CONNECTION ELEMENT, METHOD FOR MANUFACTURING A CONNECTION ELEMENT AND RELATED INSTALLATION KIT

Abstract

A connection element (12) made of composite material includes a bundle of fibers (13) and a binding agent, and has at least one preformed portion (14) and at least one free fiber portion (16, 18, 19). The at least one preformed portion (14) includes a section of fibers (13) embedded in the binding agent to form a monolithic structure. At least part of the fibers (13) of the at least one free fiber portion (16, 18, 19) has virgin fibers (13).

Claims

1. Connection element in composite material comprising a fibre bundle and a binding agent, said connection element comprising at least one preformed portion and at least one free fibre portion; said at least one preformed portion comprising a section of said fibre bundle embedded in said binding agent to form a monolithic structure; wherein at least part of the fibres of the at least one free fibre portion consists of virgin fibres.

2. Connection element according to claim 1, wherein said at least one free fibre portion is arranged at one or both ends of the fibre bundle.

3. Connection element according to claim 1, wherein said at least one free fibre portion is arranged between two preformed portions.

4. Connection element according to claim 1, wherein said bundle of fibres (13) comprises synthetic organic fibres, natural organic fibres, inorganic fibres, and/or metallic fibres.

5. Connection element according to claim 1, wherein said binding agent is a thermosetting or thermoplastic resin or an inorganic matrix.

6. Connection element according to claim 1, comprising a guide element sliding within said preformed portion adapted to be moved between an extracted position, protruding from said preformed portion at said at least one free fibre portion and a retracted position in which the guide element does not protrude or protrudes from said preformed portion at said at least one free fibre portion.

7. Connection element according to claim 1, comprising a guide element protruding from said preformed portion at said at least one free fibre portion.

8. Connection element according to claim 1, comprising a grouping element of said fibres of said free fibre portion, in a substantially distal position with respect to the preformed portion.

9. Connection element according to claim 8, wherein said grouping element is obtained with a binding agent or a retention element.

10. Connection element according to claim 9, wherein said at least one preformed portion is hollow, and the internal volume is filled with one or more of resin, mortar, inorganic matrices, organic matrices.

11. Method for making a connection element out of composite material comprising fibres and a binding agent, said procedure comprising the steps of: providing a fibre bundle; impregnating the fibres with a binding agent; passing the fibres inside a die having a cross-section; curing the resin inside a furnace or said die; and cutting the connection element; wherein said step of impregnating the fibres with a binding agent is carried out on sections of the fibre bundles, while in some sections the fibres of the fibre bundle comprise or consist of virgin fibres.

12. Method for making a connection element according to claim 11, wherein the cutting is made at a section of the fibre bundle impregnated with resin.

13. Method for making a connection element according to claim 11, wherein the cutting is made at a section of the fibre bundle where the fibres comprise or consist of virgin fibres.

14. Installation kit of a connection element comprising a connection element according to claim 1, and an insertion funnel to facilitate insertion of the connection element into a hole in a structural or non-structural element, and to facilitate arranging the fibre bundle as the free fibre portion.

Description

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] FIG. 1 diagrammatically shows a perspective view of a first embodiment of a connection element according to the present invention;

[0032] FIG. 2 diagrammatically shows a perspective view of an alternative embodiment of a connection element according to the present invention;

[0033] FIG. 3 diagrammatically shows a perspective view of a further alternative embodiment of a connection element according to the present invention;

[0034] FIG. 4 diagrammatically shows a possible use of a connection element according to the present invention;

[0035] FIGS. 5-7 diagrammatically show perspective views of possible embodiments of a connection element according to the present invention;

[0036] FIG. 8 diagrammatically shows a possible alternative embodiment of a connection element according to the present invention;

[0037] FIG. 9 diagrammatically shows a possible alternative embodiment of a connection element according to the present invention;

[0038] FIG. 10 diagrammatically shows a possible alternative embodiment of a connection element according to the present invention;

[0039] FIG. 11 diagrammatically shows a perspective view of a component of a kit according to the present invention; and

[0040] FIG. 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] FIG. 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 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 FIGS. 1, 2, 3, 8-10.

[0051] According to a possible alternative embodiment, shown in FIG. 5, the cross section of the preformed portion may be C-shaped.

[0052] In a possible alternative embodiment, shown in FIG. 6, the preformed portion 14 may have an elongated cross-section, even with or without the presence of a reinforcing rib 21, having a longitudinal or transverse development. In the embodiment shown in FIG. 6, the reinforcing ribs 21 are two and arranged parallel.

[0053] In a further embodiment, the preformed portion may have a substantially circular and hollow section, as shown in the example of FIG. 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.

[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 FIGS. 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 FIG. 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 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] FIG. 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 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 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 FIG. 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 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. 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 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 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 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 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; [0100] curing the resin inside a curing furnace or the die itself; and [0101] cutting the connection element.

[0102] 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.

[0103] 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 consist of virgin fibres.

[0104] 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.

[0105] 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.

[0106] According to a possible embodiment of the present invention, the method may comprise a step in which the grouping element 26 is provided.

[0107] 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.

[0108] 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.

[0109] The advantages which may be achieved by a connection element according to the present invention are therefore apparent.

[0110] 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.

[0111] 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.

[0112] 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.

[0113] 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.

[0114] 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 providing a light primer already in the production step to improve the application steps, with the elements to be braced and/or tied.

[0115] Furthermore, it may be used as a continuous or 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.

[0116] Furthermore, the particular production method 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.

[0117] In order to meet specific needs, those skilled 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.