WO2016155743A1

WO2016155743A1 - Semimanufacture and construction element made thereof

Info

Publication number: WO2016155743A1
Application number: PCT/DK2016/050085
Authority: WO
Inventors: Henrik Thorning; Lars Tilsted Lilleheden
Original assignee: Fiberline Composites AS
Current assignee: Fiberline Composites AS
Priority date: 2015-03-31
Filing date: 2016-03-21
Publication date: 2016-10-06
Anticipated expiration: 2017-09-30
Also published as: DK201500202A1; DK178510B1

Abstract

A fibre reinforced semimanufacture (2) comprising a bendable tubular structure (4) is disclosed. The semimanufacture (2) comprises resin impregnated fibres (16), wherein the resin is uncured and the semimanufacture (2) is capable of being maintained uncured in at least 24 hours at room temperature (23˚C), wherein the tubular structure (4) comprises one or more injection canals (36, 38).

Description

Semimanufacture and Construction Element made thereof

Field of invention

The present invention relates to a semimanufacture (semi-finished product) and a construction element comprising said semimanufacture. The construction element may be configured to be used to reinforce concrete structures and to reinforce i.a. beams and columns in general.

Prior art

Reinforcement structures are used to reinforce masonry and concrete structures. Such reinforcement structures are typically formed as rods or bended structures.

US 3,650,864 A relates uncured filament reinforced, flexible profiles comprising resin-impregnated fibers encapsulated by a non-porous and flexible plastic film (foil). The foil is welded and shrunk to obtain a substantially airtight environment, whereby curing of the resin is hindered.

The resin may subsequently be fully or partially cured. However, this may result in the risk of encapsulating air with the resin and the fibers, thus, impairing the product. Furthermore, the foil does not hinder deformation of the product, implying the need for transferring the product to coils for storage.

In several applications there is a need for construction elements (such as rods and bendings) or alternative reinforcement systems (e.g. mesh reinforcement) that are either corrosion proof or protected against corrosion, have a low thermal and/or electrical conductivity and are light. Steel reinforcement does not fulfil these criteria not even stainless steel reinforcement.

In order to provide the required adherence between the reinforcement elements and the concrete or mortar, a certain surface structuring is required. The surface structuring facilitates that the concrete or mortar is brought into contact with the entire surface of the parts of the reinforcement elements and further provides a mechanical engagement between the reinforcement elements and the concrete or mortar.

Corrosion proof fibre- reinforced composite reinforcement elements provided with a surface structuring have been developed. These reinforcement elements are typically manufactured as cylindrical rods, which are exposed to a subsequent surface structuring process (finishing) comprising the step of establishing an outer thread having an optimised geometry in order to facilitate a mechanical engagement between the reinforcement elements and the concrete or mortar. Whereas concrete has a rather low tensile strength, fibre-reinforced composite reinforcement elements are due to their high tensile strength desirable to use in virtually any type of structure involving concrete.

In numerous applications, reinforcement structures comprising bendings are required. The bending procedure is carried out during the manufacturing process before the curing process is completed. Accordingly, it is not possible to change the geometry of the bendings afterwards. It would be desirable to be capable of providing a more flexible solution, which makes it possible to change the geometry of the bending subsequently.

If composite reinforcement elements are intended for use in a remote construction site positioned in a long distance from the production site, the composite reinforcement elements must be ordered several weeks before in order to reach the construction site in due time.

Therefore, alternative reinforcement elements e.g. made in steel are often used, even in applications in which fibre-reinforced composite reinforcement elements are optimal, because the geometry of the traditional fibre-reinforced composite reinforcement elements cannot be changed like steel reinforcement.

Accordingly, there is a need for an alternative to the prior art fibre- reinforced composite reinforcement elements. It is an object of the present invention to provide a fibre- reinforced composite reinforcement element that can be formed by means of simple fixtures after the manufacturing process has been finished. Moreover, it is an object of the present invention to provide a fibre- reinforced composite reinforcement element that can be handled and used in a simple and user-friendly manner and which provides a larger degree of freedom, with respect to the geometrical design, than the prior art steel reinforcement.

