Textile reinforced structural components

• US 4,819,395 A
• Filed: 07/02/1987
• Issued: 04/11/1989
• Est. Priority Date: 12/26/1985
• Status: Expired due to Term

• Current Assignee: Asahi Glass Matex Company Limited (Nippon Molymer Co., Ltd.), Shimizu Construction Co. Ltd.
• Original Assignee: Dainihon Glass Industry Company Limited, Shimizu Construction Co. Ltd.
• Inventors: Nishimoto, Takashi, Hiraga, Hisao, Futagawa, Minoru, Fujisaki, Tadashi, Nakatsuji, Teruyuki, Sugita, Minoru
• Primary Examiner(s): Ridgill, Jr., James L.
• Application Number:
  US07/069,483
• Time in Patent Office: 649 Days
• Field of Search: 156/181, 428/109, 428/113, 428/255, 52/309.16, 52/660-662
• US Class Current: 52/309.16
• CPC Class Codes: E04C 5/07 Reinforcing elements of material other than metal, e.g. of glass, of plastics, or not exclusively made of metal metal elements with non-structural coatings E04C5/01
• CPC Class Codes: Y10T 428/24091 with additional layer[s]
• CPC Class Codes: Y10T 428/24099 On each side of strands or strand-portions
• CPC Class Codes: Y10T 428/249942 Fibers are aligned substantially parallel
• CPC Class Codes: Y10T 428/249946 Glass fiber
• CPC Class Codes: Y10T 442/14 Including an additional scrim layer

Abstract

A textile reinforced structural component including: a structural component body made of a structural filler; first parallel textile elements; second parallel textile elements crossing the first parallel textile elements at first crossing portions, each of the first textile elements and the second textile elements including at least one row of first textiles and a first resin matrix, made of a first resin, for bonding the first textiles; and an attaching mechanism for attaching the first reinforcement elements and the second reinforcement elements at corresponding first crossing portions to form a grid member. The attaching means includes the first resin. The first and the second reinforcement elements are impregnated with the first resin before attachment thereof, and the grid member is embedded in the structural component body.

Claims

1. A textile reinforced structural component comprising:

(a) a structural component body made of a structural filler;

(b) first parallel reinforcement elements;

(c) second parallel reinforcement elements crossing said first parallel reinforcement elements at first crossing portions, each of both said first reinforcement elements and said second reinforcement elements including at least one row of first textiles and a first resin matrix, made of a first resin, for bonding said first textiles thereof; and

(d) attaching means for attaching said first reinforcement elements and said second reinforcement elements at corresponding first crossing portions to form a grid member, said attaching means comprising said first resin,

wherein;

(e) said first and said second reinforcement elements are impregnated with said first resin before attachment thereof;

(f) said grid member is embedded in said structural component body;

(g) at least one of both said first reinforcement elements and said second reinforcement elements each comprise a plurality of textile rows;

(h) the textile rows of both a corresponding first reinforcement element and a corresponding second reinforcement element are alternately stacked at said first crossing portions,

(i) said first reinforcement elements and said second reinforcement elements are bonded with said first resin at said first crossing portions;

(j) said grid member includes a plurality of grid openings; and

(k) said textile reinforced structural component further comprises first resin impregnated mesh textiles and second resin impregnated mesh textiles, each of said first and second resin impregnated mesh textiles passing through at least one of both said first reinforcement elements and said second reinforcement elements to form a mesh in each of said grid openings.

2. A textile reinforced structural component as recited in claim 1, wherein said first reinforcement elements and said second reinforcement elements have a substantially rectangular cross-section.

3. A textile reinforced structural component as recited in claim 2, wherein:

(a) said grid member is substantially two-dimensional and

(b) said grid member is embedded in said structural component body so that said grid member is parallel with a surface of said structural component body.

4. A textile reinforced structural component as recited in claim 3, wherein:

(a) said grid member has a peripheral portion;

(b) said grid member is used in the number of at least two; and

(c) adjacent grid members are disposed to overlap each other at the peripheral portions thereof.

5. A textile reinforced structural component as recited in claim 1, 2, 3 or 4, wherein:

(a) said first textiles are each formed in at least one structure of a tow, roving, strand, yarn, thread, sennit, twisted cord, and braid;

(b) said first textiles are made of at lease one fiber selected from the group consisting of a glass fiber, carbon fiber, aramid fiber, boron fiber, ceramic fiber, and metallic fiber; and

(c) said structural filler is a substance selected from the group consisting of a concrete, cement, plaster, glass, clay, mixture of both a clay and pieces of a straw, carbon, asbestos, an epoxy resin, unsaturated polyester resin, vinyl ester resin, polyurethane resin, diallylphthalate resin, phenolic resin, polyacetal resin, saturated polyester resin, unsaturated polyester resin, ABS (acrylonitrile butadien styrene copolymer), polyimide, polyamide resin, polystyrene resin, polycarbonate resin, polyvinyl chloride resin, polyethylene resin, polypropylene resin, acrylic resin, PEEK and PPS.

