Note: Descriptions are shown in the official language in which they were submitted.
CA 03165303 2022-06-17
WO 2021/124192
PCT/IB2020/062100
1
DESCRIPTION
"CONNECTION ELEMENT, METHOD FOR MANUFACTURING A
CONNECTION ELEMENT AND RELATED INSTALLATION KIT"
FIELD OF APPLICATION
[0001] The present invention relates to a connection
element, a method for manufacturing a connection element
and a related installation kit. In particular, the
present invention relates to connection elements made of
composite material to be used, for example, for
consolidating or improving the safety of structures in
the building industry and in the industry in general.
BACKGROUND ART
[0002] As known, there are many techniques for
consolidating architectural structures or the safety
thereof. In particular, there are techniques which use
rigid meshes made of composite material made with fibres
incorporated in a thermosetting resin.
[0003]In some applications, the meshes are embedded inside
a mortar with binding agents, which may be of different
types, and are used for consolidating existing structures
(masonry, concrete, reinforced concrete, etc.) creating a
reinforced plaster to be applied on the surfaces, or as
slabs for manufacturing load bearing floor slabs.
[0004] The mesh, for example, may be blocked in position by
means of the use of junction elements inserted in holes
CA 03165303 2022-06-17
WO 2021/124192
PCT/IB2020/062100
2
made in the masonry. The junction elements are generally
made of metal or another material, and have an L-shape,
in which the two sides are substantially perpendicular to
each other. In use, once an anchoring resin has been
distributed inside the hole, one side is inserted into
the hole obtained in the masonry, while the other side is
arranged parallel to the surface of the masonry. Mesh and
junction elements are therefore embedded inside a mortar
with binding agents which may be of different types.
[0005]If the mesh is positioned on both surfaces of a
masonry, it is possible to block it in position, making a
through hole so that the two meshes may be connected to
each other with two junction elements: a first junction
element inserted at one surface, and a second junction
element inserted at the opposite surface.
[0006] As an alternative to the type of junction elements
mentioned, junction elements made with preformed bars
made of composite material comprising fibres and
thermosetting resin are known.
[0007]The preformed bar made of composite material may be
obtained by means of a forging method or by means of a
pultrusion method. In both cases, the fibres are picked
up and passed through a resin impregnation bath.
[0008]In the moulding process, the impregnated fibres are
modelled directly on the die, where they are subjected to
CA 03165303 2022-06-17
WO 2021/124192
PCT/IB2020/062100
3
natural or artificial curing in suitable furnaces.
[0009]In the pultrusion process, at the exit of the area
in which the impregnation occurs, the impregnated fibres
pass through a die so as to give the manufactured item a
specific cross section, compacting the fibres together.
The impregnated fibres are then passed inside a curing
furnace which provides heat so that the resin may
polymerize and therefore cure. These two steps may be
carried out jointly in the production die.
[0010] Downstream of the plant, a so-called pulling device
is there, which provides the impregnated fibres with the
traction necessary to move through the stations mentioned
above.
[0011] The method is therefore free from downtime, since
the pulling device allows the manufactured item being
processed to move between the various stations of the
apparatus.
[0012] Downstream of the pulling device, an area may be
arranged for the automated cutting of the pultruded bars.
[0013] Bars made of composite material offer many
advantages. For example, with respect to bars made of
metal, they are lighter and are not subject to oxidation.
[0014] The main limitation of the pultruded bars is that
they may not be bent on site, for example in the case in
which an anchorage is to be made through the masonry
CA 03165303 2022-06-17
WO 2021/124192
PCT/IB2020/062100
4
between two reinforcement plates.
[0015] The only way to obtain bent bars made of composite
material is to produce them directly bent by means of
forging, in a dedicated plant. However, the production of
these elements, even if they are manufactured already
bent, fails to ensure the dimensional and inclination
flexibility which would instead be necessary.
[0016] To establish a connection between the two
reinforcement areas, or simply to perform the function
thereof as a connector, it is therefore necessary to use
two distinct L-shaped elements, then joined by means of
an overlapping of the chemical or mechanical type, at the
portions thereof, inside and not crossing the structural
element.
[0017] Furthermore, in the case of L-shaped connectors,
precisely at the connecting portion between the two sides
of the L, a decrease in resistance and stiffness is
there, with respect to the straight section.
[0018] The prior art has attempted to solve this issue by
proposing pultruded bars subjected to a processing by
means of which the fibres at one end of the bar are freed
from the already cured resin.
