat. No. 866,776 in the name of ARTRITE RESINS
Ltd. of Mar. 12, 1957 to produce containers made of polyvinyl
chloride equipped with an outer layer of reinforced polyester resin
containing a crosslinking monomer (acrylate ester) which exerts a
dissolving effect on polyvinyl chloride. This process in fact leads
to an excellent result when the layer of polyester resin, as is
claimed, is placed outside the container. It has been found,
however, that if the polyester resin is placed inside the
container, the adhesion between the layer of thermosetting resin
and the wall of polyvinyl chloride becomes very uncertain. This
defective result can be explained by the fact that, during their
crosslinking, polyester resins undergo shrinkage. Consequently,
this phenomenon leads to adhesion of a mechanical nature between
the two layers of resin when the layer of polyester resin is placed
outside the reinforced article while it promotes delamination when,
on the other hand, the layer of polyester resin is placed inside
the article. According to German Pat. application No. 1,958,647 in
the name of KARLSKRONA-VARVET A. B. of Nov. 22, 1969, adhesion of a
sheet of plastic such as polyvinyl-chloride to a layer of
thermosetting resin is achieved by using, as the adhesive, a
solution of polymethyl methacrylate in methylene chloride. However,
the laminates produced according to this process have insufficient
resistance to delamination to enable them to be used in practice."
The present invention incorporates these and other teachings of
Nanoux '341.
[0117] The present invention utilizes the teachings of Horowitz, et
al. '602. Horowitz, et al. '602 teaches of a (page 2, col. 2, line
33) " . . . method . . . " whereby a " . . . polymeric substrate is
metallized by the formation of a graft polymer coating on the
substrate with the grafting and polymerization of the coating being
initiated by a very small amount of silver ion. The grafting and
polymerization of the coating takes place in the presence of a
peroxide so that silver ion is regenerated and the reaction is
autocatalytic." The present invention incorporates these and other
teachings of Horowitz, et al. '602.
[0118] The present invention utilizes the teachings of Aoyama '874.
Aoyama '874 teaches of a composite structural architectural precast
concrete panel wherein a " . . . polymerization of the resinous
substance and the hydration of the cement composition are carried
out in the mold simultaneously." (page 4, col. 5, line 59) "This
surprising result is considered to be based on the fact that the
monomer of the acrylate (non-polymerized) and the cross-linking
monomer permeate the layer of the nonsetting cement composition,
and the cross-linking polymerization is carried out at the
surroundings of the inorganic particles, for example, the sand and
gravel particles in the boundary layer thereof, and in the layer of
the cement composition, the hydration of the cement proceeds in the
water containing partially dissolved monomer, and the boundary
layer of the resin and the cement composition is formed as a mixed
layer of monomer, water and aggregates, and by water,
polymerization of the monomer and hydration of the cement proceeds,
with the result that an architectural precast concrete having a
strong adhesive power is produced as one body." The present
invention incorporates these and other teachings of Aoyama
'874.
[0119] The present invention utilizes the teachings of Horowitz, et
al. '811. Horowitz, et al. '811 teaches that (page 2, col. 1, line
14) "Aluminum is an excellent structural material because of its
low cost and great strength per unit weight. Aluminum has chemical
characteristics, however, which make it subject to corrosion,
particularly by salt water and/or salt spray. The corrosion takes
the form of a white rust (aluminum oxide) and the aluminum finish
itself is easily spoiled by scratching or abrasion due to its
inherent softness. Further, the painting of aluminum generally does
not provide satisfactory corrosion resistance since the aluminum
oxide layer under the paint prevents good bonding of the paint to
the aluminum surface. Accordingly, painting is generally not a
satisfactory corrosion inhibitor for aluminum. The principal prior
art method of protecting the finish of aluminum and aluminum alloys
is that of anodizing. The process generally is performed by the
immersion of aluminum in a sulfuric or chromic acid bath with the
aluminum piece being the anode in an electrolytic process. This
anodization forms a hard aluminum oxide coating on the aluminum
surface, but the coating itself is porous and undesirably
absorptive. Accordingly, the aluminum oxide layer formed by
anodization may be further sealed by hydration in hot water.
Another prior art approach is the use of sodium dichromate as a
corrosion inhibitor and seal. The sodium dichromate provides
improved corrosion resistance but leaves the coating a greenish
yellow color. The corrosion inhibiting chromate ions are absorbed
in the aluminum oxide matrix and are sealed in place by the
formation of the hydrate. The greenish-yellow color is undesirable
for many applications. The prior art approaches thus have one or
more drawbacks of unwanted color or lack of sufficient abrasion and
corrosion resistance or stain resistance. Further, these
conventional coating processes are usually inadequate because the
bonding is physical in nature and the coating can become
mechanically dislodged. The porosity of prior art coatings also is
a major problem in preventing corrosion over a long period of time.
Accordingly, it is an object of the present invention to provide a
process for the sealing of aluminum surfaces through the graft
polymerization of monomers to the aluminum surface through the
aluminum oxide on the aluminum surface." The Horowitz method " . .
. provides a process by which a transparent coating is formed by an
in situ graft polymerization of sealing monomers to provide a
chemical bonding through the aluminum oxide on the aluminum
surface. Further, the graft polymerization provides for a side
group interaction for cross-linking. The process of the invention
involves the use of silver ions as graft initiators for the
grafting of monomers and prepolymers to the aluminum surface to be
protected. The polyfunctional monomers and prepolymers which are
bonded to the aluminum are vinyl monomers and polyurethane and
epoxy resins and are believed to chemically bond to the aluminum
oxide on the substrate. The monomers are preferably acrylic
monomers having one or more hydroxy, carboxy, glycidyl or
aziridinyl groups. The epoxy resins are aliphatic, cycloaliphatic
or aromatic together with appropriate curing agents. The
polyurethane contains up to about 6%--NCO-- groups. The protective
coating is very resistant to corrosion because of the chemically
bonded polymeric coating and the cross-linked nature of the coating
itself. It has been found that the presence of a small amount of a
peroxide regenerates silver ion and also provides free radicals for
further polymerization within the polymeric coating, thus acting as
a catalyst for the process and accelerating the
polymerization."
[0120] "The process for coating aluminum panels, for example,
comprises the steps of cleaning the panels and then immersing them
in a solution containing monomers, prepolymers and the silver ion
and peroxide. The panels upon removal from the monomer and
prepolymer solution are then cured and dried. The epoxy, glycidyl,
carboxyl, hydroxyl, isocyanate, acrylic and/or amine groups in the
coating solution polymerize and cross-link to form an impervious
protective coating. The coatings formed on the aluminum are clear
and transparent and provide excellent corrosion resistance to salt
water and the like. Further, the polymeric coating on the aluminum
substrate provides a good base for the application of paints or
dyes to the aluminum, if desired." The present invention
incorporates these and other teachings of Horowitz, et al.
'811.
[0121] The present invention utilizes the teachings of Horowitz, et
al. '228. Horowitz, et al. '228 teaches that (page 2, col. 1, line
7) "This invention pertains to novel paint compositions and the
painted objects produced from the use of such compositions. More
particularly, this invention relates to a universal paint
composition which is capable of providing a superior surface
coating chemically bonded to the object coated therewith,
irrespective of the nature of the material from which the object is
formed."
[0122] "It is well-known in the art that many materials which are
important in the production of manufactured articles and which
require a finished or painted surface are difficult to paint
effectively. Such materials as steel, aluminum and certain plastics
exhibit little adhesion for many conventional paint formulations
accordingly, normally require the utilization of paints which are
specially tailored for the specific substrate to be painted or the
utilization of a separate adhesion-promoting primer layer between
the substrate and the paint layer in order to produce a painted
surface meeting minimum service requirements with respect to
chemical and mechanical properties. Wholely apart from such
adherence difficulties, separate tailoring of paints for different
substrates has generally been required in order to achieve the
mechanical and chemical properties which are necessitated both by
the differing physical characteristics of the substrate and the
diverse environments to which the coated objects are exposed in
use." "The prior art, see for example, Bragole, U.S. Pat. No.
3,764,730 and Burlant, U.S. Pat. No. 3,437,514, discloses
compositions and processes for improving the adherence of paint to
various substrates by employing unsaturated monomers or polymers in
conjunction with electron beam or ultraviolet radiation to generate
cross-linking reactions between certain polymers. Such techniques,
of course, require the use of special equipment and do not
automatically produce paints which are universally applicable to a
variety of substrates. Horowitz, U.S. Pat. Nos. 3,401,049 and
3,698,931 describe chemical processes for intimately bonding vinyl
monomers to a substrate utilizing silver or selected silver
compounds to generate free radicals on the substrate surface.
However, the utilization of such molecular grafting techniques does
not, in and of itself, result in a universal paint
composition."
[0123] "It is an object of the present invention to provide novel
paint compositions which may be employed to produce surface
coatings which may be intimately bonded to any of a wide variety of
substrates."
[0124] "It is another object of the invention to provide universal
paint compositions exhibiting mechanical and chemical properties
such that they have utility on a broad spectrum of substrate
materials and the materials coated therewith may be employed in
diverse environments."
[0125] "Yet, another object of the invention is to provide painted
objects in which the paint or coating is chemically bonded to the
surface of the object." The present invention incorporates these
and other teachings of Horowitz, et al. '228
[0126] The present invention utilizes the teachings of Belousofsky
'082. Belousofsky '082 teaches (page page 5, col. 4, line 17) " . .
. structure has the advantages of the outer reinforced laminate of
fiberglass and the advantages of the inner cementitious
ferro-cement structure 16. These two structures are integrally
secured and coupled to each other so that the integral structure
can be used for a wide variety of purposes including that of boats,
barges and other marine structures as well as for other
ferro-cement applications including decorative building panels,
storage tanks whose molded similar sections can be assembled in the
field, and for complete structures such as dome sections and the
like which can be molded in a factory and assembled on site."
[0127] "The coupling of the fiberglass laminate to the ferro-cement
structure (or vice versa) is provided by a device which has
separate elements which serve to reinforce respectively the
fiberglass laminate and the armature of the cement structure. These
two elements of the coupling device are themselves interengaged and
formed in a strong connection which is enhanced by the reinforcing
bonding of the fiberglass tape in the fiberglass laminate. Thus,
the tying wires 26 for the reinforcing armature of the ferro-cement
structure are anchored to the fiberglass laminate 10 by the
fiberglass strips 24, which in turn reinforce the fiberglass
laminate."
