Lightweight fiber reinforced polymer composite modular panel

• US 6,591,567 B2
• Filed: 12/10/2001
• Issued: 07/15/2003
• Est. Priority Date: 12/09/2000
• Status: Active Grant

• Current Assignee: West Virginia University
• Original Assignee: West Virginia University
• Inventors: Hota, Siva Ram V., Hota, GangaRao V. S.
• Primary Examiner(s): Chapman, Jeanette
• Application Number:
  US10/013,768
• Publication Number:
  US 20020062607A1
• Time in Patent Office: 582 Days
• Field of Search: 521/77, 521/79, 521/80, 521/81, 525/81, 525/821, 525/881, 527/821, 527/831, 525/921, 525/924, 526/503, 527/312, 527/313, 527/316, 527/321, 527/322, 525/78, 525/862, 527/931, 527/931.1, 525/861, 527/831.1, 527/831.7, 14/3, 14/7, 14/13, 14/14, 14/73
• US Class Current: 52/578
• CPC Class Codes: B29C 65/342 comprising at least a single wire, e.g. in the form of a winding
• CPC Class Codes: B29C 65/348 with a polymer coating
• CPC Class Codes: B29C 65/4815 Hot melt adhesives, e.g. thermoplastic adhesives
• CPC Class Codes: B29C 65/58 Snap connection
• CPC Class Codes: B29C 66/1282 comprising at least one overlap joint-segment
• CPC Class Codes: B29C 66/12841 comprising at least two butt joint-segments
• CPC Class Codes: B29C 66/1286 comprising at least one bevelled joint-segment
• CPC Class Codes: B29C 66/14 the joint having the same thickness as the thickness of the parts to be joined B29C66/1142 takes precedence
• CPC Class Codes: B29C 66/438 Joining sheets for making hollow-walled, channelled structures or multi-tubular articles
• CPC Class Codes: B29C 66/524 Joining profiled elements
• CPC Class Codes: B29C 66/71 characterised by the composition of the plastics material of the parts to be joined welding bar compositions B29C65/125
• CPC Class Codes: B29C 66/721 Fibre-reinforced materials B29C66/729 takes precedence
• CPC Class Codes: B29C 66/72141 Fibres of continuous length
• CPC Class Codes: B29C 66/72143 Fibres of discontinuous lengths
• CPC Class Codes: B29C 66/72523 multi-channelled or multi-tubular B29C66/438, B29C66/5227 take precedence
• CPC Class Codes: B29K 2031/00 Use of polyvinylesters or derivatives thereof as moulding material
• CPC Class Codes: B29K 2061/04 Phenoplasts
• CPC Class Codes: B29K 2063/00 Use of EP, i.e. epoxy resins or derivatives thereof, as moulding material
• CPC Class Codes: B29K 2067/00 Use of polyesters or derivatives thereof, as moulding material
• CPC Class Codes: B29K 2105/06 containing reinforcements, fillers or inserts
• CPC Class Codes: B29L 2024/006 : multi-channelled
• CPC Class Codes: E01D 19/125 : Grating or flooring for bridges waterproofing thereof E01D19/083; floors in general E04B5/00
• CPC Class Codes: E01D 2101/40 : Plastics
• CPC Class Codes: E04B 5/026 : with beams or slabs of plastic
• CPC Class Codes: E04C 2/22 : reinforced E04C2/205 takes precedence
• CPC Class Codes: E04C 2/34 : composed of two or more spaced sheet-like parts E04C2/32 takes precedence; spacers for cavity walls E04B2/44
• CPC Class Codes: E04F 15/02172 : Floor elements with an anti-skid main surface, other than with grooves
• CPC Class Codes: E04F 15/10 : of other materials, e.g. fibrous or chipped materials, organic plastics, magnesite tiles, hardboard , or with a top layer of other materials

Abstract

A modular fiber reinforced polymer (FRP) module that interlocks with other similarly designed modules. Specifically, each FRP module has a female, receiver, end and a male, inserter, end such that the inserter of a first FRP module interlocks with, or “snaps into” or “slids into,” a receiver of an adjacent second FRP module. Once interlocked, the two connected FRP modules are further secured by either adhesive and/or thermal connections. An FRP module is made of multiple layers of multi-axial fiber reinforcement and a resin matrix, the layers being continuous throughout the entire shape of the module. An overlay may be placed over the top face of one or more FRP modules joined together to provide a uniform surface. In addition, one or more exterior FRP composite laminates, grids, plates or fabrics may be bonded continuously to the top face. In certain embodiments, one or more of the internal spaces of a FRP module may be filled with a filler for thermal insulation, noise reduction insulation, or a strength and stability enhancement of the FRP module.

