Modular polymeric matrix composite load bearing deck structure

Abstract

A load bearing support structure in the form of a traffic-bearing highway bridge including at least one modular structural section. The at least one modular structural section includes at least one beam, the beam comprising a pair of lateral flanges and a medial web between and extending below the flanges. The beam preferably has a flat floor. A load bearing deck is positioned above and supported by the flanges of the at least one beam. The beam and load bearing deck are preferably formed of a polymer matrix composite material. The beam is positioned on and supported by one of a plurality of support members. The beam has a contoured shape configured to be matably supported by a support member having a reciprocally configured contoured shaped. Alternatively, a flat or L-shape support member can be utilized. Further alternatively, the load bearing deck comprising at least one sandwich panel is suitable for applications such as barge decks, hatchcovers, and other load bearing wall applications. Methods of constructing a support structure utilizing the modular structural section and support members are also provided.

That which is claimed:  
     
         1 . A load bearing support structure comprising: 
 at least one modular structural section; and    support means having a surface having a predetermined contoured shape for supporting said at least one modular structural section,    said at least one modular structural section comprising: 
 at least one beam, said beam having a pair of lateral flanges and a medial web between said lateral flanges, said flanges and said web having a predetermined shape matable with said predetermined shape of said surface of said support means, each of said flanges and said medial web positioned on and supported by said support means, and  
 a load bearing deck positioned above and supported by said at least one beam.  
   
     
     
         2 . A support structure as defined in  claim 1 , wherein said medial web of each of said at least one beam extends below said flanges.  
     
     
         3 . A support structure as defined in  claim 1 , wherein said medial web of said at least one beam has spaced-apart inclined side walls and a floor therebetween, said side walls and said floor forming a U-shape of said at least one beam; and 
 wherein said predetermined contoured shapes of said surface of said support means has a plurality of spaced apart peak portions and a plurality of trough portions positioned adjacent opposite sides of said peak portions.    
     
     
         4 . A support structure as defined in  claim 1 , wherein said load bearing deck comprises: 
 at least one sandwich panel including: 
 a core including a plurality of elongate core members having side walls positioned generally adjacent one another;  
 an upper facesheet having a lower surface;  
 a lower facesheet having an upper surface;  
 said elongate core members being sandwiched between and connected with said lower surface of said upper facesheet and said upper surface of said lower facesheet.  
   
     
     
         5 . A support structure as defined in  claim 4 , wherein said at least one sandwich panel comprises a plurality of interconnected sandwich panels.  
     
     
         6 . A support structure as defined in  claim 1 , wherein said support means are connected with said at least one modular structural section, such that said support structure is a simply-supported support structure.  
     
     
         7 . A support structure as defined in  claim 1  wherein at least one of said at least one beam and said surface of said support means are formed of a first polymer matrix composite material comprising reinforcing fibers and a polymer resin.  
     
     
         8 . A support structure as defined in  claim 4 , wherein at least one of said upper facesheet, said lower facesheet and said core members is formed of a polymer matrix composite material comprising reinforcing fibers and a polymer resin.  
     
     
         9 . A support structure as defined in  claim 3 , wherein said at least one beam is formed of a polymer matrix composite comprising reinforcing fibers and a polymer resin and wherein a first portion of said fibers positioned in said floor of said medial web are unidirectionally orientated between longitudinally opposite end portions.  
     
     
         10 . A support structure as defined in  claim 1 , further comprising a wear surface overlying an upper surface of said deck for withstanding foot and vehicular traffic.  
     
     
         11 . A support structure as defined in  claim 1 , wherein said support structure has a span of 60 feet, said support structure has a maximum deflection in inches under a predetermined load of 72000 pound lane load which is less than or equal to 0.9 inches.  
     
     
         12 . A modular structural section for constructing a support structure comprising: 
 at least one beam, said beam having a pair of lateral flanges and a medial web between said lateral flanges, said flanges and said medial web having a predetermined shape adapted to mate with a surface of at least one support member having a predetermined shape, each of said flanges and said medial web adapted to be positioned on and supported by said at least one support member; and    a load bearing deck positioned above and supported by said beam.    
     