Summary of the invention

The object of the present invention can be achieved by a fibre reinforced semimanufacture as defined in claim 1. Preferred embodiments are defined in the dependent sub claims, explained in the following description and illustrated in the accompanying drawings.

The product according to the invention is a fibre reinforced semimanufacture comprising a bendable tubular structure, wherein the semimanufacture comprises resin impregnated fibres provided in the tubular structure, wherein the resin is uncured and the semimanufacture is capable of being maintained uncured in at least 24 hours at room temperature, wherein the tubular structure comprises one or more injection canals. Hereby, it is possible to provide a fibre reinforced semimanufacture that can be formed by means of simple fixtures for at least 24 hours after the manufacturing process has been finished.

Moreover, it is possible to provide a fibre reinforced semimanufacture that can be handled and used in a simple and user-friendly manner and which provides a larger degree of freedom, with respect to the geometrical design, than the prior art steel reinforcement.

Accordingly, it is possible for the end-user to apply a fibre reinforced semimanufacture according to the invention in a construction site or in a close distance therefrom even if the semimanufacture is produced in a remote distance from the construction site. The fibre reinforced semimanufacture according to the invention can be cured just before it is intended to be used, in such a manner that the final geometry can meet requirements that occur late in the process (e.g. just before the fibre reinforced semimanufacture needs to be used).

The invention furthermore makes it possible to provide semimanufacture capable of being used in a simple and user-friendly manner, wherein the semimanufacture is suitable of being used as a construction element.

In one preferred embodiment according to the invention, the semimanufacture comprises a resin allowing the semimanufacture to be maintained in an uncured state during more than 24 hours at room temperature, (23°C). The resin may be a pre-catalysed resin.

It is possible to change the "pot life", which depends on the storage temperature and the type of resin applied. Accordingly, by lowering the storage temperature and by selecting optimised types of resin, it is possible to achieve a longer "pot life".

It is possible to apply the semimanufacture according to the invention to manufacture an armouring element formed as a reinforcement element (in order to increase the mechanical strength) or as a machine component or a construction element (e.g. a spring).

The product according to the invention is a fibre reinforced semimanufacture comprising resin impregnated fibres. These fibres may be glass fibres, basalt fibres, metal fibres or natural fibres. It may be an advantage that the fibres are continuous fibres.

The semimanufacture may comprise fibre textures or one or more fibre mats.

The semimanufacture comprises a bendable tubular structure. The tubular structure may have any suitable shape dependent on the application in which the tubular structure is applied. If the semi manufacture is applied as a reinforcement element in reinforced concrete, the tubular structure may have a cylindrical geometry and be provided with profiling ribs/ridges shaped as a thread structure (spiral ridge).

By applying a surface profiled tubular structure, the need for cutting such structure into the bars/rods is eliminated. Furthermore, by applying a tubular structure provided with profiling ribs/ridges shaped as a thread structure, the profiling ribs/ridges may function as injection canals.

The one or more injection canals of the tubular structure facilitate injection of resin into the tubular structure. Hereby, it is possible to fill resin into the interior of the tubular structure by means of the one or more injection canals, when fibres have been placed into the interior of the tubular structure. Accordingly, the injection canals facilitate resin impregnation of the fibres in the tubular structure. The injection canals reduce the pressure required to carry out the resin impregnation of the fibres in the tubular structure.

It may be an advantage that one or more injection canals extend along the inside surface of the tubular structure.

It may be beneficial that the injection canals are integrated in the tubular structure.

It is possible to provide a separate injection canal in the tubular structure (e.g. extending along the fibres in the central portion of the tubular structure).

The tubular structure may have any suitable geometry. The tubular structure may have a circular, oval, triangular, rectangular, pentagonal, hexagonal or octagonal shape. The tubular structure may comprise several completely or partly overlapping-portions. In case the tubular structure comprises several portions, the tubular structure preferably comprises one or more attachment structures configured to establish attachment of corresponding (adjacent structures) such as corresponding mechanical attachment structures. The tubular structure may comprises one or more axial (longitudinal) joining structures configured to be mechanically attached to each other or joint by means of welding or gluing.