[0019] The end of the bar, after the pultrusion process, is
subjected to a solvent bath and/or a pyrolysis at a
temperature to eliminate the resinous matrix and keep the
CA 03165303 2022-06-17
WO 2021/124192
PCT/IB2020/062100
fibre dry.
[0020] The bars thus obtained may be inserted inside a hole
made in the support to be reinforced or positioned where
previously defined, while the end consisting of free
5 fibres (called, in the technical jargon, the unravelled
end) is radially widened and glued to the desired surface
with specific organic and/or inorganic adhesives or
embedded in the mortar with which the surface of the
support is coated. Thereby, the unravelled end ensures
the mechanical continuity of the elements.
[0021] The procedure used to free the fibres from the
resin, however, has some disadvantages.
[0022]In the first place, it is a further processing which
must be carried out on the bar, and therefore affects the
production costs and the time required for the production
of the preformed connector.
[0023] Furthermore, the fibres which are freed from the
cured resin have worse mechanical features with respect
to the intact bar, but also with respect to the fibres
before the impregnating step, since the invasiveness of
the process modifies the structure of the fibre and the
priming thereof, the lubrication and assembly thereof,
substantially removing the gripping power of the free and
dry end.
PRESENTATION OF THE INVENTION
CA 03165303 2022-06-17
WO 2021/124192
PCT/IB2020/062100
6
[0024] Therefore, the need is felt to solve the drawbacks
and limitations mentioned above with reference to the
prior art.
[0025] Therefore, the need is felt to provide a connection
element for the building industry and industry in
general, which may be adapted to different conditions of
use.
[0026] Furthermore, the need is felt for a connection
element for the building industry which may be easily
used for the junction through a through hole in the
support to be consolidated by means of reinforcement
plates on the surfaces thereof, or simply as a connection
element with the ends to be embedded in two or more
solids to be connected.
[0027] Furthermore, the need is felt for a connection
element for the building industry which is simple and
cost effective to manufacture with respect to preformed
connectors of the known type.
[0028] Furthermore, the need is felt for a connection
element which is easier to use with respect to the
connectors of the prior art.
[0029] Such needs are at least partially met by a
connection element according to claim 1, by a method for
manufacturing a connection element according to claim 11,
and by a related installation kit according to claim 14.
CA 03165303 2022-06-17
WO 2021/124192
PCT/IB2020/062100
7
DESCRIPTION OF THE DRAWINGS
[0030] Further features and advantages of the present
invention will be more comprehensible from the following
description of preferred embodiments given by way of non-
limiting examples, in which:
[0031] - Figure 1 diagrammatically shows a perspective view
of a first embodiment of a connection element according
to the present invention;
[0032] - Figure 2 diagrammatically shows a perspective view
of an alternative embodiment of a connection element
according to the present invention;
[0033] - Figure 3 diagrammatically shows a perspective view
of a further alternative embodiment of a connection
element according to the present invention;
[0034] - Figure 4 diagrammatically shows a possible use of
a connection element according to the present invention;
[0035] - Figures 5-7 diagrammatically show perspective
views of possible embodiments of a connection element
according to the present invention;
[0036] - Figure 8 diagrammatically shows a possible
alternative embodiment of a connection element according
to the present invention;
[0037] - Figure 9 diagrammatically shows a possible
alternative embodiment of a connection element according
to the present invention;
CA 03165303 2022-06-17
WO 2021/124192
PCT/IB2020/062100
8
[0038] - Figure 10 diagrammatically shows a possible
alternative embodiment of a connection element according
to the present invention;
[0039] - Figure 11 diagrammatically shows a perspective
view of a component of a kit according to the present
invention; and
[0040] - Figure 12 diagrammatically shows a sectional view
of a component of a kit according to the present
invention.
[0041] Elements or parts in common to the embodiments
described will be indicated hereafter using the same
reference numerals.
DETAILED DESCRIPTION
[0042] Figure 1 shows a connection element according to the
present invention, which is indicated with the generic
reference 12.
[0043] The connection element 12 is made of composite
material comprising a bundle of fibres 13 and a binding
agent. The binding agent may be a resin or an inorganic
matrix.
[0044]In this disclosure, the term matrix and the term
binding agent will be used indifferently to indicate the
same material.
[0045]In particular, the connection element 12 comprises
at least one preformed portion 14 and at least one free
CA 03165303 2022-06-17
WO 2021/124192
PCT/IB2020/062100
9
fibre portion 16, 18.
