Note: Descriptions are shown in the official language in which they were submitted.
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DESCRIPTION
MESH MADE OF A COMPOSITE MATERIAL
FIELD OF APPLICATION
[0001] The present invention relates to a mesh made of a
composite material. In particular, the present invention
relates to connection elements made of a composite
material to be used, e.g., for consolidating, protecting,
or securing structures in the construction and industry
field and the infrastructure and road sector.
BACKGROUND ART
[0002] It is known that there are many techniques for
consolidating architectural structures or securing them
or more in general for strengthening or reinforcing
infrastructures and road pavements. In particular, there
are techniques which use rigid meshes made of a composite
material made with fibers embedded in a thermosetting
resin. The yarns thus composed are woven together to form
the mesh, twisting the resin-impregnated transverse
fibers to the longitudinal ones.
[0003] The meshes made of a composite material are made
starting from fibers (e.g., glass, carbon, aramid,
basalt, and/or PBO) embedded in a thermosetting or
possibly thermoplastic resin.
[0004] In some applications, the meshes are embedded in a
mortar with binding agents, which may be of different
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types, and are used for consolidating existing structures
(masonry, concrete, reinforced concrete, etc.) creating a
reinforced plaster to be applied onto the surfaces, or as
slabs for manufacturing load-bearing floors.
[0005] The mesh, for example, may be blocked in position by
using junction or connection elements inserted in holes
made in the substrate to be consolidated/reinforced. The
junction elements are generally made of metal or another
material and are typically L-shaped, 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. The mesh and junction
elements are therefore embedded inside a mortar with
binding agents which may be of different types.
[0006] If the mesh is positioned on both surfaces of the
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.
[0007] In other applications, the mesh made of a composite
material is inserted into a bituminous road surface to
reduce the long-term effects of vehicle traffic or to
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extend the service life of the operation.
[0008] Furthermore, in further applications, this type of
mesh made of a composite material is used to create
exposed fencing using structures, such as posts and
bracing.
[0009] For example, document EP 3431666A1 describes a
process for making a mesh made of a composite material
which can be made from fibers totally embedded in resin.
[0010] Meshes of this type are also described in KR 102 102
435 B1 and US 5,244,693 A.
[0011] The prior art, although widely appreciated, is not
without drawbacks.
[0012] First of all, if it is necessary to reinforce a wall
with changes of surfaces, e.g., in the case of
intersections between masonry walls, intersections
between ceilings, and masonry walls, it is necessary to
prepare two separate meshes on the two walls and join
them together, overlapping each mesh with a preformed
element made in the factory to avoid creating
discontinuities between reinforcement elements.
[0013] Indeed, being rigid, each mesh does not allow the
mesh itself to be placed straddling two surfaces which
are not consecutive and parallel. In other words, it is
not possible to turn the mesh over on changes of surface.
[0014] The same problem occurs in the case of meshes used
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as fencing.
[0015]Furthermore, if the mesh is used to reinforce
horizontal or sub-horizontal surfaces (e.g., road
screeds), it is difficult to keep it in position during
the screed or bituminous conglomerate laying operations.
Today the problem is solved by nailing or, alternatively,
by creating piles made of the same material as the screed
on top of the mesh, which prevent the mesh from lifting.
PRESENTATION OF THE INVENTION
[0016] Therefore, the need is felt to solve the drawbacks
and limitations mentioned above with reference to the
prior art.
[0017]Firstly, the need is felt for a mesh made of
composite material adapted to reinforce a wall with
changes of surfaces, e.g., in the case of intersections
between masonry walls.
[0018]Furthermore, the need is felt for a mesh that can be
turned around easily and quickly to follow a change of
surface, without having a drastic drop in performance at
the portion subject to folding.
[0019] The need is also felt for a mesh made of a composite
material which can be used to reinforce horizontal or
sub-horizontal surfaces without the difficulty of keeping
it in position during screed-laying operations.
[0020] Such needs are at least partially fulfilled by a
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mesh made of a composite material according to claim 1.
DESCRIPTION OF THE DRAWINGS
MU Further features and advantages of the present
invention will be more comprehensible from the following
5 description of preferred embodiments given by way of non-
limiting examples, in which:
- figure 1 diagrammatically shows a perspective view of a
first embodiment of a mesh made of a composite material
according to the present invention;
- figure 2 diagrammatically shows a perspective view of
an alternative embodiment of a mesh made of a composite
material according to the present invention;
- figures 3 and 4 diagrammatically show two views of a
component of a mesh made of a composite material
according to the present invention;
- figure 5 diagrammatically shows a view of a component
of a mesh made of a composite material according to the
present invention; and
- figure 6 diagrammatically shows a perspective view of a
further alternative embodiment of the present invention.