     
         13 . A modular structural section as defined in  claim 12 , wherein said medial web of said at least one beam extends below said flanges.  
     
     
         14 . A modular structural section as defined in  claim 12 , wherein said medial web of said at least one beam has spaced-apart inclined side walls and a floor therebetween, said side walls and said floor forming a U-shape adapted to mate with and connect with said predetermined contoured shape of said surface of said at least one support member including a plurality of spaced-apart peak portions and a plurality of trough portions positioned adjacent opposite sides of said peak portions.  
     
     
         15 . A modular structural section as defined in  claim 12 , wherein said load bearing deck comprises: 
 at least one sandwich panel including: 
 a core including a plurality of elongated core members having side walls positioned generally adjacent one another;  
 an upper facesheet having a lower surface;  
 a lower facesheet having an upper surface;  
 said elongate core members being sandwiched between and connected with said lower surface of said upper facesheet and said upper surface of said lower facesheet.  
   
     
     
         16 . A modular structural section as defined in  claim 15 , wherein said at least one sandwich panel comprises a plurality of interconnected sandwich panels  
     
     
         17 . A modular structural section as defined in  claim 15 , said at least one sandwich panel being an integrally formed, unitary pultruded sandwich panel comprising said upper and lower facesheets formed by pultrusion and said at least one elongate core member formed by pultrusion.  
     
     
         18 . A modular structural section as defined in  claim 15 , wherein at least one of said upper facesheet, said lower facesheet and said plurality of elongate core members are formed of a polymer matrix composite comprising reinforcing fibers and a polymer resin.  
     
     
         19 . A modular structural section as defined in  claim 12 , wherein said at least one beam is formed of a polymer matrix composite comprising reinforcing fibers and a polymer resin.  
     
     
         20 . A modular structural section as defined in  claim 19 , wherein a first portion of said fibers of a floor portion of said medial web of said at least one beam are unidirectionally oriented between said longitudinally opposite end portions.  
     
     
         21 . A modular structural section as defined in  claim 19 , wherein said web has a generally inclined side wall, said reinforcing fibers in said inclined side wall being in a quasi-isotropic orientation.  
     
     
         22 . A modular structural section as defined in  claim 12 , further comprising a wear surface overlying an upper surface of said deck for withstanding foot and vehicular traffic.  
     
     
         23 . A modular structural section as defined in  claim 12 , wherein said modular structural section has a maximum deflection in inches under a predetermined load of 72000 lane load is less than 0.9 inches.  
     
     
         24 . A modular structural section as defined in  claim 12 , wherein said at least one modular structural section is formed of a polymer matrix composite material comprising reinforcing fibers and a polymer resin and said fibers and said resin are selected such that said support structure will have a positive margin of safety under predetermined required lane loads and a predetermined safety factor using a first-ply failure as the failure criteria.  
     
     
         25 . A load bearing, support structure comprising: 
 at least one modular structural section; and    support means having a surface having a generally flat portion for receiving and supporting structures thereon;    at least one modular structural section comprising: 
 at least one beam, said at least one beam having a pair of lateral flanges, said at least one beam further comprising a medial web between and extending below said flanges, said web portion having inclined side walls and a floor therebetween, said floor portion positioned on and supported by said flat portion of said support means; and  
 a load bearing deck positioned above and supported by said at least one beam.  
   
     
     
         26 . A support structure as defined in  claim 25 , wherein said floor portion includes at least one substantially flat portion, said flat floor portion floor positioned on and supported by said flat portion of said support means.  
     
     
         27 . A support structure as defined in  claim 25 , wherein said floor portion includes at least one substantially curved portion, said curved floor portion floor positioned on and supported by said flat portion of said support means.  
     
     
         28 . A support structure as defined in  claim 25 , wherein said at least one beam is formed of a polymer matrix composite material comprising reinforcing fibers and a polymer resin.  
     
     
         29 . A support structure as defined in  claim 25 , wherein a first portion of said fibers in said floor of said at least one beam are unidirectionally oriented between said longitudinally opposite end portions.  
     
