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    • 专利摘要:
    A plural-component, composite-material highway dowel bar and an associated fabrication methodology. The dowel bar includes an elongate, solid- cylindrical high-shear-strength core bar, preferably steel, and an elongate, fibre- reinforced plastic-resin jacket, Including an elongate, pultrusion-formed, tabular sleeve, and sleeve-received, opposite-end, end-well sleeve end plugs, fully surrounding and protectively covering the core bar.
    公开号:AU2013215004A1
    申请号:U2013215004
    申请日:2013-02-01
    公开日:2014-08-28
    发明作者:Trent J. Garber；Robert C. Gibson；Matthew H. Noble
    申请人:COMPOSITE REBAR TECHNOLOGIES Inc；
    IPC主号:E01C11-14
    专利说明:
    WO 2013/116578 PCT/US2013/024239 1 PLURAL-COMPONENT, COMPOSITE-MATERIAL HIGHWAY DOWEL BAR STRUCTURE AND FABRICATION METHODOLOGY Cross Reference to Related Application 5 This application claims filing-date priority to U.S Provisional Patent Application Serial No. 61/595,042. filed February 4, 2012, for "Highway-Slab Dowel Interconnect Structure the entire disclosure content in which is hereby incorporated herein by reference, Background and Sumary of the Invention 10 This invention pertains to plural-component, composite-material highway (especially concrete-highway) dowel bar structure and associated fabrication methodology, and in particular, relates to such structure and methodology which successfully addresses, and resolves, key, serious, and intertwined, functional reliability, componentry cost, and highway lifecycle economic problem issues that 15 have for years been associated with highway dowel-bar technology, and relationally, with certain aspects of highway functionality longevity. Dowel bars are ubiquitous in concrete highway construction. They take the form of elongate, cylindrical, high-shear-strength, smooth-exterior rods, typically formed of conventional, structural steel (non-stainless), which are employed in 20 multiple numbers, typically at 1-foot lateral-spacing intervals, as shear-bridging: slab to-slab load-transfer structure at each separation interface (joint) which exists between adjacent, travel-direction-oriented, highway slabs that arc usually formed of poured concrete, and preferably, in many instances of what is known in the art as high-performance concrete. Their most important functions are to furnish 25 appropriate load-transfer shear strength between adjacent slabs while at the same time (a) accommodating slab expansion and contraction (with slight, but recurrent, slab-joint openings and closings) due to ambient thermal changes, and additionally (b) minimizing the phenomenon known as slab faulting at the joints between adjacent slabs. They are conceived as simple structures, sometimes differently 30 formed. in relation to efforts to achieve improvements over the use alone of conventional structural steel, of materials and combinations of materials such as epoxy-coated structural steel, zinc-coated structural steel, solely stainless steel stainless-steel-jacketed conventional structural steel, and purely single-unit plastic WO 2013/116578 PCT/US2013/024239 2 composite materials -- all intended to perform the above-mentioned, important "highway--pe rforma nc-suppor functions flawlessly for long periods of time However, for a number of costly and disappointing reasons outlined below, they do not do this, intent and reality historically have not matched successfully, and 5 the resulting hunt for necessary, important, and fundamental dowel-bar improvement, has for years been., and is still, ongoing. We believe that the present invention changes this situation, and that the "hunt" just mentioned may now be substantially over Further regarding aspects of the background, dowel-bar setting which has 10 triggered the conception and reduction to practice of the present invention, dowel bars are employed in the multi-millions in concrete highway construction, both in the United States and in numerous other countries. In such highway construction, the usual, adjacent highway-pavement slabs that lie along a normally constructed highway lane may typically have a length of about 15-feet, and a width of about 12 15 feet, Between each, successive, adjacent lane slab, dowel bars, at about 1-foot lateral intervals, are included as interconnecting structures. Because of what are currently very predictable, current-dowel-bar--materials' wear and corrosion characteristics, and due to the facts (1) that dowel bars, and the confronting, concrete faces of their associated highway slabs, are both exposable at 20 all inter-slab, concrete highway joints, and (2) that dowel bars, during their operative lives, are subjected to substantial cyclic shear loads in the multi-millions even over relatively short periods of time -- a condition which is very relevant to the durabilities and configurations of the intended, protective coatings that are furnished for various types of coated steel bars (mentioned below), they are not, and cannot comfortably 25 be considered to be, permanent, or even satisfactorly and relatively long-lasting components of concrete highway structure in many applications A result is the need for too-frequent dowel-bar (and associated concrete-slab) replacement -- an extraordinarily costly need. Despite many improvement-focused efforts launched in the past to minimize 30 the necessity for, and the attendant frequencies of, highway dowel-bar replacement these efforts have not been entirely successful, For example: and considering commonly understood corrosion and wear issues that are associated with known dowel-bar constructions, typical, widely-used, conventional steel dowel bars are WO 2013/116578 PCT/US2013/024239 3 obviously subjected to environmental-conditons rusting and corrosion, and do not possess characteristics which inherently help to resist these issues Among past "improvement" attempts, purely stainless steel dowel bars, while less vulnerable, though not immune, to corrosion. nevertheless are eventually corrodible, and, very $ significantly, are extremely expensive as items, per se, and often prohibitively so. Other improvement approaches taken in the past, such as coating traditional structural steel dowel bars with, for example, thin layers of epoxy or zinc, is expensive, and, for a variety of reasons, has not worked particularly well. Apart from the expense issue, and considering specifically structural matters, epoxy coatings 10 are typically applied by spraying (or by some other suitable, surface-application technique) to long "over-lengths" of conventional, structural-steel, dowel-bar core material, with the resulting, long, core-coated