Method for manufacturing a structural beam, structural beam, and building comprising such a beam.

Patent metadata

Field	Value
Publication number	US-2020123774-A1
Application number	US-201716474584-A
Country	US
Kind code	A1
Filing date	Jan 2, 2017
Priority date	Jan 2, 2017
Publication date	Apr 23, 2020
Grant date	—

Abstract

A method of manufacturing a structural beam comprising an elongate base part comprising a polymer. The base part has a length, a width and a height. The beam also comprises an elongate reinforcement part comprising a strip comprising a unidirectional polymer, bonded to the base part at an outer surface of the base part and extending in the length direction along the length of the base part. The strip has a higher Young's modulus than the base part. The method also relates to a beam and to a building comprising such a beam.

First claim

1 . A method of manufacturing a structural beam comprising
an elongate base part comprising a polymer, the base part having a length, defining a length direction of the beam, and having a width and a height, and an elongate reinforcement part comprising a strip comprising a polymer and unidirectional fibers, bonded to the base part at an outer surface of the base part and extending in the length direction along the length of the base part, the strip of the elongate reinforcement part having a higher Young's modulus than the base part, the method comprising
feeding a composition comprising the polymer for forming the elongate base part, via an extruder, to an extrusion die,
feeding the elongate reinforcement part comprising the strip to the extrusion die,
forming the beam by extrusion, while bonding the elongate reinforcement part to the base part by joining the elongate reinforcement part and the composition within the extrusion die.

2 . The method according to claim 1 , further comprising
bonding a further elongate reinforcement part comprising a further strip comprising a polymer and unidirectional fibers to the base part at a further outer surface of the base part opposite the outer surface and extending in the length direction along the length of the base part.

3 . The method according to claim 1 , wherein the elongate reinforcement part of the beam to be formed comprises multiple strips comprising a polymer and unidirectional fibers bonded to each other,
wherein during the step of feeding, said elongate reinforcement part comprising the multiple strips is fed to the extrusion die.

4 . The method according to claim 2 , wherein the further elongate reinforcement part of the beam to be formed comprises multiple strips comprising a polymer and unidirectional fibers bonded to each other,
wherein during the step of feeding, said further elongate reinforcement part comprising the multiple strips is fed to the extrusion die for the purpose of bonding said further elongate reinforcement part to said further outer surface of the base part.

5 . The method according to claim 1 , wherein the polymer of the base part is chosen from the group consisting of thermoplastic polymers, including co-polymers, or blends thereof.

6 . The method according to claim 1 , wherein the polymer of the strip is chosen from the group consisting of thermoplastic polymers, including co-polymers, or blends thereof.

7 . The method according to claim 1 , wherein a width of the elongate reinforcement part and/or the further elongate reinforcement part is at least substantially equal to the width of the base part.

8 . The method according to claim 1 , the base part being constituted by a hollow profile.

9 . The method according to claim 8 , the hollow profile of the base part being filled with a foam.

10 . The method according to claim 1 , wherein the strip comprising a polymer and unidirectional fibers has a thickness in the range of 0.1-5 mm.

11 . The method according to claim 1 , wherein the base part has a height in the range of 50-700 mm.

12 . A structural beam, manufactured in accordance with claim 1 , the structural beam comprising an elongate base part comprising a polymer, the base part having a length, defining a length direction of the beam, and having a width and a height, and an elongate reinforcement part comprising a strip comprising a polymer and unidirectional fibers, bonded to the base part at an outer surface of the base part and extending in the length direction along the length of the base part, the strip having a higher Young's modulus than the base part.

13 . A building, comprising a structural beam manufactured in accordance with claim 1 , the structural beam comprising an elongate base part comprising a polymer, the base part having a length, defining a length direction of the beam, and having a width and a height, and an elongate reinforcement part comprising a strip comprising a polymer and unidirectional fibers, bonded to the base part at an outer surface of the base part and extending in the length direction along the length of the base part, the strip having a higher Young's modulus than the base part,
the structural beam supporting a part of the building, such as a roof of the building, the structural beam being provided such that it is mainly subject to forces in the height direction of the structural beam, the elongate reinforcement part being provided at a lower outer surface of the base part of the beam.

14 . The method according to claim 1 ,
further comprising bonding a further elongate reinforcement part comprising a further strip comprising a polymer and unidirectional fibers to the base part at a further outer surface of the base part opposite the outer surface and extending in the length direction along the length of the base part; wherein the elongate reinforcement part of the beam to be formed comprises multiple strips comprising a polymer and unidirectional fibers bonded to each other; wherein during the step of feeding, said elongate reinforcement part comprising the multiple strips is fed to the extrusion die; wherein the strip comprising a polymer and unidirectional fibers has a thickness in the range of 0.1-5 mm; wherein the base part has a height in the range of 50-700 mm; and wherein the base part has a width in the range of 10-50 percent of the height.

15 . The method according to claim 14 , the base part being constituted by a hollow profile filled with a foam.

16 . The method according to claim 14 , wherein the further elongate reinforcement part of the beam to be formed comprises multiple strips comprising a polymer and unidirectional fibers bonded to each other,
wherein during the step of feeding, said further elongate reinforcement part comprising the multiple strips is fed to the extrusion die for the purpose of bonding said further elongate reinforcement part to said further outer surface of the base part.

17 . The method according to claim 14 , wherein a width of the elongate reinforcement part and/or the further elongate reinforcement part is at least substantially equal to the width of the base part.

18 . The method according to claim 1 , wherein the strip comprising a polymer and unidirectional fibers has a thickness in the range of 0.2-2.5 mm.

19 . The method according to claim 1 , wherein the base part has a height in the range of 100-400 mm, and wherein the base part has a width in the range of 10-50 percent of the height.

Assignees

• Sabic Global Technologies Bv

Inventors

• Van Giesen Roland
• Steenbakkers-Menting Henrica Norberta Alberta Maria

Classifications

• B29C48/155

  Partial coating thereof · CPC title

• E04C3/28 Primary

  of materials not covered by groups E04C3/04 - E04C3/20 · CPC title

• B29K2105/106

  longitudinally · CPC title

• B29C48/304

  specially adapted for bringing together components, e.g. melts within the die · CPC title

• B29C48/16

  Articles comprising two or more components, e.g. co-extruded layers · CPC title