     
         30 . A support structure as defined in  claim 25  wherein said flanges are positioned on and supported by said support means.  
     
     
         31 . A modular structural section for constructing a support structure comprising: 
 at least one beam, said at least one beams having a pair of lateral flanges, said at least one beam further comprising a medial web between and extending below said flanges, said web portion having inclined side walls and a floor therebetween, said floor portion floor adapted to be positioned on and supported by and contact a flat portion of said at least one support member; and    a load bearing deck positioned above and supported by said at least one beam.    
     
     
         32 . A modular structural section as defined in  claim 31 , wherein said at least one beam is formed of a polymer matrix composite material comprising reinforcing fibers and a polymer resin.  
     
     
         33 . A modular structural section as defined in  claim 31 , wherein said portion of said fibers of said floor of said at least one beam are unidirectionally oriented between said longitudinally opposite end portions.  
     
     
         34 . A modular structural section as defined in  claim 31 , wherein said floor portion includes at least one substantially flat portion, said flat floor portion floor positioned on and supported by said flat portion of said support means.  
     
     
         35 . A modular structural section as defined in  claim 31 , wherein said floor portion includes at least one substantially curved portion, said curved floor portion floor positioned on and supported by said flat portion of said support means.  
     
     
         36 . A modular structural section as defined in  claim 31 , wherein each of said flanges is configured to be positioned on and supported by at least one support member,  
     
     
         37 . A method of constructing a support structure comprising: 
 providing at least one support member having a predetermined contoured shape;    providing at least one modular structural section comprising: 
 at least one beam, said at least one beam having a predetermined shape matable with the predetermined shape of said at least one support member, and;  
   positioning said at least one modular structural section on said at least one support member, said at least one support member supporting said at least one beam such that said at least one beam and said at least one support member having corresponding shape portions generally aligned.    
     
     
         38 . A method of constructing a support structure as defined in  claim 37 , wherein said step of providing at least one modular structural section comprises: 
 providing a load bearing deck adapted to be positioned above and supported by said at least one beam, and said step of positioning said at least one modular structural section further comprises:    positioning said deck on said at least one support member such that said deck is supported by said at least one support member.    
     
     
         39 . A method of constructing a support structure as defined in  claim 37 , wherein said step of providing at least one beam further comprises, 
 providing at least one beam, said at least one beam having a pair of lateral flanges and a medial web between said lateral flanges, said flanges and said medial web defining a predetermined shape of said beams; and    said step of positioning said at least one beam further comprising: 
 positioning each of said flanges and said medial web on said at least one support member such that said at least one beam is supported by and matably joined with a portion of said at least one support member.  
   
     
     
         40 . A method of constructing a support structure as defined in  claim 37 , wherein said step of providing said at least one support member further comprises: 
 providing said at least one support member having a plurality of spaced-apart peak portions and a plurality of trough portions positioned adjacent opposite sides of said peak portions, and    wherein said step of positioning said at least one beam further comprises positioning said beam having said medial web having a U-shape on said at least one support member such that said U-shape beam matably joins said trough and said peak portions of said at least one support member.    
     
     
         41 . A method of constructing a support structure as defined in  claim 38 , further comprising the step of: 
 applying a wear surface to an upper surface of said deck for withstanding foot and vehicular traffic.    
     
     
         42 . A method of constructing a support structure as defined in  claim 38 , wherein said step of positioning said deck further comprising the steps of: 
 positioning a plurality of load bearing deck panels on said at least one beam, each panel formed of a first polymer matrix composite material; and    interconnecting said each of said plurality of deck panels with adjacent deck panels.    
     
     
         43 . A method of constructing a support structure as defined in  claim 37 , wherein said connecting step comprises connecting said at least one support member and said modular structural sections such that said modular structural sections are simply supported.  
     
     
         44 . A method of constructing a support structure as defined in  claim 37 , said providing step comprises locating existing support structure support members positioned to receive and support said at least one modular structural section.  
     
     
         45 . A method of constructing a support structure as defined in  claim 44 , further comprising the step of removing an existing support structure span while retaining existing support members spaced apart a predetermined distance, said removing step preceding said locating step.  
     