product then crosscut selectively to achieve finished dowel bars of the desired lengths. The crosscut, end areas are usually then simply left uncoated, with the result that exposed steel exists at those 15 cut ends which are thus fully exposed to all nearby, corrosive environmental conditions, Where epoxy coating is applied completely over already pre-length-cut steel dowel-bar cores, ie, where no post-coating cross-cutting is involved, or under those circumstances where cross-cut ends are in fact subsequently coated with epoxy, the 20 resulting all-over epoxy coating effectively "flows"7extends as a mate rial-continuum over the sharp-edged surface discontinuities that exist: at each end of a dowel bar, between the cylindrical surface of the core steel bar material and the end surfaces of this material - a condition which thus exposes the coating material, at these sharp discontinuity regions, to very high-stress mechanical conditions, with respect to 25 which cyclic loading of dowel bars, in their installed use conditions in concrete highway slabs, easily triggers regional stress fractures in a coating - fractures which then expose the core steel material at those vulnerable locations to corrosion-attack environmental conditions. Another main concern involving epoxy-coated steel bars is that typical rough 30 handling and installation of these bars damages (i.e., cracks, chips, etc.) and noticeably compromises the protective effectiveness of the employed epoxy material. Zinc coating of conventional structural steel bar material produces dowel bars that also present a problematic issue. Zino coating is employed as a corrosion- WO 2013/116578 PCT/US2013/024239 4 accepting, sacrificial layer over steel, inhibiting steel corrosion, yes, but in its sacrificial role becoming extremely roughly surface-textured, a condition intefdring with the desired capability of a dowel bar to offer smooth-outsidesurface sliding contact with surrounding concrete to accommodate necessary temperature related 5 expansion and contraction of concrete slabs, Solid, fibre-reinforced, plastic-based, composite-material dowel bars have been proposed and tried, but, as individuals, they do not offer the shear strength of steel., and thus do not function well as comparably robust, slab-to-slab load transferors, Accordingly, where such plastic, reinforced dowel bars are selected for 10 use, they are usually employed (a) in greater numbers and (b) with closer lateral spacings, than are characteristic for steel dowel bars, and at least for this reason involve greater expense, Stainless-steeljacketed, conventional steel dowel bars are quite expensive, and notwithstanding stainless jackeling, in some instances, disappointingly, also 15 corrodible. With these negative, expense and corrosion-driven, performance-longevity matters in mind, one of the most significant issues involving extensive dowel-bar use in concrete highway construction is that, when dowel-bar replacement becomes necessary - and frequently too often so ~ the materials and labor-time and -wage 20 costs, and the related downtime associated with the need for constructionsite preparation and the subsequent pouring of new highway concrete slab material (because of the fact that, where failed dowel bars are located, the surrounding concrete highway material must be demolitioned), are extraordinary In this setting, there is clearly a need for an improved highway dowel bar 25 which offers, along with impressive-performance shear strength, great resistance to corrosion decay, with both of these qualities and charactenstics collaboratively contributing to (1) significant reduction of replacement need, (2) appreciatbIe lengthening of replacement intervals where replacements are required, and in the bargain, (3), impressive minimizing of highway lifecycle, etc, costs, These 30 considerations, while important in all concrete highway settings, are particularly important considerations where a highway is to be what is known as a high performance highway built with high-performanceiong-life concrete.
    WO 2013/116578 PCT/US2013/024239 5 Accordingly, proposed by the present invention is a plural-component, composite-material highway dowel bar including an elongate, high-s ear-strength, cyindrical core, preferably, although not necessarily, formed of steel, and an elongate., fibre-reinforced plastic-resin jacket fulby surrounding and protectively 5 covering the entirety of the core, and exposed to no high-stress-point discontinuities. such as surface-edge discontinuities, anywhere within the overab dowel-bar structure. The Jacket includes an elongate, fiber-reinforced: cylindrically tubular, plastic-resin sleeve which circunsurrounds and is bonded to the core, The jacket sleeVe, which is intentionably made longer than the inside steel core, has opposite 10 ends that extend beyond the associated opposite ends of the core, thus to define, together with the inwardly disposed core ends, a pair of spaced, single-open-ended, elongate, cylindrical sleeve end wells, or simply end wells. Two, elongate, cylindrical, fiber-reinforced, plastic-resin sleeve end plugs (also referred to herein simply as plugs), each having a diameter and a cross section matching that of the 15 steel core, fil the sleeve end wels, and are united in the overall dowehbar structure by a bonding mechanism, such as one or more of those mentioned immediately below which firmly secures them to the sleeve in the end wells. These pgs, together with the receiving sleeve, protectively seal the side and opposite ends of the core. The central, hgh-shear-strength core and the two end plugs in each dowei bar 20 are collectively referred to as a core assembly, The outside of the sleeve is smooth. Tenacious bonding between the sleeve and the inside core assembly may include any one or more of several bonding mechanisms, including sleeve shrinkage, normal milb scale roughness of steel, associated. of course just with the steel core, molecular inter-material forces with both the steel core and the end plugs, and other. 25 Thus, and very importantly, nothing about the protective Jacket involves any condition of iacket-materiai "folding"' around and over the sharp edge discontinuities that are present adjacent the ends of the central steel core. This important condition exists chiefly because of the fact that the sleeve in the jacket has a length greater than that of the steel core, extends beyond each of the opposite ends of the core, 30 and that sleeve-received and bonded end plugs having diameters and cross sections matching that of the core close the opposite ends of the sleeve to complete the core protective jacket.