It may be an advantage that the semi manufacture has a rectangular cross- sectional area in certain applications, e.g. for reinforcement of a beam. It may be an advantage that the tubular structure has a homogeneous or uniform cross-section.

The tubular structure defines the outer structure and geometric shape of the semimanufacture. The tubular structure contains the wet uncured resin and constitutes a consolidating element during the forming phase. Hereby, the tubular structure plays a central role during the forming phase in such a manner that the forming phase may be carried out by means of simple fixtures in combination with : a) thermally curing, b) UV curing (activated by ultraviolet radiation), c) microwave based curing, d) induction based curing or e) combinations thereof.

The tubular structure may further comprise a diffusion resistant layer. By "diffusion resistant layer" is meant a layer having a reduced permeability meaning that molecules, gasses (vapors) or liquids do not readily pass through the layer. The layer may preferably hinder or lower permeation of molecules, gasses (vapors) or liquids into or out from the tubular profile. The diffusion resistant layer may suitably be a film, a membrane, a thermoplastic setting material or a thermoplastic polymer as well as any combination thereof. Films and membranes are well-known in the art. Specific examples include, but are not limited to, composite membranes. Thermoplastic setting materials are well-known in the art. Specific examples include, but are not limited to, polyurethanes, phenol- formaldehyde resins, vulcanized rubber, melamine resins, epoxy resins, polyimides, and polyester resins. Thermoplastic polymers are well-known in the art. Specific examples include, but are not limited to, poly(methyl methacrylate) (PMMA), acrylonitrile butadiene styrene (ABS), polyamides such as nylon, aliphatic polyesters, polybenzimidazole (PBI), polycarbonate (PC), polyether sulfones (PES), polyether ether ketones (PEEK), polyetherimides (PEI), polyethylenes (PE), polyphenylene oxides (PPO), polyphenylene sulfides (PPS), polyethylenes such as PP, HDPE and LDPE, polystyrenes, polyvinylchlorides (PVC), and polytetrafluoroethylenes (PTFE) such as Teflon^®. The diffusion resistant layer may comprise a combination of one or more of the before-mentioned materials. Suitable combinations include, but are not limited to, Teflon^® and another PTFE.

Once the semimanufacture is cured (hardened), the tubular structure protects the resin impregnated fibres during storage, transportation and use (e.g. concreting) of the semimanufacture. Furthermore, the tubular structure is capable of providing a strong and efficient anchorage of the cured semimanufacture when a surface structuring or coating is provided.

The tubular structure can give the semimanufacture and construction elements manufactured thereof a desired aesthetic expression e.g. by dyeing or inking the tubular structure. The tubular structure may be translucent or transparent. The tubular structure may be configured to protect against ultraviolet light.

The tubular structure may be produced in a thermoplastic material such as polyethylene, polypropylene, polyvinyl chloride, polystyrene or polycarbonate, in an elastomeric material such as rubber or silicone and in metal. The material may preferably be heat-resistant (in order to tolerate a thermally curing of the resin). The tubular structure may preferably have a geometry that allows the tubular structure to be bendable and formable.

The semimanufacture is bendable and comprises an uncured resin. The semimanufacture is configured to be cured in simple fixtures by means of heat, UV light, microwaves, induction or combinations hereof. Simple fixtures may be geometric moulds, in which the semimanufacture can be formed and maintained in the desired geometry. It is possible to apply fixtures configured to shape a one-dimensional, two-dimensional or three- dimensional semimanufacture. The semimanufacture according to the invention comprises an uncured resin that makes it possible to bend and form the tubular structure in order to receive the desired geometry. When the desired geometry is received, it is possible to cure the semimanufacture thermally (e.g. in a curing oven) or by means of light (e.g. an ultraviolet light source), by microwaves or induction or combinations hereof.

