Fiber reinforcement material, products made thereform, and method for making the same

• US 7,168,232 B2
• Filed: 08/01/2003
• Issued: 01/30/2007
• Est. Priority Date: 02/21/2001
• Status: Expired due to Term

• Current Assignee: Forta, LLC
• Original Assignee: Forta Corporation
• Inventors: Biddle, Daniel T., Lovett, Jeffrey B., Pitts, H. Charles Jr.
• Primary Examiner(s): Dye; Rena
• Assistant Examiner(s): Thompson; Camie S.
• Application Number:
  US10/633,026
• Publication Number:
  US 20040038027A1
• Time in Patent Office: 1,278 Days
• Field of Search: 428/364, 428/293.4, 428/373, 428/359, 428/362, 428/400, 428/397, 428/474.4, 527/401, 572/43, 572/44, 572/45, 572/46, 572/47, 572/48, 572/49, 572/50, 572/51
• US Class Current: 57/243
• CPC Class Codes: C04B 16/0625 Polyalkenes, e.g. polyethylene
• CPC Class Codes: C04B 28/02 containing hydraulic cements other than calcium sulfates
• CPC Class Codes: C04B 40/0028 Aspects relating to the mixing step of the mortar preparation
• CPC Class Codes: Y10T 428/249928 Fiber embedded in a ceramic, glass, or carbon matrix
• CPC Class Codes: Y10T 428/2913 Rod, strand, filament or fiber

Abstract

The present invention provides a synthetic fiber and methods for its use and formation. The present invention may comprise a fiber component that is a twisted bundle comprised of multiple strands of a nonfibrillating monofilament, the degree of twist being greater than about 0.9 turns/inch (about 0.36 turns/cm). The present invention may further comprise another fiber component, discrete from the twisted fiber component, that is fibrillated.

Claims

1. A fiber reinforcement material, comprising:

a plurality of polyolefinic strands of monofilaments of about 350 to about 6000 denier per filament, twisted to form a fiber bundle, the degree of twist being greater than about 0.9 turns/inch (about 0.36 turns/cm).

2. The fiber reinforcement material of claim 1, wherein the degree of twist is less than about 2.2 turns/inch (about 0.87 turns/cm).

3. The fiber reinforcement material of claim 1, wherein the degree of twist ranges from greater than about 0.9 turns/inch (about 0.36 turns/cm) to about 1.1 turns/inch (about 0.43 turns/cm).

4. The fiber reinforcement material of claim 1, wherein the degree of twist is about 1.1 turns/inch (about 0.43 turns/cm).

5. The fiber reinforcement material of claim 1, wherein the strands are about 750 denier per filament.

6. The fiber reinforcement material of claim 1, wherein the strands are a copolymer formed of polypropylene and polyethylene.

7. The fiber reinforcement material of claim 6, wherein the copolymer is about 75–

80 percent by weight polypropylene and about 20–

25 percent by weight polyethylene.

8. The fiber reinforcement material of claim 6, wherein the polypropylene is a low melt polypropylene and the polyethylene is a high density polyethylene.

9. The fiber reinforcement material of claim 1, wherein the length of the component is about 19 to 60mm.

10. The fiber reinforcement material of claim 1, wherein the fiber bundle is non-interconnected.

11. The fiber reinforcement material of claim 1, wherein the monofilaments are nonfibrillating.

12. A reinforcement for cementitious material, comprising:

a plurality of polyolefin monofilaments of about 350 to about 6000 denier per filament, the plurality of monofilaments being in a twisted configuration, the degree of twist being greater than about 0.9 turns/inch (about 0.36 turns/cm).

13. The fiber reinforcement material of claim 12, wherein the degree of twist is less than about 2.2 turns/inch (about 0.87 turns/cm).

14. The fiber reinforcement material of claim 12, wherein the degree of twist ranges from greater than about 0.9 turns/inch (about 0.36 turns/cm) to about 1.1 turns/inch (about 0.43 turns/cm).

15. The fiber reinforcement material of claim 12, wherein the degree of twist is about 1.1 turns/inch (about 0.43 turns/cm).