    WO 2013/116578 PCT/US2013/024239 6 The jacket's included sleeve is fibre reinforced in plural, resin-embedded, fibre-d differentiated, circumferentially-adjacent circumferential layers of fibres which take the forms of (1) elongate, linear plura-elongate-fibre-including. glass-fibre roving material whose included fibres substantially parallel the long axis of the dowel 5 bar, (2) continuous-gdass-fibre mat material, and (3), glass-fibre veil material. The sleeve end plugs are formed preferably of roving-fibre-reinforced plastiC resin, wherein the included fibres are linear and also disposed substantially parallel the long axis of the dowel bar, Methodologically, the invention proposes a pultrusion-based, dowel-bar 10 making process including, in general terms, (a) preparing an elongate core train (preferably substantially horizontally disposed) possessing endo-abutting, longitudinally alternating (1) elongate, cylindrical, high-shear-strength cores, and (2) shorter, elongate, cylindrical and matching-cross-section resin and fiber-reinforced, pre-pultruded sleeve end-plug blanks, (b) using the core train as a longitudinally 15 moving mandrel, pultrusion-forming a resin and fiber-reinforced sleeve continuously and bondedly around the core train so as to produce a pultrusion-result intermediate product, and (c) cross-cuttng the pultrusion-result intermediate product at the longitudinal center locations of the sleeve end plugs to form the final dowel bars, Pre-pultrusion, of the just-above-mentioned, pre-pultruded sleeve end plugs 20 does not specifically or necessarily, form a methodologic, procedural part of the present invention, and may be conducted in an entirely conventional manner. Such pre-pultrusion, however, is a very useful end-plug-making technique for assuring that the end plugs, in order to cooperate successfully in the dowel bar of the invention, are satisfactorily reinforced with throughout-distributed, elongate. linear fibres that 25 substantially parallel the end plugs' long axes. These and other features and advantages of, and offered by, the invention will become more fully apparent as the detailed description of it which follows below is read in conjunction with the accompanying drawings. Descriptions of the Drawings 30 Fig. I is a fragmentary, plan view of a high-performance concrete highway incuding plural, adjacent slabs that are present in one of the highway s common drection highway lanes - these slabs being vertically-load-transferably linked/connected by plural, laterally spaced composite-material dowel bars that have WO 2013/116578 PCT/US2013/024239 -7 been constructed in accordance with the present invention, and that are disposed at each separation interface (joirt) between these slabs. Fig, 2 is a perspective illustration which has been prepared to be readable, along with Figs. 3-5, inclusive, for describing two, different, preferred embodirnents 5 of (Figs, 2-4, inclusive), and manners of making (Fig. 5), a plurakcomponent, composite-material highway dowel bar, lke those generally seen interconneca ng the highway slabs in Fig, 1, made in accordance with the present invention, These two embodiments, which, as determined by user choice, may be selected for different, specific applications, include two different layer-count arrangements of plastic-resin 10 embedded reinforcing fibres formed in a sleeve portion of the proposed dowel bar, one of which preferred embodiments includes three fibre layers, and the other of which includes four such layers. Also, and as will be explained below, even other specific layer arrangements may be chosen, if desired. A portion of the illustrated bar is broken open in Fig, 2 to show certain, internal, structural features, Fig, 2 is 15 drawn on a considerably larger scale than that employed in Fig, 1. Fig. 3 is an enlarged-scale, fragmentary, side elevation, taken generally along the line 3-3 in Fig. 2, further illustrating the dowel bar of Fig, 2, and also presented with portions broken away to illustrate details of internal construction. Fig, 4 is an even larger-scale, fragmentary illustration, focusing on the region 20 in Fig. 3 which is embraced by the curved arrows shown at 4-4. Fig. 5 pictures, on a scale which differs from than that employed in Fi,. 2, a fragmentary, side elevation, schematic in nature, of apparatus for implementing the pultrusion-based methodology preferably employed in accordance with the present invention for making a plural-component, composite-material dowel bar, such as that 25 pictured in Figs. 2-4, inclusive. Fig, 6 is a block/schematic diagram illustrating the architecture of the preferred, pultrusion-based, dowel-bar-making methodology implemented as shown in Fig, 5, Components, structures and positional relationships between elements 30 presented in Figs, 1-5, inclusive, are not drawn to scale. Detailed Description of the Invention Turning now to the drawings, and referring first of all to Figs, 1-4, inclusive, indicated generally at 8 in Fig. 1, in plan view, is a fragmentary portion of a high- WO 2013/116578 PCT/US2013/024239 8 performance, concrete highway, including a representative, common-ravel-direction lane 8a formed with plural, adjacent concrete slabs 8b that are vertically-load transferably interconnected, each to an adjacent slab, by plural, laterally spaced, composite-material dowel bars 10 which are disposed at about 1-foot lateral intervals 5 at each separation interface (joint) Sc between these slabs. Focusing especially on Figs, 2-4, inclusive, which illustrate details of dowel bar construction as proposed by the present invention, each dowel bar 10 takes the form of an elongate, cylindrical, plural-corponent. composite-material structure. fabricated, at least in part (as will shortly be described) by a pultrusion process 10 utilizing an appropriately heated pultrusion die - this process also being referred to herein as a pultrusion-based methodology. Dowel bar 10 has a long axis shown at 10a. The principal components present in bar 10 include (1) an elongate, cylindrical, high-shear-strength core 12, preferably, though not necessarily, made of 15 steel having a long axis 12a which is coincident with ax's 1a, and spaced, opposite ends 12b. (2) an elongate, pultrusion-formed, fiber-reinforced plastic-resin jacket 14 having an elongate, pultrusion-formed, cylindrically tubular sleeve 16 which, within its elongate, hollow, cylindrical interior, or inside, 16a, snugly and circumsurroundingly receives core 12, and (3) a pair of pre-pultrusion-formed, cylindrcau sleeve end 20 plugs 18 which, disposed immediately next to core 12's ends 12b, as seen, are adhesively/bondedly received complementarily within the cylindrical, opposite ends or end wells, 16b of sleeve 16 to close off the ends of this sleeve. Sleeve 16 includes a long axis 16c which is coincident with axes 10a, 12a, and a circumferential wall 16d, Plugs 18, together with sleeve 16, form the entirety of 25 jacket 14 which completely surrounds and sealingly protects steel core 12. While different dimensions designed to suit different particular applications are of course entirely possible throughout the structure of the dowel bar of the present invention, dowel bar 10 herein has a fairly typical set of outer dimensions, with a length (D. in Fig. 3) of about 18-inches, and an outside diameter (D 2 in Fig. 3) of 30 about 1-1/2-inches. Within bar 10, in accordance with the embodiment of the invention now being described, core 12 has a length (D, in Fig. 3) of about 16 inches, and a diameter (D4 in Fig, 3) of about 1-1/4-inches, Sleeve 16 has a tubular wall thickness (05 in Fig. 3) of about 1/8-inches - this wall thickness preferably lying WO 2013/116578 