U.S. patent application number 14/916231 was filed with the patent office on 2016-07-07 for composite fiber for the reinforcement of concrete.
The applicant listed for this patent is OCV Intellectual Capital, LLC. Invention is credited to Bryan BARRAGAN, David BLANDIN, Daniel GIL, Olivier LAURENCE, Benoit LORRE, Gerard TARDY.
Application Number | 20160194246 14/916231 |
Document ID | / |
Family ID | 51541351 |
Filed Date | 2016-07-07 |
United States Patent
Application |
20160194246 |
Kind Code |
A1 |
TARDY; Gerard ; et
al. |
July 7, 2016 |
COMPOSITE FIBER FOR THE REINFORCEMENT OF CONCRETE
Abstract
Composite fibers and methods of manufacturing composite fibers
for the reinforcement of concrete are provided. The composite
fibers include fibers and a polymeric coating. The composite fibers
have a length of about 10 to about 80 mm and an equivalent diameter
from about 0.3 to about 2 mm. A method for reinforcing concrete
using the composite fibers is further provided.
Inventors: |
TARDY; Gerard; (Sonnaz,
FR) ; BLANDIN; David; (Chambery, FR) ; GIL;
Daniel; (Jacob-Bellecombette, FR) ; LORRE;
Benoit; (Saint-Sulpice, FR) ; LAURENCE; Olivier;
(Vertou, FR) ; BARRAGAN; Bryan; (Chambery,
FR) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
OCV Intellectual Capital, LLC |
Toledo |
OH |
US |
|
|
Family ID: |
51541351 |
Appl. No.: |
14/916231 |
Filed: |
September 2, 2014 |
PCT Filed: |
September 2, 2014 |
PCT NO: |
PCT/US2014/053655 |
371 Date: |
March 3, 2016 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61873444 |
Sep 4, 2013 |
|
|
|
Current U.S.
Class: |
523/209 ;
427/553; 428/375 |
Current CPC
Class: |
C04B 28/02 20130101;
C04B 20/1014 20130101; C04B 20/0068 20130101; C04B 28/02 20130101;
C04B 20/1037 20130101; C04B 20/0068 20130101; C04B 20/1037
20130101; C04B 14/38 20130101; C04B 14/38 20130101; B05D 3/065
20130101; C04B 18/022 20130101; C04B 40/0003 20130101; C04B 18/022
20130101; C04B 40/0017 20130101; C04B 14/42 20130101; C04B 20/0068
20130101; C04B 14/44 20130101 |
International
Class: |
C04B 20/10 20060101
C04B020/10; B05D 3/06 20060101 B05D003/06 |
Claims
1. A composite fiber for the reinforcement of concrete, said
composite fiber comprising a plurality of fibers and a polymeric
coating, wherein said composite fiber has a length of about 10 to
about 80 mm and an equivalent diameter of about 0.3 to about 2
mm
2. The composite fiber of claim 1, wherein said composite fiber has
a length of about 30 to about 50 mm.
3. The composite fiber of claim 1, wherein said composite fiber has
an equivalent diameter of about 0.5 to about 1.0 mm.
4. The composite fiber of claim 1, wherein said fiber is a mineral
fiber.
5. The composite fiber of claim 1, wherein said fiber is a glass
fiber.
6. The composite fiber of claim 5, wherein said fiber is an
alkali-resistant glass fiber.
7. The composite fiber of claim 1, wherein said polymeric coating
is a radiation cured polymeric coating.
8. The composite fiber of claim 7, wherein said polymeric coating
is a UV cured polymeric coating.
9. The composite fiber of claim 1, wherein the coating is a
polyurethane or polyester resin.
10. The composite fiber of claim 1, wherein said polymeric coating
is from 5 to 50 wt % of the composite fiber.
11. The composite fiber of claim 10, wherein said polymeric coating
is from 10 to 30 wt % of the composite fiber.