The semimanufacture may be used to produce construction elements for concreting, masonry (e.g. in the form of a lintel, a wall tie or other construction elements), earthquake-resistant structures for buildings and load bearing structures. The semimanufacture may alternatively be used to produce general construction elements such as balconies. It may be an advantage that the semimanufacture comprises a resin that is configured to be thermally cured at a predefined temperature, preferably above 80°C, such as 80-150°C. Hereby, it is possible to thermally cure semimanufacture by using known thermally curing tools (e.g. a curing oven). It may be an advantage to apply a pre-catalysed resin.

It may be advantageous that the semimanufacture is configured to be stored during longer time periods such as days, weeks or months, before the semimanufacture is formed, cured and used in a specific application. Hereby, it is possible to supply the semimanufacture according to the invention on remote construction sites, at which a further processing (forming, curing and application) is carried out. In this manner, it is possible to achieve the same degree of freedom (with forming perspective) as is known from steel reinforcement. At the same time, a plurality of advantages (low thermal and electrical conductivity as well as low density/weight) can be achieved by using fibre reinforced composite reinforcement structure.

It may be an advantage that the semimanufacture is configured to be formed merely by means of simple fixtures and heat, ultraviolet light. Hereby, it is possible to process the semimanufacture according to the invention in an easy way and in a remote distance from the production destination.

The resin may by any suitable type of resin capable of being impregnated in the fibres and be maintained uncured in at least 24 hours at room temperature.

The resin may preferably be an alkali-resistant resin . The resin may be any suitable type of resin. The resin may comprise epoxy, a phenol system, vinyl ester, polyurethane or other suitable types of resin that are injectable at room temperature (23°C) or by higher temperatures. It is possible to add a hardener that is thermally activated at temperatures above 80°C, such as 80-150°C, e.g. 80-90° or 90-100°C or 100-110° or 110-120°C or 120-130°C or 130-140° or 140-150°C to the resin.

It may be beneficial that the tubular structure is provided with an outer thread extending along at least part of the tubular structure.

It may be advantageous that the tubular structure is provided with an outer thread extending along at least part of the end portions of the tubular structure.

Hereby, it is possible to seal off (plug) the tubular structure by attaching (screwing) an end member (a plug) to each end of the tubular structure. The thread can furthermore, facilitate a strong and efficient anchorage (e.g. in concreting).

By using mechanically attached end members, it is further possible to provide a safe and simple sealing of the semi manufacture according to the invention.

It may be an advantage that the tubular structure is cylindrical and comprises an outer thread extending along the entire length of the tubular structure. The outer thread makes it possible to provide a strong and efficient anchorage (e.g. in concreting or mortar). It may be an advantage to apply a viscosity regulating composition in order to regulate/control the viscosity of the resin. Hereby, it is possible to increase the viscosity of the resin in order to minimise the risk of leakage. It may be advantageous to add one or more additives to the resin. Such an additive may be a thickening agent or a viscosity regulating agent.

It may be an advantage that the semi manufacture comprises at least one end member (plug) attached to the end portion(s) of the tubular structure. Application of one more end members makes it possible to provide a simple and secure sealing of the tubular structure in such a manner that the resin is kept inside the tubular structure during storage and transport of the semimanufacture. It may be an advantage that the tubular structure is translucent or transparent. Hereby, it is possible to visually inspect the content of the tubular structure including the resin and fibres. Accordingly, quality control can be conducted by visual inspection. Furthermore, since light may be transmitted through the translucent or transparent tubular structure, it is possible to provide a UV light activated curing of the resin.

By the term "translucent or transparent" is meant completely or partly light-permeable. It may be an advantage that the tubular structure is ultraviolet light permeable, since ultraviolet light can be used to activate the curing process of the resin of the semimanufacture.

It may be an advantage that the resin is a light-activated resin. By using a light-activated resin, it is possible to cure the resin by using a light source, preferably an ultraviolet light source.

In order to provide a strong and robust semimanufacture it may be an advantage that the fibre content of the tubular structure is above 30% Vol, preferably above 50% Vol, such as 55% Vol or 60% Vol or 65% Vol or 70% Vol or 75% Vol or more. It may be an advantage that the gas content of the tubular structure is below 5% Vol, preferably below 3% Vol, such as 2% Vol.