Claims

1. A fiber reinforced polymer (FRP) module for a panel, deck, or wall system, comprising:

a top piece having a top face, a length, a width, a thickness, a first end, and a second end;

a bottom piece having a bottom face, a length, a width, a thickness, a first end, and a second end; and

a means for supporting said top face a predefined distance from said bottom face;

wherein said first end of said top face and said first end of said bottom face comprise a receiver having a length and said second end of said top face and said second end of said bottom face comprise an inserter having a length, wherein said length of each said receiver and said inserter is within a range of about 15 percent to about 25 percent of said length of said top piece;

wherein the FRP module is adapted to be pressure fit to a first adjacent FRP module and a second adjacent FRP module, such that said receiver of the FRP module interlocks with an inserter of said first adjacent FRP module and said inserter of the FRP module interlocks with a receiver of said second adjacent FRP module;

wherein the FRP module is made of two or more layers of multi-axial fiber reinforced fabric adhered together by a resin matrix, said layers of fabric being continuous throughout the entire shape of the FRP module.

2. The FRP module according to claim 1, wherein said inserter comprises one or more recessed portions and said receiver comprises one or more interior recessed portions such that said inserter and said receiver form a tongue and groove joint when interlocked.

39. The FRP module according to claim 1, wherein said top piece and said bottom piece are graduated in thickness such that the thickness of the center of said top piece is greater than the thickness of the first end and the second end of said top piece and the thickness of the center of said bottom piece is greater than the thickness of the first end and the second end of said bottom piece.

3. A fiber reinforced polymer (FRP) module for a panel, deck, or wall system, comprising:

a top piece having a top face, a length, a width, a thickness, a first end, and a second end;

a bottom piece having a bottom face, a length, a width, a thickness, a first end, and a second end; and

a means for supporting said top face a predefined distance from said bottom face, wherein said means for supporting comprises a first web connecting said top piece at a first intersection to said bottom piece at a second intersection, a second web a predefined distance from said first web connecting said top piece at a third intersection to said bottom piece at a fourth intersection, and one or more diagonal webs diagonally connecting said first web at a fifth intersection to said second web at a sixth intersection, thereby defining one or more internal spaces, wherein said fifth intersection is at a point on said first web between said first intersection and said second intersection and said sixth intersection is at a point on said second web between said third intersection and said fourth intersection;

wherein said first end of said top face and said first end of said bottom face comprise a receiver having a length and said second end of said top face and said second end of said bottom face comprise an inserter having a length,

wherein the FRP module is adapted to be pressure fit to a first adjacent FRP module and a second adjacent FRP module, such that said receiver of the FRP module interlocks with an inserter of said first adjacent FRP module and said inserter of the FRP module interlocks with a receiver of said second adjacent FRP module;

wherein the FRP module is made of two or more layers of multi-axial fiber reinforced fabric adhered together by a resin matrix, said layers of fabric being continuous throughout the entire shape of the FRP module.

4. The FRP module according to claim 3, wherein said first web and said second web are vertically aligned between said top piece and said bottom piece.

5. The FRP module according to claim 3, further comprising:

a means for reinforcing one or more intersections of the FRP module.

7. The FRP module according to claim 3, further comprising one or more intermediary webs connecting said top piece and said bottom piece positioned between said first web and said second web.

8. The FRP module according to claim 7, wherein said intermediary webs are vertically aligned with said first web and said second web.

10. The FRP module according to claim 3, further comprising:

a means for reinforcing an interlocking of said receiver of the FRP module with said inserter of said first adjacent FRP module.

13. The FRP module according to claim 10, wherein said means for reinforcing comprises an adhesive bond between said receiver of the FRP module and said inserter of said first adjacent FRP module.

14. The FRP module according to claim 3, wherein the FRP module is manufactured by a manufacturing process selected from the group consisting of Vacuum Assisted Resin Transfer Molding (VARTM) process, Seeman Composite Resin Infusion Molding Process (SCRIMP), and pultrusion process.

17. The FRP module according to claim 3, further comprising an overlay placed over said top face thereby resulting in a uniform wearing surface.

