REBAR TIE WIRE WITH BONDED COATING AND METHOD OF MAKING THE SAME

Abstract

A rebar tie wire, including an inner wire portion including a radially outward facing surface, and a coating arranged on the radially outward facing surface, the coating including high density polyethylene (HDPE), and a bonding agent.

Claims

1. A rebar tie wire, comprising: an inner wire portion including a radially outward facing surface; and a coating arranged on the radially outward facing surface, the coating including: at least 85% by weight high density polyethylene (HDPE); and at least 3% by weight bonding agent.

2. The rebar tie wire as recited in claim 1, wherein the coating further comprises a coloring agent.

3. The rebar tie wire as recited in claim 2, wherein the coating comprises at least 90% by weight HDPE.

4. The rebar tie wire as recited in claim 2, wherein the coating comprises at least 3% by weight coloring agent.

5. The rebar tie wire as recited in claim 2, wherein the coating comprises: 90% by weight HDPE; 5% by weight bonding agent; and 5% by weight coloring agent.

6. The rebar tie wire as recited in claim 1, wherein the coating comprises at least 90% by weight HDPE.

7. The rebar tie wire as recited in claim 1, wherein the coating is bonded to the inner wire portion.

8. The rebar tie wire as recited in claim 1, wherein the coating consists of the HDPE and the bonding agent.

9. The rebar tie wire as recited in claim 2, wherein the coating consists of the HDPE, the bonding agent, and the coloring agent.

10. The rebar tie wire as recited in claim 1, wherein the bonding agent is a reactive adhesive.

11. The rebar tie wire as recited in claim 1, wherein the bonding agent is an anhydride modified high density polyethylene.

12. A rebar tie wire, comprising: an inner wire portion including a radially outward facing surface; and a coating bonded to the inner wire portion, the coating comprising: high density polyethylene (HDPE); and a bonding agent comprising a reactive adhesive.

13. The rebar tie wire as recited in claim 12, wherein the coating comprises at least 85% by weight HDPE.

14. The rebar tie wire as recited in claim 12, further comprising a coloring agent.

15. The rebar tie wire as recited in claim 14, wherein the coating consists of: 90% by weight HDPE; 5% by weight reactive adhesive; and 5% by weight coloring agent.

16. The rebar tie wire as recited in claim 13, wherein the coating comprises: at least 3% by weight bonding agent; and at least 3% by weight coloring agent.

17. The rebar tie wire as recited in claim 13, wherein the coating comprises: 90% by weight HDPE; 5% by weight bonding agent; and 5% by weight coloring agent.

18. The rebar tie wire as recited in claim 12, wherein the coating comprises: at least 90% by weight HDPE; and at least 3% by weight bonding agent.

19. A rebar tie wire, comprising: an inner wire portion including a radially outward facing surface; and a coating arranged on the radially outward facing surface, the coating including: high density polyethylene (HDPE); and a bonding agent comprising anhydride modified high density polyethylene.

20. The rebar tie wire as recited in claim 19, wherein the coating comprises: at least 85% by weight HDPE; and at least 3% by weight anhydride modified high density polyethylene.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0021] Various embodiments are disclosed, by way of example only, with reference to the accompanying schematic drawings in which corresponding reference symbols indicate corresponding parts, in which:

[0022] FIG. 1 is a perspective view of a rebar cage.

[0023] FIG. 2 is a cross-sectional view of a rebar tie wire taken generally along line 2-2 in FIG. 1.

[0024] FIG. 3 shows a cross-sectional view of a crosshead die.

DETAILED DESCRIPTION

[0025] At the outset, it should be appreciated that like drawing numbers on different drawing views identify identical, or functionally similar, structural elements. It is to be understood that the claims are not limited to the disclosed aspects.

[0026] Furthermore, it is understood that this disclosure is not limited to the particular methodology, materials and modifications described and as such may, of course, vary. It is also understood that the terminology used herein is for the purpose of describing particular aspects only, and is not intended to limit the scope of the claims.

[0027] Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood to one of ordinary skill in the art to which this disclosure pertains. It should be understood that any methods, devices or materials similar or equivalent to those described herein can be used in the practice or testing of the example embodiments.