[0128] "In the fabrication process of the outer laminate 10, a
conventional fiberglass mold 11 (FIG. 2) is prepared in a normal
manner, and its molding surface is coated with wax and polyvinyl
alcohol or other acceptable parting agents for easy release of the
molded object from the mold. A gelcoat 12 of desired thickness
(e.g., 20-30 mils) and color is applied to the prepared mold
surface and then cured. The unreinforced gelcoat 12 is then
reinforced with a desired thickness of fiberglass matt, cloth or
fiberglass woven roving 13 which varies for different strengths of
fiberglass laminate. This reinforcement 13 is bonded with polyester
resin 14 (e.g., the same as that used for the gelcoat 12) to the
previously applied gelcoat 12. The desired number of reinforced
layers (which varies with the application of the structure being
molded) of cloth or roving 13 and resin 14 are so applied and
cured. Up to this point the described method is generally similar
to that of conventional structure molding of fiber-reinforced
plastic." The present invention incorporates these and other
teachings of Belousofsky '082.
[0129] The present invention utilizes the teachings of Ascher '536.
Ascher '536 teaches of (page 4, col. 1, line 37) " . . . a
composite building panel which comprises at least one metal
reinforcing member; a layer comprised of glass fiber, said layer
being fastened to said metal reinforcing member(s); and a
three-dimensional, crosslinked polyester layer which abuts said
fiberglass layer." The present invention incorporates these and
other teachings of Ascher '536.
[0130] The present invention utilizes the teachings of Morimura, et
al. '586. Morimura, et al. '586 teaches that (page 4, col. 1, line
21) "(w)ith the popularization of vehicles such as automobile,
railroad, airplane and the like, and machines such as office
machine, electric goods and the like, countermeasures against
noises and vibrations generated from these vehicles and machines
have recently been highlighted as an urgent subject. In particular,
it has strongly been demanded to reduce noises and vibrations
generated from the vibration members such as members (oil pan,
engine cover, ceiling member, floor member, etc.) arranged around
motorcar engine, home electric appliances, metal working machines
and the like. For this end, many vibration damping metal panels
have been proposed or sold in markets up to the present." The
present invention incorporates these and other teachings of
Morimura, et al. '586.
[0131] The present invention utilizes the teachings of Sobolev
'629. Sobolev '629 teaches that (page 9, col. 1, line 18) "This
invention relates to the field of structural laminates, and in
particular to sandwich laminates comprising two metal sheets and a
resin core. This invention also relates to the field of trailer
body construction."
[0132] The Sobolev " . . . invention relates to structural
laminates which comprise two metal sheets or two metal skin layers
with a polymer core disposed between and attached to each of the
inside surfaces of the metal sheets. The laminates of this
invention have improved structural strength compared to prior
laminates of this type. The laminates of this invention are also
useful in decorative and protective applications as well as
structural applications."
[0133] "In the field of laminates, metal-resin-metal laminates are
disclosed in U.S. Pat. No. 4,313,996 to Newman, et al. and U.S.
Pat. No. 4,601,941 to Lutz, et al. Additional laminates are
disclosed in U.S. Pat. No. 3,382,136 to Bugel, et al., U.S. Pat.
No. 3,392,045 to Holub, U.S. Pat. No. 3,455,775 to Pohl, et al.,
U.S. Pat. No. 3,594,249 to Mueller-Tamm, et al., U.S. Pat. No.
3,623,943 to Altenpohl, et al., U.S. Pat. No. 3,655,504 to
Mueller-Tamm, et al., U.S. Pat. No. 3,952,136 to Yoshikawa, et al.,
U.S. Pat. No. 4,330,587 to Woodbrey, U.S. Pat. No. 4,369,222 to
Hedrick et al., U.S. Pat. No. 4,416,949 to Gabellieri, et al., U.S.
Pat. No. 4,424,254 to Hedrick et al., U.S. Pat. No. 4,477,513 to
Koga, and U.S. Pat. No. 4,594,292 to Nagai, et al. In these
references, a property which is generally important is that the
laminates be formable, particularly thermoformable. Other
properties which have been important for metal-resin-metal
laminates have been the resistance of the metal skin to heat,
weather, chemicals and impact, as well as the metal skin's
hardness, impermeability and strength. Multi-layer laminates have
been made with multiple, alternating layers of resin and metal.
Laminates in this field have been used also for heat insulation and
vibration damping."
[0134] "In U.S. Pat. No. 3,499,819 to Lewis, the resin core is a
polypropylene which contains a foaming agent additive to cause the
polypropylene to form a foam between the metal layers. In U.S. Pat.
No. 3,560,285 to Schroter, et al. a mixture of polyether polyols is
reacted with polyisocyanate and a blowing agent to form foamed
urethane cores between metal layers. U.S. Pat. No. 4,421,827 to
Phillips discloses metal-clad articles which use a combination of
thermosetting resins and particular adhesives to bond a resin layer
to a metal facing."
[0135] "As disclosed by Vogelesang (Ind. Eng. Chem. Prod. Res. Dev.
1983, 22, 492-496) aluminum laminates with high tensile strength
and fatigue resistance have also been made with multiple core
layers of aramid fiber-reinforced epoxy resins. These aluminum
laminates, known as "ARALL" laminates, have been developed for use
as aircraft skins. See also U.S. Pat. Nos. 4,489,123 and 4,500,589
to Schijve, et al." The present invention incorporates these and
other teachings of Sobolev '629.
[0136] The present invention utilizes the teachings of Brooks '543.
Brooks '543 teaches (col. 1, line 43) "It has been found that with
the prior art processes for preparing the zinc surface for the
finished coating, typically by sandblasting, silica particles
(impurities) become embedded in the zinc layer. These silica
particles subsequently are oxidized and the oxidation reaction
results in corrosion, i.e. cracking and peeling of the surface.
That is, the prior art processes generally treat the zinc surface
with materials which remain embedded in the zinc layer. These
materials are impurities in the zinc coating and form oxidation
sites which are the basis for the subsequent corrosion of the top
coating." (col. 1, line 62) "Broadly the invention comprises a
method for preparing galvanized steel stock for the application of
a top coating. As is understood in the art, for galvanized steel
there are typically four layers in the zinc coating. A first eta .
. . layer which interfaces with the steel surface, a zeta . . .
layer, a delta . . . layer and then finally a gamma . . . layer."
(col. 2, line 29) "The present invention broadly embodies a
galvanized coating process and particularly an architectural finish
which provides more than twenty years of protection against more
than 10% surface rust in an ambient environment, such as outdoor
ornamental fence and railing. In a preferred embodiment the steel
should contain carbon below 0.25%, phosphorous below 0.5% and
manganese below 1.35%. The pre-treatment comprises steel members
and assemblies that have been dipped utilizing a dry kettle process
and a bath of molten zinc containing nickel and other
state-of-the-art alloys designed to address the particular steel
composition and to ensure homogeneous metallurgical growth and
greater corrosion resistance in the hot dipped galvanizing
process." (col. 2, line 44) "Within twelve hours of galvanizing,
the coated surface is treated to impart to the surface a
pebble-like or grain-like surface of substantial uniformity. A
metallurgically compatible blasting material, specifically zinc
pellets, are employed to remove the .gamma. outer layer and to form
the pebble-like surface in the delta layer. This ensures that in
the preparation of the surface no impurities are incorporated into
the layer which would later form a site for galvanic action
(rusting)." The present invention incorporates these and other
teachings of Brooks '543.
[0137] The present invention utilizes the teachings of Saitoh, et
al. '867. Saitoh, et al. '867 teaches of (Abstract) "A reinforcing
and vibration-damping material has a laminate body which includes a
constraining layer acting to reinforce an adherend to which the
material is to be applied, a vibration-damping layer acting to damp
vibrations in the adherend and a binder layer interposed between
the constraining layer and the vibration-damping layer. Further, a
hardenable pressure sensitive adhesive layer is formed on the
vibration-damping layer of the laminate body, and a release liner
is placed around the hardenable pressure sensitive adhesive layer.
The constraining layer exhibits the advantageous effect of
reinforcing the adherend, and comprises, for example, a hard
material such as a metal. The binder layer comprises a pressure
sensitive adhesive, a bonding agent or a hardenable pressure
sensitive adhesive. The vibration-reinforcing layer comprises a
viscoelastic material containing unvulcanized rubber and a
vulcanizing agent for example. The hardenable pressure sensitive
adhesive layer comprises a hardenable pressure sensitive adhesive
which is tacky in the uncured state but has a strong adhesive force
when it is cured by heating, irradiation or being blocked from air.
Thus constructed, the reinforcing and vibration-damping material
has the advantageous effects of damping vibrations in and
reinforcing the adherend." The present invention incorporates these
and other teachings of Saitoh, et al. '867.
[0138] The present invention utilizes the teachings of Kress '191.
Kress '191 teaches of a structural composite (page 16, col. 1, line
54) " . . . compris(ing) of an outer ceramic filled gelcoat layer
and a fiber reinforced filled resin layer and are attached to the
respective tread surfaces and landing surface using fasteners. The
fasteners preferably are captured in part in each tread member and
landing member during molding so as to be integral therewith."
Kress achieves shear-transfer by means of mechanical " . . .
fasteners . . . ", as shown in Kress FIG. 5." The present invention
incorporates these and other teachings of Kress '191.
[0139] The present invention utilizes the teachings of Montano et
al. '976. Montano et al. '976 teaches of (col. 1, line 9) "The
present invention is directed to a method of improving adhesion
between metal and polymeric materials. More specifically, the
present invention is directed to a method of improving adhesion
between metal and polymeric materials by treating the metal with an
epoxy resin following an adhesion promotion step." (col. 5, line 6)
"a process and composition for improving the adhesion between a
metal surface and a polymeric material by treating the metal
surface with an adhesion promotion composition followed by
contacting the treated metal surface with an epoxy resin
composition. The epoxy resin composition may be aqueous based, or
organic based. The epoxy resin composition makes the metal surface
more accessible to contact with a polymeric material that is coated
on the metal surface. After the treated metal surface is
post-treated with the epoxy resin composition, the polymeric
material is placed on the surface of the metal to form a high
integrity bond between the metal surface and the polymer material.