12. A method of manufacturing a composite fiber, said method
comprising: preparing a viscous polymeric coating composition;
applying the viscous polymeric coating composition to a plurality
of fibers to form a coated element; and exposing the coated element
to radiation which cures the viscous coating composition to form a
composite fiber.
13. The method of claim 12, wherein said radiation is UV
radiation.
14. The method of claim 12, wherein said composite fiber has a
length from about 10 to about 80 mm and an equivalent diameter of
about 0.3 to about 2 mm
15. A method for reinforcing concrete, said method comprising:
preparing a viscous polymeric coating composition; applying the
viscous polymeric coating composition to a plurality of fibers to
form a plurality of coated elements, each of said coated elements
including one or more of said fibers; exposing the coated elements
to radiation and which cures the polymeric coating composition to
form a plurality of composite fibers; preparing a concrete; and
mixing the composite fibers in said concrete.
16. The method of claim 15, wherein said composite fibers are
included in the concrete in an amount from about 2 to about 75
kg/m.sup.3 of said concrete.
17. The method of claim 16, wherein said composite fibers are
included in the concrete in an amount from about 5 to about 25
kg/m.sup.3 of said concrete.
18. The method of claim 15, wherein said composite fibers have a
length of about 10 to about 80 mm and an equivalent diameter from
about 0.3 to about 2 mm.
Description
RELATED APPLICATIONS
[0001] The present application claims the priority/benefit of the
U.S. provisional patent application having Ser. No. 61/873,444 and
filed on Sep. 4, 2013, the entire disclosure of which is fully
incorporated herein by reference
FIELD OF THE INVENTION
[0002] general inventive concepts relate to composite fibers for
the reinforcement of concrete, a process of manufacturing and a way
of reinforcing concrete and other building materials using such
fibers.
BACKGROUND
[0003] Building materials such as concrete can be reinforced with
fibers in order to overcome specific issues that can arise when
using conventional reinforcement members, such as steel rebars
and/or welded wire mesh. Fibers can introduce toughness (i.e.,
energy absorption capacity during failure) to concrete, overcoming
its intrinsic brittleness and providing post-cracking strength
under direct or indirect tensile stresses. The vast majority of
conventional fibers used for reinforcing concrete reinforcement are
made out of low or high carbon content steel, or polymers such as
polypropylene, polyvinyl alcohol, polyester, etc. These
conventional fibers suffer from limitations. Processability issues
can be generated by the relatively high dosages required (such as
clustering during mixing, blockings during pumping, reduction of
workability, and difficult compaction and finishing). Additionally,
the cost-performance benefit of such conventional fibers is often
less than that of traditional solutions due to the relatively high
dosages required; durability concerns; health, safety, and
environment problems; etc. Composite reinforcing materials, such as
composite fibers, can overcome the shortcomings of conventional
fibers; i.e., by achieving a very high performance at relatively
low dosages.
[0004] JP2002154853A1 describes composite fibers produced by
impregnating a continuous inorganic fiber bundle with a resin,
hardening the resulting material and thereafter cutting the
hardened material. The resin content of this composite fiber is 10
to 80 mass %. Its length is 10 to 80 mm and its cross section is
0.1 to 12 mm.
[0005] WO2006059041 A1 discloses composite fibers or composite
tapes based on co-melted glass fibers and polypropylene fibers,
such as the composite products sold under the Twintex.RTM. brand
(available from Owens Corning) and manufactured by thermoplastic
pultrusion.
[0006] However, these known composite fibers suffer from the
problem of relatively high production costs. Key to production cost
is the production rate. For example, JP2002154853A1 describes line
speeds of only 5 meters/minute.
[0007] Higher production rates can be achieved by using radiation
curing technology. U.S. Pat. No. 4,861,621, incorporated herein by
reference, discloses a pultrusion process which cures materials by
ultraviolet radiation for optic cable applications. Specifically, a
reinforcing filamentary material, in the form of a glass roving, is
impregnated with a curable coating material and then passed
underneath a unit for UV radiation. The pultrusion speed is 10
meters/minute (Example 2).