[0028] It should be appreciated that the term substantially is synonymous with terms such as nearly, very nearly, about, approximately, around, bordering on, close to, essentially, in the neighborhood of, in the vicinity of, etc., and such terms may be used interchangeably as appearing in the specification and claims. It should be appreciated that the term proximate is synonymous with terms such as nearby, close, adjacent, neighboring, immediate, adjoining, etc., and such terms may be used interchangeably as appearing in the specification and claims. The term approximately is intended to mean values within ten percent of the specified value.

[0029] It should be understood that use of or in the present application is with respect to a non-exclusive arrangement, unless stated otherwise. For example, when saying that item x is A or B, it is understood that this can mean one of the following: (1) item x is only one or the other of A and B; (2) item x is both A and B. Alternately stated, the word or is not used to define an exclusive or arrangement. For example, an exclusive or arrangement for the statement item x is A or B would require that x can be only one of A and B. Furthermore, as used herein, and/or is intended to mean a grammatical conjunction used to indicate that one or more of the elements or conditions recited may be included or occur. For example, a device comprising a first element, a second element and/or a third element, is intended to be construed as any one of the following structural arrangements: a device comprising a first element; a device comprising a second element; a device comprising a third element; a device comprising a first element and a second element; a device comprising a first element and a third element; a device comprising a first element, a second element and a third element; or, a device comprising a second element and a third element.

[0030] Moreover, as used herein, the phrases comprises at least one of and comprising at least one of in combination with a system or element is intended to mean that the system or element includes one or more of the elements listed after the phrase. For example, a device comprising at least one of: a first element; a second element; and, a third element, is intended to be construed as any one of the following structural arrangements: a device comprising a first element; a device comprising a second element; a device comprising a third element; a device comprising a first element and a second element; a device comprising a first element and a third element; a device comprising a first element, a second element and a third element; or, a device comprising a second element and a third element. A similar interpretation is intended when the phrase used in at least one of: is used herein.

[0031] Adverting now to the figures, FIG. 1 is a perspective view of rebar cage 10. As shown, rebar cage 10 comprises a plurality of reinforcing bars (i.e., rebar) 20 tied together via a plurality of rebar tie wire or wires 30.

[0032] Reinforcing bars 20 arranged to intersect, forming joints 22. In some embodiments, reinforcing bars 20 are arranged substantially perpendicular to each other. In some embodiments, and as shown, reinforcing bars 20 vary in diameter. In some embodiments, reinforcing bars 20 comprise a constant diameter. It should be appreciated that, while reinforcing bars 20 are shown having no coating, in some embodiments reinforcing bars 20 comprise a coatings, for example, epoxy.

[0033] Each joint 22 comprises at least two reinforcing bars 20 intersecting. At each joint 22, reinforcing bars 20 are secured or tied together via rebar tie wire 30. Rebar tie wire 30 is wrapped around the at least two reinforcing bars 20 and tied, thereby securing the reinforcing bars. This process is repeated throughout rebar cage 10 thereby forming a structure over which concrete is poured. The rebar tie wire 30 may be tied using an electric rebar tier, for example, a MAX USA RB398 rebar tier. In some embodiments, reinforcing bars 30 comprise one or more protrusions and/or textured radially outward facing surfaces.

[0034] FIG. 2 is a cross-sectional view of rebar tie wire 30 taken generally along line 2-2 in FIG. 1. Rebar tie wire 30 comprises inner wire portion 32 and coating 34. In some embodiments, inner wire portion 32 comprises carbon steel. In some embodiments, inner wire portion 32 comprises a metal. In some embodiments, inner portion 32 comprises a metal alloy. In some embodiments, coating 34 comprises high density polyethylene (HDPE), a coloring agent (e.g., a colored linear low density polyethylene), and a bonding agent. In some embodiments, coating 34 consists of HDPE, a coloring agent, and a bonding agent. In some embodiments, the coloring agent is a colored linear low density polyethylene, for example yellow. In some embodiments, the coloring agent is AVIENT ONCOLOR YELLOW P7548C PP linear low density polyethylene pellets.