Advantageously, the method and composition of the present invention
provide for improved adhesion between a metal surface and a
polymeric material as compared with known adhesion promoting
processes. Accordingly, the adhesion between the metal surface and
the polymeric material is such that . . . using the method of the
present invention may be employed . . . without concern that the
polymeric material may delaminate or peel from the metal surface."
The present invention incorporates these and other teachings of
Montano et al. '976
[0140] The following Structural Iron and Steel Present Art
background and review focus on:
[0141] U.S. Pat. No. 826, dated Jul. 9, 1838, to Johnson (Johnson
'826)
[0142] U.S. Pat. No. 869, dated Aug. 3, 1838, to Alger (Alger
'869)
[0143] U.S. Pat. No. 22,864, dated Feb. 8, 1859, to Gardiner
(Gardiner '864)
[0144] U.S. Pat. No. 51,724, dated Dec. 26, 1865, to Jenkins
(Jenkins '724)
[0145] U.S. Pat. No. 178,460, dated Jun. 6, 1876, to Pauly (Pauly
'460)
[0146] U.S. Pat. No. 199,973, dated Feb. 5, 1878, to Hadfield
(Hadfield '973)
[0147] U.S. Pat. No. 390,969, dated Oct. 9, 1888, to Hooper &
Clark (Hooper '969)
[0148] U.S. Pat. No. 1,731,346, dated Oct. 15, 1929, to Meehan
(Meehan '346)
[0149] U.S. Pat. No. 1,844,994, dated Feb. 16, 1932, to van Boyen
(van Boyen '994)
[0150] U.S. Pat. No. 2,796,373, dated Jun. 18, 1957, to Overum
(Overum '373)
[0151] U.S. Pat. No. 3,951,697, dated Apr. 20, 1976, to Sherby,
Young, Walser & Cady, Jr. (Sherby et al. '697)
[0152] U.S. Pat. No. 4,272,211, dated Jun. 9, 1981, to Sabel (Sabel
'211)
[0153] The present invention utilizes the teachings of Johnson
'826. Johnson '826 teaches (page 1, paragraph 1) " . . . a new and
useful Improvement in the Art of Increasing the Strength of
Wrought-Iron and Steel . . . " (page 3, claim 2) "The increasing of
the strength of bars, rods, or plates of iron by drawing them while
hot through the rolls by mechanical power . . . . " The present
invention incorporates these and other teachings of Johnson
'826.
[0154] The present invention utilizes the teachings of Alger '869.
Alger '869 teaches of (page 1, paragraph 2) " . . . giving to the
iron-work of the whole body of the plow, consisting of the
mold-board, land-side, share, movable or permanent points, and
other parts requiring it, that malleability which will allow of its
being altered in shape in the same way in which wrought-iron may be
altered, and at the same time giving to all the cutting-edges, and
to such other parts as from their exposure to wear may require it,
the necessary degree of hardness and temper and the capability of
being softened, drawn out, and again hardened and tempered whenever
it may be desired." (page 1, paragraph 3) "I cast the respective
parts of the plow to be made of iron from any of the known
patterns, and I then subject those parts to the well-known process
of annealing by which cast-iron is rendered malleable. Having
carried this process to the necessary extent by which the iron is
brought into that state in which it is susceptible of being
hardened and tempered like steel, I then harden such of the
cutting-edges and other operating parts as may require it, and
temper the same in the manner in which steel is ordinarily hardened
and tempered. I thus obtain a plow which, while it can be
manufactured at but little cost, will possess all the useful
properties of a plow the body of which is made of wrought-iron, and
its cutting edges and points and such other parts as are most
subject to wear laid with steel." The present invention
incorporates these and other teachings of Alger '869.
[0155] The present invention utilizes the teachings of Gardiner
'864. Gardiner '864 teaches of (page 1, paragraph 1) " . . . a new
and useful process for the treatment of cast-steel while passing
from the molten to the hardening condition for the purpose of
making unmanufactured ingots or other unmanufactured forms of steel
of a peculiarly soft, tough, and malleable quality . . . " (page 1,
paragraph 3) "The nature of my discovery and invention does not
consist in the gradual and prolonged cooling of the metal after
melting for the purpose aforesaid; but it consists in the process
of pouring the melted metal into intensely-heated molds and placing
them immediately into the heated oven or furnace, then to cool and
congeal away from the external atmosphere to a cherry-red heat, and
then immediately plunging the ingots or bars into the highly-heated
oil and retaining them immersed in it for a considerable period, as
described." The present invention incorporates these and other
teachings of Gardiner '864.
[0156] The present invention utilizes the teachings of Jenkins
'724. Jenkins '724 teaches of having (page 1, paragraph 2) " . . .
discovered that when the substance known in the arts as malleable
cast-iron is submitted to a certain process, to be hereinafter
described, it acquires entirely new properties never heretofore
found in malleable cast-iron. It is rendered more tough and becomes
as hard as hardened steel, so that articles requiring such
properties, and which heretofore have been made of steel, and which
could only be made of steel at great expense, can be produced of
this new substance at much less cost, as they can be cast of the
form required, subjected to the usual and well-known process of
rendering cast-iron malleable, and then subjected to the process to
be hereinafter described, which imparts to it the new and required
properties of toughness and steel-like property of hardness." (page
1, paragraph 3) "The articles desired to be produced are cast of
the form desired in the usual way of cast-iron, and then is well
known as `malleable cast-iron,` and then, whether in the rough or
smooth state, I heat then to what is known as a `cherry-heat` heat,
and at or about that heat hammer them to compact the metal. After
this I heat them up again to a cherry-red heat if during the hammer
operation the temperature has been materially reduced. I then
sprinkle over the surface of them a composition consisting of seven
parts, by weight, of prussiate of potash and one part by weight of
charcoal well pulverized and mixed, and again subject them to heat
until the said composition disappears, taking care to heat them up
again to about a cherry-red heat and at that heat plunge them in a
liquid bath . . . . When taken out this solution the malleable iron
will be found to have been materially changed in its properties, to
have become tough and as hard as hardened steel." The present
invention incorporates these and other teachings of Jenkins
'724.
[0157] The present invention utilizes the teachings of Pauly '460.
Pauly '460 teaches that (page 1, paragraph 5) "When a steel bar is
hardened throughout it may be broken in pieces by a sharp blow of
sufficient force, and is consequently worthless for the purpose. To
meet the difficulty the bars have been made partly of steel and
partly of iron, the steel exterior covering an interior plate of
wrought-iron, which, of course, remained unaffected by the
hardening process, and consequently prevented the bar from being
broken by concussion. This construction is expensive, and does not
meet the difficulties as fully as they are met by my improved bar .
. . " (page 1, paragraph 7) "The bar A, when heated to a bright
cherry-red, is placed between the straight bars . . . of the
dipping-frame. Those faces of the bars . . . which are in contact
with the bar A are made somewhat narrower than said bar, so that a
little of each edge of the bar A is exposed, to come directly in
contact with the water in the dip-trough . . . . " "The effect of
the immersion in water under these circumstances is to render the
edges a very hard, so that the hardest saw or file can have little
effect upon them, and the middle a' is left soft . . . and will
prevent fracture by concussion." The present invention incorporates
these and other teachings of Pauly '460.
[0158] The present invention utilizes the teachings of Hadfield
'973. Hadfield '973 teaches taking (page 1, paragraph 3) " . . .
either molten crucible, Bessemer, Siemens-Martin, or any other
cast-steel the temper and quality of which render it suitable for
the purpose, and pour such molten metal either into a suitable
metallic mold or molds into a sand or other suitable composition
mold or molds. I cast such shells hollow . . . . " . . . "When so
cast such steel shells are of an extremely brittle and crystalline
character, and of uniform temper throughout. They are therefore too
brittle for the purpose of piercing armor-plates . . . to obviate
this disadvantage I subject such shells to an annealing process,
which, by reducing the carbon contained therein to any desired
ratio, modifies and alters the material by causing a more perfect
cohesion of the particles, and consolidating the atoms or molecules
into a dense, close, fine-grained steel, and, by eliminating all
brittleness therefrom, greatly increases the strength and density
of the shell." (page 1, paragraph 5) "One of the principal
advantages possessed by projectiles so manufactured is that the
steel is not subjected either to hammering, forging, rolling, or
any other mechanical treatment as hitherto practiced, thus
effecting a considerable economy in the time and labor necessary
for their manufacture," The present invention incorporates these
and other teachings of Hadfield '973.
[0159] The present invention utilizes the teachings of Hooper '969.
Hooper '969 teaches to (page 1, line 16) " . . . produce a
cast-iron blank of a shape approximating that of the article when
finished, but of considerable and uniform thickness at that portion
which is subsequently to form the steel cutting edge or edges . . .
. The hard casting or blank is . . . packed in iron scale, hematite
ore, or other oxidizing agent, (as in the ordinary annealing
process for converting cast-iron into malleable iron,) and inserted
in an annealing-oven, where it is subjected to the usual
temperature incident to the process of annealing. The annealing
process thus begun is, however, interrupted at about two-thirds of
the ordinary period which would be required to convert the article
treated into malleable iron, (which of course will differ according
to the character of the cast-iron composing it,) and the casting is
removed. The casting will then be found to be partially
decarbonized and in a uniform manner along its outer edges, which
retain from one and a half to two per cent of carbon. These edges,
however, have still the coarse grain or structure of the original
cast-iron, and are therefore unsuitable to be sharpened and
tempered at once. We therefore, after removing the blanks from the
annealing-ovens, heat them to a cherry-red heat and condense the
grain at the edges by blows of a hammer, at the same time working
the blank out into the shape of the finished article by . . . if
need be, by grinding. The blanks are thereupon reheated to the
required temperature, depending upon the thickness of the . . .
edge and the amount of carbon retained, and the edges are tempered
by being immersed in the heated condition in water, oil, or other
tempering-liquid, thereby effecting the desired molecular change
and distribution of the carbon essential to . . . " the article.
The present invention incorporates these and other teachings of
Hooper '969.
[0160] The present invention utilizes the teachings of Meehan '346.
