Non-metallic reinforcement member for the reinforcement of a structure and process of its manufacture

Abstract

Disclosed herein is a non-metallic reinforcement member ( 10 ) such as a rod to be embedded in a structure of material such as concrete ( 30 ). This member comprises a longitudinal main body ( 20 ) having an outer surface ( 14 ) and spaced apart embossments ( 22 ) formed along its length and being integral therewith. When this member ( 10 ) is embedded in concrete ( 30 ), the embossments ( 22 ) mechanically interlock with the concrete ( 30 ). This reinforcement member ( 10 ) may be made of a plastic material such as thermoplastic resin so as to be bendable. The outer surface ( 14 ) may comprise layers of fiber reinforcement ( 18 ). Also disclosed herein is a process of making such a reinforcement member ( 10 ).

What is claimed is:  
     
         1 . A reinforcement member to be embedded in a structure of material for the reinforcement thereof, said member comprising a longitudinal main body having an outer surface and spaced apart embossments formed along the length of said longitudinal main body, said embossments being integral with said longitudinal main body, wherein, when said member is embedded in the structure, said embossments mechanically interlock with the structure.  
     
     
         2 . A reinforcement member according to  claim 1 , wherein the member is non-metallic.  
     
     
         3 . A reinforcememt member according to  claim 1 , wherein the member is non-corrosive.  
     
     
         4 . A reinforcement member according to  claim 1 , wherein said outer surface is free of metallic material.  
     
     
         5 . A reinforcement member according to  claim 1 , wherein said outer surface is free of corrosive material.  
     
     
         6 . A reinforcement member according to  claim 1 , wherein the structure is concrete.  
     
     
         7 . A reinforcement member according to  claim 1 , wherein said member is a rod.  
     
     
         8 . A reinforcement member according to  claim 1 , wherein said longitudinal body is made of a plastic material.  
     
     
         9 . A reinforcement member according to  claim 8 , wherein said plastic material is thermoplastic resin.  
     
     
         10 . A reinforcement member according to  claim 1 , wherein said longitudinal main body includes a tube over an appropriate core member.  
     
     
         11 . A reinforcement member according to  claim 10 , wherein said tube is a braided tube made from yarns.  
     
     
         12 . A reinforcement member according to  claim 11 , wherein said yarns include intermingled first and second fibers, said first fibers selected from the group consisting of carbon, glass and aramid, said second fibers including of thermoplastic materials.  
     
     
         13 . A reinforcement member according to  claim 10 , wherein said core is made of a material selected from the group consisting of ceramic, metal and plastic.  
     
     
         14 . A reinforcement member according to  claim 1 , wherein said outer surface comprises fiber reinforcement.  
     
     
         15 . A reinforcement member according to  claim 1 , wherein said embossments have a generally ellipsoidal configuration.  
     
     
         16 . A reinforcement member according to  claim 1 , wherein said embossments are equally spaced apart.  
     
     
         17 . A reinforcement member according to  claim 1 , wherein said embossments are unequally spaced apart.  
     
     
         18 . A reinforcement member according to  claim 1 , wherein said member is bendable.  
     
     
         19 . A process for making the reinforcement member of  claim 1 , said process comprising: 
 (a) making a core having the configuration of the member;    (b) making a tube of yarns;    (c) incorporating said core within said tube so as to provide a core-tube assembly;    (d) placing said core-tube assembly within a bag of high temperature resistant material;    (e) exposing said bagged core-tube assembly to such temperature and pressure as to mold said core-tube assembly into the reinforcement member;    (f) providing for the reinforcement member to solidify; and    (g) removing said bag from the reinforcement member.    
     
     
         20 . A process according to  claim 19 , wherein making a core in (a) includes machining a larger diameter rod into a smaller diameter rod thereby forming embossments along the length of said core.  
     
     
         21 . A process according to  claim 19 , wherein said making a core in (a) includes molding the core.  
     
     
         22 . A process according to  claim 19 , wherein said core is made of a material selected from the group consisting of ceramic, metal and plastic.  
     
     
         23 . A process according to  claim 19 , wherein said making a tube in (b) includes braiding yarns into a braided tube.  
     
     
         24 . A process according to  claim 23 , wherein said yarns are made from intermingled first and second fibers, said first fibers being selected from the group consisting of carbon, glass and aramid, said second fibers including thermoplastic fibers.  
     
     
         25 . A process according to  claim 24 , wherein said thermoplastic fibers are selected from the group consisting of polyamide, polypropylene and polyethylene.  
     
     
         26 . A process according to  claim 19 , wherein said incorporating in (c) includes sliding said core inside said tube.  
     
     
         27 . A process according to  claim 19 , wherein said making a tube in (b) and said incorporating in (c) are simultaneous and include braiding yarns into a braided tube about said core thereby providing said core-tube assembly.  
     
     
         28 . A process according to  claim 19 , wherein said placing in (d) includes subjecting said bag to a vacuum such that said bag presses said tube against core to conform to the configuration of said core.  
     
     
         29 . A process according to  claim 19 , wherein said bag is made of material capable of resisting temperatures high enough to melt thermoplastic fibers.  
     
     
         30 . A process according to  claim 19 , wherein said exposing in (e) includes placing said bagged core-tube in an oven configured to apply both high temperature and high pressure.  
     
     
         31 . A process according to  claim 24 , wherein said bagged core-tube assembly is subject to such temperature as to melt said thermoplastic fibers.  
     
     
         32 . A process according to  claim 31 , wherein said temperature is at least 200° C.  
     
     
         33 . A process according to  claim 24 , wherein said pressure is such as to consolidate said intermingled fibers to the configuration of said core.  
     
     
         34 . A process according to  claim 33 , wherein said pressure is between 683 kPa to 1367 kPa.  
     
     
         35 . A process according to  claim 19 , wherein providing in (f) includes allowing sufficient time for the reinforcement member to cool down.