[0035] The bonding agent is operatively arranged to bond coating 34 to inner wire portion 32 which prevents the ingress of water therebetween. By bonding it is meant that coating 34 is joined securely to inner wire portion 32 by an adhesive or bonding agent. This differs from current electrical wire, for example, which do not bond the coating to the wire. In some embodiments, the bonding agent is a reactive glue or adhesive. Reactive adhesive means an adhesive that requires a hardener or catalyst in order for the bond to occur and includes, but is not limited to, epoxies, urethanes, and silicones. In some embodiments, the bonding agent is an anhydride modified high density polyethylene, for example, FUSABOND E265 anhydride modified high density polyethylene. In some embodiments, the bonding agent is a functional polymer. In some embodiments, coating 34 consists of 90% HDPE by weight, 5% coloring agent by weight, and 5% bonding agent (e.g., FUSABOND E265 anhydride modified high density polyethylene) by weight. In some embodiments, coating 34 consists of 90% HDPE by weight, 7% coloring agent by weight, and 3% bonding agent (e.g., FUSABOND E265 anhydride modified high density polyethylene) by weight. In some embodiments, coating 34 comprises 90% HDPE by weight, a coloring agent in the range of 0-10% by weight, and bonding agent in the range of 1-10% (e.g., FUSABOND E265 anhydride modified high density polyethylene) by weight.

[0036] To manufacture rebar tie wire 30, inner wire portion 32 is heated, for example using induction heating. Inner portion 32 is heated to a temperature in the range of 280 F. to 350 F., for example 300 F., or in the range of 320 F. to 340 F. The heated inner wire portion 32 is fed through a crosshead die for crosshead extrusion. In some embodiments, prior to heating, inner wire portion 32 is cleaned, for example, by applying boiling water thereto. In some embodiments, prior to heating, a wire drawing solution or lubricant is applied to inner wire portion 32 to aid in the wire drawing process. The wire drawing solution can be a dry soap lubricant or a liquid lubricant (e.g., neat oil, water-miscible solvent, or solution synthetic lubricant).

[0037] The HDPE (e.g., in pellet form), coloring agent, and bonding agent is heated and mixed together to form mixture 36. Mixture 36, in liquid (i.e. molten) or substantially liquid form (i.e., colloid), is fed into the crosshead die. Specifically, mixture 36 is fed into the crosshead die as heated inner wire portion 32 passes therethrough, and is applied to inner wire portion 32 forming coating 34. In some embodiments, mixture 36 is applied to inner wire portion 32 at a temperature in the range of 400 F. to 500 F., or in the range of 400 F. to 470 F., for example, 450 F. The flow of the mixture can be adjusted to obtain the desired thickness of coating 34.

[0038] FIG. 3 shows a cross-sectional view of example crosshead die 40. As shown, inner wire portion 32 is fed and/or pulled through crosshead die 40. At the same time, the molten mixture of coating 34, referred to herein as mixture 36, is fed through crosshead die 40. Mixture 36 is directed via crosshead die 40 to coat the radially outward facing surface of inner wire portion 32.

[0039] After the now coated inner wire portion 32 exits crosshead die 40, it is quenched in a bath, for example, in water. This quenching solidifies mixture 36 (i.e., the HDPE) and cures the bonding agent, resulting in coating 34 being bonded to inner wire portion 32. In some embodiments, after quenching rebar tie wire 30 is air dried. One attribute of this bonding process (i.e., coating 34 is bonded to inner wire portion 32 via the bonding agent) is that coating 34 cannot be easily removed from inner wire portion 32 and prevents the ingress of water and other corrosive materials. Such a feature is not seen in any known coated wires, which are specifically designed to be easily stripped of their coating for electrical connection. Another attribute of the bonding process is that coating 34 acts as a cushion, or elastic material, that prevents rebar tie wire 30 from ripping any epoxy coating on reinforcing bars 20.

[0040] It will be appreciated that various aspects of the disclosure above and other features and functions, or alternatives thereof, may be desirably combined into many other different systems or applications. Various presently unforeseen or unanticipated alternatives, modifications, variations, or improvements therein may be subsequently made by those skilled in the art which are also intended to be encompassed by the following claims.

REFERENCE NUMERALS

[0041] 10 Rebar cage or system [0042] 20 Reinforcing bars [0043] 22 Joints [0044] 30 Rebar tie wire [0045] 32 Inner wire portion [0046] 34 Coating or casing [0047] 36 Mixture or coating mixture or casing mixture [0048] 40 Crosshead die