[0022] Elements or parts in common to the embodiments
described will be indicated hereafter using the same
reference numerals.
DETAILED DESCRIPTION
[0023] Figure 1 diagrammatically shows a component of a
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mesh made of a composite material according to the
present invention indicated by reference numeral 12.
[0024] The mesh made of a composite material 12 comprises
fibers mutually arranged to form a weft 14 and a warp 16.
According to a possible embodiment, weft 14 and warp 16
are substantially perpendicular to each other. In
alternative embodiments, weft 14 and warp 16 may be
arranged at mutually different angles, e.g., 450
.
[0025] According to a possible embodiment, the mesh made of
a composite material may comprise two warps 16, 216. In
this case, the intersection points 18 may comprise one
weft yarn and two warp yarns. Advantageously, the warp
yarns 16, 162 may have substantially perpendicular mutual
directions. Furthermore, in a possible embodiment, the
weft yarns may be arranged at about 450 to the warp
yarns.
[0026] The weft 14 comprises at least one weft yarn 142,
which comprises at least one fiber. The warp 16 comprises
at least one warp yarn 162, which comprises at least one
fiber.
[0027] The weft 14 and the warp 16 are mutually connected
at intersection points 18 by interlacing means 20.
[0028] According to a possible embodiment, the mesh made of
a composite material 12 may comprise a binder. The weft
14 and/or the warp 16 are impregnated with said binding
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agent in predetermined impregnation zones so that some
portions of weft yarns 142 and/or some portions of warp
yarns 162 consist of portions of virgin fibers.
[0029] According to a possible embodiment, the
predetermined impregnation zones comprise intersection
points 18 between weft 14 and warp 16 and thus act as
interlacing means 20.
[0030] According to a possible embodiment, the warp yarns
162 may be impregnated with the binder only at
intersections 18 with the weft yarns 142. In this case,
the predefined impregnation zones comprise the entirety
of the weft yarns 142 or only a small circumference of
weft yarns 142 at the intersections between the weft
yarns 142 and the warp yarns 162.
[0031] According to possible alternative embodiments, the
interlacing means 20 between the weft 14 and the warp 16
may comprise mechanical type junction elements, polymeric
material elements, or bonding through an adhesive. In
particular, the mechanical type interlacing means may be,
for example, banding made of metallic material.
[0032]For example, an example of banding made of metallic
material, obtained by means of a tie, is diagrammatically
shown in figure 5.
[0033] On the other hand, the interlacing means 20 of
polymeric type may be, for example, banding made of
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polymeric material, obtained with a tie similar to the
one shown in figure 5, but made of polymeric material.
[0034] Figures 3 and 4 show a further embodiment of the
interlacing means 20 made in the form of a button. In
this case, the interlacing means 20 may comprise two
components: a first component 202 provided with pins 206
(e.g., two), and a second component 204 provided with
respective seats 208. The coupling between first
component 202 and second component 204 may be achieved by
coupling between pins 206 and respective seats 208.
Advantageously, such a coupling may be non-reversible.
[0035] Again in this case, the first and second components
can be made of metal or polymeric material.
[0036] In this discussion, the expression virgin fibers is
understood to mean fibers which were not been embedded in
the binder at a portion thereof. In technical jargon,
virgin fibers can also be referred to as "dry" fibers.
[0037] The fibers may comprise synthetic organic fibers,
natural organic fibers, inorganic fibers, and/or even
metallic fibers.
[0038] Synthetic organic fibers may comprise, for example,
aramid fibers, polyester, and/or even polyparaphenylene
benzobisoxazole (PBO).
[0039] Natural organic fibers may comprise, for example:
cotton, hemp, flax, sisal, bamboo, wood, wool, silk, etc.
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[0040] The inorganic fibers may comprise, for example:
glass, carbon, basalt, quartz, etc.
[0041]The metallic fibers may comprise, for example:
stainless steel, carbon steel, copper, brass, aluminum,
titanium, etc.
[0042] According to a possible embodiment of the present
invention, each weft yarn 142 and/or even each warp yarn
162 may comprise fibers of a mutually different type. In
other words, the mesh made of a composite material can be
made by combining various types of fiber, even with
different percentages in weft 14 and warp 16.
[0043] According to a possible embodiment, the
interconnecting means 20 may be a tie, e.g., of a fibrous
type in winding and/or metallic type in the same manner.
[0044] According to a possible embodiment, the binder (also
called a matrix) may be a resin.
[0045] The resin can be either of the thermosetting or the
thermoplastic type.
[0046] In the case of thermosetting resin, this may, for
example, be of the vinyl-ester, polyester, bisphenol,
acrylic type, etc.
[0047] In the case of thermoplastic resins, the resin may
be selected from the group comprising PVA, PP, Pen, etc.