[0008] Other UV curing processes are known in the art. However,
there remains a need in the art for solutions for the reinforcement
of concrete that overcome the drawbacks mentioned above,
particularly solutions that improve the production rate of
composite fibers, which will in turn lower the manufacturing
costs.
SUMMARY
[0009] The general inventive concepts refer to composite fibers
used in the reinforcement of concrete. The composite fibers
comprise a plurality of fibers coated with a polymeric material.
Required dosages of the composite fibers allow for better
processability of concrete and provide high toughness or
post-cracking strength up to large crack openings while involving
low manufacturing costs.
[0010] In some exemplary embodiments, the composite fibers are
characterized in that the length of the composite fiber is from 10
to 80 mm and the equivalent diameter of the composite fiber is from
0.3 to 2 mm.
[0011] In other exemplary embodiments, the polymeric coating is a
radiation (e.g., UV) cured polymeric coating.
[0012] In other exemplary embodiments, the polymeric coating is
from 5 to 50 wt % of the composite fiber.
[0013] The general inventive concepts further relate to methods of
manufacturing a composite fiber. In some exemplary embodiments, the
method includes preparing a liquid polymeric coating composition;
applying the liquid polymeric coating composition to the surface of
a plurality of fibers to form a coated surface; and exposing the
coated surface to radiation and curing the liquid coating
composition to form a composite fiber.
[0014] The general inventive concepts further relate to methods of
forming reinforced concrete. The method includes the steps of
preparing a concrete and mixing one or more composite fibers of the
invention in that concrete, forming reinforced concrete.
[0015] In other exemplary embodiments, the dosage of composite
fibers in the applied concrete is from 2 to 75 kg of fibers per
cubic meter of wet concrete.
[0016] In other exemplary embodiments, the dosage of composite
fibers in the applied concrete is from 5 to 25 kg of fibers per
cubic meter of wet concrete.
[0017] In other exemplary embodiments, the dosage of composite
fibers in the applied concrete is from 7.5 to 12.5 kg of fibers per
cubic meter of wet concrete.
[0018] Additional features and advantages will be set forth in part
in the description that follows, and in part may be obvious from
the description, or may be learned by practice of the exemplary
embodiments disclosed herein. The objects and advantages of the
exemplary embodiments disclosed herein will be realized and
attained by means of the elements and combinations particularly
pointed out or otherwise recited in the appended claims. It is to
be understood that both the foregoing summary and the following
detailed description are exemplary and explanatory only and are not
restrictive of the general inventive concepts as disclosed herein
or as claimed.
DETAILED DESCRIPTION
[0019] Various exemplary embodiments will now be described more
fully. These exemplary embodiments may, however, be embodied in
different forms and should not be construed as limited to the
descriptions set forth herein. Rather, these exemplary embodiments
are provided so that this disclosure will be thorough and complete
in illustrating and conveying the general inventive concepts to
those skilled in the art.
[0020] Unless otherwise defined, all technical and scientific terms
used herein have the same meaning as commonly understood by one of
ordinary skill in the art to which these exemplary embodiments
belong. The terminology used in the description herein is for
describing particular exemplary embodiments only and is not
intended to be limiting of the general inventive concepts.
[0021] As used in the specification and the appended claims, the
singular forms "a," "an," and "the" are intended to include the
plural forms as well, unless the context clearly indicates
otherwise. All publications, patent applications, patents, and
other references mentioned herein are incorporated by reference in
their entirety.
[0022] Unless otherwise indicated, all numbers expressing
quantities of ingredients, reaction conditions, and so forth used
in the specification and claims are to be understood as being
modified in all instances by the term "about." Accordingly, unless
indicated to the contrary, the numerical parameters set forth in
the specification and attached claims are approximations that may
vary depending upon the desired properties sought to be obtained by
the present exemplary embodiments. At the very least, and not as an
attempt to limit the application of the doctrine of equivalents to
the scope of the claims, each numerical parameter should be
construed in light of the number of significant digits and ordinary
rounding approaches.