16. The fiber reinforcement material of claim 12, wherein the cementitious material is concrete.

17. A reinforcement for cementitious material, comprising:

a plurality of polyolefin monofilaments, the plurality of monofilaments being in a twisted configuration, the degree of twist being greater than about 0.9 turns/inch (about 0.36 turns/cm), wherein the cementitious material is asphalt.

18. A reinforced cementitious material, comprising:

a cementitious mass; and

,

a fiber component dispersed throughout the mass, the fiber component being a plurality of polyolefinic strands of monofilaments of about 350 to about 6000 denier per filament twisted to form a fiber bundle, the degree of twist being greater than about 0.9 turns/inch (about 0.36 turns/cm).

19. The fiber reinforcement material of claim 18, wherein the degree of twist is less than about 2.2 turns/inch (about 0.87 turns/cm).

20. The fiber reinforcement material of claim 18, wherein the degree of twist ranges from greater than about 0.9 turns/inch (about 0.36 turns/cm) to about 1.1 turns/inch (about 0.43 turns/cm).

21. The fiber reinforcement material of claim 18, wherein the degree of twist is about 1.1 turns/inch (about 0.43 turns/cm).

22. The fiber reinforcement material of claim 18, wherein the strands are a copolymer formed of polypropylene and polyethylene.

23. The fiber reinforcement material of claim 22, wherein the copolymer is about 75–

80 percent by weight polypropylene and about 20–

25 percent by weight polyethylene.

24. The fiber reinforcement material of claim 18, wherein the length of the component is about 19 to 60 mm.

25. The fiber reinforcement material of claim 18, wherein the monofilaments are nonfibrillating and the fiber bundle is non-interconnected.

26. The fiber reinforcement material of claim 18, wherein the cementitious mass is concrete.

27. A reinforced cementitious material, comprising:

a cementitious mass; and

,

a fiber component dispersed throughout the mass, the fiber component being a plurality of polyolefinic strands of monofilaments of about 350 to about 6000 denier per filament twisted to form a fiber bundle, the degree of twist being greater than about 0.9 turns/inch (about 0.36 turns/cm), wherein the cementitious mass is asphalt.

28. A reinforcement material for a cementitious material formed by twisting a plurality of polyolefinic strands of monofilaments of about 350 to about 6000 denier per filament into a fiber bundle for mixing into a cementitious mass, the degree of twist being greater than about 0.9 turns/inch (about 0.36 turns/cm).

29. The reinforcement material of claim 28, wherein the degree of twist is less than about 2.2 turns/inch (about 0.87 turns/cm).

30. The reinforcement material of claim 28, wherein the degree of twist ranges from greater than about 0.9 turns/inch (about 0.36 turns/cm) to about 1.1 turns/inch (about 0.43 turns/cm).

31. The reinforcement material of claim 28, wherein the degree of twist is about 1.1 turns/inch (about 0.43 turns/cm).

32. The reinforcement material of claim 28, wherein the cementitious mass is concrete.

33. A reinforcement material for a cementitious material formed by twisting a plurality of polyolefinic strands of monofilaments into a fiber bundle for mixing into a cementitious mass, the degree of twist being greater than about 0.9 turns/inch (about 0.36 turns/cm), wherein the cementitious mass is asphalt.

34. A reinforced cementitious material, comprising:

a synthetic fiber blend distributed through a matrix of the cementitious material, the synthetic fiber blend, including;

a first fiber component formed of a homopolymer polypropylene fiber; and

a second fiber component being discrete from the first fiber component and being a copolymer formed of a polypropylene and a high density polyethylene, the second fiber component being a plurality of monofilaments twisted to form a non-interconnected bundle, the degree of twist being greater than about 0.9 turns/inch (about 0.36 turns/cm).

35. The reinforced cementitious material of claim 34, wherein the degree of twist is less than about 2.2 turns/inch (about 0.87 turns/cm).

36. The reinforced cementitious material of claim 34, wherein the degree of twist ranges from greater than about 0.9 turns/inch (about 0.36 turns/cm) to about 1.1 turns/inch (about 0.43 turns/cm).

