Non-metallic structural member and method of installing same

Abstract

The present application relates to a non-metallic structural member and a method of installing the non-metallic structural member in concrete. The non-metallic structural member includes a plurality of fibers and a resin at least partially encased by a membrane. The non-metallic structural member has a textured outer surface. The method includes positioning the non-metallic structural member in a predetermined location and then at least partially encasing the membrane of the non-metallic structural member with concrete. The membrane is configured to bond with the resin. The method further includes hardening the concrete around the non-metallic structural member and forming a bond between the membrane of the non-metallic structural member and the concrete during hardening of the concrete.

Description

Cross-references to related applications

[0001] This application claims priority to U.S. Provisional Patent Application No. 63 / 600,992, filed November 20, 2023, and U.S. Provisional Patent Application No. 63 / 605,979, filed December 4, 2023, the entire contents of which are incorporated herein by reference. Technical Field

[0002] This disclosure relates to a method for manufacturing a composite material, and more specifically, to a method for manufacturing a fiber-reinforced polymer material. Background Technology

[0003] Fiber-reinforced polymers comprise fibrous materials bonded together by a matrix, typically provided by an adhesive such as a resin. Fiber-reinforced polymers are generally manufactured using a pultrusion process. Figure 1 An example of this process is shown.

[0004] In the pultrusion process, feed fibers 5 are drawn through production line 10 by a pulling mechanism 15 (e.g., a pair of drive rollers 20). The fibers 5 are drawn into an adhesive tank 25 containing one of several adhesives. Once wetted, the fibers 5 are drawn through a static die 30, which may have one or more heating zones to initiate the hardening of the adhesive. In the pultrusion process, the die 30 serves multiple functions. It promotes the wetting of the fibers 5 by applying pressure, heats the adhesive and fibers 5, controls the hardening of the adhesive, and controls the final shape of the pultruded product.

[0005] The curing profile of an adhesive is determined by chemical reactions (curing, crosslinking, drying, etc.). These curing profiles depend on the chemical activity of the adhesive, the process temperature, and the residence time at that temperature. As production speeds increase, ensuring adequate curing of the adhesive becomes increasingly difficult.

[0006] like Figure 1 The conventional pultrusion process shown has inherent limitations that severely restrict process speed. The length of the die 30 is the main limiting factor affecting process speed, while process temperature, process friction, and process gas venting constitute other limiting factors. The adhesive tank 25 itself also has drawbacks, including difficulty in mixing and maintaining multi-component reactive adhesives, excessive waste generation, and high operating costs due to the typically large amount of adhesive required to fill the adhesive tank 25. For at least the above reasons, manufacturing fiber-reinforced products has historically been uneconomical, especially when using one or more fast-curing thermosetting polymers and / or multi-component thermosetting polymers as part of the binder. Summary of the Invention

[0007] In some embodiments, this disclosure provides a method for installing a nonmetallic structural member in concrete. The nonmetallic structural member comprises a plurality of fibers and resin at least partially covered by a membrane. The nonmetallic structural member has a textured outer surface. The method of installing the nonmetallic structural member includes positioning the nonmetallic structural member in a desired location and then surrounding the membrane of the nonmetallic structural member at least partially with concrete. The membrane is configured to bond with the resin. The method further includes hardening the concrete surrounding the nonmetallic structural member and, during concrete hardening, forming a bond between the membrane of the nonmetallic structural member and the concrete.

[0008] In some embodiments, this disclosure provides non-metallic structural members used in methods for installing non-metallic structural members in concrete.

[0009] In some embodiments, this disclosure includes a nonmetallic structural member configured to be placed in concrete. The nonmetallic structural member comprises a plurality of fibers and resin, and a film at least partially covering the plurality of fibers and resin. The film is chemically bonded to the resin. The nonmetallic structural member is positioned in a predetermined location and, upon positioning, is at least partially surrounded by concrete. During concrete hardening, the nonmetallic structural member is retained within the concrete. During concrete hardening, the film of the nonmetallic structural member bonds with the concrete.

[0010] In some embodiments, the film is a polymer compound comprising at least some polypropylene and / or polyethylene, such that the polymer compound is capable of chemically bonding with the concrete during the concrete hardening process. Possible examples of polymer compounds include biaxially oriented polypropylene, dual-weighted median-correlated oriented polypropylene, impact-modified polypropylene, biaxially oriented polyethylene, dual-weighted median-correlated oriented polyethylene, and / or impact-modified polyethylene.

[0011] In some embodiments, the method and apparatus include encapsulating fibers and resin at least partially in a film to reduce odors released by the resin during curing. Optionally, the method and apparatus include shrinking the film encapsulating the resin and fibers after at least partially surrounding the resin and fibers and before at least partially surrounding the non-metallic structural member with concrete.

[0012] In some embodiments, the method and apparatus include mixing Portland cement and lime with the resin before at least partially coating the fibers and resin with a film, such that after the film is at least partially dissolved, the Portland cement and lime form a bond with the concrete.

[0013] In some embodiments, the film includes water-soluble paper that dissolves in the concrete during the concrete hardening process to allow the resin to bond with the concrete, and the water-soluble paper includes printed paper with acidic ink, wherein the acidic ink reacts with the concrete, causing the water-soluble paper to dissolve.

[0014] In some embodiments, the method and apparatus include forming a mechanical bond between the film and concrete through contact between the concrete and one or more embossed features of the film, and / or through contact between the concrete and the textured outer surface of a non-metallic structural member.

[0015] In some embodiments, the resin comprises dicyclopentadiene and / or tricyclopentadiene.

[0016] In some embodiments, the fibers and resin are at least partially encapsulated within the film before the film is chemically bonded to the resin, and then a portion of the film is ultrasonically welded to another portion of the film surrounding the plurality of fibers and resin.