[0046] The preformed portion 14 comprises a section of the
bundle of fibres 13 embedded in the binding agent to form
a monolithic structure.
[0047]In particular, the preformed portion 14, which in
use may be inserted inside a hole in the support to be
consolidated or in the solids to be connected, may have
an external surface with sand or grit and binding agent
fillings, or an external surface subjected to roughing by
means of a mechanical processing, by removing material or
by forging, in order to improve the performance of the
connection.
[0048] The length of the preformed portion 14 may, for
example, range from 10 mm to 20000 mm. In any case, the
length of the preformed portion 14 may be adapted to
specific needs.
[0049] Advantageously, the length of the preformed portion
14 may be decided on the basis of the thickness of the
structural or non-structural element crossed and/or the
distance of the elements to be connected in which it must
be inserted.
[0050] The preformed portion 14 may have a substantially
circular cross-section, as shown in the embodiments of
Figures 1, 2, 3, 8-10.
[0051] According to a possible alternative embodiment,
CA 03165303 2022-06-17
WO 2021/124192
PCT/IB2020/062100
shown in Figure 5, the cross section of the preformed
portion may be C-shaped.
[0052]In a possible alternative embodiment, shown in
Figure 6, the preformed portion 14 may have an elongated
5 cross-section, even with or without the presence of a
reinforcing rib 21, having a longitudinal or transverse
development. In the embodiment shown in Figure 6, the
reinforcing ribs 21 are two and arranged parallel.
[0053]In a further embodiment, the preformed portion may
10 have a substantially circular and hollow section, as
shown in the example of Figure 7.
[0054] The cross section may, for example, be T-, L-, C-,
double T-shaped, rectangular, square, cylindrical or
according to specific design requirements.
[0055] Advantageously, in the case where the section of the
preformed portion 14 is hollow, the internal volume of
the preformed portion 14 may be filled to increase the
resistance, or in general the performance, thereof. The
internal volume may be filled, for example, with resins,
mortars, organic or inorganic matrices or matrices of
another type.
[0056] The external surface may be continuous, provided
with holes or subjected to other surface treatments
capable of improving the adhesion of the connection
element.
CA 03165303 2022-06-17
WO 2021/124192
PCT/IB2020/062100
11
[0057] The free fibre portion 16, 18 may be arranged at one
or both ends of the bundle of fibres 13. Embodiments of
this type are shown for example in Figures 1 and 2.
[0058] According to a possible embodiment, the free fibre
portion may be arranged between two preformed portions
14. An embodiment of this type is shown in Figure 3.
[0059] In particular, the length of the free fibre portion
16, 18 may, for example, range from 10 mm and 20,000 mm.
[0060] In any case, the length of the free fibre portion
may be adapted to specific needs.
[0061] At the free fibre portion 16, 18, 19, at least one
part of the fibres 13 consists of virgin fibres.
[0062] In this disclosure, the term virgin fibres means
fibres which, at a portion thereof, have not been
embedded in the resin, mortar, organic matrix, inorganic
matrix, or matrix of another type. In technical jargon,
virgin fibres may also be defined as dry fibres.
[0063] In particular, virgin fibres are fibres which, in
the free fibre portion 16, 18, 19 have not been embedded
with resin, mortar, organic matrix, inorganic matrix or
another matrix to make a monolithic or preformed
structure.
[0064] In other words, the fibres 13 which form the
connection element 12 have been impregnated at the
preformed portion 14, while they have not been
CA 03165303 2022-06-17
WO 2021/124192
PCT/IB2020/062100
12
impregnated in the free fibre portion 16, 18, 19.
[0065] In any case, as it will be obvious to those skilled
in the art, such fibres may, for example, be processed or
treated in line or during a subsequent step to obtain
products or elements with shape and features based on the
specific function thereof, such as, for example, the
possibility of impregnating with matrices and/or gripping
material with different properties.
[0066] In other words, the free fibre portion 16, 18, 19
may comprise or consist of virgin fibres.
[0067] According to a possible embodiment, advantageously,
the free fibre portion 16, 18, 19 may be made with at
least 90% of virgin fibres.
[0068] Figure 4 shows some examples of installation of
connection elements 12 according to the present
invention, in which the free fibre portion 16 is visible,
the fibres 13 of which are arranged radially.
[0069] According to alternative embodiments, the fibres of
the free fibre portion 16, 18, at the ends, may also be
arranged in different manners, as it may be easily
assumed by those skilled in the art.
[0070] According to a possible embodiment of the present
invention, the free fibre portion may consist of virgin
fibres.