It is possible to reduce the gas content of the tubular structure to below 5% Vol, preferably below 3% Vol, such as 2% Vol by injecting the resin by using a high pressure.

The semimanufacture according to the invention makes it possible to produce uncured reinforcement rods/bars and other construction elements, which can be formed and cured when the reinforcement elements are needed (e.g. on a construction site). The semimanufacture according to the invention makes it possible to export construction elements to remote countries, where the local supplier can store the construction elements (e.g. reinforcement rods/bars and other construction elements), wherein user specific constructions/bendings can be provided by means of suitable forming and curing means.

Description of the Drawings

The invention will become more fully understood from the detailed description given herein below. The accompanying drawings are given by way of illustration only, and thus, they are not limitative of the present invention. In the accompanying drawings:

Fig. 1A shows a schematic view of a semimanufacture according to the invention;

Fig. IB shows a close-up view of a section of the semimanufacture shown in Fig. 1A;

Fig. 1C shows a cross-sectional view of the semimanufacture shown in

Fig. 1A and Fig. IB;

Fig. 2A shows a schematic view of a semimanufacture according to the invention in a first uncured state;

Fig. 2B shows a schematic view of the semimanufacture shown in Fig.

2A while being formed and cured;

Fig. 2C shows a close-up view of the semimanufacture shown in Fig.

2A; Fig. 3 shows different embodiments according to the invention;

Fig. 4 shows different embodiments provided with injection canals according to the invention;

Fig. 5 shows a beam being reinforced by a mechanical support according to the invention and

Fig. 6 shows different examples of semimanufactures according to the invention.

Detailed description of the invention

Referring now in detail to the drawings for the purpose of illustrating preferred embodiments of the present invention, a semimanufacture 2 of the present invention is illustrated in Fig. 1A.

Fig. 1A shows a schematic view of a semimanufacture 2 according to the invention. The semimanufacture 2 has been cut. The semimanufacture 2 is formed as a ribbed reinforcing bar comprising an outer tubular structure 4 provided with an outer thread 12.

Continuous fibres 16 of e.g. glass, carbon, amide, basalt, metal or natural fibres are filled into the interior of the tubular structure 4. The fibres 16 are resin impregnated with a pre-catalysed resin that may be either heat activated or light activated.

The semimanufacture 2 is bendable and comprises uncured resin. The resin may preferably be injected under pressure in such a manner that the gas content of the resin impregnated fibres is low. Hereby gas bobbles in the resin can be avoided. Injection of resin under pressure will evacuate the gas from the tubular structure 4. By using such method, it is possible to produce a semimanufacture 2 with low gas content. Hereby, it is possible to produce a strength-optimised construction element by means of the semimanufacture 2.

Fig. IB illustrates a close-up view of a section of the semimanufacture 2 shown in Fig. 1A. It can be seen that the thread 12 comprises a thread profile comprising a continuous track-like structure (a root) 24 provided in a cylindrical surface 20. The width D₂ of the surface 20 is significantly larger than the width Di of the track-like structure (a root) 24. The surface 20 extends along the longitudinal axis X of the tubular structure 4. The angle between adjacent flanks 22, 22' as well as the inner and outer diameter of the thread 12 may vary from application to application in order to meet specific requirements.

Fig. 1C illustrates a cross-sectional view of the semimanufacture 2 shown in Fig. 1A and Fig. IB. The semimanufacture 2 comprises an outer tubular structure 4 provided with an inner diffusion resistant layer 52. The diffusion resistant layer 52 prevents molecules, gasses (vapors) and liquids from readily passing through the layer. Fig. 2A illustrates a schematic view of a semimanufacture 2 according to the invention in a first uncured state. The semimanufacture 2 comprises a tubular structure 4 containing uncured resin impregnated fibres. The resin may be pre-catalysed. The viscosity of the resin is so low that the semimanufacture 2 can be bent and formed according to the requirements of the end user.