[0017] In some embodiments, the method further includes bending the non-metallic structural member into a non-linear shape before the film is chemically bonded to the resin; stretching the film and causing the fibers to slide relative to one or more adjacent fibers in response to bending; and hardening the resin after stretching the film and causing the fibers to slide, thereby holding the non-metallic structural member in the aforementioned non-linear shape.

[0018] This embodiment may optionally include sliding the fibers relative to the film in response to bending.

[0019] In some embodiments, the apparatus and method include positioning a plurality of particles between the film and the fiber and resin bundles, wherein the melting point of the film differs from the melting point of the particles by no more than 15 degrees Celsius. Optionally, the melting point of the film differs from the melting point of the particles by 0 to 5 degrees Celsius.

[0020] In some embodiments, the particles include phenolic open-cell foam particles and / or polymer abrasive particles.

[0021] Other features and aspects of this disclosure will become apparent from the following detailed description and accompanying drawings. Attached Figure Description

[0022] Figure 1 This is a schematic diagram of a typical pultrusion process.

[0023] Figure 2 This is a schematic diagram of an assembly line according to certain embodiments of the present disclosure.

[0024] Figure 3 yes Figure 2 A perspective view of the assembly line section shown.

[0025] Figure 4 yes Figure 2 A perspective view of the assembly line section shown.

[0026] Figure 5 An embodiment of a method for... is shown. Figure 2 The adhesive application device shown is for the assembly line.

[0027] Figure 6 and Figure 7 It shows the use of Figure 2 The adhesive coating assembly of the assembly line shown, according to certain embodiments.

[0028] Figure 8 yes Figure 2 The perspective view of another part of the assembly line shown illustrates the mold being wound around a section of wetted fiber.

[0029] Figure 9 It is a perspective diagram of the mold winding around the wetted fiber segment.

[0030] Figure 10 yes Figure 2 The end view of the forming station in the assembly line shown.

[0031] Figure 11 This is a schematic diagram of a molding station according to certain embodiments.

[0032] Figure 12 This is a schematic diagram of a molding station according to certain embodiments.

[0033] Figure 13 This is a schematic diagram of a molding station according to certain embodiments.

[0034] Figure 14 This is a schematic diagram of a molding station according to certain embodiments.

[0035] Figure 15 This is a schematic diagram of a molding station according to certain embodiments.

[0036] Figure 16 This is a schematic diagram of a molding station according to certain embodiments.

[0037] Figure 17 It is a representative cross-sectional view of a structural component that includes multiple fibers and traction agents.

[0038] Figure 18 An example of traction agent particles observed under a microscope is shown.

[0039] Figure 19 Another embodiment of traction agent particles observed under a microscope is shown.

[0040] Figure 20 A through 20D showcases a variety of possible curved shapes.

[0041] Figures 21A to 21D The various steps of the bending forming process are shown.

[0042] Figure 22A and 22B This is a perspective view of an embossed film used for non-metallic structural components.

[0043] Before detailing any embodiment of this disclosure, it should be understood that the application of this disclosure is not limited to the structural details and component arrangements described below or shown in the figures. This disclosure may have other implementations and may be practiced or performed in various ways. Furthermore, it should be understood that the wording and terminology used herein are for descriptive purposes only and should not be considered limiting. Detailed Implementation

[0044] Figure 2 and Figure 3 An assembly line 100 for manufacturing fiber-reinforced polymer (FRP) structural composite materials (i.e., matrix composites) is shown. This structural composite material can be formed into various structural components, such as reinforcing bars, I-beams, C-channels, pipes, structural laminates, etc. The assembly line 100 shown includes a threading station 105, an adhesive application station 110, and multiple forming stations 115. In some embodiments, the assembly line 100 may include additional or alternative workstations. The assembly line 100 is typically linearly arranged and defines a central axis 120 along which the structural composite material is produced (…). Figure 3 As described in detail here, assembly line 100 is capable of continuously manufacturing FRP structural composite materials at high speed.

[0045] The rib station 105 includes multiple spools or reels 125 for supporting and releasing fiber bundles or threads 130 to be incorporated into the structural composite material. In the illustrated embodiment, the fibers 130 comprise basalt; however, the fibers 130 may also comprise glass fibers, aramid fibers, carbon fibers, or any other desired fiber material. The spools 125 may be connected to a power drive system that controls the fiber feed rate. In such embodiments, a tension regulator or other automatic tension control device (not shown) may be provided to maintain a constant tension on the fibers 130.

[0046] After being released from the spool 125, the fiber 130 passes through the guide assembly 135, which aligns the fiber 130 for wetting at the adhesive coating station 110. Figure 3 and Figure 4In some embodiments, the guide assembly 135 may align the fibers 130 on the same plane to provide a relatively large, rectangular wetting surface. Alternatively, the guide assembly 135 may also align the fibers 130 into other patterns, such as linear, cylindrical, tubular, or spiral patterns.

[0047] In some embodiments, the rib station 105 includes one or more heating elements (not shown) for preheating the fibers 130 to a desired temperature before conveying them to the adhesive coating station 110. The heating elements may be located inside or outside the spool 125. For example, hot air may be directed upwards as the fibers 130 exit the rib station 105. Preheating the fibers 130 reduces the energy input required by the adhesive coating station 110 and helps stabilize the adhesive curing process (described in detail below).

[0048] Because the fiber diameter is relatively small (compared to the diameter of the bundled fibers in the mold and forming station), the time and / or energy required to preheat a single fiber is less than that required to heat bundled fibers in one or more forming stations. The forming station is operable to maintain the preheated fiber at a high temperature. In some embodiments, the adhesive is preheated before being applied to the fiber 130.