6. A textile reinforced structural component as recited in claim 5, wherein said first resin matrixes are each made of at least one substance selected from the group consisting of an epoxy resin, unsaturated polyester resin, vinyl ester resin, polyurethane resin, diallylphthalate resin, phenolic resin, polyacetal resin, saturated polyester resin, polyamide resin, polystyrene resin, polycarbonate resin, polyvinyl chloride resin, polyethylene resin, polypropylene resin and acrylic resin.

7. A textile reinforced structural component as recited in claim 6, wherein said first reinforcement elements and said second reinforcement elements each contain about 10 to about 90% by volume of said first textiles and about 90 to about 10% by volume of said first resin.

8. A textile reinforced structural component as recited in claim 7, wherein said first reinforcement elements and said second reinforcement elements each contain about 30 to about 70% by volume of a glass fiber and about 70 to about 30% by volume of a vinyl ester resin.

9. A textile reinforced structural component as recited in claim 8, wherein said first reinforcement elements and said second reinforcement elements each contain about 20 to 60% by volume of a carbon fiber and about 80 to about 40% by volume of a vinyl ester resin.

10. A textile reinforced structural component as recited in claim 1, 2 or 3, and further comprising:

(a) at least three longitudinal parallel reinforcement elements disposed in a three-dimensional manner and

(b) second attaching means for attaching said longitudinal parallel reinforcement elements to said first reinforcement elements and said second reinforcement elements,

(c) wherein said first reinforcement elements and said second reinforcement elements cross corresponding longitudinal reinforcement elements at second crossing portions and are attached to said corresponding longitudinal reinforcement elements at said second crossing portions with said second attaching means.

11. A textile reinforced structural component as recited in claim 10, wherein said longitudinal reinforcement elements each comprises:

(a) at least one row of second parallel textiles and

(b) a second resin matrix, made of a second resin, for bonding integrally said at least one row of said second textiles, p1 wherein;

(c) the textile rows of each of a corresponding first reinforcement element, a corresponding second reinforcement element, and a corresponding longitudinal reinforcement element are alternately stacked at each of said second crossing portions and

(d) said second attaching means is one of both said first resin and said second resin.

12. A textile reinforced structural component as recited in claim 11, wherein said first reinforcement elements and said second reinforcement elements extend between adjacent two longitudinal reinforcement elements so that said first reinforcement elements and said second reinforcement elements each define generally a spiral in an overall shape thereof.

13. A textile reinforced structural component as recited in claim 11, wherein:

(a) said first textiles and said second textiles are each formed in at least one structure of a tow, roving, strand, yarn, thread, sennit, twisted cord, and braid;

(b) said first textiles and said second textiles are each made of at least one fiber selected from the group consisting of a glass fiber, carbon fiber, aramid fiber, boron fiber, ceramic fiber, and metallic fiber; and

(c) said structural filler is a substance selected from the group consisting of a concrete, cement, plaster, glass, clay, mixture of both a clay and pieces of a straw, carbon, asbestos, an epoxy resin, unsaturated polyester resin, vinyl ester resin, polyurethane resin, diallylphthalate resin, phenolic resin, polyacetal resin, saturated polyester resin, polyamide resin, polystyrene resin, polycarbonate resin, polyvinyl chloride resin, polyethylene resin, polypropylene resin, acrylic resin, and polyetheretherketone.

14. A textile reinforced structural component as recited in claim 13, wherein said first resin matrixes and said second resin matrixes are each made of a substance selected from the group consisting of an epoxy resin, unsaturated polyester resin, vinyl ester resin, polyurethane resin, diallylphthalate resin, phenolic resin, polyacetal resin, saturated polyester resin, polyamide resin, polystyrene resin, polycarbonate resin, polyvinyl chloride resin, polyethylene resin, polypropylene resin and acrylic resin.

15. A textile reinforced structural component as recited in claim 14, wherein:

(a) said first reinforcement elements and said second reinforcement elements each contain about 10 to about 90% by volume of said first textiles and about 90 to about 10% by volume of said first resin and

(b) said longitudinal reinforcement elements each contain about 10 to about 90% by volume of said second textiles and about 90 to about 10% by volume of said second resin.

16. A textile reinforced structural component as recited in claim 15, wherein said first reinforcement elements, said second reinforcement elements, and said longitudinal reinforcement elements each contain about 30 to about 70% by volume of a glass fiber and about 70 to about 30% by volume of a vinyl ester resin.

17. A textile reinforced structural component as recited in claim 16, wherein said first reinforcement elements, said second reinforcement elements, and said longitudinal reinforcement elements each contain about 20 to 60% by volume of a carbon fiber and about 80 to about 40% by volume of a vinyl ester resin.