The semimanufacture 2 is shaped as a reinforcement rod 2 provided with a continuous outer thread 12. The reinforcement rod 2 has a homogeneous (uniform) outer geometry extending along its entire length. The reinforcement rod 2 is configured to be formed when exposed to a subsequent forming and curing process.

A first end member (plug) 6 is mechanically attached to the first end of the tubular structure 4. The end member 6 is provided with an inner thread that engages the outer tread 12 of the tubular structure 4. The end member 6 and the tubular structure 4 are screwed together. The inner thread of the end member 6 may be slightly conical in such a manner that the inner diameter is gradually reduced towards the closed end portion of the end member. Hereby, the end member 6 can be sealingly attached to the tubular structure 4 by simple means. Fig. 2C illustrates a close-up view of a section of the semi manufacture 2 shown in Fig. 2A. It can be seen that the thread 12 has a uniform, helical structure extending along the length of the semimanufacture 2.

Fig. 2B illustrates a schematic view of the semimanufacture 2 shown in Fig. 2A in a shaped and cured configuration. It should be noted that the surface structure (thread) is not shown in Fig. 2B. The semimanufacture 2 comprises a U-shaped tubular structure 4 comprising a first straight portion 10 connected to a second straight portion 10' via a first 90-degree bending 8. The tubular structure 4 further comprises a third straight portion 10" connected to the second straight portion 10' via a second 90-degree bending 8'. A first end member (plug) 6 is provided in the first end of the tubular structure 4, whereas a second end member (plug) 6' is provided in the opposite end of the tubular structure 4.

The end members 6, 6' are screwed onto threaded end portions of the tubular structure 4. When the tubular structure 4 is shaped as shown in Fig. 2C, it is possible to cure the semimanufacture 2 thermally or by means of light (e.g. by using a UV light source) dependent on the resin, with which the fibres in the tubular structure 4 are impregnated.

It is possible to provide a semimanufacture 2 having another geometric shape (examples of such shapes are shown in Fig. 6).

Fig. 3 illustrates different embodiments of a semimanufacture 2 according to the invention. Fig. 3A, Fig. 3B, Fig. 3C, Fig. 3D and Fig. 3E illustrate examples of semimanufacture 2 shaped as machine elements in the form of springs 18. Fig. 3F illustrates a semimanufacture 2 according to the invention comprising a tubular structure 4. The semimanufacture 2 comprises four straight portions 10, 10', 10", 10"' connected by four corrugated zones provided with bendings 8, 8', 8", 8"'. The embodiment shown in Fig. 3F is configured to provide bendings 8, 8', 8", 8"' in a number of predefined corrugated zones. The straight portions 10, 10', 10" of the tubular structure 4 are provided without an outer surface structuring.

Fig. 3G illustrates another semi manufacture 2 according to the invention comprising a tubular structure 4. The semimanufacture 2 comprises three straight portions 10, 10', 10" connected by three corrugated zones provided with bendings 8, 8', 8". The embodiments shown in Fig. 3F and Fig. 3G may be formed in two or three dimensions dependent on the actual requirements. It is possible to provide wall ties as shown in Fig. 3H .

Fig. 3H illustrates a brick construction comprising a plurality of bricks 26. An insulation structure 28, 30 is provided between the two walls 32, 34 (e.g. an inner wall and an outer wall). A semimanufacture 2 according to the invention which is formed as a wall tie 2 on the top surface of the bricks 26. The wall tie 2 replaces the traditional stainless steel wall ties. It is an advantage of a wall tie 2 according to the invention that the thermal conductivity is [W/(m K)] about 0.25-1.0 [W/(m K)], whereas the steel wall ties have a thermal conductivity in the range of 14-16 [W/(m K)] . Accordingly, thermal bridges can be reduced by replacing steel wall ties with wall ties according to the invention. Moreover, the invention makes it possible to provide a wall tie 2 having an increased mechanical strength (e.g. tensile strength) by using e.g. glass fibres or carbon fibres.

It is important to underline that the semimanufacture 2 shown in Fig. 3 can be formed to construction elements when exposed to a curing process. If the semimanufactures 2 shown in Fig. 3 are exposed to a curing process, construction elements having the same geometric shape are achieved.