[0049] Reference Figure 2 and Figure 3 The adhesive coating station 110 is located downstream of the rib station 105, such that fibers 130 exiting from the guide assembly 135 are introduced into the adhesive coating station 110 to be wetted by an adhesive (e.g., a resin). In some embodiments, the adhesive is a very low-viscosity short-chain monomer or combination of monomers, such as dicyclopentadiene (DCPD) or tricyclopentadiene (TCPD). In some embodiments, the adhesive comprises one or more low-viscosity polyurethane polymers and systems, such as mDI-based two-component elastomers. In other embodiments, the adhesive is a thermosetting polymer, such as a phenolic resin or an epoxy resin. In other embodiments, the adhesive may include polyester, vinyl ester, Portland cement, or any other suitable adhesive.

[0050] The adhesive has a viscosity of less than 25 centipoise (cP) in a temperature range of 20°C to 55°C. In some embodiments, the adhesive has a viscosity of less than 20 centipoise in a temperature range of 20°C to 55°C. In some embodiments, the adhesive has a viscosity of less than 15 centipoise in a temperature range of 20°C to 55°C. In some embodiments, the adhesive has a viscosity of less than 10 centipoise in a temperature range of 20°C to 55°C.

[0051] The extremely low viscosity adhesive can rapidly diffuse between fibers 130 and, as fibers 130 pass through assembly line 100 at high speed, requires no traction agent. This allows for consistent final products even at extremely high speeds.

[0052] The adhesive coating station 110 can precisely meter the amount of adhesive applied to the fibers. Specifically, based on the required adhesive-to-fiber ratio, an appropriate amount of adhesive can be applied directly to the fibers. This is consistent with... Figure 1 The adhesive bath shown presents a stark contrast to the traditional method where the amount of adhesive applied to the fibers cannot be controlled. Excess adhesive must be removed, resulting in more waste. Furthermore, the entire adhesive bath must be maintained at the appropriate temperature, and heating excess adhesive wastes energy, especially when some of the heated adhesive is removed from the fibers. Simultaneously, because the fiber-to-adhesive ratio cannot be controlled, products made using an adhesive bath may exhibit inconsistent quality. In this disclosure, the amount of adhesive applied to the fibers can be controlled to ensure the expected quality and consistency of the produced products.

[0053] Figures 3 to 5 An embodiment of an adhesive coating station 110 is shown. In the illustrated embodiment, the adhesive coating station 110 includes a pressure trap 140. The pressure trap 140 draws adhesive from a source 145 (e.g., a hopper or tank, see below). Figure 2 The pressure trap 140 receives adhesive. It includes an end plate 150 with an inlet 155 through which adhesive can be injected (see...). Figure 5 Subsequently, the adhesive is extruded under pressure through a plurality of channels 160 extending radially outward from the feed port 155. The channels 160 are connected to the wetting area 165 located on the outer periphery of the end plate 150.

[0054] During operation, the adhesive is continuously squeezed into the wetting zone 165 through channel 160.

[0055] Fiber 130 passes through wetting zones 165 and is wetted by the adhesive, thus initiating the formation of the matrix composite. In the illustrated embodiment, end plate 150 includes two wetting zones 165 offset from each other by approximately 180 degrees. Therefore, fiber 130 can be arranged along two simultaneously wetted paths. Fiber 130 remains spaced as it passes through the wetting zones 165 to facilitate adequate coating of the adhesive onto the fiber 130. In other embodiments, end plate 150 may contain any number of wetting zones. The operating pressure of pressure trap 140, as well as the number and size of channels 160, are adjustable to provide the desired wetting rate.

[0056] Figure 6 and Figure 7A partial structure of an adhesive coating station 110a according to another embodiment is shown. The adhesive coating station 110a can be used in conjunction with any of the embodiments described herein. In some embodiments, the adhesive coating station 110a is used as a supplement to the adhesive coating station described and illustrated in other embodiments; while in other embodiments, the adhesive coating station 110a is used to replace the adhesive coating station described and illustrated in other embodiments. In the illustrated embodiment, the adhesive coating station 110a includes a die 170 that guides the input fibers 130 into a generally tapered or conical arrangement. The die 170 is movable longitudinally (i.e., along the central axis 120). This movement facilitates forming the input fibers 130 into a generally continuous wall or sheet. The adhesive coating station 110a includes a nozzle 175 that receives adhesive from a source 145 (… Figure 2 The nozzle 175 receives adhesive and can operably spray the adhesive stream onto the feed fiber 130. The position of the nozzle 175 can be adjusted in the longitudinal direction to regulate the spray characteristics of the adhesive.

[0057] In another alternative embodiment, the adhesive coating station may include an adhesive tank. After passing through the adhesive tank, the fibers 130 may be guided through a series of parallel rollers to mechanically agitate and physically press the adhesive into the passing fibers. The adhesive content of the impregnated fibers can be controlled by a scraper and / or rollers. Alternatively, the adhesive content can also be controlled by guiding a portion of the fibers 130 around the adhesive impregnation tank.

[0058] In this alternative embodiment, assembly line 100 may also include an oven bundling station between the adhesive coating station and one or more forming stations 115 for heating the adhesive-impregnated fibers 130 to complete the wetting process, initiate the curing process, and roughly shape the wetted fibers. Furthermore, the oven bundling station may include one or more drive rollers for pulling the fibers from the rib station 105 and feeding them into the adhesive coating station.

[0059] Reference Figure 2 In some embodiments, the assembly line 100 shown includes two separate traction agent sources 177a and 177b for supplying traction agent to the fibers 130. Either or both of traction agent sources 177a and 177b may be used in any of the embodiments described herein. In some embodiments, the traction agent may increase the friction between adjacent fibers 130 to prevent the fibers 130 from slipping against each other during processing on the assembly line 100. In some embodiments, the traction agent may increase the friction between the fibers 130 and the mold 180. The traction agent preferably comprises a non-metallic powder, such as diatomaceous earth. In other embodiments, the traction agent may comprise talc, mica, perlite, calcium carbonate, fumed silica, quartz, alumina, silicon carbide, polymer abrasives, carbon black, carbon nanotubes, etc.

