Composition and method for manufacturing a high ductility fiber reinforced polymer rebar

Patent metadata

Field	Value
Publication number	US-2023331629-A1
Application number	US-202217659264-A
Country	US
Kind code	A1
Filing date	Apr 14, 2022
Priority date	Apr 14, 2022
Publication date	Oct 19, 2023
Grant date	—

Abstract

A fiber reinforced polymer rebar composition and a method of forming the rebar composition is described. The method includes the steps of feeding a first fiber and a second fiber simultaneously through a preforming guide into a resin impregnator, pulling the fibers through the liquid polymeric resin in the resin impregnator to form a resin-soaked hybrid fiber, and passing the resin-soaked hybrid fiber through a heated stationary die where the resin of the resin-soaked hybrid fiber undergoes polymerization and cross-linking.

First claim

What is claimed is:

1 . A method of forming a rebar composition, comprising:
feeding a first fiber and a second fiber simultaneously into a resin impregnator, thereby forming a hybrid fiber, wherein the first and second fibers are different; pulling the fibers through a liquid polymeric resin in the resin impregnator to form a resin-soaked hybrid fiber; and passing the resin-soaked hybrid fiber through a heated stationary die, where resin of the resin-soaked hybrid fiber undergoes polymerization and cross-linking to form a fiber reinforced polymer rebar.

2 . The method of claim 1 , wherein at least one of the first fiber and the second fiber is passed through an atmospheric plasma treatment chamber prior to being fed to the resin impregnator.

3 . The method of claim 1 , wherein the polymer of the fiber reinforced polymer rebar is a thermoset polymer or thermoplastic polymer.

4 . The method of claim 1 , wherein the liquid polymer resin is selected from the group consisting of a vinyl ester, a polymethyl methacrylate, and combinations thereof.

5 . The method of claim 1 , wherein the first fiber is an ultra-high molecular weight polyethylene.

6 . The method of claim 1 , wherein the second fiber is selected from the group consisting of a carbon fiber, a glass fiber, and combinations thereof.

7 . The method of claim 1 , wherein the polymer is present in the fiber reinforced polymer rebar in an amount ranging from 35 to 43 wt % based on total weight of the rebar.

8 . The method of claim 1 , wherein the first fiber is present in the fiber reinforced polymer rebar in an amount ranging from 30 to 55 wt % based on total weight of the rebar.

9 . The method of claim 1 , wherein the second fiber is present in the fiber reinforced polymer rebar in an amount ranging from 2 to 35 wt % based on total weight of the rebar.

10 . The method of claim 1 , wherein the first fiber and the second fiber are passed through a preforming guide prior to the feeding step.

11 . The method of claim 10 , wherein an arrangement of holes of the preforming guide determines an arrangement of fibers in the fiber reinforced polymer rebar.

12 . The method of claim 1 , wherein the heated die is at a temperature ranging from 80° C. to about 150° C.

13 . The method of claim 1 , wherein the first fiber to the second fiber ratio is in an amount ranging from 1:1 to 4:1.

14 . A rebar formed from the method of claim 1 .

15 . The rebar of claim 14 , wherein the polymer has a Young's modulus of at least 3,700 MPa.

16 . The rebar of claim 14 , wherein the first fiber is an ultra-high molecular weight polyethylene having a Young's modulus of at least 110,000 MPa.

17 . The rebar of claim 16 , wherein the ultra-high molecular weight polyethylene has a molecular weight of between 3 million Da to 7.5 million Da.

18 . The rebar of claim 14 , wherein the rebar has a ductility ratio of at least 30% greater than a reference rebar comprising of one fiber.

19 . The rebar of claim 14 , wherein the rebar has an elongation at break at least twice as large as a reference rebar comprising of one fiber when measured according to ASTM D7205M.

Assignees

• Saudi Arabian Oil Co

Inventors

• Villette Thibault Tarik
• Al Nasser Waleed
• Jazzar Abdullatif
• Al Mehthel Mohammed
• Salazar Oscar

Classifications

• C04B14/386 Primary

  Carbon (carbon nanotubes C04B14/026) · CPC title

• C04B26/06 Primary

  Acrylates · CPC title

• C04B16/0683

  Polyesters, e.g. polylactides · CPC title

• C04B14/42

  Glass · CPC title

• C04B2111/00905

  as preforms · CPC title