Fig. 4 illustrates different tubular structures 4 according to the invention. The shown tubular structures 4 are provided with injection canals 36, 38 configured to facilitate and ease the injection of resin during the resin impregnation process, wherein the fibres in the tubular structure 4 are impregnated with resin.

Fig. 4A illustrates a perspective view of a cut tubular structure 4 according to the invention. The tubular structure 4 is provided with a centrally arranged injection canal 36 provided with a number of openings 40 for distribution of resin during the fibre impregnation process in the tubular structure 4. The tubular injection canal 36 may extend along the entire length of the tubular structure 4 in order to facilitate fibre impregnation of fibres along the entire length of the tubular structure 4. It is possible to arrange the tubular injection canal 36 in a different place (non-centrally arranged).

Fig. 4B illustrates another view of the tubular structure 4 shown in Fig. 4A.

Fig. 4C illustrates a cylindrical tubular structure 4 according to the invention. The tubular structure 4 is cut and provided with several injection canals 38. A longitudinal opening 40 for distribution of resin during the fibre impregnation process in the tubular structure 4 is provided in the injection canals 38. The injection canals 38 extend along the inner wall of the tubular structure. The injection canals 38 may preferably extend along the entire length of the tubular structure in order to facilitate distribution of resin during the fibre impregnation process in the tubular structure 4 (as illustrated in Fig. 4D). The openings 40 are directed towards the central portion of the tubular structure 4.

Fig. 4D illustrates a perspective view of a tubular structure 4 according to the invention. The tubular structure 4 is cylindrical and provided with eight injection canals 38 distributed along the wall of the tubular structure 4. A plurality of openings are provided in the injection canals 38. These openings are configured to guide the resin radially. Accordingly, the resin can flow axially along the injection canals 38 and be distributed radially through the openings 40 in order to impregnate the fibres in the tubular structure 4.

The injection canal 38 extends along the inner wall of the tubular structure. The injection canal 38 may extend along the entire length of the tubular structure in order to facilitate distribution of resin along the entire length of the tubular structure during the fibre impregnation process. It may be an advantage that the openings 40 face towards the centre axis of the tubular structure 4.

Fig. 4E illustrates a cross-sectional view of a tubular structure 4 according to the invention. The tubular structure 4 is provided with injection canals 38 provided with an inner thread 38 extending along the inner wall of the tubular structure.

Fig. 4F illustrates a cross-sectional view of a tubular structure 4 according to the invention. The tubular structure 4 is provided with an injection canal 38 corresponding to the one shown in Fig. 4E. A thread is provided in the outer surface of the tubular structure 4.

Fig. 5 illustrates a beam 42 that needs reinforcement in the form of a mechanical support. The illustration shown to the left is a cross-sectional view, whereas the illustration to the right shows a side view of the beam 42.

Fig. 5A illustrates a situation, in which a recess 44 has been provided in the bottom portion of the beam 42. A semimanufacture 2 according to the invention is arranged below the beam 42. The semimanufacture 2 is provided with a first end member (plug) 6 in the first end and a second end member (plug) 6' in the second end.

Fig. 5B illustrates a situation, in which the semimanufacture 2 is shaped basically to fit the recess 44 in such a manner that the shape of the semimanufacture 2 corresponds to the geometry of the surface 48 of the recess 44.

In Fig. 5C, the semimanufacture 2 is arranged in the recess 44 and a curing process by means of an ultraviolet light source 46 transmits ultra violet light 50. The semimanufacture 2 comprises a light-activated resin.

Fig. 6 illustrates different semimanufactures 2 according to the invention and examples of configurations. Fig. 6 illustrates different semimanufactures 2 all comprising a number of straight portions 10, 10' and a number of bendings 8, 8'. Fig. 6 illustrates examples of bendings 8, 8' that can constructed by using semimanufactures 2 according to the invention.

It is possible to cure the semimanufacture 2 by using ultraviolet light or thermally by means of microwaves and/or induction or combinations of ultraviolet light and/or microwaves and/or induction.