[0023] Notwithstanding that the numerical ranges and parameters
setting forth the broad scope of the exemplary embodiments are
approximations, the numerical values set forth in the specific
examples are reported as precisely as possible. Any numerical
value, however, inherently contains certain errors necessarily
resulting from the standard deviation found in their respective
testing measurements. Every numerical range given throughout this
specification and the claims will include every narrower numerical
range that falls within such broader numerical range, as if such
narrower numerical ranges were all expressly written herein.
[0024] As used herein, "fiber" means a collection of one or more
monofilaments.
[0025] As used herein, "polymeric coatings" means a mixture of
monomers and/or oligomers that are hardened by one of the curing
methods described or otherwise suggested herein. herebelow.
[0026] As used herein, "impregnated" means partially or fully
impregnated.
[0027] As used herein, "radiation cured" means that the monomers
have been polymerized with the help of radiation preferably in
presence of a suitable catalyst.
[0028] As used herein, UV cured means polymerization of the
monomers in presence of UV radiation.
[0029] As used herein, the term "polymer" includes the term
"copolymer," and, unless otherwise indicated, the term "copolymer"
refers to polymers made from any two or more different monomers,
including, for example, terpolymers, pentapolymers, homopolymers
functionalized after polymerization so that two or more different
functional groups are present in the product copolymer, block
copolymers, segmented copolymers, graft copolymers, and any mixture
or combination thereof. As used herein, "(co)polymer" means
homopolymer or copolymer.
[0030] As used herein "composite fiber" means a collection of one
or more fibers coated with a polymeric material.
[0031] As used herein, "equivalent diameter" means diameter as
defined in EN14889 Standard.
[0032] As used herein, "aspect ratio" means a length-to-diameter
ratio as defined in EN14889 Standard.
[0033] As used herein, "concrete" means any type of building
material containing aggregates embedded in matrix (the cement or
binder) that fills the space among the aggregate particles and
glues them together e.g. Portland Cement based concrete, mineral
mortar but also asphalt.
[0034] In accordance with various exemplary embodiments, composite
fibers are provided for the reinforcement of concrete. The length
of the composite fibers may be from about 10 to about 80 mm. The
equivalent diameter of the composite fibers may be from about 0.3
to about 2 mm. In other exemplary embodiments, the length of the
composite fibers is from about 30 to about 50 mm and the equivalent
diameter of the composite fibers is from about 0.5 to about 1.0
mm.
[0035] The shape of the composite fiber may vary. In some exemplary
embodiments the composite fibers are generally cylindrical or
ellipsoidal. Additionally, the surface of the composite fibers may
vary, such as from smooth to rough or embossed.
[0036] In certain exemplary embodiments, the fiber is an inorganic
fiber, such as a glass or other mineral fiber. Non-exclusive
exemplary glass fibers include A-type glass fibers, C-type glass
fibers, G-type glass fibers, E-type glass fibers, S-type glass
fibers, E-CR-type glass fibers (e.g., Advantex.RTM. glass fibers
commercially available from Owens Corning), R-type glass fibers,
biosoluble glass fibers, alkali-resistant glass, or combinations
thereof, all of which may be suitable for use as the reinforcing
fiber. In some exemplary embodiments, an alkali-resistant glass
fiber, such as Cemfil.RTM. available from Owens Corning, is
suitable for use as the reinforcing fiber.
[0037] The diameter of the monofilaments forming the fiber may vary
from about 10 to about 27 microns, or from about 13 to about 20
microns.
[0038] The tex of the fibers may be from 300 to 2400 tex. In some
exemplary embodiments, the tex is in the range of 400 to 1200
tex.
[0039] According to various exemplary embodiments, at least 50% of
the surface of the filaments is impregnated with a polymeric
coating. In other exemplary embodiments, up to 95% of the surface
of the filaments is impregnated with the polymeric coating. The
polymeric coating may be a radiation cured polymeric coating, such
as, for example, a UV cured polymeric coating. A wide range of
radiation, and in particular UV curable monomers, oligomers or
polymers, are known in the art. Particularly suitable UV curable
monomers, oligomers or polymers include acrylates, methacrylates,
vinylethers and vinyl derivatives based on polyurethane, epoxy,
polyester, polyether structures with or without aliphatic or
aromatic backbones, and copolymers based on such structures. In
some exemplary embodiments, the polymeric coating includes
polyurethanes based on aromatic structure, alone or in a mixture
with epoxy or polyether derivative. In some exemplary embodiments,
the polymeric coating is a polyurethane resin.