Meehan '346 teaches of (page 1, line 5) " . . . a new and improved
method for heat treating cast iron whereby improved physical
properties are obtained . . . these results being obtainable
primarily by reason of the character of the iron treated." (page 1,
line 72) "The heat treatments will, of course, vary depending upon
the result desired." (page 2, line 24) this iron contains . . .
manganese as a neutralizing agent for the sulphur . . . physical
characteristics of this metal
2 Tensile strength 50,000 to 60,000 pounds per square inch.
Elongation Nil. Reduction of area Nil. Brinell hardness 320 to 360.
. . . "
[0161] (page 2, line 48) "In heat treating this cupola iron two
slightly different methods are used: (1) The castings are placed in
an oven and heated as quickly as quickly as possible to
approximately 1650.degree. F. at which temperature they are held
for from 20 to 25 hours. The casting are then remove and cooled at
room temperature. After this treatment, the castings show the
following physical properties:
3 Tensile strength 80,000 to 90,000 pounds per square inch.
Elongation 1% to 11/2 % Reduction of area 1% to 2% Brinell hardness
220 to 240. . . . "
[0162] (page 2, line 66) "(2) If the casting made from cupola iron
is to be given somewhat different physical properties, such as
greater malleability and softness, a slightly varied heat treatment
is followed. In this case, the castings are placed in a furness and
heated as quickly as possible to 1650.degree. F., at which
temperature they are held from 20 to 25 hours. The castings are
then allowed to cool very slowly, preferably at a rate not in
excess of 10.degree. per hour, until the furness has reached a
temperature of approximately 1000.degree. F. The castings are then
removed and are allowed to cool at room temperature. This heat
treatment results in the following physical properties:
4 Tensile strength 45,000 to 55,000 pounds per square inch.
Elongation 4% to 6% Reduction of area 5% to 7% Brinell hardness 120
to 150. . . . "
[0163] (page 2, line 93) "The effect of the calcium upon these heat
treatments has been found to be very definite. For example, white
iron test bars were all made from the same ladle of iron. This
white iron without treatment by calcium and not heat treated
showed:
5 Tensile strength 24,700 pounds per square inch. Brinell 402. . .
. "
[0164] (page 2, line 105) "The same white iron not treated with
calcium and given the first (1) heat treatment showed the following
characteristics:
6 Tensile strength 43,800 pounds per square inch. Brinell 394. . .
. "
[0165] (page 2, line 113) "The same metal without the calcium, and
given the second (2) heat treatment showed the following:
7 Tensile strength 48,700 pounds per square inch. Brinell 202. . .
. "
[0166] (page 2, line 122) "In neither case was there an elongation
or reduction of area apparent. The calcium treated metal given the
first (1) treatment showed the following characteristics:
8 Tensile strength 62,100 pounds per square inch. Brinell 302. . .
. "
[0167] (page 3, line 1) "Given the second (2) treatment, the metal
treated by calcium disclosed the following characteristics:
9 Tensile strength 49,500 pounds per square inch. Elongation 4.7. .
. . "
[0168] (page 3, line 9) "It has also been found that the calcium
employed in the form of calcium silicide will materially effect the
heat treatment. The calcium silicide treated white metal shows the
following characteristics, when not given the first (1) heat
treatment
10 Tensile strength 29,700 pounds per square inch. Brinell 402. . .
. "
[0169] (page 3, line 20) "When this calcium silicide metal was
given heat treatment (1) it showed:
11 Tensile strength 83,700 pounds per square inch. Brinell 212. . .
."
[0170] (page 3, line 33) "When given the second (2) treatment, the
calcium silicide treated metal shows:
12 Tensile strength 44,800 pounds per square inch. Elongation 7.8.
Brinell 95. . . ."
[0171] (page 3, line 129) " . . . in the absence of other
neutralizing agents for sulphur, or any other element in the
mixture, it would be necessary to use a greater amount of calcium
or other alkaline earth metal. The metal then may be given either
of the following heat treatments: (1) The castings are placed in a
furnace and heated as quickly as possible to 1650.degree. F. At
this temperature they are held for at least approximately 16 hours,
and then immediately withdrawn and allowed to cool at room
temperature. The physical characteristics of castings thus treated
are:
13 Tensile strength 90,000 to 110,000 pounds per square inch.
Elongation 11/2% Reduction of area 11/2% Brinell hardness 200 to
230. . . ."
[0172] (page 4, line 23) "If softer and more ductile castings are
desired at the sacrifice of some tensile and transverse strength,
the following heat treatment (2) is employed. (2) The castings are
placed in a furnace and heated as quickly as possible to
1650.degree. F. This temperature is maintained for at least
approximately 16 hours when the castings are allowed to cool slowly
in the furnace, preferably at a rate not exceeding 100 per hour to
1000.degree. F., and thereafter the castings are allowed to cool at
room temperature. This slightly varied heat treatment for calcium
treated cupola iron produces the following physical
characteristics:
14 Tensile strength 55,000 to 65,000 pounds per square inch.
Elongation 6.9% Reduction of area 10% to 12% Brinell hardness 100
to 135. . . ."
[0173] (page 4, line 96) "By `white iron` is meant such castings as
are substantially free from graphitic carbon. By `gray iron` is
meant castings in which more or less graphite is present. By
`molten white iron` is meant such molten iron as will produce
castings substantially free from graphitic carbon, and by `molten
gray iron` is meant such molten iron as will produce castings
containing more or less graphitic carbon." The present invention
incorporates these and other teachings of Meehan '346
[0174] The present invention utilizes the teachings of van Boyen
'994. Van Boyen '994 teaches that (page 1, line 6) "Articles
manufactured from hard or mild steel, which must undergo a cold
deformation, also undergo a substantial reduction in toughness or
tenacity Cold deformation consists in working the metal at a
temperature which is below the temperature of recrystallization.
Recrystallization is that change in structure which is produced in
cold worked material by annealing the same below the Ac.sub.3
point. (page 1, line 20) "It may further be noted that ageing of
said cold deformed articles further reduces the toughness and
tenacity thereof." The present invention incorporates these and
other teachings of van Boyen '994.
[0175] The present invention utilizes the teachings of Overum '373.
Overum '373 teaches that (col. 2, line 3) "The prior art is replete
with disclosures of the production of malleable iron cast products
in which an iron casting that is termed to be more or less a white
iron casting is annealed and then heat treated to obtain carbon in
the combined form. The tensile strength obtained in the prior art
methods as far as is known, has a general maximum of 100,000
p.s.i." (col. 2, line 14) "In accordance with the method fully set
forth hereinafter, the present invention results in the production
of a casting that is of such improved tensile strength that this
factor has been increased to 200,000 p.s.i. and somewhat above."
The present invention incorporates these and other teachings of
Overum '373.
[0176] The present invention utilizes the teachings of Sherby et
al. '697. Sherby et al. '697 teaches of a (col. 10, line 42) " . .
. microstructure . . . " with (col. 10, line 44) " . . . the
presence of proeutectoid cementite in spheroidized form and a
transformation product consisting of fine pearlite. (col. 10, line
48) "In compression tests at room temperature, the plate exhibited
a yield strength of 190 ksi . . . . " The present invention
incorporates these and other teachings of Sherby et al. '697.
[0177] The present invention utilizes the teachings of Sabel '211.
Sabel '211 teaches of a (col. 1, line 54) " . . . wear-resistant
slab . . . characterized in that it includes a hard wear-resistant
material having a hardness of more than 400 Brinell and being in
the form of granules, these granules being cast into a material
which serves as a bonding agent, such as e.g. synthetic resin,
ceramic materials, rubber or a combination of said materials."
(col. 2, line 29) "The slab . . . is composed from a wear-resistant
material, preferably a martensite chromium/nickel alloyed cast
iron." and " . . . a synthetic resin ceramic material in which the
resin component is one of a number of thermosetting resins such as
exoxy resin, polyester resin, phenolic plastic, aminoplastic or
polyimide resin." (col. 3, line 46) "As a example may be mentioned
that in casting sheet metal having a thickness of 15 millimeter one
obtains an HB hardness of between 650 and 700, whereas by quenching
martensite cast iron to form granules it is possible to achieve an
estimated hardness of up to as much as HB 1000." The present
invention incorporates these and other teachings of Sabel '211.
[0178] The following Structural Fiber Present Art background and
review focus on:
[0179] U.S. Pat. No. 214,085, dated Apr. 8, 1879, to Beck (Beck
'085)
[0180] U.S. Pat. No. 232,122, dated Sep. 14, 1880, to Hammesfahr
(Hammesfahr '122)
[0181] U.S. Pat. No. 354,788, dated Dec. 21, 1886, to Hickley
(Hickley '788)
[0182] U.S. Pat. No. 2,133,238, dated Oct. 11, 1938, to Slayter et
al. (Slayter et al. '238)
[0183] U.S. Pat. No. 3,255,875, dated Jun. 14, 1966, to Tierney
(Tierney '875)
[0184] U.S. Pat. No. 3,627,466, dated Dec. 14, 1971, to Steingiser,
Phillips & Cass (Steingiser '466)
[0185] U.S. Pat. No. 3,627,571, dated Dec. 14, 1971, to Cass &
Steingiser (Cass '571)
[0186] U.S. Pat. No. 4,842,923, dated Jun. 27, 1989, to Hartman
(Hartman '923)
[0187] U.S. Pat. No. 5,324,563, dated Jun. 28, 1994, to Rogers,
Crane & Rai (Rogers '563)
[0188] The present invention utilizes the teachings of Beck '085.
Beck '085 teaches of (page 1, paragraph 5) "A flat layer of
parallel threads of fine-spun glass of the desired length . . . is
placed between some textile fabric . . . and the whole then sewed
together by longitudinal stitching . . . at short distances. For
sewing I use, by preference, chain-stitch. . . . thus formed . . .
a series of channels or tubes, each of them inclosing a number of
fine glass threads . . . . " The present invention incorporates
these and other teachings of Beck '085.
[0189] The present invention utilizes the teachings of Hammesfahr
'122. Hammesfahr '122 teaches of (page 2, line 19) " . . . making a
fabric or cloth, either in whole or in part, of fine-spun glass."