[0060] Reference Figure 17 The traction agent comprises particles 178a and 178b with a diameter smaller than that of fiber 130. Traction agent particles 178a are dispersed between fibers 130 and can fill gaps between adjacent fibers 130. In some embodiments, the average diameter of the traction agent particles 178a is less than about 17 micrometers. In other embodiments, the average diameter of the traction agent particles 178a is less than about 15 micrometers. In still other embodiments, the average diameter of the traction agent particles 178a is about 13 micrometers. In other embodiments, the average diameter of the traction agent particles 178a is between about 5 micrometers and about 20 micrometers. In other embodiments, the average diameter of the traction agent particles 178a is between about 20% and about 90% of the average diameter of fiber 130. In other embodiments, the average diameter of the traction agent particles 178a is about 75% of the average diameter of fiber 130.

[0061] The hardness of the traction agent is preferably lower than that of fiber 130. In some embodiments, the Mohs hardness of the traction agent particles 178a is about 6 or lower. In other embodiments, the Mohs hardness of the traction agent particles 178a is about 4 or lower. In other embodiments, the Mohs hardness of the traction agent particles 178a is about 2 or lower. In other embodiments, the Mohs hardness of the traction agent particles 178a is between about 0.5 and about 2. In some embodiments, the hardness of the traction agent particles 178a is between about 10% and about 50% of the hardness of fiber 130.

[0062] In some embodiments, the traction agent particles 178a are spherical and generally without sharp edges, corners, or points. In some embodiments, the traction agent particles 178a also contain multiple surface pores. These surface pores can increase the contact area between the traction agent particles 178a and the fibers 130, and improve resin retention and penetration. The particles 178a can also interact with the resin to produce thixotropic or gelling effects, which help maintain the wetted fibers 130 in the desired shape before the resin hardens.

[0063] Reference Figure 2 Traction source 177a is positioned to introduce traction agent particles 178a into adhesive source 145. The traction agent is mixed with the adhesive to form an adhesive mixture in which the traction agent particles 178a are suspended. In some embodiments, traction source 177a and adhesive source 145 may separately deliver the traction agent and adhesive to a mixing chamber, where the traction agent combines with the adhesive to form the adhesive mixture. The adhesive mixture is then conveyed to adhesive coating station 110 and coated onto fiber 130. In embodiments using a low-viscosity resin, the traction agent particles 178a are an optional component and may be omitted.

[0064] Continue to refer to Figure 2A traction agent source 177b is positioned at the point where the fiber 130 exits the adhesive coating station 110 to introduce traction agent particles 178b onto the wetted fiber 130. In some embodiments, the traction agent source 177b is positioned above the fiber 130 and is equipped with one or more vibrators or other agitators to evenly distribute the desired amount of traction agent particles 178b onto the fiber 130 under gravity. In other embodiments, the traction agent particles 178b may be entrained in a compressed air stream and sprayed onto the fiber 130. In still other embodiments, the traction agent particles 178b may be mixed with a liquid before being sprayed onto the fiber 130.

[0065] In some embodiments, the particle size of the traction agent particles 178b is between 54 mesh (0.012 inches) and 220 mesh (0.0012 inches). The traction agent particles 178b are applied to the fiber 130 at a rate corresponding to the process speed.

[0066] Before the adhesive hardens, traction agent particles 178a and 178b are applied to the fiber 130 and the adhesive. Traction agent sources 177a and 177b may be integrated into the assembly line 100 individually or in combination. For example, in one embodiment, the assembly line 100 includes only traction agent source 177a, such that traction agent particles 178a are applied to the fiber 130 only through the resin mixture. In another embodiment, the assembly line 100 includes only traction agent source 177b, such that traction agent particles 178b are applied only to the already wetted fiber 130. In yet another embodiment, the assembly line 100 includes both traction agent sources 177a and 177b, such that traction agent particles 178a are applied to the fiber 130 as part of the resin mixture, while traction agent particles 178b are applied to the wetted fiber 130 as it leaves the adhesive coating station 110.

[0067] Figure 18 One possible embodiment of traction agent particles 278 is shown, which can be applied to the outer surface of resin-coated fiber 130 in place of traction agent particles 178b. A mold 180 can capture the traction agent particles 278 and apply them to the circumference of the resin-coated fiber 130. In some embodiments, traction agent particles 178a are omitted entirely, such that the traction agent particles 278 are not mixed with the resin before the resin is applied to the fiber.

[0068] Extensive research and testing were conducted to determine feasible traction agent options suitable for low-viscosity resins. One ideal parameter during these studies and tests was limited abrasiveness to metals, such as polymer materials. Some tested traction agents caused significant wear to the mold, which was undesirable. Another ideal parameter was a sharp, angular overall shape. This shape provides a larger surface area, thereby increasing the friction between fiber 130 and mold 180. Yet another ideal parameter was that the material should possess properties such as brittleness, crushability, and fragility to ensure that it does not expand after being compressed between fiber 130 and mold 180. Furthermore, it was advantageous if the material was inexpensive and readily available (e.g., as waste material).

[0069] The illustrated traction agent particles 278 are sharp, irregular, and angular. Each individual particle 278 typically has multiple irregular angles within a single particle. In some embodiments, the traction agent particles 278 have a significant aspect ratio between their average length and average width. For example, the aspect ratio is typically at least 10:1. The traction agent particles 278 do not cause significant wear to the mold. The traction agent particles 278 are porous and do not expand under pressure. Figure 17 The material shown contains phenolic open-cell foam particles.

[0070] Figure 19 Another possible implementation of traction agent particles 378 is shown, which can be applied together with traction agent particles 278 to the outer surface of the resin-coated fiber 130, replacing traction agent particles 178b. A mold 180 can capture traction agent particles 278 and 378 and apply them to the perimeter of the resin-coated fiber 130. In some embodiments, traction agent particles 178a are omitted entirely, such that traction agent particles 278 and 378 do not mix with the resin before the resin is applied to the fiber.