37. The reinforced cementitious of claim 34, wherein the degree of twist is about 1.1 turns/inch (about 0.43 turns/cm).

38. The reinforced cementitious material of claim 34, wherein the first fiber component is fibrillated and present in the synthetic fiber blend in amounts ranging from about 5 to about 50 by total weight percent, and the second fiber component is comprised of one or more twisted nonfibrillating monofilaments present in the synthetic fiber blend in amounts ranging from about 50 to about 95 by total weight percent.

39. The reinforced cementitious material of claim 34, wherein the first fiber component is present in the synthetic blend in about 6.7 total weight percent and second fiber component is present in the synthetic fiber blend in about 93.3 percent by total weight percent.

40. The reinforced cementitious material of claim 34, wherein the synthetic fiber blend is present in the cementitious material in amounts ranging from about 0.1 to about 2.0 percent by volume.

41. The reinforced cementitious material of claim 34, wherein the synthetic fiber blend is present in the cementitious material in amounts ranging from about 0.5 to about 2.0 percent by volume.

42. The reinforced cementitious material of claim 34, wherein the synthetic fiber blend is present in the cementitious material in amounts ranging from about 0.3 to about 2.0 percent by volume.

43. The reinforced cementitious material of claim 34, wherein the cementitious material is reinforced concrete.

44. The reinforced cementitious material of claim 34, wherein the cementitious material is reinforced asphalt.

82. The reinforced cementitious material of claim 34, wherein the plurality of monofilaments are twisted to form the non-interconnected bundle in the absence of a wetting agent.

83. The reinforced cementitious material of claim 34, wherein the first fiber component and the second fiber component are blended in the absence of a wetting agent.

84. The reinforced cementitious material of claim 34, wherein the first fiber component is about 100 to about 20,000 denier per filament, and the second fiber component is about 350 to about 6000 denier per filament.

45. A fiber reinforcement material, comprising:

a plurality of polyolefinic strands of monofilaments of about 350 to about 6000 denier per filament, twisted to form a fiber bundle, the degree of twist being greater than about 0.9 turns/inch (about 0.36 turns/cm), wherein the plurality of strands of monofilaments are twisted to form a non-interconnected bundle in the absence of a wetting agent.

46. A fiber reinforcement material, comprising:

a plurality of polyolefinic strands of monofilaments of about 350 to about 6000 denier per filament, twisted to form a fiber bundle, the degree of twist being greater than about 0.9 turns/inch (about 0.36 turns/cm), wherein the plurality of strands of monofilaments form a first fiber component, the fiber reinforcement material further comprising a second fiber component that is discrete from the first fiber component and is fibrillated and formed of a homopolymer material.

47. The fiber reinforcement material of claim 46, wherein the first fiber component is present in amounts ranging from about 50 to 95 weight percent and the second fiber component is present in amounts ranging from about 5 to about 50 weight percent.

48. The fiber reinforcement material of claim 46, wherein the first fiber component and the second fiber component are blended in the absence of a wetting agent.

49. The fiber reinforcement material of claim 46, wherein the first fiber component has a fiber length of about 19 to about 60 mm and the second fiber component has a fiber length of about 19 to about 60 mm.

50. The fiber reinforcement material of claim 46, wherein the first fiber component and the second fiber component have about the same fiber length.

51. The fiber reinforcement material of claim 46, wherein the first fiber component is a copolymer formed of a major amount of a polypropylene and a minor amount of a high density polyethylene, and the second fiber component is formed of a homopolymer polypropylene fiber.

52. The fiber reinforcement material of claim 46, wherein the second fiber component is about 100 to about 20,000 denier per filament.

53. A reinforcement for cementitious material, comprising:

a plurality of polyolefin monofilaments, the plurality of monofilaments being in a twisted configuration, the degree of twist being greater than about 0.9 turns/inch (about 0.36 turns/cm), wherein the plurality of monofilaments are twisted to form a non-interconnected bundle in the absence of a wetting agent.