[0071] The bundle of fibres 13 may comprise synthetic
CA 03165303 2022-06-17
WO 2021/124192
PCT/IB2020/062100
13
organic fibres, natural organic fibres, inorganic fibres,
and/or metallic fibres. Advantageously, a connection
element may comprise fibres of a different type.
[0072] The synthetic organic fibres may comprise, for
example, aramid fibres, poly-para-phenyl benzobisoxazole
(PBO), and/or polyester.
[0073] Natural organic fibres may comprise, for example:
cotton, hemp, flax, sisal, bamboo, wood, wool, silk, etc.
[0074] The inorganic fibres may comprise, for example:
glass, carbon, basalt, quartz, etc.
[0075] The metallic fibres may comprise, for example:
stainless steel, carbon steel, copper, brass, aluminum,
titanium, etc.
[0076] According to a possible embodiment of the present
invention, the bundle of fibres 13 may comprise fibres of
different type.
[0077] According to a possible embodiment, the binding
agent may be a resin.
[0078] As for the resin, this may be of the thermosetting
type, of the thermoplastic type, it may use inorganic
matrices and/or matrices of another type.
[0079]In the case of thermosetting resin, this may, for
example, be of the vinyl-ester, polyester, bisphenol,
acrylic type, etc.
[0080]In the case of thermoplastic resins, the resin may
CA 03165303 2022-06-17
WO 2021/124192
PCT/IB2020/062100
14
be selected from the group comprising PVA, PP, Pen, etc.
[0081]In the case of inorganic matrices, the matrix may be
cement, quartz, lime, gypsum, etc.
[0082] According to a possible embodiment of the present
invention, the connection element 12 may comprise a guide
element 24 (shown in Figure 8) sliding within the
preformed portion 14, so as to be adapted to be moved
between an extracted position, protruding from the
preformed portion 14 at the at least one free fibre
portion 16, 18 and a retracted position in which it does
not protrude or protrudes from the preformed portion 14
at the at least one free fibre portion 16, 18.
[0083] The guide element 24 may be made of rigid polymeric
material. For example, the guide element 24 may be made
of thermoplastic, thermosetting, metallic material, etc.
[0084] According to an alternative embodiment, the guide
element 24 protrudes from the preformed portion 14 at the
at least one free fibre portion 16, 18, but it does not
slide inside the preformed portion 14.
[0085] The guide element 24 is used to optimize the
unravelling of the at least one free fibre portion 16, 18
of the ends of the connection element 12.
[0086] According to a possible embodiment of the present
invention, the free fibre portion may comprise a grouping
element 26 in a position substantially distal with
CA 03165303 2022-06-17
WO 2021/124192
PCT/IB2020/062100
respect to the preformed portion 14.
[0087] The grouping element 26 is adapted to group the
virgin fibres together, in one or more positions of the
section distal with respect to the preformed portion 14.
5 In other words, between the grouping element 26 and the
preformed portion 14 there is a section comprising or
consisting of virgin fibres.
[0088] According to a possible embodiment of the present
invention, the grouping element 26 may, for example, be a
10 resin, or a retention element such as, for example, a
ring or a device for grouping the fibres made of plastic
material, or of any material durable in time, tightened
about the guide element 24.
[0089] According to a possible embodiment of the present
15 invention, the grouping element 26 may slide with respect
to the guide element 24. In this case, once the preformed
portion 14 has been inserted inside the hole obtained in
the masonry, the grouping element 26 is made to slide on
the guide element 24 which is fixed, so that the virgin
fibres are arranged in the desired regular or irregular
shape on the surface of the support to be consolidated or
to be made integral. The excess part of the guide element
24, protruding from the surface of the masonry, may be
cut before or after the adhesive or the matrix has been
distributed on the surface of the support to embed and
CA 03165303 2022-06-17
WO 2021/124192
PCT/IB2020/062100
16
fix the virgin fibres.
[0090] In accordance with a possible
alternative
embodiment, the grouping element 26 may slide with
respect to the guide element following a predefined
arrangement, for example, using a preformed portion 14
having a helical development.
[0091]In this case, once the preformed portion 14 has been
inserted inside the masonry, the guide element is made to
slide, dragging the grouping element 26 by means of the
movement thereof.
[0092]In accordance with a possible embodiment, the
grouping element 26 may also be rotated about the main
axis.
