Inorganic matrix-fabric system and method

• US 20040025465A1
• Filed: 07/30/2002
• Published: 02/12/2004
• Est. Priority Date: 07/30/2002
• Status: Active Grant

• Current Assignee: Saint-Gobain Adfors Canada Ltd. (Compagnie De Saint-Gobain)
• Original Assignee: Saint-Gobain Technical Fabrics Canada Limited (Compagnie de Saint-Gobain SA)
• Inventors: Aldea, Corina-Maria, Roberts, David Geraint
• Granted Patent: US 7,311,964 B2
• Time in Patent Office: Days
• US Class Current: 52/514
• CPC Class Codes: B32B 17/04 bonded with or embedded in a plastic substance
• CPC Class Codes: C03C 25/103 Organic coatings
• CPC Class Codes: C03C 25/1095 to obtain coated fabrics
• CPC Class Codes: C04B 14/42 Glass
• CPC Class Codes: C04B 20/023 Chemical treatment
• CPC Class Codes: C04B 28/02 containing hydraulic cements other than calcium sulfates
• CPC Class Codes: C04B 32/02 with reinforcements contains no documents; reinforcing elements E04C5/00
• CPC Class Codes: E04G 2023/0251 by using fiber reinforced plastic elements
• CPC Class Codes: E04G 23/0218 Increasing or restoring the load-bearing capacity of building construction elements E04G23/0203 and E04G23/0266 take precedence
• CPC Class Codes: Y10T 156/10 Methods of surface bonding and/or assembly therefor
• CPC Class Codes: Y10T 29/49618 Restoring existing member, e.g., reinforcing, repairing
• CPC Class Codes: Y10T 428/249924 Noninterengaged fiber-containing paper-free web or sheet which is not of specified porosity
• CPC Class Codes: Y10T 428/249928 Fiber embedded in a ceramic, glass, or carbon matrix
• CPC Class Codes: Y10T 428/249929 Fibers are aligned substantially parallel
• CPC Class Codes: Y10T 428/249932 Fiber embedded in a layer derived from a water-settable material [e.g., cement, gypsum, etc.]
• CPC Class Codes: Y10T 428/24994 Fiber embedded in or on the surface of a polymeric matrix
• CPC Class Codes: Y10T 428/249946 Glass fiber
• CPC Class Codes: Y10T 428/249948 Fiber is precoated

Abstract

A method of reinforcing a structural support, includes applying a reinforcement system comprising an AR-glass fibrous layer embedded in an inorganic matrix to the structural support. The AR-glass fibrous layer has a sizing applied thereon, and a resinous coating applied is applied over the sizing. The inorganic matrix is adherent to the resinous coating and the resinous coating is adherent to the sizing.

Claims

18. A method of reinforcing a structural support, comprising:

applying a first layer of an inorganic matrix to the structural support;

embedding a first AR-glass open fibrous layer into the matrix, said AR-glass fibrous layer having a sizing applied thereon, and a resinous coating applied over said sizing, said inorganic matrix being adherent to said resinous coating, and said resinous coating being adherent to said sizing; and

applying a second layer of the inorganic matrix to the first AR-glass open fibrous layer.

19. The method of claim 18, wherein the steps of applying a first and second layer of the inorganic matrix includes trowelling the matrix.

20. The method of claim 18, wherein the fibrous layer is embedded into the matrix by hand.

21. The method of claim 18, further comprising:

embedding a second AR-glass fibrous layer into the second layer of matrix; and

applying a third layer of the inorganic matrix to the second AR-glass fibrous layer.

22. The method of claim 18, further comprising:

embedding a third AR-glass fibrous layer into the third layer of the inorganic matrix, and

applying a fourth layer of the inorganic matrix to the third AR-glass fibrous layer.

23. The method of claim 21, wherein the first and second fibrous layer is a bi-directional fibrous layer comprising two rovings of fibers per inch in the weft direction and one roving of fibers per inch in the warp direction.

24. The method of claim 23, wherein one of the first or second fibrous layers is orientated so that the weft direction is parallel to the bottom of the support structure and the other of the first or second fibrous layers is orientated so that the weft direction is perpendicular to the bottom of the support structure.

25. The method of claim 23, wherein one of the first or second fibrous layers is oriented at a clockwise 45°

angle to the bottom of the structural support and the other of the first or second fibrous layers is oriented at a counterclockwise 45°

to the bottom of the structural support.

26. The method of claim 22, wherein each of the first, second and third fibrous layer is a bidirectional fibrous layer comprising two rovings of fibers in the weft direction and one roving of fibers in the warp direction, and wherein one of the fibrous layers is oriented at a clockwise 45°

angle to the bottom of the structural support, one of the fibrous layers is oriented at a counterclockwise 45°

angle to the bottom of the structural support, and one of the fibrous layers is oriented so that the weft direction of the fibrous layer is parallel to the bottom of the structural support.

27. The method of claim 18, wherein the layers of inorganic matrix are approximately ⅛

inch thick.

28. The method of claim 18, wherein the wetting step comprises spraying the structural support with water.

29. The method of claim 18, further comprising wetting the structural support, and wherein the step of wetting the structural support is performed prior to applying the first layer of inorganic matrix.

30. The method of claim 18, wherein the coating comprises PVC plastisol and the sizing comprises a blend of anhydrous polymerized epoxy amine, vinyl and amine coupling agents and a non-ionic surfactant.