PCT/US2013/024239 9 within a range of about 0,07- to about 0.8-iinches. Sleeve end plugs 18 each nas a length (D6 in Fig. 3) of about 1-inches, and a circular cross section, and' therefore a diameter, essentially matching those of core 12. Conventional structural steel is employed for core 12, and a particular steel 5 which is very suitable is known as Grade ASTM 615~60 carbon steel, Within jacket 14, three, different, or differentiated, characters of plastic-resin embedded, reinforcing fibers, preferably made of glass, and most preferably of e~ glass, are employed, These differentiated fibre characters include (1) glass-fibre roving, also referred to herein as eogate linear, plura-elonga 10 glass-fibre roving material whose included fibres substantially parallel previously mentioned axes 10a, 12a, 16, (2) giass-fibre mat, also referred to as continuous glass-fibre mat material, and (3) glass-fibre veil or veil material Al! three of these characters of fibres are employed in sleeve 16 in what are referred to as ci rcumferentialy-adjacent, fibre-differentiated. radially spaced, circumferential 15 (effectively cylindrically tubular) layers that are disposed circumferentially around the long axis 16c of the sleeve, within its wall 16d Solely the roving material is employed in cylindrical end plugs 18, the fibres in which material are distributed across each plug s entire, circular cross section, with the linear fibres in such roving material substantially paralleling axes 10a, 12a and I6c. 20 While the reinforcing fibers employed are most preferably made of e-glass, we recognize that they might alternatively be made. for other examples, of stgas basat, or carbon. Each type of the just-mentioned, three fibre-reinforcing materials is conventional, is offered commercially in a wide variety of choices, particular sizes 25 and other characteristics, and may freely be selected for use successfiuly in the dowel bar of the present invention, with such selecting being made according to specific hig hway applications and designer-choice considerations. Representatively, fibre-reinforcing materials which we have found to be well-suited for use in many high-performance highways include- (a), for mat material, continuous-strand glass 30 fibre products made and offered by Owens Corning in Pennsylvania, USA (b), for roving material, a selection drawn from the products also made by Owens Coming: and (c), for veil material, what are referred to respectively as "tissue veil" and "veil WO 2013/116578 PCT/US2013/024239 10 cloth) products made available by Freudenberg Nonwovens in Durham, North Carolina. and Xamax in Seymour, Connecticut, The embedding, plastic-resin material preferably used with the reinforcing fibres in the sleeve is a conventional, urethane-modified, thermoset. vinylester resin c material such as Dion 31038-00, made by Reichhold Inc. n Durham, North Carolina, USA, in the end plugs, we have chosen., as a preferred plastic resin material, a conventional, thermoset polyester material, made by Razor Composites in Baraboo, As was mentioned in relation to what is iflustrated in Figs. 2-4, inclusive, two 10 different embodiments of the invention, different in relation to the specific structure of sleeve 16, are effectively lustrated in these figures, with the viewer thereof appropriately considering, and then taking appropriately into account, the different descriptions of these two embodiment' given below herein. Language which commonly describes both of these embodiments, in relation 15 to the structure of sleeve 16, is that this sleeve, which is, as already mentioned, elongate and cyindrically tubular, is pultrusion formed, in accordance with the present invention, of fiber-reinforced plastic resin, and specifically is formed with plural, plastic-resin-embedded, fiber-differentiated, circumferentially-adjacent circumferential (generally cylindrical and tubular-like) layers of fibers which are 20 preferably glass fibers, and specifically, most preferably e-glass fibers, as mentioned above, In one preferred embodiment of the invention, chooseable for employment in many, high-performance highway applications, there are three, circumferential layers of stnucturally differentiated fibers, and in the other preferred embodiment, selectable for use in many, other., high-performance highway applications, there are four such 25 layers, Accordingly, in Figs. 2 and 3, a total of four reinforcing-fibre layers are pictured, of which three should be considered as being present in sleeve 16 (i,e_ within sleeve wall 16d) in the first ustabove-mentioned dowel-bar embodiment., and all four in the second just-above-metioned embodiment These four layers are shown at 20, 22, 24 and 26. Regarding the "first embodiment of the invention, what 30 should be visualized by looking at Figs 3 and 4 is that only those three layers which appear at 20, 22 and 26 are present. In both preferred embodiments of the invention described herein, the glass material present in sleeve 16 occupies about 6X0% by weight of the sleeve, WO 2013/116578 PCT/US2013/024239 11 Layer 20. which appears as a wavy lne in Fig 4, includes glass-fibre nat material Layer 22, which appears as a thickenedn straight line in Fig. 4, includes glass-fibre roving material. Layer 24, which also appears as a wavy line in Fig, 4, includes glass-fibre mat material, And, layer 26, which appears as a thin, straight, 5 dash-double-dot line in Fig, 4, includes glass-fibre veil material. Discussing this illustrated, overall layer organization in what may be thought of as a "one-removed-layer" manner that relates specifically to the first, above mentioned, preferred sleeve embodiment, ie,, the one which features only three fibre-reinforcing layers, and hence to the first; preferred dowel-bar erbodient., one 10 sees in sleeve 16, i.e., in its wall 16d, by appropriately visualizing Figs. 3 and 4 to imagine the presence of only three of the therein pictured, four layers, an arrangement of three, relevant, cooperative, fibre-reinforcing layers, which arrangement, progressing radially outwardly in the sleeve from its inside 16a, takes the form of a first-encountered, mat-material ayer 20, a later-encountered, roving 15 material layer 22 disposed outwardly of layer 20, and an even latervencountered Vl material layer 26 disposed outwardly of roving-matenial layer 22. 'These three layers rake up the previously mentioned wail 16d thickness in sleeve 16, Alternatively, by looking at Figs. 3 and 4 without "eliminating" from consideration one of the four, pictured layers, and instead by positively recognizing 20 the presences of all four layers shown in these figures, one sees the second preferred embodiment of sleeve 16, and hence of the dowel-bar structure of the invention, which features an alternative arrangement of four, relevant, cooperative, fibre-reinforcing layers, which alternative arrangement, progressing radially outwardly in the sleeve from its iside 16a, takes the form of "first-encountered, mat 25 material layer 20, later-encountered roving-material layer :22 disposed outwardly of layer 20, a second mat-material layer 24, and what was just referred to above as "even later-encountered" veil-material layer 26 shown disposed outwardly of layer 22. Here, too, in this arrangement of layers, the four, included layers make up the previously mentioned wall 16d thickness in sleeve 16, 30 The pre-pultruded sleeve end plugs, as mentioned earlier herein, include elongate roving fibers distributed across the entireties of the plugs' circular cross secions, embedded in the mentioned, thermoset, polyester resin present in the sleeve. These fibres extend substantially parallel to axes 10a, 12a and 16c.