18. The FRP module according to claim 17, wherein said overlay is selected from the group consisting of concrete, asphalt, polymer concrete, and bonded grid anti-skid surface.

19. The FRP module according to claim 3, further comprising one or more exterior FRP composite laminates, grids, plates or fabrics bonded continuously to said top face.

20. The FRP module according to claim 3, further comprising one or more protrusion areas for receiving an overlap of said one or more layers of multi-axial fiber reinforced fabric.

21. The FRP module according to claim 20, wherein said protrusion areas are positioned at high stress areas of the FRP module.

34. The FRP module according to claim 3, wherein the length of each said receiver and said inserter is within a range of about 15 percent to about 25 percent of said length of said top piece.

35. The FRP module according to claim 3, wherein said fifth intersection is located on said first web at a distance from said first intersection or said second intersection equal to about ten percent of said length of said first web.

36. The FRP module according to claim 35, wherein said sixth intersection is located on said second web at a distance from said third intersection or said fourth intersection equal to about ten percent of said length of said second web.

37. The FRP module according to claim 3, wherein said inserter comprises one or more recessed portions and said receiver comprises one or more interior recessed portions such that said inserter and said receiver form a tongue and groove joint when interlocked.

38. The FRP module according to claim 3, wherein said top piece and said bottom piece are graduated in thickness such that the thickness of the center of said top piece is greater than the thickness of the first end and the second end of said top piece and the thickness of the center of said bottom piece is greater than the thickness of the first end and the second end of said bottom piece.

6. A fiber reinforced polymer (FRP) module for a panel, deck, or wall system, comprising:

a top piece having a top face, a length, a width, a thickness, a first end, and a second end;

a bottom piece having a bottom face, a length, a width, a thickness, a first end, and a second end;

a means for supporting said top face a predefined distance from said bottom face, wherein said means for supporting comprises a first web connecting said top piece at a first intersection to said bottom piece at a second intersection, a second web a predefined distance from said first web connecting said top piece at a third intersection to said bottom piece at a fourth intersection, and one or more diagonal webs diagonally connecting said first web at a fifth intersection to said second web at a sixth intersection, thereby defining one or more internal spaces; and

a means for reinforcing one or more intersections of the FRP module, wherein said means for reinforcing is a thermoplastic rod with whiskers that are melted to bond said layers of fabric at said intersections;

wherein said first end of said top face and said first end of said bottom face comprise a receiver and said second end of said top face and said second end of said bottom face comprise an inserter, such that said receiver of the FRP module interlocks with an inserter of an adjacent FRP module and said inserter of the FRP module interlocks with a receiver of said adjacent FRP module;

wherein the FRP module is made of two or more layers of multi-axial fiber reinforced fabric adhered together by a resin matrix, said layers of fabric being continuous throughout the entire shape of the FRP module.

9. A fiber reinforced polymer (FRP) module for a panel, deck, or wall system, comprising:

a top piece having a top face, a length, a width, a thickness, a first end, and a second end;

a bottom piece having a bottom face, a length, a width, a thickness, a first end, and a second end;

a means for supporting said top face a predefined distance from said bottom face, wherein said means for supporting comprises a first web connecting said top piece at a first intersection to said bottom piece at a second intersection, a second web a predefined distance from said first web connecting said top piece at a third intersection to said bottom piece at a fourth intersection, and one or more diagonal webs diagonally connecting said first web at a fifth intersection to said second web at a sixth intersection, thereby defining one or more internal spaces;

wherein the FRP module has one diagonal web and the fifth intersection is positioned on said first web a distance from said bottom piece equal to about ten percent of the length of said first web, and the sixth intersection is positioned on said second web a distance from said top piece equal to about ten percent of the length of said second web;

wherein said first end of said top face and said first end of said bottom face comprise a receiver and said second end of said top face and said second end of said bottom face comprise an inserter, such that said receiver of the FRP module interlocks with an inserter of an adjacent FRP module and said inserter of the FRP module interlocks with a receiver of said adjacent FRP module;

wherein the FRP module is made of two or more layers of multi-axial fiber reinforced fabric adhered together by a resin matrix, said layers of fabric being continuous throughout the entire shape of the FRP module.