[0071] The traction agent particles 378 shown in the illustration are sharp and elongated in shape. Each individual particle 378 typically has multiple irregular angles within a single particle. The traction agent particles 278 and 378 do not cause significant wear to the mold. Figure 19 The materials shown include phenolic open-cell foam particles 278 and relatively large (60-80 mesh) polymer abrasive particles 378. The phenolic open-cell foam particles and polymer abrasive particles are available as waste materials at extremely low cost.

[0072] Reference Figure 2 , 4 Assembly line 100 also includes a continuously malleable translational die 180 that wraps the wetted fiber 130 as it leaves the adhesive coating station 110. The illustrated die 180 is from a roll 185 (… Figure 4The paper tape is fed out. The paper mold 180 moves along the central axis 120 next to the moistened fiber 130, and a series of Teflon guide plates 190 gradually wrap the mold 180 around the moistened fiber 130 until the mold completely surrounds and wraps the moistened fiber 130. Figure 8 and Figure 9 When the moistened fiber 130 enters the first part of the mold 180 or the inlet 195, the fiber 130 is compressed, changing from a relatively large rectangular area to a smaller and roughly circular area corresponding to the diameter of the mold at the inlet 195.

[0073] The mold 180 passes through the rest of the assembly line 100 along with the moistened fiber 130. As described below, the mold 180 facilitates the passage of the moistened fiber 130 through the molding station 115 by preventing the moistened fiber 130 from adhering to the molding station 115. Furthermore, the mold 180 constrains the moistened fiber 130 during the curing process, promoting mixing of the adhesive with the fiber 130 to ensure adequate impregnation and helping to maintain stable curing pressure and temperature.

[0074] The process speed or product output of assembly line 100 and any other continuous FRP manufacturing process is determined by the following formula:

[0075] Because the continuously malleable and translatable die 180 moves together with the wetted fiber 130, its length can be greater than that of a typical pultrusion process ( Figure 1The static die 30 used in the assembly line 100 is several times longer. Therefore, the process speed of the assembly line 100 can be several times higher than that of a typical pultrusion process. For example, if the translation die length is 2,000 feet and the adhesive takes 2 minutes to harden, the potential process speed of the assembly line 100 can reach 1,000 feet per minute. In some embodiments, the assembly line 100 is configured to have a process speed greater than about 20 feet per minute. In other embodiments, the assembly line 100 is configured to have a process speed of about 20 feet per minute to about 50 feet per minute. In other embodiments, the assembly line 100 is configured to have a process speed of about 50 feet per minute to about 100 feet per minute. In other embodiments, the assembly line 100 is configured to have a processing speed of about 100 feet per minute to about 250 feet per minute. In other embodiments, the assembly line 100 is configured to have a processing speed of about 100 feet per minute to about 500 feet per minute. In other embodiments, assembly line 100 is configured to have a processing speed of about 100 feet per minute to about 1,000 feet per minute. In other embodiments, assembly line 100 is configured to have a processing speed of about 20 feet per minute to about 100 feet per minute. In other embodiments, assembly line 100 is configured to have a processing speed of about 20 feet per minute to about 1,000 feet per minute. In other embodiments, assembly line 100 is configured to have a processing speed of about 100 feet per minute to about 1,000 feet per minute.

[0076] The paper mold 180 may be coated with a release agent (such as silicone) to facilitate removal of the paper mold 180 from the finished structural composite material. Furthermore, the paper mold 180 may have relatively high porosity to allow gases and vapors to escape through it. Alternatively, the mold 180 may be substantially airtight.

[0077] In some embodiments, the paper mold 180 includes water-soluble paper that dissolves in the concrete during the concrete hardening process, thereby bonding the resin to the concrete. In some embodiments, the water-soluble paper includes printed paper with acidic ink that reacts with the concrete, causing the water-soluble paper to dissolve.

[0078] The mold 180 may comprise other substrates or combinations of materials and be applied to the moistened fiber 130 in various ways. For example, in some embodiments, the mold 180 may comprise a powder or liquid (e.g., molten wax) applied to the moistened fiber 130 and subsequently cured or hardened by ultraviolet light, temperature, chemical reactants, or other suitable means. In other embodiments, the mold 180 may comprise a breathable microporous membrane, such as GORE-TEX. In other embodiments, the mold 180 may comprise a macroporous material, such as woven fabric or fiber felt. In still other embodiments, the mold 180 may comprise one or more metal films, such as non-sacrificial stainless steel, carbon steel cladding, or copper. In some embodiments, the mold 180 encapsulates a mixture of Portland cement and lime around the fiber and resin. The mold 180 is designed to dissolve at least partially in concrete so that the Portland cement and lime can bond with the concrete after the film has at least partially dissolved.

[0079] In some embodiments, mold 108 is a film bonded to an adhesive. In some embodiments, the film is a polymer film and comprises at least a portion of polypropylene and / or polyethylene. Some possible polymer compounds include biaxially oriented polypropylene, biaxially oriented polyethylene, dual-weighted median-correlated oriented polypropylene, dual-weighted median-correlated oriented polyethylene, impact-modified polypropylene, and / or impact-modified polyethylene.

[0080] In some embodiments, mold 180 is a film containing a film additive that allows the resin to bond with resins that would otherwise be difficult to bond with. This film allows for near-complete, or in some cases, complete coverage of the reinforcing steel during manufacturing, enabling it to fuse with the final product. This non-sacrificial mold eliminates most of the odors emitted during manufacturing by sealing and almost completely encapsulating the finished product. In some embodiments, the ends of the product are not covered, but in other embodiments, both ends are at least partially covered. The final product is covered along almost its entire or full length, thereby capturing almost all potential emissions during the curing process. This is a significant advantage for manufacturers using DCPD, TCPD, or any resin that produces volatile organic compounds (“VOCs”).