    WO 2013/116578 PCT/US2013/024239 12 Retuming here far a moment to the very important topic mentioned above involving the fact that jacket 14. as distinguished from known, prior-art, core component, over-coating structures, is not subjected to contact with any sharp edged, high-stress, surface discontinuity regions within the dowel bar of the present 5 invention, it is easy to see and understand, from the descriptions and illustrations which have now been presented of the sleeve and end-plug components which make up jacket 14, that no part af this jacket structure bears upon the sharp-edged surface discontinuity regions that exist adjacent the opposite ends of core 12. as can be seen at the two, such, regional locations in Fig. 4 marked i12c, This comes 10 about, of course. because of the fact that sleeve 16 is a pultruded structure which has been pultrusion formed so that it extends, without any transitional shape change included in it, effectively as a continuum beyond the opposite ends of core 12 rather than folding over regions 12c and that and plugs 18 possess circular cross-s'ections which match that of core 12. Moreover, it is very evident, from the above-stated, K5 preferred dimensions of the sleeve and end plugs, and from the attendant fact that they are fibre reinforced, that these dowel-bar structural components are very robust and unlikely ever to be cracked or penetrated under normal use conditions. Turning attention now in succession to Figs. 5 and 6, Fig. 5 illustrates, at 28, an apparatus for implementing the pultrusion-based methodology of the present 20 invention -- this apparatus possessing a ptunormaton axis 28a, and, in block/schematic fashion generally at 30 in Fig, 6, the preferred architecture of that methodology. Progressing from left to right, ie from upstream to downstream ends of apparatus 28, across Fig, 5, apparatus 28 includes (1) a core-train pusher 32, simply 25 represented by a darkened arrow whose arrowhead points in the direction of processing flow through apparatus 28, (2) a core-train formation, or forming, station 34, (3) a steel-core heater HI which is disposed within station 34 and designed to heat cores 12, as will be further explained, to a temperature of about 1504F before actual. sleeve-formation pultrusion begins, (4) a reinforcing-fiber supply station 36 30 which, represented necessarily just in the plane of Fig 5 (ie. on one side Only of pultrusion-formation axis 2a), is seen to include herein four, reinforcing-iber material distributing devices that are illustrated as rotary fibre-delivery spools 38, 40, 42. 44 -- devices that are representative of user-selectable, conventional structures WO 2013/116578 PCT/US2013/024239 designed to pay out. respectively, elongate, fibre--material runs, such as those appearing as straight, angularly inclined lines in Fig. 5, of glass-fiber mat material 20, glass-fiber roving material 22, glass-fiber mat material 24. and glass-fiber veil material 26, (5) a resin fibre-bathing, or resin bathing: station 45, and a fibre gude 5 station 46 which. like fibre supply station 36. are respectively pictured necessarily just in the plane of Fig, 5 only on one side of axis 28a, (6) another heater, HZ (7) a conventional, and appropriately sized (herein with a length of about 5- to 6-feet, and an Internal, elongate, cylindrical pultrusion channel with a diameter of about 1-1/2 inches) pultrusion die 48, the inside of which is heated to a temperature of about 10 280"T by heater H2. (8) a conventional, power-driven, pultrusion puller of any suitable design, such as a crawler-tread design, represented simply by a darened arrow 50, operable herein to establish a pultrusion throughput speed of about 3- to 4 .5-feet-per-rninute, and (9) a suitable cross-cutter 52 which is employed to cross cut what is referred to herein as a. pultrusion-result, intermediate, dowel-bar product, 15 such as that designated 54 in Fig. 5, emerging from die 48, A fragmentary, end portion of a finished, cut-separated dowe-bar 10 is pictured to the right of cutter 52. It should be understood that, while four, fibre-delivery spools (devices) have been illustrated in Fig, 5 in order to relate to a discussion regarding the delivery of fiber-reinforcing materials suitable to create four layers within a sleeve 16 in the 20 context of fabricating the above-mentioned second preferred embodiment of the invention, in a circumstance where the first preferred embodiment of the invention is to be manufactured, only three such delivery spools (devices) would be required, and, in terms of what is illustrated in Fig, 5. these three spools would include spools 38, 40 and 44. 25 Further discussing what has just been described respecting Fig. 5: the three, upstream processing stations, and the associated structures illustrated therein, which are involved with (I) supplying, i.e, paying out, from suitable delivery devices, such as the representatives pictured delivery spools, elongate runs of the several different kinds of reinforcing-fibre materials, (2) for bathing the these reinforcing 30 fibre-material runs en route to the pultrusion die with the appropriate plastic resin, and (3) for guiding the bathed fiber-material runs into the indeed, upstream end of the pultrusion die, must necessarily be constructed, and this may be done in entirely conventional, user chooseable manners, so as to be distributed relative evenly WO 2013/116578 PCT/US2013/024239 14 around, i.e. circumferentially around, pultrusion-forming axis 28a so that a sleeve 16 ultimately becomes pultrusion-formed uniformly circumferentia ly around a core 12, Just how this circumferential distrbution of paying out. bathing and guiding equipment is organized, and what particular type of such equipment is employed, is 5 entirely a matter of user/designer choice, and forms no part of the present invention, Located preferably adjacent both (1) the upstream, or infeed, and (2) the downstream, or discharge, ends of apparatus 28. are suitable track-like, such as trough-like, and preferably, though not necessarily, stationary, support structures, not illustrated herein, that provide appropriate, underlying support (a), adjacent the 10 upstream end of the apparatus for what will shortly be described as a stream of elements that make up a pre-pultrusion core-train of dowel-bar central elements (i.e, endo-abutting, longitudinally alternating cores and end-piug banks) that are to be fed into die 48 for putrusion forming of sleeve structure 16, (b) adjacent the downstream end of the apparatus, and of die 