[0040] The polymeric coating may comprise about 5 to about 50 wt %,
of the composite fiber. In some exemplary embodiments, the
polymeric coating is from about 10 to about 30 wt % of the
composite fiber.
[0041] The exemplary composite fibers described herein may be
manufactured using any suitable type of fiber, such as, for
example, a glass fiber. A liquid, or otherwise viscous, monomeric
or oligomeric coating composition may be prepared and applied to
the surface of the fiber, forming a coated element. In some
exemplary embodiments, the polymeric coating comprises a polyester
or vinylester. The coated element may then be exposed to radiation,
such as UV radiation, which cures the coating composition to form a
composite fiber.
[0042] In some exemplary embodiments, the composite fibers
described herein may be used to reinforce concrete. The reinforced
concrete may be formed by preparing a concrete (e.g., using a
conventional method of forming concrete) followed by mixing the
composite fibers into the concrete, thereby forming a composite
fiber reinforced concrete. In some exemplary embodiments, the
dosage of composite fibers in the reinforced concrete is from about
2 to about 75 kg of fiber per cubic meter of concrete, or from
about 5 to about 25 kg of fiber per cubic meter of concrete. In
some exemplary embodiments, the dosage of composite fibers in the
reinforced concrete is from about 7.5 to about 12.5 kg of fiber per
cubic meter of concrete.
[0043] Thus, the general inventive concepts also encompass using
the composite fibers for the reinforcement of concrete or other
building materials.
[0044] The composite fibers have a combination of particular
dimensions that result in a surprisingly good performance in the
reinforcement of concrete while showing a surprisingly good
workability in the process of manufacturing concrete. This
workability performance is evaluated through the Slump test, as
defined in EN12350-2 Standard.
[0045] Other advantages of the composite fibers described herein
include a high speed of dispersion during the mixing process, ease
in achieving a uniform distribution of fibers in the concrete mass,
reduced wearing of mixing and pumping systems, less risk of
clogging pumping pipes and blockings when filling structural
elements, and less risk of honeycombs and consequent durability
issues when used in combination with conventional
reinforcement.
[0046] The composite fibers are also safe for handling by workers.
Exemplary reasons for this safety include the low weight of the
composite fiber and the nonexistence of any sharp pins.
[0047] In some exemplary embodiments, the composite fibers do not
corrode and, hence, do not develop corrosion stains in case of
exposed concrete surfaces. Additionally, the composite fibers make
the hardened concrete easier to recycle, as compared to traditional
steel fibers.
[0048] Moreover, the manufacturing process of the composite fibers
leads to low or reduced manufacturing costs. The process is
flexible and adaptable to fit in with other stages in a continuous
production line. For instance, the line speed may be easily varied
to accommodate overall production variations. Additionally, the
coating is immediately functional and able to be handled and
requires no post-heating or drying. In that respect, the process
allows for line speeds that can reach over 50 m/min, such as, for
example, over 100 m/min.
[0049] The general inventive concepts have been described above
both generally and with regard to various specific exemplary
embodiments. Although the general inventive concepts have been set
forth in what are believed to be exemplary illustrative
embodiments, a wide variety of alternatives will be apparent to
those of skill in the art from reading this disclosure. The general
inventive concepts are not otherwise limited, except for those
instances when presented in specific claims. Additionally, the
following examples are meant to better illustrate the present
invention, but do not limit the general inventive concepts.
EXAMPLES
[0050] The following examples describe the performance of various
exemplary embodiments of the composite fibers of the present
invention, as used for concrete reinforcement. Composite fibers
were prepared with Cemfil.RTM. glass fibers available from Owens
Corning and polyester resin standard cured using UV radiation.