Hammesfahr defines the pre-1880 art with the statement (page 2,
line 22) "In the manufacture of so-called glass cloth as heretofore
practiced the glass has been introduced only in comparatively small
quantities--i.e., in the shape of an ornamental pattern having
silk, wool, cotton, or other fibrous material as the basis or
ground-work, and in such cases the glass forming such part has of
necessity been protected from the action of the reed in weaving by
strands of silk or other fibrous material." Hammesfahr offers (page
2, line 38) " . . . a fabric made entirely of glass, spun very fine
and woven in any suitable manner." (page 2, line 43) " . . . and at
the same time possess the required degree of toughness . . . and to
withstand the beating up . . . without breaking into fine
particles." (page 2, line 49) "The spinning of the glass into
threads is accomplished in any well-known manner." (page 2, line
74) "This fabric is capable of being used for shawls, table-covers
. . . and in all articles . . . . " The present invention
incorporates these and other teachings of Hammesfahr '122.
[0190] The present invention utilizes the teachings of Hickley
'788. Hickley '788 teaches (page 1, line 47) "For example, in
manufacturing a carbon . . . I will take, say, two pieces of
broom-corn, soak them in a strong alkali until they become soft and
gelatinous, and may place them side by side with a certain quantity
of spun glass . . . . " The present invention incorporates these
and other teachings of Hickley '788.
[0191] The present invention utilizes the teachings of Slayter et
al. '238. Slayter et al. '238 teaches of (page 2, col. 1, line 22)
" . . . fabricating . . . yarns composed of a multiplicity of glass
fibers, we may use an adhesive . . . which increases the mass
integrity of the group of fibers, and inhibits mutual scratching of
the fibers . . . " (page 2, col. 1, line 29) "The . . . coating
material may be . . . cellulose products or derivatives, resins,
plastics . . . rubber . . . or the like." (page 4, col. 2, line 30)
"Ordinarily the degree of stretch which any individual fiber may
possess before breaking, is extremely small, and even for fine
fibers, is seldom more than one or two, or at the most about 3
percent . . . the inherent non-stretchability of the fibers . . . "
(page 4, col. 2, line 49) " . . . we have discovered that by
providing yarn having sufficiently fine fibers, which may be
intertwisted a sufficiently high degree, the yarns themselves may
possess a relatively high degree of elongation, in the order of
magnitude of about 10 to 30 percent before breakage." The present
invention incorporates these and other teachings of Slayter et al.
'238.
[0192] The present invention utilizes the teachings of Tierney
'875. Tierney '875 teaches that (col. 1, line 16) "The highest
strength reinforced resin structural members are made with sheets
of lineally-aligned, contiguous, continuous glass filaments
impregnated with thermosetting resin, particularly epoxy resin."
(col. 4, line 66) "Fourteen layers of . . . composite sheet were
laid up in . . . crossply fashion, with the direction of filament
in each layer offset 90.degree. from those of adjacent layers."
(col. 4, line 72) "The laminated panel had . . . an organic content
(resin plus polyester tissue) of 31.2% by weight (about 49% by
volume)." (col. 5, line 1) "Test specimens cut from this panel,
with their length-wise direction parallel to one set of the
filaments, had the following properties:
15 Tensile strength . . . p.s.i. 68,000 Compressive strength . . .
psi 80,300 . . ."
[0193] (col. 5, line 15) "Another test panel was prepared in the
same manner except that the fourteen layers of the composite sheet
were laid with all filaments in the same direction. The cured panel
. . . had an organic content of 37.4% . . . yielded the following
data:
16 Tensile strength . . . p.s.i. 119,000 Compressive strength . . .
psi 99,800 . . ."
[0194] The present invention incorporates these and other teachings
of Tierney '875.
[0195] The present invention utilizes the teachings of Steingiser
'466. Steingiser '466 teaches of (col. 1, line 30) "Graphite fibers
having high tensile strength, e.g. over 200,000 p.s.i. . . . have
recently become available . . . " (col. 2, line 6) "Although the
term `graphite` is used, the fibers need not be highly crystalline
as determined by X-ray diffraction analysis." The present invention
incorporates these and other teachings of Steingiser '466
[0196] The present invention utilizes the teachings of Cass '571.
Cass '571 teaches (col. 4, line 3) " . . . of heat-treatment . . .
in chlorine at various yarn temperatures as shown by fiber and
composite properties are summarized in the table (dwell time about
30 sec.).
17 Fiber Property Temp. .degree. C. Tensile Strength kp.s.i. 100
260 200 269 300 275 400 282 500 279 600 186 700 131 Control
(unheated) 238 . . ."
[0197] The present invention incorporates these and other teachings
of Cass '571.
[0198] The present invention utilizes the teachings of Hartman
'923. Hartman '923 teaches (col. 3, line 42) "Magnesia
aluminosilicate glass fibers used herein are high strength fibers
and typically have a tensile strength in excess of about 500,000
psi." The present invention incorporates these and other teachings
of Hartman '923.
[0199] The present invention utilizes the teachings of Rogers '563.
Rogers '563 teaches that (col. 1, line 51) "The technical basis for
this invention is the recognition that the fibers in a cured
laminate must be straight or much straighter then they are now in
order for the laminate to posses the axial properties predicted by
theory." (col. 2, line 30) " . . . strenght in excess of 310,000
psi can be demonstrated analytically while current material forms
typically yield 250,000 psi. or less." The present invention
incorporates these and other teachings of Rogers '563.
[0200] The following Structural Composite Present Art background
and review focus on:
[0201] U.S. Pat. No. 2,035,977, dated Mar. 31, 1936, to Nichols
(Nichols '977)
[0202] U.S. Pat. No. 2,155,121, dated Apr. 18, 1939, to
Finsterwalder (Finsterwalder '121)
[0203] U.S. Pat. No. 2,255,022, dated Sep. 2, 1941, to Emperger
(Emperger '022)
[0204] U.S. Pat. No. 5,613,334, dated Mar. 25, 1997, to Petrina
(Petrina '334)
[0205] The present invention utilizes the teachings of Nichols
'977. Nichols '977 teaches that (col. 1, line 6) "Reenforced
concrete construction is in wide-spread use to-day utilizing two
totally different structural materials; namely, concrete and steel.
It is a well known fact that the modulus of elasticity of steel is
approximately 30,000,000 and that of concrete, while not a
constant, may usually be found between 3,000,000 and 4,000,000, so
that the modulus ratio, commonly called "n", varies around 6, 8 or
10 according to the quality of the concrete. Furthermore, steel in
tension can support between 30,00 and 60,000 pounds per square inch
before reaching its yield point, while the ultimate strength of
concrete is usually between 300 pounds and 500 pounds per square
inch in tension. In other words, concrete must be expected to
stretch but {fraction (1/10,000)} of its length before cracking,
whereas steel will stretch more than {fraction (1/1000)} of its
length and recover without injury or permanent set. The difference
between these two deformation characteristics causes much trouble
in practice." (col. 1, line 27) "Especially is this true in the
design of a reenforced concrete structural member such as a simple
beam in which the theory is that only the concrete above the
neutral axis or surface may be depended upon to resist the effects
of bending by the compressive stresses found therein and that the
steel reenforcement, usually placed near the bottom of the beam,
carries all the tensile stresses. Of course, the stress in the
matrix below the neutral axis is tensile in character and actually
does assist the steel by furnishing a small part of the tensile
component in the resisting moment couple. Furthermore, the usual
procedure did not stress the reenforcement in any way during the
formation of the beam, and because of the shrinkage of the matrix
and difference between the steel and concrete tended to form
incipient cracks in the bottom of the matrix and put the
reenforcement in compression prior to loading." (col. 1, line 48)
"It is also necessary that a good bond be had between the concrete
and steel in order that the beam may act as one homogeneous
material, and an entire design practice has grown up around the
straight line variation between stress and deformation and upon the
theory that only a small part of the plane cross-sectional area in
a beam takes the compressive stresses. This area is that above the
neutral axis, which is relatively high up in the body of the beam.
The portion below the neutral axis is not considered to be safely
dependable in resisting bending moment. Speaking loosely, the
compression stresses forming the compressive component of the
resisting moment couple in the present day beam are confined to
only a small part of the matrix such as the upper half." The
present invention incorporates these and other teachings of Nichols
'977.
[0206] The present invention utilizes the teachings of
Finsterwalder '121. Finsterwalder '121 teaches that (col. 1, line
1) "The use of ferro-concrete beams for structures of wide-span,
especially for bridges, is limited as regards width of span." (col.
1, line 10) "With increasing width of span of the beam and constant
relation of the depth of the structure to the span-width the
bending stress increases and thus the quantity of iron necessary
with uniform weight per metre of the structure increases linearly.
Even with very small span widths of about 13 metres the web-breadth
of 25 centimeters no longer suffices for the disposal of the
necessary tension irons. Therefore the webs must be broadened,
whereby the weight of the structure, calculated on the area of
surface, is substantially increased, so that with a freely
supported beam the limit is reached with a span width of about 25
metres." The present invention incorporates these and other
teachings of Finsterwalder '121.