[0048] According to a possible embodiment, the resin may
contain catalysts for the polymerization/crosslinking
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process. The catalysts may be such that they are
activated e.g., by heat, radiation, infrared or UV
radiation.
[0049] Advantageously, the fibers may be treated with
5 surface additives to improve their durability and/or
adhesion with the resin and/or other organic/inorganic
and other matrices, such as asphalt, both before and
after the application of the interlacing means 20.
[005O] According to a possible embodiment of the present
10 invention, the weft yarns 142 may comprise a plurality of
fibers, e.g., glass and steel fibers.
[0051] According to a possible embodiment of the present
invention, the warp yarns 162 may comprise two fiber
bundles 164, 166 of balanced (same amount of fiber) or,
alternatively, unbalanced content.
[0052] According to alternative embodiments, the warp yarns
162 may comprise a plurality of fibers, e.g., glass and
steel fibers.
[0053] According to alternative embodiments, the weft 14
may be made from preformed bars or bars resulting from a
pultrusion process.
[0054] As shown in figure 1, according to a possible
embodiment, the weft yarns 142 or warp yarns 162 may be
impregnated with said binder and preformed. For example,
the weft yarn 142 or warp yarn 162 may be substantially
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flat, or circular, or otherwise shaped (e.g.,
trapezoidal).
[0055] Again with reference to figure 1, the warp yarns 162
may be made by fibers 164, 166 twisted about an axis of
the warp yarn 162 itself.
[0056] Thus, with reference to the embodiment shown in
figure 1, since the warp yarns between one intersection
18 and the other are not impregnated with resin, the mesh
made of a composite material can be easily bent in
directions substantially parallel to the weft yarns 142.
In alternative embodiments, the weft yarns between one
intersection 18 and the other are not impregnated with
resin, the mesh made of a composite material can be
easily bent in directions substantially parallel to the
warp yarns 162.
[0057] According to alternative embodiments, the
predetermined impregnation zones may also refer, for
example, to a plurality of warp yarn portions 162 between
one intersection 18 and another, leaving virgin fiber
portions on the warp yarns 142 between two consecutive
weft yarns 142.
[0058] According to possible embodiments, the impregnation
can take place in spots (drip), with a continuous process
and/or by molding.
[0059] The advantages which can be achieved by a mesh made
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of a composite material according to the present
invention are therefore apparent.
[0060] Firstly, a mesh made of a composite material adapted
to reinforce a wall with changes of surfaces, e.g., in
the case of intersections between masonry walls, is made
available.
[0061] Furthermore, a mesh which would allow it to be
turned back to follow a change of surface is made
available.
[0062] Again, the mesh made of a composite material
according to the present invention can be used to
reinforce horizontal or sub-horizontal surfaces without
the difficulty of keeping it in position during the
screed or the bituminous conglomerate laying operations.
[0063] Furthermore, when the predetermined impregnation
zones are made near and on the intersection of weft 14
and warp 16, keeping only the nodal zone of the rigid
mesh, it is possible to fold and arrange the mesh 12 in a
three-dimensional manner, thus adapting it, for example,
to a spherical truncated element (e.g., the surface of a
dome).
[0064] In particular, the predetermined impregnation zones
can be arranged according to specific requirements, e.g.,
such as the need to bend the mesh in several directions,
even at a mutual angle. Advantageously, the impregnation
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zones are such as to leave portions of weft yarns 142
and/or portions of warp yarns 162 made of virgin fibers,
which can thus allow the mesh to be bent in inclined
directions relative to the direction of the respective
portions of weft yarns 142 and/or portions of warp yarns
162.
[0065]For example, the predetermined impregnation zones
may comprise parallel and consecutive portions of weft
yarns 142 and/or parallel and consecutive portions of
warp yarns 162.
[0066] According to a possible embodiment, a mesh may
comprise mutually different weft yarns 142 and/or even
mutually different warp yarns 16. For example, a weft 14
and/or even a warp may be made from yarns that have
mutually different fibers.
[0067] According to a possible embodiment, in a mesh at
least part of the weft yarns 142 can be made from fibers
of different materials to make mesh zones with
predetermined technical characteristics, and/or in a mesh
at least part of the warp yarns 162 can be made from
fibers of different materials to make zones of the mesh
with predetermined technical characteristics.
[0068]In the embodiments described above, a person skilled
in the art will be able to make changes and or
substitutions of elements described with equivalent
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elements without departing from the scope of the appended
claims to satisfy specific requirements.
[0069] For example, the mesh made of a composite material
may be used in conjunction with coatings, laminates,
fabrics, non-woven fabrics, coupling films by means of
the intersection points 18 or dry fibers. Again,
mechanical or polymeric connection means may be adapted
to connect with corresponding elements for joining with a
matched element.