48, for the emerging intermediate, 15 pultrusior result, dowel-bar product, such as that shown at 54, and (c) beyond cross-cutter 52, for the finished and thereafter separated dowel bars 10. Other modes, etc, of underlying "omponent-hroughput-transport" support may, of course, be implemented. While the process of sleeve formation herein is clearly a puitrusion-based 20 process, at the extreme upstream end of apparatus, there are engaged herein, as will now be described, upstream, core4rain-forrming and core-rain-pushing. operational stages that relate to the needed formation, and then the downstream transport-moving, of what has been described, referred to above, as a core train of components that become organized into a horizontal, linear train in any suitable, 25 component-placement manner in station 34 for feeding from that station toward stations 45, 46, and puitrusion die 48, As mentioned earlier herein, what is referred to as a core train, such as the one pictured fragmentarily, and horizontally, at 56 in Fig. 5, is made up of a continuous train of endo-abutting, longitudinally alternating, elongate. cylindrical, high-shear-strength, steel cores 12, and shorter, elongate. 30 cylindrical and matching-cross-section, plastic-resin and fiber--reinforced, p-re puitruded sleeve end-plug blanks, such as the two end-plug blanks shown at 58 in this figure -- one of these blanks being disposed just upstream from die 48, and the other being disposed within the die, As will become apparent shortly, each end-plug WO 2013/116578 PCT/US2013/024239 15 blank has a length which is about twice that of a finished end plug and namely about 2-inches, Considering now the overall dowel-bar formation pultrusion process proposed by the present invention, a core train, including endo-abutting, longitudinally 5 alternating cores and end-plug blanks is suitably formed along a line in forrning staton 34. Within th station, as the formed core train is moved by pusher 32 toward the pultrusion die, and by appropriately timed and staged operation of previously described heater HI. which may take any suitable form of a heater selected by the user, and which may conveniently and conventonalIly be operated 10 under the control of a suitably programmed. dgital computer (not part of the present invention) the steel cores in the train are preferably heated, as mentioned earlier herein, to a temperature of about 150*, Such heating is preferably done in order to prevent the cores, during processing within pultrusion die 48. from acting as undesired heat sirnks which could retard, and perhaps interfere with, appropriate 15 curing of the resin which coats the fiber reinforcing materials within the die. The formed Core train, with its included, appropriately pre-pu -tusion-activity, heated, steel cores, is moved from the forming station toward and into the die by pusher 32 which is operated in any appropriate fashion, entirely selectable by the user., to shift the core-train components at an appropriate rate toward and into the 20 pultrusion die, and in a manner so as to accommodate, as far as the pultrusion die is conceded", a substantially steady and effectively continuous stream of freshly die introduced core-train components. There are many conventional ways that a pusher, such as schemnatically illustrated pusher 32, may be constructed and operated so as (1) to permit eayi 25 essentially continuous assembly in station 34 of a progressively formed core-train line of components, and (2), at appropriate moments to push these tran-formed components in proper, endo-abutting conditions so that the puitrusion die will exoerence a continuity inflow of dowel-bar, core-component material. Those skilled in the art will recognize that once the substantial "endless" core train, pushed to an 30 appropriate location along pultrusion-formation axis 28a, is sufficiently disposed within the pultrusion die, and specifically sufficiently contained therewithin so that resin-coated: fibre reinforcing, sleeve material has begun to stick to the core train, the downstream operation of puler 50 "takes over' in conventional pultrusion WO 2013/116578 PCT/US2013/024239 fashion: and functions, in a continuity manner to drive the downstream-directed, flowing motion of all within the die, It should be noted here that proper endo abutment between the cores and end-plug blanks in a core train: dunng the coredrain formingprocess, and the 5 associated moving of a formed core train into die 48, depends upon the opposite ends of the cores and end-plug blanks lying correctly in parallel planes that are disposed normal to the respective long axes of these components, While these core-train forming and pushing activities are underway in apparatus 28 in station 34 and by pusher 32: eongate runs, such as those 10 previous mentioned, shown at 20, 22, 24, 26 in Fig. 5, of the appropriate number of reinforcing-fibre materials, , i.e. three or four such materials depending upon which of the two preferred embridiments of the dowel bar is to be fabricated, are (1) paid out from the spools in fiber supply station 36, (2) lead through resin bathing station 45 wherein they are bathed in, and wetted with, the selected plastic resin, and <5 thereafter (3) guided through, and by, guide station 46 toward and into the intake end of puitrusion die 48, appropriately disposed, circumferentially about apparatus axis 28a, and, of course, in the appropriate radially organized layer arrangement, which has been mentioned earlier herein, distributed circurnferentiaiy around the now centrally (on axis 28a) located core train so as to be arranged, within the putrusion 20 die, for the correct formation of a sleeve 16. if the first preferred dowe[-bar embodiment is to be made, fibre-mater paying out takes place from spools 20, 22, 26, whereas if the second preferred embodiment is to be formed. such paying out occurs from al four, illustrated spools, Within puitrusion die 48, as the through-moving core train: and the associated 25 surrounding wettedfbreinforced, materials pass through the die, an appropriate level of heat, generated inside the die (at the previously mentioned, representative, internal temperature of about 2801F) by heater H 2 coupled wit h the attendant, moving-surface-contact which occurs with the internal cylindrical pultrusion channel within the die. cause the resin-coated mass of material to form appropriately around 30 the core train in the configuration of what is to become a sleeve 16. The plastic resin material cures effectively to doneness by the time that all of these materials emerge from the downstream end of the die- Curing of the plastic resin material within die 48 is, of course, promoted by heat which is generated by heater H 2 , and to some extent WO 2013/116578 PCT/US2013/024239 17 by heat radiated from the pre-heated steel cores which, because of their pre-heated conditions, do not negatively act as unwanted heat sinks within the die. It will be well understood by those skilled in the art that (1) the rate of throughput of materials established selectively in apparatus 28 in the formation of the 5 dowel bars of the invention, (2) the selected level of internal-die heating which is created by heater H.