[0081] This non-sacrificial mold is a rigid, low-elongation film designed for bonding with DCPD and / or TCPD resins while providing the flexural modulus required to compress the impregnated fiber bundle. The non-sacrificial mold is stretched around the impregnated fiber bundle and welded shut using rotary ultrasonic welding technology, resulting in an airtight, pressurized, and continuously bondable mold.

[0082] In addition, the non-sacrificial mold can employ an embossed structure to maximize its mechanical adhesion to the internal impregnated fiber bundles and the external concrete, thereby improving process performance. Figure 22A and 22B An example of an embossed non-sacrificial film mold encapsulating a hardened resin and fiber bundle is shown. Figure 22A and 22B An embossed non-sacrificial film mold 180a is shown. In the illustrated embodiment, mold 180a is a non-sacrificial film that remains on the resin and fiber bundles during installation. Mold 180a includes a plurality of raised elements 196a and a plurality of recessed regions 196b, which together form a textured pattern. The illustrated raised elements 196a form a rhomboid profile, with recessed regions 196b within the rhomboid. Essentially, the raised elements 196a are adjacent helical structures extending in opposite directions along the circumference of a cylinder. Other patterns and configurations of embossing features may also be used; the rhomboid profile shown here is merely an example. This textured outer surface forms a mechanical and chemical bond with the concrete, thereby enhancing the bond between mold 180a and the concrete. In some embodiments, traction particles 178b located beneath the film give the film a textured outer surface. This textured outer surface also enhances the bond between the film and the concrete.

[0083] The mold 180a shown in the figure has been welded together around the beam body by ultrasonic welding. That is, a part of the mold 180a has been welded to another part, thereby fixing the mold 180a around the beam body. The connected and welded ends of the mold 180a form a joint 197a extending longitudinally along the mold 180a. In addition to ultrasonic welding, other methods can also be used to connect the opposite ends of the mold 180a together.

[0084] This non-sacrificial mold addresses global climate and air pollution by essentially eliminating the need for expensive and cumbersome volatile organic compound (VOC) capture, air purification procedures, and activated carbon air purification media waste (or energy for waste incineration). The non-sacrificial mold also reduces process waste, allowing production facilities to be located globally with minimal concerns about air pollution control.

[0085] In some embodiments, the melting points of the traction agent particles 178a, 178b, 278, and 378 are very close to the melting point of the mold 180. This is particularly advantageous for embodiments in which the mold 180 is fixed to the fiber using ultrasonic welding. For example, in some embodiments, the melting points of the traction agent particles 178a, 178b, 2678, and 378 differ from the melting point of the mold 180 by less than 15 degrees Celsius. In some embodiments, the melting points of the traction agent particles 178a, 178b, 2678, and 378 differ from the melting point of the mold 180 by less than 10 degrees Celsius. In some embodiments, the melting points of the traction agent particles 178a, 178b, 2678, and 378 differ from the melting point of the mold 180 by less than 5 degrees Celsius. In some embodiments, the melting points of the traction agent particles 178a, 178b, 2678, and 378 differ from the melting point of the mold 180 by less than 2 degrees Celsius.

[0086] In some embodiments, the mold 180 may be wetted with an adhesive to bond the mold 180 to the matrix composite material, thereby forming an integrated structure comprising all or part of the mold 180. Therefore, the mold material can be selected to impart additional desired properties to the resulting structural composite material. For example, the mold 180 may contain a conductive material to impart conductivity to a composite material that would otherwise be non-conductive. The mold material may have affinity for an external adhesive (e.g., Portland cement), thereby facilitating the integration of the structural composite material (e.g., reinforcing steel) with its specific application (e.g., reinforced concrete).

[0087] Now for reference Figure 2-4 The molding station 115 is located downstream of the adhesive application station 110. In the illustrated embodiment, the assembly line 100 includes first, second, and third molding stations 115, which are located along the central axis 120. Figure 2 The assembly lines 100 and 115 are spaced apart from each other. In other embodiments, the assembly line 100 may include any number of forming stations 115.

[0088] Each forming station 115 includes at least one guiding device for contacting and forming the fiber 130. In some embodiments, the guiding device may include one or more rollers having one or more grooves sized to receive and form the fiber 130. In some embodiments, the guiding device may include one or more stationary or rotating molds having one or more openings sized to receive and form the fiber 130. The grooves on the rollers and the openings on the stationary molds may each have different shapes and sizes to shape the fiber 130 into different shapes and sizes.

[0089] Each forming station 115 shown in the diagram includes multiple rollers 200. These rollers 200 are arranged in pairs, and each roller has a groove 205 through which the fibers 130, which are encased in a mold, are rolled and shaped. Figure 10In some embodiments, the pairs of rollers 200 may employ different positioning orientations. For example, a pair of rollers 200 may alternate between horizontal and vertical orientations. Some or all of the rollers 200 may be driven by a variable-speed drive motor to pull the mold 180 and the fiber 130 through the assembly line 100.

[0090] Refer again Figure 2 and Figure 3 Each forming station 115 may also include a heat transfer plate (not shown) to enable precise control of the process temperature. For example, each forming station 115 may be controlled to maintain the wetted fiber 130 at a stable and controlled temperature that hardens the adhesive at a rate matching the process speed. The specific temperature depends on the type of adhesive used and the process speed of the assembly line. In some embodiments, phenolic resin is used as the adhesive, and the fiber is maintained at a temperature of about 160 degrees Celsius. In some embodiments, epoxy resin is used as the adhesive, and the fiber is maintained in a temperature range of about 50 to about 90 degrees Celsius. In embodiments using low-viscosity resins (such as DCPD and / or TCPD), preheating may not be necessary. However, in some cases, preheating the fiber to a temperature of about 25 degrees Celsius to about 105 degrees Celsius allows for a slightly faster processing speed. Therefore, the adhesive hardening process can be completed as the formed and wetted fiber 130 passes through the forming station 115. Alternatively, the wound fiber can be cut to the desired length, removed from the forming station 115, and then placed in a designated location to harden for a certain period of time. In some configurations, the designated location is heated to promote hardening.