Resin content was 20 wt % of the composite fiber. The consistency
or workability of the fresh concrete was measured according to the
EN 12350-2 Standard. This test is reflected in the tables below as
the Slump measurement. The flexural performance of hardened
concrete was measured according to the EN 14651 after 28 days of
standard curing (i.e., 20.degree. C. and 100% relative humidity).
The concrete compressive strength measured according to the EN
12390-3 standard was 30 MPa.
[0051] In the tables below, LOP refers to the limit of
proportionality, which corresponds to the flexural tensile strength
at the first crack produced. The residual flexural tensile
strengths are reflected as f.sub.R1 and f.sub.R3.
Example 1
Influence of Equivalent diameter and Aspect Ratio on the
Performance
[0052] Dosage of the fiber was 10 kg fiber per cubic meters of
concrete. Length of the composite fiber was 40 mm. The
manufacturing speed of the composite fibers was 200 meters/min.
Table 1 shows the influence of the equivalent diameter and aspect
ratio of the composite fiber on performance.
TABLE-US-00001 TABLE 1 Impact of the equivalent diameter of the
composite fiber on performance Equivalent Slump LOP f.sub.R1
f.sub.R3 diameter (mm) (cm) (MPa) (MPa) (MPa) 0.40 8 3.86 1.36 0.69
0.60 12 3.65 1.97 2.13 0.70 17 3.72 2.77 2.73
Example 2
Influence of Fiber Length on Performance
[0053] Dosage of the fiber was 10 kg of fiber per cubic meters of
concrete. The equivalent diameter of the composite fiber was 0.70
mm. The composite fiber manufacturing speed was 200 meters/min.
Table 2 shows the influence of the length and aspect ratio of the
composite fiber on performance.
TABLE-US-00002 TABLE 2 Influence of the length of the composite
fiber on performance Length Slump LOP f.sub.R1 f.sub.R3 (mm) (cm)
(MPa) (MPa) (MPa) 25 25 3.94 2.18 1.73 40 17 3.72 2.77 2.73
Example 3
Influence of Resin Content on Performance
[0054] Dosage of the fiber was 10 kg of fibers per cubic meters of
concrete. The length of the composite fiber was 40 mm and its
equivalent diameter was 0.7 mm. The manufacturing speed of the
composite fiber was 200 m/min. Table 3 shows the influence of the
resin and aspect ratio of the composite fiber on performance.
TABLE-US-00003 TABLE 3 Influence of the resin content of the
composite fiber on performance Resin Equivalent Slump LOP f.sub.R1
f.sub.R3 content (%) Diameter (mm) (cm) (MPa) (MPa) (MPa) 20 0.70
17 3.72 2.77 2.73 24 0.72 22 3.97 2.83 2.91
Example 4
Influence of the Dosage on the Performance
[0055] Length of the composite fiber was 40 mm and its equivalent
diameter was 0.70 mm and its length was 40 mm. Line speed was 200
m/min. Table 4 shows the influence of different dosages on
performance.
TABLE-US-00004 TABLE 4 Influence of the dosage on the performance
Dosage Slump LOP f.sub.R1 f.sub.R3 (kg/m3) (cm) (MPa) (MPa) (MPa) 7
22 3.68 1.9 1.91 10 17 3.72 2.77 2.73
Example 5
Influence of the Line Speed on the Performance
[0056] Dosage of the fiber was 10 kg of fiber per cubic meter of
concrete. Length of the composite fiber was 40 mm and its
equivalent diameter was 0.70 mm. Table 5 shows the influence of
different line speeds on performance.
TABLE-US-00005 TABLE 5 Influence of the line speed on performance
(impregnation quality) Line speed Slump LOP f.sub.R1 f.sub.R3
(m/min) (cm) (MPa) (MPa) (MPa) 100 19 3.92 2.58 2.78 200 17 3.72
2.77 2.73 280 14 3.85 2.17 1.78
* * * * *