54. A reinforcement for cementitious material, comprising:

a plurality of polyolefin monofilaments, the plurality of monofilaments being in a twisted configuration, the degree of twist being greater than about 0.9 turns/inch (about 0.36 turns/cm), wherein the plurality of monofilaments form a first fiber component, the reinforcement for cementitious material further comprising a second fiber component that is discrete from the first fiber component and is fibrillated and formed of a homopolymer material.

55. The reinforcement for cementitious material of claim 54, wherein the first fiber component is present in amounts ranging from about 50 to 95 weight percent and the second fiber component is present in amounts ranging from about 5 to about 50 weight percent.

56. The reinforcement for cementitious material of claim 54 wherein the first fiber component and the second fiber component are blended in the absence of a wetting agent.

57. The reinforcement for cementitious material of claim 54, wherein the first fiber component has a fiber length of about 19 to about 60 mm and the second fiber component has a fiber length of about 19 to about 60 mm.

58. The reinforcement for cementitious material of claim 54, wherein the first fiber component and the second fiber component have about the same fiber length.

59. The reinforcement for cementitious material of claim 54, wherein the first fiber component is a copolymer formed of a major amount of a polypropylene and a minor amount of a high density polyethylene, and the second fiber component is formed of a homopolymer polypropylene fiber.

60. The reinforcement for cementitious material of claim 54, wherein the first fiber component is about 350 to about 6000 denier per filament and the second fiber component is about 100 to about 20,000 denier per filament.

61. The reinforcement for cementitious material of claim 54 wherein the first fiber component is formed of about 70 to 80 percent by weight polypropylene and about 20 to 30 percent by weight high density polyethylene.

62. A reinforced cementitious material, comprising:

a cementitious mass; and

,

a fiber component dispersed throughout the mass, the fiber component being a plurality of polyolefinic strands of monofilaments of about 350 to about 6000 denier per filament twisted to form a fiber bundle, the degree of twist being greater than about 0.9 turns/inch (about 0.36 turns/cm), wherein the plurality of strands of monofilaments are twisted to form a non-interconnected bundle in the absence of a wetting agent.

63. A reinforced cementitious material, comprising:

a cementitious mass; and

,

a fiber component dispersed throughout the mass, the fiber component being a plurality of polyolefinic strands of monofilaments of about 350 to about 6000 denier per filament twisted to form a fiber bundle, the degree of twist being greater than about 0.9 turns/inch (about 0.36 turns/cm), wherein the plurality of strands of monofilaments form a first fiber component, the reinforced cementitious material further comprising a second fiber component that is discrete from the first fiber component and is fibrillated and formed of a homopolymer material.

64. The reinforced cementitious material of claim 63, wherein the first fiber component is present in amounts ranging from about 50 to 95 weight percent and the second fiber component is present in amounts ranging from about 5 to about 50 weight percent.

65. The reinforced cementitious material of claim 63, wherein the first fiber component and the second fiber component are blended in the absence of a wetting agent.

66. The reinforced cementitious material of claim 63, wherein the first fiber component has a fiber length of about 19 to about 60 mm and the second fiber component has a fiber length of about 19 to about 60 mm.

67. The reinforced cementitious material of claim 63, wherein the first fiber component and the second fiber component have about the same fiber length.

68. The reinforced cementitious material of claim 63, wherein the first fiber component is a copolymer formed of a major amount of a polypropylene and a minor amount of a high density polyethylene, and the second fiber component is formed of a homopolymer polypropylene fiber.

69. The reinforced cementitious material of claim 63, wherein the second fiber component is about 100 to about 20,000 denier per filament.

70. The reinforced cementitious material of claim 63, wherein the first fiber component and the second fiber component form a synthetic fiber blend, the synthetic fiber blend being present in the cementitious mass in amounts ranging from about 0.1 to about 2.0 percent by volume.

71. The reinforced cementitious material of claim 70, wherein the synthetic fiber blend is present in the cementitious mass in amounts ranging from about 0.3 to about 2.0 percent by volume.

72. The reinforced cementitious material of claim 70, wherein the synthetic fiber blend is present in the cementitious mass in amounts ranging from about 0.5 to about 2.0 percent by volume.