List of reference numerals

2 Semimanufacture

4 Tubular structure

6, 6' End member

8, 8', 8", 8"' Bending

10, 10', 10", 10"' Straight portion

12 Thread

14, 14' End

16 Fibre

18 Spring member

20 Surface

22, 22' Flank

24 Root

26 Brick

28 Insulation

30 Insulation

32 Wall

34 Wall

36 Injections canal

38 Injections canal 1

40 Opening

42 Beam

44 Recess

46 Ultraviolet (UV) light sou

48 Surface (irregular)

50 Ultraviolet (UV) light

52 Diffusion resistant layer

Ri, R₂ Radius of curvature

Di, D₂ Width (diameter)

Li, L₂ Width

a Angle

X, Y Axis

Claims

1. A fibre reinforced semimanufacture (2) comprising a bendable tubular structure (4), characterised in that the semimanufacture (2) comprises resin impregnated fibres (16), wherein the resin is uncured and the semimanufacture (2) is capable of being maintained uncured in at least 24 hours at room temperature (23°C), wherein the tubular structure (4) comprises one or more injection canals (36, 38).

2. A fibre reinforced semimanufacture (2) according to claim 1, characterised in that the semimanufacture (2) comprises: a) a thermally curable resin configured to be cured at a predefined temperature, preferably above 80°C, such as 80-150°C; b) a UV curable resin; c) a microwave curable resin; d) an induction curable resin or e) a resin that is thermally curable and/or UV curable and/or microwave curable and/or induction curable.

3. A fibre reinforced semimanufacture (2) according to claim 2, characterised in that the resin comprises epoxy, a phenol system, vinyl ester, polyurethane or other suitable types of resin.

4. A fibre reinforced semimanufacture (2) according to one of the preceding claims, characterised in that a viscosity regulating additive is added to the resin in order to regulate the viscosity of the resin.

5. A fibre reinforced semimanufacture (2) according to one of the preceding claims, characterised in that the resin is uncured in such a manner that the tubular structure (4) is bendable.

6. A fibre reinforced semimanufacture (2) according to one of the preceding claims, characterised in that the tubular structure (4) is provided with an outer thread (12) extending along at least part of the tubular structure (4).

7. A fibre reinforced semimanufacture (2) according to one of the preceding claims, characterised in that the tubular structure (4) is cylindrical and comprises an outer thread (12) extending along the entire length of the tubular structure (4).

8. A fibre reinforced semimanufacture (2) according to one of the preceding claims, characterised in that the fibre reinforced semimanufacture (2) is sealed in at least one end (14, 14'), preferably in both ends (14, 14').

9. A fibre reinforced semimanufacture (2) according to one of the preceding claims, characterised in that the tubular structure (4) is translucent or transparent.

10. A fibre reinforced semimanufacture (2) according to claim 9, characterised in that the resin is a light-activated resin.

11. A fibre reinforced semimanufacture (2) according to one of the preceding claims, characterised in that the tubular structure (4) comprises a diffusion resistant layer (52).

12. A fibre reinforced semimanufacture (2) according to claim 11, characterised in that the diffusion resistant layer (52) is provided at the inside of the tubular structure (4).

13. A fibre reinforced semimanufacture (2) according to claim 11 or 12, characterised in that the diffusion resistant layer (52) comprises one or more of the following components: poly(methyl methacrylate) (PMMA), acrylonitrile butadiene styrene (ABS), polyamides such as nylon, aliphatic polyesters, polybenzimidazole (PBI), polycarbonate (PC), polyether sulfones (PES), polyether ether ketones (PEEK), polyetherimides (PEI), polyethylenes (PE), polyphenylene oxides (PPO), polyphenylene sulfides (PPS), polyethylenes such as PP, HDPE and LDPE, polystyrenes, polyvinylchlorides (PVC) or polytetrafluoroethylenes (PTFE) such as Teflon^®.

14. A fibre reinforced composite construction element manufactured by means of a semimanufacture (2) according to one of the preceding claims.