11. A fiber reinforced polymer (FRP) module for a panel, deck, or wall system, comprising:

a top piece having a top face, a length, a width, a thickness, a first end, and a second end;

a bottom piece having a bottom face, a length, a width, a thickness, a first end, and a second end, wherein said first end of said top face and said first end of said bottom face comprise a receiver and said second end of said top face and said second end of said bottom face comprise an inserter, such that said receiver of the FRP module interlocks with an inserter of an adjacent FRP module and said inserter of the FRP module interlocks with a receiver of said adjacent FRP module;

a means for supporting said top face a predefined distance from said bottom face; and

a means for reinforcing an interlocking of said receiver of the FRP module with said inserter of said adjacent FRP module, wherein said means for reinforcing comprises a thermoplastic rod having a length, a metal rod in contact with said thermoplastic rod, and a means for heating said metal rod such that said thermoplastic rod melts along the length of said thermoplastic rod, thereby fusing said receiver of the FRP module with said inserter of said adjacent FRP module;

wherein the FRP module is made of two or more layers of multi-axial fiber reinforced fabric adhered together by a resin matrix, said layers of fabric being continuous throughout the entire shape of the FRP module.

12. The FRP module according to claim 11, wherein the length of said thermoplastic rod is about the length of the FRP module.

15. A fiber reinforced polymer (FRP) module for a panel, deck, or wall system, comprising:

a top piece having a top face, a length, a width, a thickness, a first end, and a second end;

a bottom piece having a bottom face, a length, a width, a thickness, a first end, and a second end;

a means for supporting said top face a predefined distance from said bottom face, wherein said means for supporting comprises a first web connecting said top piece at a first intersection to said bottom piece at a second intersection, a second web a predefined distance from said first web connecting said top piece at a third intersection to said bottom piece at a fourth intersection, and one or more diagonal webs diagonally connecting said first web at a fifth intersection to said second web at a sixth intersection, thereby defining one or more internal spaces; and

a filler in one or more of said one or more internal spaces;

wherein said first end of said top face and said first end of said bottom face comprise a receiver and said second end of said top face and said second end of said bottom face comprise an inserter, such that said receiver of the FRP module interlocks with an inserter of an adjacent FRP module and said inserter of the FRP module interlocks with a receiver of said adjacent FRP module;

wherein the FRP module is made of two or more layers of multi-axial fiber reinforced fabric adhered together by a resin matrix, said layers of fabric being continuous throughout the entire shape of the FRP module.

16. The FRP module according to claim 15, wherein said filler is selected from the group consisting of thermal insulation, noise reduction insulation, and strength and stability enhancement.

22. A fiber reinforced polymer (FRP) module for a panel, deck, or wall system, comprising:

a top piece having a top face, a length, a width, a thickness, a first end, and a second end;

a bottom piece having a bottom face, a length, a width, a thickness, a first end, and a second end; and

a means for supporting said top face a predefined distance from said bottom face;

wherein said first end of said top face and said first end of said bottom face comprise a receiver and said second end of said top face and said second end of said bottom face comprise an inserter, such that said receiver of the FRP module interlocks with an inserter of an adjacent FRP module and said inserter of the FRP module interlocks with a receiver of said adjacent FRP module;

wherein the FRP module is made of two or more layers of multi-axial fiber reinforced fabric adhered together by a resin matrix, said layers of fabric being continuous throughout the entire shape of the FRP module;

wherein said top piece and said bottom piece are graduated in thickness such that the thickness of the center of said top piece is greater than the thickness of the first end and the second end of said top piece and the thickness of the center of said bottom piece is greater than the thickness of the first end and the second end of said bottom piece.

23. A method for building a panel, deck or wall system, comprising the steps of:

(a) positioning a fiber reinforced polymer (FRP) module having a top piece with a top face, a length, a width, a thickness, a first end, and a second end, a bottom piece having a bottom face, a length, a width, a thickness, a first end, and a second end, a first web connecting said top piece at a first intersection to said bottom piece at a second intersection, a second web a predefined distance from said first web connecting said top piece at a third intersection to said bottom piece at a fourth intersection, and one or more diagonal webs diagonally connecting said first web at a fifth intersection to said second web at a sixth intersection, thereby defining one or more internal spaces, wherein said fifth intersection is at a point on said first web between said first intersection and said second intersection and said sixth intersection is at a point on said second web between said third intersection and said fourth intersection, wherein said first end of said top face and said first end of said bottom face comprise a receiver having a length and said second end of said top face and said second end of said bottom face comprise an inserter having a length, wherein said FRP module is adapted to be pressure fit to a first adjacent FRP module and a second adjacent FRP module, such that said receiver of said FRP module interlocks with an inserter of said first adjacent FRP module and said inserter of said FRP module interlocks with a receiver of said second adjacent FRP module, and wherein said FRP module is made of two or more layers of multi-axial fiber reinforced fabric adhered together by a resin matrix, said layers of fabric being continuous throughout the entire shape of said FRP module; and

(b) inserting an inserter of a second FRP module into said receiver of said FRP module.