73. A reinforcement material for a cementitious material formed by twisting a plurality of polyolefinic strands of monofilaments into a fiber bundle for mixing into a cementitious mass, the degree of twist being greater than about 0.9 turns/inch (about 0.36 turns/cm), wherein the plurality of strands of monofilaments are twisted to form a non-interconnected bundle in the absence of a wetting agent.

74. A reinforcement material for a cementitious material formed by twisting a plurality of polyolefinic strands of monofilaments into a fiber bundle for mixing into a cementitious mass, the degree of twist being greater than about 0.9 turns/inch (about 0.36 turns/cm), wherein the plurality of strands of monofilaments form a first fiber component, the reinforcement material further comprising a second fiber component that is discrete from the first fiber component and is fibrillated and formed of a homopolymer material.

75. The reinforcement material of claim 74, wherein the first fiber component is present in amounts ranging from about 50 to 95 weight percent and the second fiber component is present in amounts ranging from about 5 to about 50 weight percent.

76. The reinforcement material of claim 74, wherein the first fiber component and the second fiber component are blended in the absence of a wetting agent.

77. The reinforcement material of claim 74, wherein the first fiber component has a fiber length of about 19 to about 60 mm and the second fiber component has a fiber length of about 19 to about 60 mm.

78. The reinforcement material of claim 74, wherein the first fiber component and the second fiber component have about the same fiber length.

79. The reinforcement material of claim 74, wherein the first fiber component is a copolymer formed of a major amount of a polypropylene and a minor amount of a high density polyethylene, and the second fiber component is formed of a homopolymer polypropylene fiber.

80. The reinforcement material of claim 74, wherein the first fiber component is about 350 to about 6000 denier per filament and the second fiber component is about 100 to about 20,000 denier per filament.

81. The reinforcement material of claim 74 wherein the first fiber component is formed of about 70 to 80 percent by weight polypropylene and about 20 to 30 percent by weight high density polyethylene.

85. A fiber reinforcement material, comprising:

a plurality of polyolefinic strands of monofilaments of about 350 to about 6000 denier per filament, twisted to form a fiber bundle in the absence of a wetting agent.

86. The fiber reinforcement material of claim 85, wherein the reinforcement is a reinforcement for cementitious material.

87. The fiber reinforcement material of claim 86, wherein the cementitious material is concrete.

88. The fiber reinforcement material of claim 86, wherein the cementitious material is asphalt.

89. A reinforcement for cementitious material, comprising:

a plurality of polyolefin monofilaments of about 350 to about 6000 denier per filament, the plurality of monofilaments being in a twisted configuration in the absence of a wetting agent.

90. The reinforcement of claim 89, wherein the cementitious material is concrete.

91. The reinforcement of claim 89, wherein the cementitious material is asphalt.

92. A reinforced cementitious material, comprising:

a cementitious mass; and

,

a fiber component dispersed throughout the mass, the fiber component being a plurality of polyolefinic strands of monofilaments of about 350 to about 6000 denier per filament twisted to form a fiber bundle in the absence of a wetting agent.

93. The reinforced cementitious material of claim 92, wherein the cementitious material is concrete.

94. The reinforced cementitious material of claim 92, wherein the cementitious material is asphalt.

95. A reinforcement material for a cementitious material formed by twisting a plurality of polyolefinic strands of monofilaments of about 350 to about 6000 denier per filament into a fiber bundle in the absence of a wetting agent for mixing into a cementitious mass.

96. The reinforcement material of claim 95, wherein the cementitious material is concrete.

97. The reinforcement material of claim 95, wherein the cementitious material is asphalt.

98. A reinforced cementitious material, comprising:

a synthetic fiber blend distributed through a matrix of the cementitious material, the synthetic fiber blend, including;

a first fiber component formed of a homopolymer polypropylene fiber; and

a second fiber component being discrete from the first fiber component and being a copolymer formed of a polypropylene and a high density polyethylene, the second fiber component being a plurality of monofilaments of about 350 to about 6000 denier per filament twisted to form a fiber bundle in the absence of a wetting agent.

99. The reinforced cementitious material of claim 98, wherein the cementitious material is concrete.

100. The reinforced cementitious material of claim 98, wherein the cementitious material is asphalt.