[0091] Multiple temperature control zones can be provided along the length of each forming station 115 to adjust the hardening rate of the die 180 along its length. Rollers 200 apply pressure to the die 180 to provide the required hardening pressure. As the die 180 and fiber bundle 130 pass between adjacent forming stations 115, the product can be cooled as needed (either by exposure to the environment between adjacent forming stations 115 or by controlled cooling zones), and gaseous or vaporous byproducts can be discharged through the die 180. This is not feasible in typical pultrusion processes because the static die 30 ( Figure 1 The material is typically airtight. In some embodiments, one or more molding stations 115 cool the mold 180 and fiber 130 to a level below the glass transition temperature of the binder. Therefore, the mold 180 and fiber 130 exiting the molding station 115 are able to retain their shape. In other embodiments, the mold 180 and fiber 130 are not cooled below the glass transition temperature before leaving the molding station 115, so that the mold 180 and fiber 130 are ultimately shaped into the desired final shape and / or form any surface structures (e.g., ribs, protrusions, grooves, and / or other suitable surface structures).

[0092] In typical processes, the gaps between workstations must be minimized to provide adequate support for the fibers throughout the entire length of the assembly line. In contrast, the forming stations 115 illustrated are spaced apart in the die flow direction because the dies 180 provide sufficient support for the fibers 130 between the forming stations 115. The gaps between the forming stations 115 allow air and water to escape from the dies 180 and the fibers 130. Furthermore, the distance covered by the spaced-apart forming stations 115 is greater than when the forming stations 115 are directly adjacent. This increased overall distance between the forming stations 115 allows the dies 180 to pass through the forming stations 115 at a faster speed, while the fibers still partially or fully harden within the forming stations 115. Therefore, by using more and spaced-apart forming stations 115, process speed can be increased, thereby improving productivity and profitability. The spacing between the forming stations 115 also reduces the construction and installation capital costs of the assembly line compared to a layout where forming stations are adjacent throughout the entire length of the forming apparatus. Molding station 115 can be modularly designed, allowing one or more molding stations 115 to be added, removed, or repaired without significant production loss. Unlike equipment using a single fixed mold (which typically requires shutting down the entire assembly line), adding, removing, or replacing one or more molding stations 115 can be accomplished with only a short production stoppage. Removed molding stations 115 can be repaired or stored while the assembly line is running.

[0093] Reference Figure 11-16 One or more molding stations 115 can also dynamically manipulate the mold 180 and the fiber 130 to promote adequate wetting and uniform hardening. Wetting can be improved by dynamically altering the shear viscosity changes induced by the cross-sectional area of ​​the matrix composite. Shear mixing of the matrix composite can be further induced by selectively increasing or decreasing the mechanical pressure applied by the molding station 115. In some embodiments, the molding station 115 can be configured to keep the fiber 130 in a partially wetted state to improve the flexibility of the fiber 130 after hardening.

[0094] In some embodiments, the guiding device may be configured to progressively increase the applied mechanical pressure along the length of the die 180. In some embodiments, the pressure increase is achieved by passing the fiber 130 through a tapered fixed die whose opening diameter gradually decreases along its length. In other embodiments, the increase in mechanical pressure can be achieved by passing the fiber 130 through a series of fixed dies, each with a progressively smaller opening size. In some embodiments, the holes in the fixed dies may have openings of different shapes and sizes to dynamically change the cross-sectional shape of the die 180 and the fiber 130.

[0095] exist Figure 11In the illustrated embodiment, roller 200 is configured to progressively increase the applied mechanical pressure along the length of die 180. Therefore, the cross-sectional area of ​​die 180 may gradually decrease with each pair of rollers 200 passing through. This facilitates adequate wetting and compaction of the fibers 130. In other embodiments, roller 200 may be configured to dynamically change the cross-sectional shape of die 180 and fibers 130. Figure 12-15 For example, the die 180 can be rolled into an elliptical shape and exhibit different orientations at alternating pairs of rollers 200 to facilitate further shear mixing. Figure 12 Alternatively, die 180 can be rolled into various other shapes, such as ovals, circles, rectangles, squares, triangles, etc. (see example) Figure 13 In other embodiments, one or more forming stations 115 may cause the die 180 and fiber 130 to twist about a central axis 120. Figure 14 In other embodiments, one or more molding stations 115 may alternately increase and decrease the cross-sectional area of ​​the mold 180. Figure 15 In other embodiments, the rollers 200 may be arranged in an offset manner to form corrugations on the die 180 and the fiber 130. Figure 16 Each forming station 115 may employ rollers 200 in different arrangements and configurations and / or fixed molds.

[0096] In some embodiments, assembly line 100 may further include an ablation station 210 for thermally grinding the hardened surface of the composite structure. Figure 2 Ablation station 210 can be used to remove molds, expose areas of fibers, and / or form carbonaceous coke that may have an affinity for external adhesives such as Portland cement.

[0097] In some embodiments, assembly line 100 may further include a post-curing station 215. The post-curing station 215 may include one or more heating elements to provide necessary secondary curing time and temperature control. Furthermore, the post-curing station 215 may also include one or more processing devices for processing the structural composite material into the desired final shape. For example, the structural composite material may be bent or cut and folded into C-groove shapes, spiral shapes, or other desired shapes.

[0098] In some embodiments, assembly line 100 may further include packaging station 220. Packaging station 220 may include one or more cutting devices for cutting the structural composite material into desired lengths suitable for sale and transport. Product information, brand information, or other markings may be affixed to the structural composite material before packaging for shipment.

[0099] During operation, multiple fibers 130 are fed from the thread station 105 and move along the assembly line 100 to the adhesive coating station 110. The fibers 130 typically enter the adhesive coating station 110 in a spaced-out arrangement, such that the fibers 130 cover a first, relatively large surface area. The fibers 130 are wetted with adhesive, or in some embodiments, with an adhesive mixture containing a traction agent. In some embodiments, a traction agent is applied to the wetted fibers 130 as they leave the adhesive coating station 110.