[0207] The present invention utilizes the teachings of Emperger
'022. Emperger '022 teaches of (col. 1, line 1) " . . . object or
structures of reinforced concrete, such as girders, arches, frames,
beams and parts thereof." (col. 1, line 4) "The concrete of
structures of such type is subject to cracks in zones where tensile
stresses occur under load, and it has been suggested to prevent
formation of such cracks and to increase the strength of the
structure by preliminary or prestressing all the reinforcements
which therefore had to be made of high quality steel." (col. 1,
line 20) "Taking a cylindrical reinforcement embedded in concrete,
it has been shown (cf. 0. Graf "Beton und Eisen," 1910, p. 177 and
"Handbuch fur Eisenbetonbau," 4.sup.th ed., first vol., p. 40) that
the increase in plasticity of the concrete by reinforcement is very
small, and the less the thicker the layer or body of concrete
covering the reinforcement is. The maximum plastic or elastic
deformation of a layer of 2 mm. thickness around the cylindrical
reinforcement has been found to be 0.4% at most before rupture
occurs, and if the thickness of the covering cylindrical layer or
body amounted to 30 mm., the maximum elongation without rupture has
been found to be only 0.2%. Taking a steel the elongation of which
amounts to 0.2% at a stress of 400 kg./sq. cm., the covering layer
of 30 mm. thickness will yield and form cracks if that stress of
400 kg./sq. cm. is exceeded." (col. 1, line 39) "Taking however a
higher quality steel the elongation of which amounts to 1.4% at a
stress of 2800 kg./sq. cm., experiments made by the inventor have
shown that a relatively thin cover of concrete will be sufficiently
plastic so as to crack only at the yield point of that high quality
steel." (col. 1, line 46) "It has been suggested therefore to use
high quality steel for reinforcements of concrete and to arrange
them in such numbers and proximity to each other, furthermore to
prestress them uniformly to such an extent that due to the bond of
the set and shrunk concrete with the individual reinforcements,
crack formation was prevented under predetermined maximum load. The
compressive stresses exerted by the prestressed reinforcements
through the bond upon the concrete were so high that they
counter-balanced the tensile stresses exerted upon the concrete by
the predetermined maximum load." (col. 2, line 4) "It has been
found however that crack formation is not dangerous as long as
cracks, when formed, are prevented from widening in continuous use
and under recurrent load, and substantially close when the load is
moved." (col. 5, line 41) "Corners of reinforced concrete
structures are particularly subject to hair line cracking and
should be reinforced in the way to be derived from FIG. 3 without
further comment." (col. 5, line 53) "Most surprisingly, the tensile
strength of the concrete, as small as it may be, can also be taken
into consideration in calculating the structure according to the
invention." (col. 5, line 68) "Now, in calculating the structure,
its cross section has to be taken into consideration in which the
largest tensile stress occurs under predetermined maximum load. It
is common to consider in such case only the total tensile strength
of the reinforcements positioned in the stressed area of that cross
section. If however the tensile stress . . . in that area does not
exceed . . . " the tensile unit strength of the concrete " . . .
the tensile strength of the concrete in that area can be taken into
consideration in addition to that of the total tensile strength of
the reinforcements, main and additional, arranged in that area."
The present invention incorporates these and other teachings of
Emperger '022.
[0208] The present invention utilizes the teachings of Petrina
'334. Petrina '334 teaches (col. 1, line 24) "Concrete is strong
under compression, but relatively low in strength under tension.
When a structural member such as a beam is made of concrete, it is
under both compressive stress at the top of the beam and tension at
the bottom of the beam. Thus a concrete beam would tend to fail by
being cracking and pulling apart at the bottom, where the stress is
tensile. The same is true of concrete roads, or any other
application where tensile forces will be applied to concrete."
(col. 1, line 32) "This can be overcome by placing reinforcement
where it is necessary for structural members to resist tensile
forces. The result is called `reinforced concrete.` The
reinforcement is typically in the form of steel bars (usually
called `reinforcing bars` or simply `rebars`) or welded wire fabric
(in the case of flat areas such as roads, floors, or other concrete
slabs)." (col. 1, line 39) "In a concrete beam, the steel rebar is
placed in the lower part of the beam, so that the tensile forces
are countered by the reinforcement. The steel reinforcement is
bonded to the surrounding concrete so that stress is transferred
between the two materials." (col. 1, line 44) "In a further
development the steel is stretched before the development of bond
between it and the surrounding concrete. When the force that
produces the stretch is released, the concrete becomes
precompressed in the part of the structural member that is normally
the tensile zone under load. The application of loads when the
structure is in service reduces the precompression, but generally
tensile cracking is avoided. Such concrete is known as `prestressed
concrete`." The present invention incorporates these and other
teachings of Petrina '334.
[0209] The following Prestressed Structural Composite Present Art
background and review focus on:
[0210] U.S. Pat. No. 851,118 dated Apr. 23, 1907, to Chadwick
(Chadwick '118)
[0211] U.S. Pat. No. 903,909 dated Nov. 17, 1908, to Steiner
(Steiner '909)
[0212] U.S. Pat. No. 1,684,663 dated Feb. 7, 1925, to Dill (Dill
'663)
[0213] U.S. Pat. No. 1,781,699 dated Nov. 18, 1930, to Parmley
(Parmley '699)
[0214] U.S. Pat. No. 2,303,394, dated Dec. 1, 1942, to Schorer
(Schorer '394)
[0215] U.S. Pat. No. 2,319,105 dated May 11, 1943, to Billner
(Billner '105)
[0216] U.S. Pat. No. 2,435,998, dated Feb. 17, 1948, to Cueni
(Cueni '998)
[0217] U.S. Pat. No. 2,453,079 dated Nov. 2, 1948, to Rossmann
(Rossmann '079)
[0218] U.S. Pat. No. 2,660,049, dated Nov. 24, 1953, to Maney
(Maney '049)
[0219] U.S. Pat. No. 2,781,658 dated Feb. 19, 1957, to Dobell
(Dobell '658)
[0220] U.S. Pat. No. 2,857,755 dated Oct. 28, 1958, to Werth (Werth
'755)
[0221] U.S. Pat. No. 2,869,214 dated Jan. 20, 1959, to Van Buren
(Van Buren '214)
[0222] U.S. Pat. No. 3,950,905 dated Apr. 20, 1976, to Jeter (Jeter
'905)
[0223] U.S. Pat. No. 6,170,209 dated Jan. 9, 2001, to Dagher, et
al. (Dagher, et al. '209)
[0224] The present invention utilizes the teachings of Chadwick
'118. Chadwick '118 teaches of (page 2, col. 1, line 12) " . . . a
flexible cable on which a series of sleeves are strung which, when
jammed tightly together, form a rod of sufficient stiffness so as
not to buckle or bend when in use. Upon loosening the sleeves, the
cable and sleeves can be wound on a drum . . . " (page 2, col. 1,
line 40) "The rod is made ready for use by jamming the sleeves 11
tightly together. This is done by screwing down the nut 15 . . . .
" The present invention incorporates these and other teachings of
Chadwick '118.
[0225] The present invention utilizes the teachings of Steiner
'909. Steiner '909 teaches that (page 3, col. 1, line 16) " . . . a
very high initial strain is imparted to the most important
tension-rods, while the concrete is gaining in coherence and
hardness within the next few hours, after being placed." (page 3,
col. 1, line 29) "The adjustment of the length of the tension-rods
must begin shortly after placing a suitable block or portion of the
structure and must be repeated while the concrete is shrinking and
tightened up gradually to a higher strain as the concrete gains in
hardness. Since there is no appreciable bond between the concrete
and the rods at the start of this operation, while at the outside
of the concrete resistance against pressure soon increases, there
is provided an anchorage at the ends . . . " The present invention
incorporates these and other teachings of Steiner '909.
[0226] The present invention utilizes the teachings of Dill '663.
Dill '663 teaches of limitations on elasticity of tensile members
of prestressed structural composites (page 4, col. 2, line 1) "It
is the present practice to use mild steel because since the modulus
of elasticity of mild, semi-hard, and hard steel is practically the
same there is no advantage within limits in the use of hard steel.
The distortion of a reinforced concrete structure sufficient to
develop the full strength of mild steel, is sufficient to
completely ruin the concrete." Dill points out the general
engineering properties of concrete and steel and some of the
composite-structural consequences of such. (page 2, col. 2, line
93) "It is a scientific fact well known to all concrete engineers,
that the modulus of elasticity of steel is approximately 30,000,000
while that of concrete is about 3,000,000, or approximately
one-tenth that of steel. The strength of steel in tension is
approximately 30,000 pounds per square inch, while that of concrete
is only about 300 pounds. In other words, concrete will stretch
about {fraction (1/10,000)} of its length before cracking, and
steel will stretch about {fraction (1/1,000)} of its length before
reaching its yield point. So that if a concrete post, or beam, or
pile, or floor, or any structure of concrete and steel that is
called upon to resist a tensile strain, is stretched {fraction
(1/10,000)} of its length the concrete will crack. If it is
stretched {fraction (1/1,000)} of its length the concrete will
crack in ten different places, or if in a lesser number of places
the cracks will be relatively wider. The cracks will form in
advance of the full loading of the steel."
[0227] Dill '663 expanses on engineering issues of concrete-steel
composite design. (page 3, col. 1, line 33) "(1) Concrete, during
the setting process, shrinks. The degree of shrinkage is variable.
In general the richer the concrete in cement the greater the
shrinkage.
[0228] (2) Concrete, after the set is apparently completed, will
shrink with loss of moisture.
[0229] (3) Concrete will shrink under compression at the same rate
that it will expand under tension.
[0230] Therefore, when the steel is held under tension and the
plastic concrete is poured about it, what happens is this: As the
concrete is initially setting it shrinks or attempts to shrink, or
in other words, it is in tension. If later it dries out it will
shrink some more and increase its tension, so that the product of
concrete and steel will lose part or all of the tension placed in
the steel and may, in addition, develop such tensional strains on
the concrete as to cause the concrete to crack. In the very
exceptional case where the mixture is very thin and the concrete is
left moist so that it does not shrink, the tension of the steel
allowed to come on the concrete will compress it so that part of
its tension is lost and the product is not perfect even in that
case. In reinforced concrete, as ordinarily manufactured, no
tension is placed in the steel during the manufacture, and the
tension developed by the concrete almost always results in
compression of the steel, relieved in part by numerous cracks in
the concrete. It is to be remembered that this relief is in part
only. The sections of concrete between the cracks is not at rest
but is in tension and being in tension holds the steel in
compression. Each section is in a state of unstable equilibrium."
The present invention incorporates these and other teachings of
Dill '663
[0231] The present invention utilizes the teachings of Parmley
'699. Parmley '699 teaches the limitations of a homogeneous
material which has asymmetric engineering properties whereby its
compressive strength is significantly greater than its tensile
strength, i.e. concrete or cast iron. (page 2, col. 2, line 89)
"With homogeneous concrete, contraction can take place with
practically no internal stress being set up within the mass of the
concrete. The resulting . . . will therefore, when subjected to
bending stresses of loading, be able to withstand these stresses up
to the normal limit of the tensile strength of the concrete. The
modulus of the concrete in tension therefore, usually runs two or
three hundred pounds per sq. in. and it is this transverse strength
which makes the . . . use . . . possible." The present invention
incorporates these and other teachings of Parmley '699.