-, and (3) the overall length of die 48 per se, are appropriately determined by the specifically chosen sizes of the materials that are to be employed in the making of a particular size and character of a dowel bar 10, and in relation to the formation curing characteristics of the chosen plastic resin materia. 10 As has been mentioned herein, what emerges continuously during dowed-bar making. from the downstream, discharge end of die 48, is what has been referred to hereinabove as an intermediate, pultrusion-result, dowel-bar product, as seen at 54 in Fig, 5, Downstream from die 48, and under appropriate operations and timing control, such 15 as might be implemented by a suitably programmed digital computer, cross-cutter 52 is operated to produce a cross cut in this emerging "intermediate" product, with each such cut being made at a location which is substantially exactly midway between the opposite ends of each core-piug blank. Such a cross cut is shown generally at 59 in Fig. 5. 20 The result of this operation is, of course, separation, one after another, of completed dowel bars 10 made in accordance with the invention. Outlining now compactly, in relation to the block/schematic diagram presented in Fig. 6, and in one manner of expressing the methodology of the present invention, what is proposed and offered is a plural-component, composite-materiaL highway 25 dowekbar raking method 30 including (a) preparing an elongate core train having a long axis, and possessing, along that axis, endo-abutting, longitudinally alternating, (1) elongate, highshear-strength, cylindrical cores having a common certain cross section, and (2) elongate, but shorter, cylindrical, fibre-reinforced plastic-resin end-plug blanks having opposite 30 ends, and each having a cross section matching the certain cross section of the cores - Block 60: (b) using the core train as a longitudinally moving mandrel, pultrusion-forming a fibre-reinforced plastic-resin sleeve continuously and bondedly around the core WO 2013/116578 PCT/US2013/024239 18 train so as to produce a pultrusion-result, intermediate, dowelkbar product .Block 64, and following puitrusion-forming cross-cutting the intenmediate. dowei-bar.- product at each longitudinal location therein which is intermediate the opposite ends of the 5 end-plug blanks, and thereby morning completed dowel bars - Block 66, From an augmented point of view, this methodology further contemplates that puitrusiornforming is preceded by (a) paying out, from suitable supplies; continuous, elongate runs of reinforcing fibre materials, (b) bathing these materials runs in curable. liquid plastic resin, and guiding the bathed runs into circumferental layer 0 structure for puitrusion in a tubular region circumsurroundingly disposed relative to the outside of the prepared core train - Block 62. Other features of this methodology are discussed above, and include employing, as reinforcing fibre materials, (1) glass-fibre roving possessing plural, elongate: linear fibres, (2) continuous-glass-fbre mat, and (3), glass-fibre veil, and 15 the paying out and guiding steps collaboratively perform arranging of the different reinforcing fibre materials whereby, relative to the outside surface of the core train during the pultrusion-sleeve-forming step, mat material becomes disposed as part of an innermost puitrusion layer, veil material becomes disposed as part of an outermost pulitrusion layer, and roving material becomes part of a iayer which is 20 intermediate these innermost and outerms layers, with its included., elongate fibers disposed with their long axes substantially paraleling the core train's long axis, Accordingly, in a pair of representative preferred embodiments, and manners of fabrication, an important new, advanced-performance and significantly enh.anced iongevity highway dowel bar, and an impotant pultrusion-based methodology for 25 making it, have been described and illustrated herein. Variations and modifications are, of course, possible which will come within the spirit of the invention, and which may wel. come to the minds of those generally skilled in the relevant art,
    权利要求:
    Claims (6)
    [1] 2. The dowei bar of clairn 1, wherein said jacket includes (a) an elongate, cylindrcally tubutar sleeve which is (1 fibre-rei-nforced in pluralc plastic-resin embedded, fibre-differentiated, circurnfe rent aIx ac n c <r rental ayers of fibres, (2) longer than said core, and (3) configured with a hollow, cylindrical inside 10 which bondedly receives said core in a manner defining opposite-end, cylindrical end wells that are disposed within the sleeve beyond opposite ends of the received core, and (b, a pair of spaced, elongate, fibre-reinforced, cylindrical, sleeve end plugs bondedly affixed, one each. complementariy within said end wells,
    [2] 3. The dowe bar of clain 2 which possesses a long axis, and wherein 15 said circurnferentiaty-adjacent fbre differentiated, crcurnferential :ayers include different, respective, characters of seeveIc fibres which take the forms of (1) elongate, linear, pura-elongate-nhre-incudin glass-fibre roving material whose included fibres substantially parallel said long axis (2) continuou-glss-fibre mat material, and (3), glass-fibre veil material, and said fibre-reinforced sleeve end plugs 20 include glass-fibre roving also possessing plural, elongate fibres which substantially parallel said long axis, 4, The dowel bar of claim 3, wherein said fibre-reinforced, circumferentiaily-adjacent, circumferential layers of fibres in said sleeve possess an arrangement which, progressing radially outwardly in the sleeve from its inside, takes 25 the form, generally, of a first-encountered mat-material layer, a later-encountered, roving-material layer disposed outwardly of said mat-material layer, and an even later-encountered veil-material layer disposed outwardly of said roving-material layer.