[0093] According to a possible embodiment, a free fibre
portion 19 may be arranged between two preformed portions
14. In other words, the preformed part may comprise at
least two monolithic sections separated from each other
by a section at least partially made with virgin fibres.
Advantageously, it is therefore possible to make the
connection element 12 maintaining one or more
intermediate dry portions, for example, by means of a
pultrusion process interrupted by bath or by
impregnation. In this specific case, the use may be
extended to the creation of real brackets of elements to
be consolidated, keeping the dry section in the positions
CA 03165303 2022-06-17
WO 2021/124192
PCT/IB2020/062100
17
in which the preformed sections may not be used.
[0094] According to a possible embodiment of the present
invention, said virgin fibres may comprise impregnation
points 30, adapted to improve the grip of the virgin
fibres in the binding agent used to cover the surface of
the masonry.
[0095] A method for making a connection element 12 made of
composite material comprising fibres and a resin-based
binding agent according to the present invention will be
described below.
[0096] The method comprising the steps of:
[0097] - providing a bundle of fibres 13;
[0098] - impregnating the fibres 13 with a binding agent;
[0099] - passing the impregnated fibres 13 inside a die
having a certain cross-section;
[00100] - curing the resin inside a curing furnace or
the die itself; and
[00101] - cutting the connection element.
[00102] In particular, the step of impregnating the
fibres 13 may occur by means of a binding agent such as a
resin of the thermosetting or thermoplastic type, or an
inorganic matrix.
[00103] In particular, the impregnation is carried out
at sections of the bundle of fibres 13, while in some
sections the fibres of the fibre bundle comprise or
CA 03165303 2022-06-17
WO 2021/124192
PCT/IB2020/062100
18
consist of virgin fibres.
[00104] According to a
possible embodiment of the
present invention, the cutting may occur at a section of
the bundle of fibres 13 impregnated with resin, or at a
section of the fibre bundle in which the fibres comprise
or consist of virgin fibres.
[00105] According to a
possible embodiment of the
present invention, the method may comprise a step in
which the element 24 is provided inside the fibre bundle.
[00106] According to a
possible embodiment of the
present invention, the method may comprise a step in
which the grouping element 26 is provided.
[00107] The present
invention also relates to an
installation kit comprising an insertion funnel 40
adapted to facilitate the insertion of the connection
element 12 inside a hole in a masonry. Advantageously,
the insertion funnel may comprise a tubular portion 44 at
one end of which a flaring 42 is provided.
[00108] Advantageously,
the insertion funnel may also
be used to guide the virgin fibres of the free fibre
portion at the curving area on the surface of the
masonry.
[00109] The advantages
which may be achieved by a
connection element according to the present invention are
therefore apparent.
CA 03165303 2022-06-17
WO 2021/124192
PCT/IB2020/062100
19
[00110] First, a single
connection element has become
available, which may be used to connect two plate-like
resistant elements through a hole in a masonry. In this
case, the ends of the connection element are both
prepared with a free fibre portion.
[00111] The virgin
fibres are therefore modelled and
embedded in the resin or in the cement matrix, so as to
create an effective anchorage and ensure a better yield
of the tensile connection element.
[00112] Furthermore, in
the case where the ends of the
connection element are both provided with a free fibre
portion, the need to join two L-shaped elements inside
the masonry has been eliminated.
[00113] The connection
element according to the present
invention may be used, for example, as a connection
system between reinforcement elements for the
wall/resistant element which is required to increase the
performance by means of a symmetrical or partially
symmetrical reinforcement layout.
[00114] The connection
element also acts as a tie rod
or bracing, the dry terminals/free ends thereof being
possibly made on site with any geometric shape, by means
of pre-moulding in the factory or direct pre-application
on site, with or without the application of a mat to
facilitate the creation of a junction plate or finally by
CA 03165303 2022-06-17
WO 2021/124192
PCT/IB2020/062100
providing a light primer already in the production step
to improve the application steps, with the elements to be
braced and/or tied.
[00115]
Furthermore, it may be used as a continuous or
5 discontinuous bracket or reinforcement in general, for
structural or non-structural elements made of reinforced
concrete, completing the construction steps in the
factory (co-moulding or similar techniques) or on site.
[00116]
Furthermore, the particular production method
10 allows to manufacture a product which maintains the
mechanical resistance and stiffness properties of the
connection in the anchorage area of the elements to be
connected unaltered.
[00117] In
order to meet specific needs, those skilled
15 in the art will be able to make changes to the
embodiments described above and/or replace the elements
described with equivalent elements without departing from
the scope of the appended claims.