[0232] The present invention utilizes the teachings of Schorer
'394. Schorer '394 teaches that (col. 1, line 8) "Various methods
and means have been devised for subjecting concrete to initial
compression for the purpose of reducing or eliminating tensile
stresses in the concrete. The prior art methods and means include
deformation of the moulds and thereby compressing the concrete in
the mould while the concrete hardens and/or applying initial
tension forces to the reinforcing steel and maintaining such forces
until the concrete has hardened and then releasing said forces and
thereby transmitting them to the adjacent concrete and setting up
compression therein. With some of the prior art methods the bond
between the reinforcements and the concrete is destroyed and
monolithic action is not possible. Due to the fact that the
reactions of the tensioning forces are generally transmitted to the
moulds the methods and devices proposed so far are expensive and
their application is limited . . . . " (col. 5, line 7) "After
releasing the compression member the initial tension . . . is
somewhat reduced due to the elastic and plastic deformation and
skrinkage of the concrete, the proportion depending on the amount
of prestress. The balance is available for the initial compression
of the concrete. The design and proper arrangement of the
prestressed reinforcing units permits the complete elimination of
all tensile stresses in the concrete also under extreme load
conditions." The present invention incorporates these and other
teachings of Schorer '394.
[0233] The present invention utilizes the teachings of Billner
'105. Billner '105 teaches of (page 2, col. 1, line 1) " . . .
reinforced plastic bodies and methods of producing them . . . . By
its very nature, concrete is intended to assume compressive
stresses only, while its reinforcing elements are relied upon to
receive the tensile stresses." Billner teaches that prestressing
such composite structures can be (page 2, col. 2, line 8) " . . .
obtained by thermally expanding the reinforcing elements after the
plastic body has hardened. This is accomplished by forming the
plastic body about the reinforcing element and releasing any bond
between the body and the element so that the element may be
expanded with respect to the body, whereupon the element is
permitted to partially contract so as to bear upon the body and
produce compressive stresses therein . . . . The reinforcing
element is expanded preferably by the application of heat . . . "
(page 2, col. 2, line 41) "When the reinforcing element has
expanded an amount sufficient to impose the desired stresses upon
subsequent contraction, it is suitably secured against excessive
contraction so that the desired amount of its contracting force
will be applied to produce compressive stresses within the body."
The present invention incorporates these and other teachings of
Billner '105.
[0234] The present invention utilizes the teachings of Cueni '998.
Cueni '998 teaches that (col. 1, line 10) "Prestressed reinforced
concrete had previously been proposed and some use thereof has been
made in structures. However, it has been subject to numerous
disadvantages. For instance, it has been customary to apply such
prestressing in the field, but the prestressing of the reinforcing
bars has required such a large force that it was difficult to
provide the necessary machinery and the auxiliary equipment
together with the skilled labor, to allow it to be economically
applied. It has also been practically impossible to obtain uniform
results in the field because of the practical impossibility of
obtaining uniform and reproducible conditions of operation." (col.
1, line 34) "Another construction which had previously been used
embodied a steel beam which was connected to a concrete slab by
suitable shear reinforcements so that the parts did act as a single
unit, the steel sustaining the tensile stresses and the concrete
sustaining the compressive stresses." (col. 2, line 10) "By
prestressing the high tensile steel reinforcement up to 70% of its
strength before the concrete is poured, and releasing the
prestressing force after the concrete has set, such compressive
stresses will be introduced into the concrete, that it can be
stressed in tension as well as in compression without developing
cracks, and the full strength of the reinforcement is developed."
(col. 4, line 37) "If more than the design load is applied, the
compressive stresses in the bottom of the concrete will gradually
change to tensile stresses and finally, when the tensile strength
of the concrete is reached, the concrete will crack. From then on
the section will act like a reinforced concrete . . . beam and has
to be designed as such." (col. 4, line 48) " . . . three steps are
required in computing the stresses of such a beam. a. For the
computation of the stresses in the prestressed beam due to the dead
load: It is assumed that the precast beam is acting like any
prestressed reinforced concrete beam. b. For the computation of the
stresses in the composite section due to the live load: It is
assumed that the composite section acts in a similar way as a steel
beam composite section, the poured-in-place concrete slab
sustaining the compressive stresses, and the prestressed concrete
of the precast beam sustaining the tensile stresses. c. For the
computation of the ultimate load: It is assumed that the composite
section acts like a reinforced concrete . . . beam section, the
poured-in-the-field concrete slab sustaining the compressive
stresses and the bottom steel of the precast beam, the tensile
stresses." (col. 4, line 67) "All prestressed beam composite
sections have to be checked for ultimate load, for the assumption
of a certain working stress for the steel does not always mean a
corresponding factor of safety as it does in other types of
construction." (col. 4, line 72) "Such a design is very unusual and
together with the different stress diagram proves the novelty of
the construction that is the object of the present invention." The
present invention incorporates these and other teachings of Cueni
'998.
[0235] The present invention utilizes the teachings of Rossmann
'079. Rossmann '079 teaches of (page 2, col. 1, line 9) " . . . a
metallic load receiving and transmitting rod or bar which will tend
to decrease its elongation from zero to maximum load in use, and
which will at the same time tend by reason of deformation imposed
thereon to increase its tensile strength and also to extend fatigue
life." Rossmann '079 is not a structural composite. Rossmann '079
identifies the structural concern regarding metallic structural
fatigue. The present invention incorporates these and other
teachings of Rossmann '079
[0236] The present invention utilizes the teachings of Maney '049.
Maney '049 teaches that (col. 1, line 4) "Structural compression
members have heretofore been provided which include a core of
concrete or the like bound with a helical wire or band of steel or
the like, but such members have been unsatisfactory for the reason
that under load the core would fail before the lateral deformation
thereof produced sufficient tension in the helical band to permit
the band to perform its function of strengthening the core against
failure, or the helix would fail as a column before it would act to
restrain deformation of the core. In accordance with the present
invention, the shell for the core is provided by a helical wire or
band of steel or the like having a high elastic limit which is
tensioned about the core in manufacture. Since the shell is always
under tension, a compressive load on the core cannot cause failure
of the core or of the shell as a column before the shell becomes
effective to restrain the lateral deformations of the core
resulting from the compressive force." The present invention
incorporates these and other teachings of Maney '049.
[0237] The present invention utilizes the teachings of Dobell '658.
Dobell '658 teaches that (page 4, col. 1, line 30) "(f)or many
years, mild, low strength steel reinforcing was simply embedded in
ordinary concrete and the result was an improvement in the strength
of the concrete and some resistance to cracking and other failures.
Later there was an attempt to place this reinforcement under
tension so that it would have a compressive effect upon the
concrete. This slightly improved the construction although the
success of this effort was not great because those who did it did
not appreciate the fact that concrete would flow slightly under
pressure and thus that the tension on the reinforcement would be
reduced practically back to zero. Also, under tension the
reinforcement itself would suffer some permanent elongation that
would add to this reduction of tension. (page 4, col. 1, line 44)
"Accordingly, the tensioning of the reinforcement was generally
considered to be of great importance until recently, when some of
the factors influencing the effectiveness of reinforcement became
better known and it was found that if steel wire having very high
tensile strength was used and was placed under a very high tensile
strength was used and was placed under a very high tension, then,
although a part of this tension was lost by plastic flow and
shrinkage in the concrete and permanent elongation or "creep" in
the wire, nevertheless, sufficient tension would remain in the wire
and sufficient compression would remain on the concrete to cause a
major increase in the load carrying capacity of the concrete and a
major increase in the resistance of the concrete to cracking and
the like. This represented such a complete departure from
previously known facts as to present a completely new concept of
reinforced concrete and hence, this high tensioned wire reinforcing
of concrete was properly considered to furnish a completely new and
different approach to reinforced concrete construction." The
present invention incorporates these and other teachings of Dobell
'658.
[0238] The present invention utilizes the teachings of Werth '755.
Werth '755 teaches the present art method and means of prestressing
lexicon (page 4, col. 1, line 24) " . . . the following terms shall
have the indicated meanings . . . (italics in original) . . .
[0239] Prestressing.--denotes the action upon a structure of
applied forces calculated to impart stresses of sufficient
magnitude to permanently neutralize undesirable stresses of
opposite sign due to load.
[0240] Anchor.--denotes the means by which the prestressing force
is transferred from the tensile unit to the structure.
[0241] Structure.--defines structures and structural members,
units, elements or portions thereof.
[0242] Concrete structure.--defines a structure made of concrete or
any other material capable of withstanding compressive forces.
[0243] Grout.--defines any hydraulically compressible material used
for the filling of cavities in structures.
[0244] (page 4, col. 1, line 41) "In order to illustrate the
shortcomings of the prior art prestressing methods . . . a resume
of the principal features of prior art prestressing methods is
given as follows: (italics in original)
[0245] Type 1. Pre-tensioning.--The prestressing force is applied
externally to the prestressing units, positioned inside of the
forms prior to the pouring or casting of the concrete.
[0246] Type 2. Post-tensioning at anchor terminals.--The structure
is poured monolithically, i.e., in one continuous operation, or is
formed by assembling prefabricated members and wherein cavities, if
used, are left for the prestressing units only. The prestressing
force is then applied externally to the prestressing unit at
terminals only or at terminals and intermediate anchors, by means
of removable mechanical tools or devices, such as jacks and
wrenches. In order to apply prestressing force at the intermediate
anchors, the latter have to be made accessible by means of
temporary openings in the structure. Such openings subsequently
have to be filled.
[0247] Type 3. Post-tensioning at joints.--The structure is divided
by joints into two or more portions and is held together by
prestressing units only, which units are placed in cavities and
anchored in the concrete. The prestressing force is applied
externally at the joints by means of jacks, pressure pillows,
cells, etc., or by gravity action. The joints have to be filled in
after the structure is prestressed. In some systems the
prestressing devices remain in the structe permanently. This
circumstance does not alter the fact that the structure is
prestressed externally." The present invention incorporates these
and other teachings of Werth '755.
[0248] The present invention utilizes the teachings of Van Buren
'214. Van Buren '214 teaches of (page 3, col. 1, line 21) " . . .
methods for making so-called prestressed concrete bodies or members
is to cast the concrete in a suitable mold provided with removable
mandrels or other core means which, when removed after the concrete
has set, will leave holes therethrough, through which wires or
cables are threaded. Such wires or cables are then heavily
tensioned by the use of jacks which apply tensioning forces to the
wire ends, which forces react against the body of concrete causing
the latter to be subjected to heavy compression . . . such wired
are then permanently anchored at their ends to maintain the tension
therein by the use of suitable end anchorage means which, after
same is applied, permits the jacks to be removed while the concrete
remains under permanent compression. It has been proposed to then
introduce cement mortar or the like in fluid condition along the
tensioned wires in the holes in the concrete for the purpose
principally of protecting the wires against corrosion. Other
experts have advocated the injection of cement grout under pressure
into the holes along the wires in such a manner as to securely bond
the wires in place under tension so that the end anchorage means
may thereafter be removed for reuse elsewhere . . . " The present
invention incorporates these and other teachings of Van Buren
'214.