31. A method of reinforcing a structural support, comprising:

applying a first layer of an inorganic matrix to the structural support;

embedding a first AR-glass open fibrous layer into the matrix, said AR-glass fibrous layer having a resinous coating applied thereon, said inorganic matrix being adherent to said resinous coating;

applying a second layer of the inorganic matrix to the first AR-glass open fibrous layer;

embedding a second AR-glass fibrous layer into the second layer of matrix; and

applying a third layer of the inorganic matrix to the second AR-glass fibrous layer;

wherein the first and second fibrous layer is a bi-directional fibrous layer, and wherein one of the first or second fibrous layers is orientated so that the weft direction is parallel to the bottom of the support structure and the other of the first or second fibrous layers is orientated so that the weft direction is perpendicular to the bottom of the support structure.

32. A structural support system comprising:

a structural support, and

a reinforcement system adhered to the structural support, said reinforcement system comprising an AR-glass fibrous layer embedded in an inorganic matrix, wherein said AR glass fibrous layer has a sizing applied thereon, and a resinous coating applied over said sizing, said inorganic matrix being adherent to said resinous coating, and said resinous coating being adherent to said sizing.

1. A method of reinforcing a structural support, comprising applying a reinforcement system comprising an AR-glass fibrous layer embedded in an inorganic matrix to the structural support, wherein said AR glass fibrous layer has a sizing applied thereon, and a resinous coating applied over said sizing, said inorganic matrix being adherent to said resinous coating, and said resinous coating being adherent to said sizing.

2. The method of claim 1, wherein the fibrous layer is a bidirectional open fibrous layer having two rovings per inch in a weft direction and one roving per inch in a warp direction

3. The method of claim 1, wherein the fibrous layer is a bi-directional open fibrous layer having one roving in a weft direction and one roving in a warp direction.

4. The method of claim 1, wherein the fibrous layer is comprised of AR-glass yarns.

5. The method of claim 1, wherein the fibrous layer is formed by needling, weaving, knitting, or adhesive bonding of cross laid mesh.

6. The method of claim 1, wherein the fibrous layer is formed from continuous or discontinuous fibers randomly oriented in a non-woven mat.

7. The method of claim 1, wherein the inorganic matrix comprises a cementitious material.

8. The method of claim 7, wherein in the inorganic matrix includes a resin which forms an adhesive bond with said resinous coating.

9. The method of claim 1, wherein the cementitious material includes chopped alkali-resistant glass fibers.

10. The method of claim 1, wherein the coating comprises at least one polymer containing one or more of an acrylate and a vinyl chloride.

11. The method of claim 1, wherein the coating comprises an acrylic.

12. The method of claim 1, wherein the coating comprises PVC plastisol.

13. The method of claim 1, wherein the structural support is comprised of an unreinforced masonry.

14. The method of claim 1, wherein the structural support is comprised of concrete.

15. The method of claim 1, wherein the structural support is comprised of bricks.

16. The method of claim 1, wherein the inorganic matrix is applied in two or more layers.

17. The method of claim 1, wherein the coating comprises PVC plastisol and the sizing comprises a blend of anhydrous polymerized epoxy amine, vinyl and amine coupling agents and a non-ionic surfactant

33. The support system of claim 32, wherein the inorganic matrix comprises a cementitious material.

34. The support system of claim 32, wherein the coating comprises an acrylic or PVC plastisol.

35. The support system of claim 32, wherein the AR-glass fibrous layer is formed by weaving, knitting or adhesive-bonded cross-laid fibers.

36. The support system of claim 31, wherein the fibrous layer is formed from continuous or discontinuous fibers randomly oriented in a non-woven mat.

38. The support system of claim 32, wherein the inorganic matrix directly adheres to the structural support.

39. The support system of claim 32, wherein the structural support comprises an unreinforced masonry.

40. The support system of claim 32, wherein the structural support is comprised of bricks.

41. The support system of claim 32, wherein the structural support is comprised of concrete.

42. The support system of claim 32, wherein the structural support is comprised of cement.

43. The support system of claim 32, wherein the inorganic matrix comprises a cementitious material and chopped AR-glass fibers.

44. The reinforcement material of claim 32, wherein the coating comprises PVC plastisol and the sizing comprises anhydrous polymerized epoxy amine, vinyl and amine coupling agents and a non-ionic surfactant.

45. The reinforcement material of claim 32, wherein the coating comprises acrylic and the sizing comprises an epoxy polymer, vinyl and amine coupling agents, and a non-ionic surfactant.

46. The reinforcement material of claim 32, wherein said inorganic matrix includes a resin which forms an adhesive bond with said resinous coating.

47. The reinforcement material of claim 32, wherein said sizing and said resinous coating form a chemical bond.

36-1. The support system of claim 32, wherein the inorganic matrix material includes chopped alkali-resistant fibers.

48. A method of reinforcing a structural support, comprising applying a reinforcement system comprising a fibrous layer embedded in an inorganic matrix to the structural support, wherein said fibrous layer comprises PVA fibers, carbon fibers, aramid fibers, or a combination thereof.

49. A structural support system comprising:

a structural support, and

a reinforcement system adhered to the structural support, said reinforcement system comprising a fibrous layer embedded in an inorganic matrix to the structural support, wherein said fibrous layer comprises PVA fibers, carbon fibers, aramid fibers, or a combination thereof.