24. The method according to claim 23, further comprising the step of:

(c) applying an adhesive between said receiver of said FRP module and said inserter of said second FRP module.

25. The method according to claim 23, further comprising the step of:

(c) reinforcing an interlocking of said receiver of said FRP module with said inserter of said second FRP module.

30. The method according to claim 23, further comprising the step of:

(c) placing an overlay over said top face thereby resulting in a uniform wearing surface.

31. The method according to claim 30, wherein said overlay is selected from the group consisting of concrete, asphalt, polymer concrete, and bonded grit anti-skid surface.

32. The method according to claim 23, further comprising the step of:

(c) applying one or more exterior FRP composite laminates, grids, plates or fabrics bonded continuously to said top face.

33. The method according to claim 23, further comprising the step of:

(c) positioning one or more support beams underneath said FRP module and said second FRP module such that said support beams are placed parallel to a flow of traffic and that said FRP module and said second FRP module are placed perpendicular to said support beams.

26. A method for building a panel, deck or wall system, comprising the steps of:

(a) positioning a first fiber reinforced polymer (FRP) module having a top piece with a top face, a length, a width, a thickness, a first end, and a second end, a bottom piece having a bottom face, a length, a width, a thickness, a first end, and a second end, a first web connecting said top piece at a first intersection to said bottom piece at a second intersection, a second web a predefined distance from said first web connecting said top piece at a third intersection to said bottom piece at a fourth intersection, and one or more diagonal webs diagonally connecting said first web at a fifth intersection to said second web at a sixth intersection, thereby defining one or more internal spaces, wherein said first end of said top face and said first end of said bottom face comprise a receiver and said second end of said top face and said second end of said bottom face comprise an inserter, such that said receiver of the FRP module interlocks with an inserter of an adjacent FRP module and said inserter of the FRP module interlocks with a receiver of said adjacent FRP module, and wherein the FRP module is made of two or more layers of multi-axial fiber reinforced fabric adhered together by a resin matrix, said layers of fabric being continuous throughout the entire shape of the FRP module;

(b) inserting an inserter of a second FRP module into said receiver of said first FRP module; and

(c) reinforcing an interlocking of said receiver of said first FRP module with said inserter of said second FRP module, wherein said reinforcing of said step (c) comprises the steps of;

(c.1) positioning a thermoplastic rod having a length inbetween said receiver of said first FRP module and said inserter of said second FRP module;

(c.2) contacting a metal rod with said thermoplastic rod; and

(c.3) heating said metal rod such that said thermoplastic rod melts along the length of said thermoplastic rod, thereby fusing said receiver of said first FRP module with said inserter of said second FRP module.

27. The method according to claim 26, wherein the length of said thermoplastic rod is equal to the length of the FRP module.

28. A method for building a panel, deck or wall system, comprising the steps of:

(a) positioning a first fiber reinforced polymer (FRP) module having a top piece with a top face, a length, a width, a thickness, a first end, and a second end, a bottom piece having a bottom face, a length, a width, a thickness, a first end, and a second end, a first web connecting said top piece at a first intersection to said bottom piece at a second intersection, a second web a predefined distance from said first web connecting said top piece at a third intersection to said bottom piece at a fourth intersection, and one or more diagonal webs diagonally connecting said first web at a fifth intersection to said second web at a sixth intersection, thereby defining one or more internal spaces, wherein said first end of said top face and said first end of said bottom face comprise a receiver and said second end of said top face and said second end of said bottom face comprise an inserter, such that said receiver of the FRP module interlocks with an inserter of an adjacent FRP module and said inserter of the FRP module interlocks with a receiver of said adjacent FRP module, and wherein the FRP module is made of two or more layers of multi-axial fiber reinforced fabric adhered together by a resin matrix, said layers of fabric being continuous throughout the entire shape of the FRP module;

(b) inserting an inserter of a second FRP module into said receiver of said first FRP module; and

(c) filling a filler in one or more of said one or more internal spaces.

29. The method according to claim 28, wherein said filler is selected from the group consisting of thermal insulation, noise reduction insulation, and strength stability enhancement.