[0249] The present invention utilizes the teachings of Jeter '905.
Jeter '905 teaches of a "(m)ethod for prestressing a structural
member." "The apparatus disclosed includes an elongated reinforcing
member with stress anchors attached to each end for embedding in a
body of hardenable material, such as concrete, when the material is
cast into the desired shape for the structural member. The
apparatus includes a member containing potential energy. After the
material has hardened, the potential energy is released to place
the material between the stress anchors in compression to prestress
the structural member before it is placed in service." The present
invention incorporates these and other teachings of Jeter '905.
[0250] The present invention utilizes the teachings of Dagher, et
al. '209. Dagher, et al. '209 teaches of " . . . a prestressing
system for wood elements and structures and a method from
prestressing wood beams. In its most basic form, the system for
prestressing structures comprises a plurality of members arranged
in a predetermined configuration, at least one non-metallic
prestressing tendon, having a material stiffness less than that of
steel, disposed in such a manner as to fasten together the members,
and stressing means attached to at least one end of the
prestressing tendon to exert a tensile force on the tendon and an
equal and opposite compressive force drawing the members together.
In the preferred embodiment, the tendons are manufactured from
fiber reinforced plastic and the members are arranged in side by
side relation to form a deck. The deck includes a series of aligned
holes through the members, through which the prestressing tendons
pass and are secured and prestressed. In alternate embodiment of
the invention, prestressing tendons are used to secure and
prestress stress laminated T sections and box sections and to
secure timber trusses. The present invention is also directed to a
system and method for prestressing beams. In its most basic form,
the system comprises at least one nonmetallic tendon, at least one
opening disposed longitudinally through a lower portion of the
element, a pair of anchors disposed at the ends of each
prestressing tendons, and a pair of bearing plates disposed between
the anchors and the bearing surface of the beam. In operation, the
tendons are disposed within the opening, the bearing plates are
disposed against the bearing surfaces and the anchors are tightened
such that a tensile force is exterted on the tendons and such that
said bearing plates exert a substantially equal an opposite
compressive force on the element beam. In an alternate embodiment,
the opening is filled along the tendon with a resin and the anchors
are removed after the resin has cured." The present invention
incorporates these and other teachings of Dagher, et al. '209.
OBJECTS AND SUMMARY OF THE INVENTION
[0251] It is an object of the present invention to provide a
fatigue and metal embrittlement resistant structure for civil and
structural applications which may be assembled in a variety of
configurations and sizes.
[0252] It is another object of the present invention to provide a
structural means for assembly of a number of structural elements
and thereby permit erection of multiple element structures in a
wide range of configurations.
[0253] It is still another object of the present invention to
provide a structural assembly that obviates the fatigue and/or
metal embrittlement problems associated with welded metallic
structures.
[0254] It is a further object of the present invention of applying
a prestressing force during assembly and/or to the assembled
structural composites when such structural composites consist of
one or more elements having asymmetric engineering materials
properties, thereby structurally allowing use of the more desired
of the asymmetric engineering properties.
[0255] It is yet another object of the present invention of
applying a prestressing force during assembly and/or to the
assembled structural composite(s) when such structural composite(s)
consist of one or more elements having fatigue susceptible metallic
properties.
BRIEF DESCRIPTIONS OF THE DRAWINGS
[0256] FIG. 1 is graph showing relationship between ductile iron
"Hardness, Brinell" (X-axis) and ductile iron compressive yield
strength (Y-axis).
[0257] FIG. 2 is a isometric-view photo of sample ferrous member 1
showing open channels 2 (with edge-distance 4 providing overall
rigidity to completed structural composite and protection of
tensile fibers from side-impact) for non-metallic tensile member
fibers and passageway 3 for said fiber placement thru said ferrous
member to intended compressive region. Intended compression region
6 is at bottom; intended tensile region 7 at top; intended
neutral-axis 5 near region of bottom of open channels.
[0258] FIG. 3 is a side-view of an assembled structural composite
subjected to three-point-bend test, after structural failure,
failure mode being tensile failure of non-metallic fiber.
Compression region 6 is at top of composite structure, tensile
region 7 is at bottom of composite structure. Hot-dip galvanized
ferrous material 8 was bonded to fiberglass/resin 9 (fiberglass is
transparent). Tensile tear 10 failure mode identifies structural
composite unbalanced in design in favor of ferrous member element
over non-metallic fiber member element. No apparent delaminating
between structural elements.
[0259] FIG. 4 is a side-view of another assembled structural
composite about to be three-point-bend tested. Compression region 6
is at top of composite structure, tensile region 7 is at bottom of
composite structure. Hot-dip galvanized ferrous material 8 was
bonded to fiberglass/resin 9.
[0260] FIG. 5 is close-up of assembled structural composite, shown
in FIG. 4, after subjected to three-point-bend test, location of
applied load is 11, failure mode being tensile failure of ferrous
material. Compression region 6 is at top of composite structure,
tensile region 7 is at bottom of composite structure. Hot-dip
galvanized ferrous material 8 was bonded to fiberglass/resin 9
(fiberglass is transparent). Tensile tear 10 failure mode
identifies structural composite unbalanced in design in favor of
non-metallic fiber member element over ferrous member element. No
apparent delaminating between structural elements.
DETAILED DESCRIPTION OF THE INVENTION
[0261] An embodiment of the present invention is a
structural-composite composed of a ferrous member (see FIG. 2) 1
such as cast-iron, a non-metallic fiber member such as fiberglass
and a resin. The cast-iron member is portioned so as to completely
occupy the compressive region of the structural-composite when said
structural-composite is subjected to design bending moment loads.
Said cast-iron member extends beyond the intended neutral-axis of
the structural-composite into the intended tensile region of said
structural-composite when said structural-composite is subjected to
design bending moment loads. Said cast-iron member's surfaces
exposed to tensile stresses when said structural-composite is
subjected to design bending moment loads are prepared to effect
shear-transfer to resin(s) applied to said surfaces. Such surface
preparation(s) may include projections and/or voids formed when the
member was cast and/or post-cast abrasion, pitting, grinding or
cutting. Such surface preparation(s) may include metallurgical
processes such as hot-dip zinc and/or aluminum and/or nickel. Such
metallurgical processes are intended to form alloy layer(s)
providing shear-transfer to the chosen resin(s) and said chosen
resin(s) providing shear-transfer to said fiberglass member. The
fiberglass member is portioned so as reside completely within the
tensile region of the structural-composite when said
structural-composite is subjected to design bending moment
loads.
[0262] An embodiment of the present invention is a
structural-composite composed of a ferrous member such as cast-iron
and a non-metallic fiber member such as fiberglass and a resin. The
cast-iron member is portioned so as to completely occupy the
compressive region of the structural-composite when said
structural-composite is subjected to design bending moment loads.
Said cast-iron member extends beyond the intended neutral-axis of
the structural-composite into the intended tensile region of said
structural-composite when said structural-composite is subjected to
design bending moment loads. Said cast-iron member's surfaces
exposed to tensile stresses when said structural-composite is
subjected to design bending moment loads are prepared to effect
shear-transfer to resin(s) applied to said surfaces. Such surface
preparation(s) may include projections and/or voids formed when the
member was cast and/or post-cast abrasion, pitting, grinding or
cutting. Beginning in the intended tensile region of the ferrous
member, open channels or open voids may be formed, either at time
of casting or post-casting, extending toward or beyond the
structural-composite's intended neutral-axis, such channels or
voids providing both additional surface-area for bonding the
non-metallic fiber thereby providing more shear-transfer and
providing additional tensile strength throughout the
structural-composite's tensile region. Surface preparation(s) may
include metallurgical processes such as hot-dip zinc and/or
aluminum and/or nickel. Such metallurgical processes are intended
to form alloy layer(s) providing shear-transfer to the chosen
resin(s) and said chosen resin(s) providing shear-transfer to said
fiberglass member. The fiberglass member is portioned so as reside
completely within the tensile region of the structural-composite
when said structural-composite is subjected to design bending
moment loads.
Preffered Embodiment
[0263] The preferred embodiment of the present invention is a
structural-composite composed of cast-iron members, fiberglass
members and resins. The cast-iron members are portioned so as to
completely occupy the compressive region of the
structural-composite when said structural-composite is subjected to
design bending moment loads. Said cast-iron members extend beyond
the intended neutral-axis of the structural-composite into the
intended tensile region of said structural-composite when said
structural-composite is subjected to design bending moment loads.
Some said cast-iron member's surfaces exposed to tensile stresses
when said structural-composite is subjected to design bending
moment loads are prepared to effect shear-transfer to resin(s)
applied to said surfaces. Such surface preparation(s) may include
projections and/or voids formed when the member in question was
cast and/or post-cast abrasion, pitting, grinding or cutting.
Beginning in the intended tensile region of the ferrous member,
open channels or open voids may be formed, either at time of
casting or post-casting, extending toward or beyond the
structural-composite's intended neutral-axis, such channels or
voids providing both additional surface-area for bonding the
non-metallic fiber thereby providing more shear-transfer and
providing additional tensile strength throughout the
structural-composite's tensile region. Surface preparation(s) may
include metallurgical processes such as hot-dip zinc and/or
aluminum and/or nickel. Such metallurgical processes are intended
to form alloy layer(s) providing shear-transfer to the chosen
resin(s) and said chosen resin(s) providing shear-transfer to said
fiberglass member. Said chosen resin(s) should be
catalyst-sensitive to the metal forming the ferrous alloy. The
fiberglass member is portioned so as reside completely within the
tensile region of the structural-composite when said
structural-composite is subjected to design bending moment loads.
The fiberglass strand should be of a continuous loop recessed into
said open channels or the like in the ferrous material. Where the
design use may cause the fiberglass to receive direct physical
shock or impact a cover of protective material may be added.
* * * * *