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US 12,024,885 B2Granted
Basalt fiber composite rebar and method of manufacturing
AssigneeBasanite Industries LLC
InventorDavid Anderson
Life of this patent
Estimating the term…
Abstract
A basalt fiber composite rebar and method of manufacturing the same that includes producing an elongated body with an outer surface, two opposing terminal ends, a longitudinal length separating the two opposing terminal ends of the elongated body, of an epoxy matrix having a plurality of longitudinally oriented and twisted basalt fibers independently embedded and bonded therein and continually spanning along the longitudinal length, and a basalt fiber overlay directly coupled to the outer surface of the elongated body in a spiral configuration to define a plurality of fiber ribs spatially displaced from one another along the longitudinal length.
Claims10
A method of manufacturing basalt fiber composite rebar comprising the steps of:
- providing a creel rack assembly with a plurality of bobbins retained thereon, each of the plurality of bobbins including basalt fiber roving strand thereon;
- pultruding the basalt fiber roving strands under tension from each of the plurality of bobbins and guiding the basalt fiber strands to and through a heater;
- deckling down the basalt fiber roving strands using at least one separator operably coupled to the basalt fiber roving strands before a resin bath;
- pultruding, after the heater, the basalt fiber roving strands through the resin bath and coating the basalt fiber roving strands with an epoxy resin matrix;
- twisting, after the resin bath, the coated basalt fiber roving strands together in a direction of the pultruding and guiding the coated and twisted coated basalt fiber roving strands through a plurality of forming dies to generate an elongated body with an outer surface and the twisted basalt fibers forming a cross section of the elongated body along the direction of the pultruding;
- wrapping a basalt fiber strand over the outer surface of the elongated body and around the twisted basalt fibers forming the cross section of the elongated body in a spiral configuration to define a plurality of fiber ribs spatially displaced from one another along a longitudinal length of the elongated body;
- and
- curing the wrapped elongated body in at least one oven assembly by heating the wrapped elongated body above the glass transition temperature of the epoxy resin matrix, thereby curing the resin matrix with a plurality of longitudinally oriented and twisted basalt fibers independently embedded and bonded therein.
5 more elements
A method of manufacturing basalt fiber composite rebar comprising the steps of:
- providing a creel rack assembly with a plurality of bobbins retained thereon, each of the plurality of bobbins including basalt fiber roving strand thereon;
- pultruding the basalt fiber roving strands under tension from each of the plurality of bobbins and guiding the basalt fiber strands to and through a heater;
- pultruding, after the heater, the basalt fiber roving strands through a resin bath and coating the basalt fiber roving strands with an epoxy resin matrix;
- twisting, after the resin bath, the coated basalt fiber roving strands together in a direction of the pultruding and guiding the coated and twisted coated basalt fiber roving strands through a plurality of forming dies generating an elongated body with an outer surface;
- wrapping a basalt fiber strand over the outer surface of the elongated body in a spiral configuration to define a plurality of fiber ribs spatially displaced from one another along a longitudinal length of the elongated body;
- pultruding, after wrapping the basalt fiber strand over the outer surface of the elongated body in the spiral configuration, the elongated body through an air misting chamber and subjecting the wrapped elongated body with a dry coating evenly applied to the entire outer surface of the elongated body;
- and
- curing the wrapped elongated body in at least one oven assembly by heating the wrapped elongated body above the glass transition temperature of the epoxy resin matrix, thereby curing the resin matrix with a plurality of longitudinally oriented and twisted basalt fibers independently embedded and bonded therein.
5 more elements
A method of manufacturing basalt fiber composite rebar comprising the steps of:
- providing a creel rack assembly with a plurality of bobbins retained thereon, each of the plurality of bobbins including basalt fiber roving strand thereon;
- pultruding the basalt fiber roving strands under tension from each of the plurality of bobbins and guiding the basalt fiber strands to and through a heater;
- pultruding, after the heater, the basalt fiber roving strands through a resin bath and coating the basalt fiber roving strands with an epoxy resin matrix;
- twisting, after the resin bath, the coated basalt fiber roving strands together in a direction of the pultruding and guiding the coated and twisted coated basalt fiber roving strands through a plurality of forming dies to generate an elongated body with an outer surface and the twisted basalt fibers forming a cross section of the elongated body along the direction of the pultruding;
- wrapping a basalt fiber strand over the outer surface of the elongated body and around the twisted basalt fibers forming the cross section of the elongated body in a spiral configuration to define a plurality of fiber ribs spatially displaced from one another along a longitudinal length of the elongated body;
- pultruding, after wrapping the basalt fiber strand over the outer surface of the elongated body in the spiral configuration, the elongated body through an air misting chamber and subjecting the wrapped elongated body with a dry coating evenly applied to the entire outer surface of the elongated body, thereby forming an increased surface area for enhanced bonding;
- and
- curing the wrapped elongated body in at least one oven assembly by heating the wrapped elongated body above the glass transition temperature of the epoxy resin matrix, thereby curing the resin matrix with a plurality of longitudinally oriented and twisted basalt fibers independently embedded and bonded therein.
5 more elements
Dependencies are inferred from the claim text.