     
         46 . A load bearing deck structure comprising: 
 at least one sandwich panel including: 
 an upper facesheet;  
 a lower facesheet;  
 a core including a plurality of substantially hollow, elongated core members positioned between said upper facesheet and said lower facesheet;  
 wherein at least one of said upper facesheet and lower facesheet comprising a polymer matrix composite material, said at least one of said upper facesheet and lower facesheet being formed a plurality of substrate layers, wherein alternating layers are formed of different reinforcing fibers and a polymer resin.  
   
     
     
         47 . A deck as defined in  claim 46 , wherein said alternating layers are formed in a first layer of carbon fibers and a vinylester resin and in a second layer glass fibers and a vinylester resin.  
     
     
         48 . A deck as defined in  claim 46 , wherein an outer layer of said alternating layers of at least one of said lower facesheet and said upper facesheet is formed of fibers having a quasi-isotropic orientation.  
     
     
         49 . A deck as defined in  claim 48 , wherein said outer layer further comprises E-glass fibers and a vinylester resin.  
     
     
         50 . A deck as defined in  claim 48 , wherein an interior layer of said alternating layers adjacent to said outer layer is formed of graphite and vinylester.  
     
     
         51 . A deck as defined in  claim 47 , wherein said fibers of said at least one of said upper and lower facesheets comprises about 42 percent graphite and about 58 percent E-glass.  
     
     
         52 . A facesheet for constructing a load bearing deck structure comprising: 
 a plurality of substrate layers formed of a polymer matrix composite material, wherein alternating layers are formed of different reinforcing fibers and a polymer resin.    
     
     
         53 . A facesheet as defined in  claim 52 , wherein said alternating layers are formed in a first layer of carbon fibers and a vinylester resin and in a second layer glass fibers and a vinylester resin.  
     
     
         54 . A facesheet as defined in  claim 52 , wherein an outer layer of said alternating layers of at least one of said lower facesheet and said upper facesheet is formed of fibers having a quasi-isotropic orientation.  
     
     
         55 . A facesheet as defined in  claim 54 , wherein said outer layer further comprises E-glass fibers and a vinylester resin.  
     
     
         56 . A facesheet as defined in  claim 54 , wherein an interior layer of said alternating layers adjacent to said outer layer is formed of graphite and vinylester.  
     
     
         57 . A facesheet as defined in  claim 52 , wherein said fibers of said at least one of said upper and lower facesheets comprises about 42 percent graphite and about 58 percent E-glass.  
     
     
         58 . A method of constructing a support structure comprising: 
 providing a support member having a surface having a generally flat portion for receiving and supporting structures thereon;    providing at least one modular structural section comprising: 
 at least one beam, said at least one beam having a pair of lateral flanges, said at least one beam further comprising a medial web between and extending below said flanges, said web portion having inclined side walls and a floor therebetween,  
   positioning said floor portion of said at least one beam on said flat portion of said support member such that said beam is support by said support member; and    positioning a load bearing deck above and supported by said at least one beam.    
     
     
         59 . A method of constructing a support structure as defined in  claim 58 , wherein said beam providing step further comprises providing at least one beam including a floor portion includes at least one substantially flat portion; and 
 said modular structural section positioning step further comprising positioning said flat floor portion floor positioned on said flat portion of said support member.    
     
     
         60 . A method of constructing a support structure as defined in  claim 58 , wherein said beam providing step further comprises providing at least one beam including a curved floor portion; and 
 said modular structural section positioning step further comprising positioning said curved floor portion on said flat portion of said support member.    
     
     
         61 . A method of constructing a support structure as defined in  claim 58  wherein said modular structural section providing step further comprising providing at least one beam formed of a polymer matrix composite material comprising reinforcing fibers and a polymer resin.  
     
     
         62 . A method of constructing a support structure as defined in  claim 58 , wherein said modular structural section providing step further comprises providing a beam having a first portion of said fibers in said floor of said at least one beam being unidirectionally oriented between said longitudinally opposite end portions.