    [3] 5. The dowel bar of claim 4. wherein said arrangement further includes a 30 second mat-material layer disposed intermediate said later-encountered roving material layer and said even latecr-encountered ve i-lmaternal layer. 6, The dowel bar of claim 1, wherein said core is formed of steel, WO 2013/116578 PCT/US2013/024239 20 7, The dowel bar of claim 6, wherein said jacket includes (a) an elongate, cylindrcally tubular sleeve which is (1) fibre-reinforced in plural pastic-resin~ embedded, fib e-differentiated. circumferntiay-adjcent circumferential layers of fibres, (2) longer than said core bar, and (3) configured with a holow, cylndrical 5 inside which bondedly receives said core bar in a manner defining opposite-end, cylindrical end wells that are disposed within the sleeve beyond opposite ends of the received core bar, and (b), a pair of spaced, elongate, fibre-reinforced, cylindrical sleeve end plugs bondedly affixed, one each, complementarily within said end wells.
    [4] 8. The dowel bar of claim 7 which possesses a long axis, and wherein 10 said circumferentialv-adjacent. fibre-differentiated, circumferential layers include different, respective, characters of sleeve-included fibres which take the forms of () elongate, linear, plural-elongateibre-inciuding, glass-fibre roving material whose included fibres substantially parallel said long axis, (2) continuous-glass-fibre mat mnateriai and (3), glass-fibre veil material, and said fibre-reinforced sleeve end plugs 15 include glass-fibre roving also possessing plural, elongate fibres which substantially parallel said long axis, 9" The dowel bar of claim 8, wherein said fibre-reinforced,. circumferentially-adjacent, circumferential layers of fibres in said sleeve possess an arrangement which, progressing radially outwardly in the sleeve from its inside., takes 20 the form, generally, of a first-encountered, mat-material layer, a later-encountered, roving-material layer disposed outwardly of said mat-material layer, and an even later-encountered veil-material layer disposed outwardly of said roving-material layer.
    [5] 10. The dowel bar of claim 9, wherein said arrangement further includes a 25 second mat--naterial layer disposed intermediate said later-encountered roving material layer and said even later-encountered veil -material layer. WO 2013/116578 PCT/US2013/024239 21 11, A plural-component, composite-materia, highway dowe!-bar making method comprising prepanng an elongate core train having a ong ax's, and possessing along that axis, endo-abutting, longitudna6ly alternating. (a) elongate., hig-shear-szrength, 5 cylindrical cores having a common, certain cross section, and (b) elongate. but shorter, cylindrical, fibre-reinforced plastic-resin end-plug blanks having opposite ends, and each having a cross sexton matching the certain cross section of the cores, using the core train as a longitudinally moving mandrel, puitrusion-forming a 10 fibre-reinforced plastic-resin sleeve continuously and bondedly around the core train so as to produce a pultrusion-result, intermediate, dowei-bar product, and following said pultrusion-forminq, cross--cutting the intermediate, dowel-bar product at each longitudinal location therein which is intermediate the opposite ends of the end-plug blanks,. and thereby forming completed dowel bars. 15 12, The method of claim 11, wherein said pultrusion-forming is preceded by (a) paying out., from suitable supplies, continuous, elongate runs of reinrorcing fibre materials, (b) bathing these materials runs in curable. liquid plastic resin, and guiding the bathed runs into circumferential layer structure for pultrus ion in a tubular region circurnsurroundingly disposed relative to the outside of the prepared core 20 train.
    [6] 13. The method of claim 12, wherein the reinforcing fibre materials include (1) glass-fibre roving possessing plural elongate, linear fibres, (2) continuous-glass fibre mat. and (3), glass-fibre veil, and said paying out and guiding steps collaboratively perform arranging of the different reinforcing fibre materials whereby, 25 relative to the outside surface of the core train during the subsequent pultrusion sleeve-forming step. mat material becomes disposed as part of an innermost pultrusion layer, veil material becomes disposed as part of an outermost puitrusion layer, and roving material becomes part of a layer which is intermediate these innermost and outermost layers, with its included, elongate fibers disposed with their 30 long axes substantially paralleling the core train's long axis. 14 The method of claim 11 which further comprises heating the high shear-strength cores prior to said pultrusion-forming. WO 2013/116578 PCT/US2013/024239 ,22 1 5.The method of clim I I which further cormpnses Performing cpuitrusK. -, formifvg in a heated envkoment.
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    同族专利:
    公开号 | 公开日
    WO2013116578A2|2013-08-08|
    CA2861049A1|2013-08-08|
    US9440400B2|2016-09-13|
    US20140021647A1|2014-01-23|
    EP2809847A4|2016-04-13|
    US8591139B2|2013-11-26|
    WO2013116578A3|2015-06-18|
    US10508390B2|2019-12-17|
    US20130202355A1|2013-08-08|
    AU2013215004B2|2016-01-28|
    IN2014MN01710A|2015-05-29|
    EP2809847A2|2014-12-10|
    BR112014018996A2|2019-09-24|
    CN105229233A|2016-01-06|
    US20170058463A1|2017-03-02|
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    法律状态:
    2016-05-26| FGA| Letters patent sealed or granted (standard patent)|
    2018-08-30| MK14| Patent ceased section 143(a) (annual fees not paid) or expired|
    优先权:
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    US201261595042P| true| 2012-02-04|2012-02-04||
    US61/595,042||2012-02-04||
    PCT/US2013/024239|WO2013116578A2|2012-02-04|2013-02-01|Plural-component, composite-material highway dowel bar structure and fabrication methodology|
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