[0100] Subsequently, the moistened fibers 130 are guided to the first portion 195 of the mold 180 near the adhesive coating station 110, and the mold 180 is curved to wrap around the moistened fibers 130. As the mold 180 wraps around the moistened fibers 130, the fibers 130 are compressed against each other. The moistened fibers 130 wrapped by the mold 180 are then fed into the forming station 115.

[0101] In molding station 115, mold 180 and moistened fibers 130 are compressed between guiding devices (e.g., roller 200 or stationary mold) to mix the adhesive with the fibers 130, thereby forming a product shape. Mold 180 separates the moistened fibers 130 from roller 200 and / or stationary mold to prevent the adhesive from adhering to roller 200 and / or stationary mold. Throughout molding station 115, heat is applied to promote the hardening of the adhesive. As mold 180 moves between adjacent molding stations, the matrix may cool and / or vent gaseous byproducts.

[0102] During the molding process, the traction agent particles 178a are dispersed between the fibers 130 and increase the friction between adjacent fibers 130. Figure 17 Therefore, the traction agent reduces interlaminar slippage, resulting in a more consistent and robust structural composite material. The traction agent particles 178a also fill the voids between the fibers 130, promoting resin penetration and imparting the desired thixotropy.

[0103] In some embodiments, traction agent particles 178b, 278, 378 may be applied to mold 180 and / or fiber 130 before or after hardening is complete. The traction agent particles 178b, 278, 378 may be selected to improve the physical bond properties between the final composite material composed of fiber 130 and binder and the material to which the final composite material will be attached (e.g., concrete).

[0104] Before hardening, the fiber 130 may need to be bent to form a non-linear shape, such as a curve or bend. In some embodiments, the die 180 remains surrounding the fiber 130 while it is being bent.

[0105] To create structurally robust corners using anisotropic fiber-reinforced composites, it is essential to understand that the length of a single fiber must differ (i.e., be shorter) on the inner side of the radius compared to the outer side. Therefore, when manufacturing components with one or more radii of curvature, a set of twisted fibers is required to bend this twisted and linearly aligned fiber assembly around these radii. Alternatively, a suitable corner can be created if individual fibers are allowed to slip or displace relative to adjacent fibers to accommodate fiber shaping around the radius. The mold 180 can be a flexible film component that accommodates and surrounds the fiber while allowing linear movement of the fiber relative to adjacent fibers. Fiber winding processes can utilize fibers of varying lengths to form radii.

[0106] In some embodiments, the mold 180 is a sealed polymer film that forms a skin, allowing the internal fibers and resin to slide relative to adjacent fibers during high-speed manufacturing, thereby producing a commercially viable shape.

[0107] In some embodiments, the mold 180 is a polymer film with a greater degree of stretch on the outer side of its radius of curvature than on the inner side. In some embodiments, the mold 180 can absorb a large amount of odor released by the resin, thereby allowing production to be carried out in locations close to residential areas. In some embodiments, the mold 180 is a polymer film that can trap loose fibers, thereby forming a protective surface that substantially prevents personnel operating the mold 180 and the fibers 130 from being scratched.

[0108] In some embodiments, the mold 180 is a polymer film, and the interfaces between the polymer film and the fibers, as well as the interfaces between adjacent fibers, allow relative movement of the fibers with respect to the polymer film and adjacent fibers. This relative movement enables the fibers to form corners, and fiber clustering at the corners is limited, or in some cases, completely absent. Fiber clustering, or small gaps between adjacent fibers at bends, can create weak points. The relative movement of the fibers with respect to the polymer film and with respect to adjacent fibers also suppresses the formation of gaps between adjacent fibers, thereby maintaining the material properties of the fiber 130 even when the fiber bundle shape is non-linear.

[0109] In some embodiments, the finished product can be made into a circle, square, trapezoid, hook shape, and other shapes. In some embodiments, the finished product can be made into a bent part with different radii of curvature, bending angles, and leg lengths.

[0110] To meet ASTM specifications, composite rebar elbows made of glass fiber reinforced polymer (GFRP) steel bars must be molded after the fibers are wetted with resin but before the resin hardens. This means that the resin-wetted fibers need to be wound onto a mandrel before curing. To date, this post-fiber impregnation process has been primarily done manually, with limited automation. Figure 20 Examples of four possible complex shapes are shown in A through 20D. Currently, there is no feasible solution in the industry to automate the forming of GFRP with different bends and shapes, for example... Figure 20 Example shapes are shown in A to 20D.

[0111] Because of the anisotropy of equal-length fibers when multiple strands are wound around corners, it is difficult to produce straight impregnated fibers of the appropriate diameter and bend them around specific corners while maintaining their overall circular shape. The outer fibers remain taut, while the inner fibers relax, spreading horizontally or wrinkling to compensate for the uneven length. Rope manufacturers (wire, hemp, and polymers) have long compensated for this deficiency by twisting multiple strands of fibers around a central axis to create flexible ropes that can bend around corners without flattening. These twisted fibers can be further twisted to produce ropes with larger diameters.

[0112] The applicant has not observed this principle being used in the composite materials industry. Clearly, completing this twisting process before the individual glass fibers are impregnated with resin but before they harden would offer the same advantages.

[0113] The challenge in manufacturing these curved components lies in the fact that their shapes are often double-ended. Shapes like circles, squares, or hexagons are easy to create by winding them into sturdy components. However, manufacturing any of the standard shapes listed below is more difficult and usually requires manual work.

[0114] The process of forming the desired shape begins by fixing the impregnated fiber bundle at the starting point, and then... Figure 21A As shown, one end is wound around a fixed mandrel, and the other end is wound around a rotatable mandrel. The position of the rotatable mandrel can be adjusted to obtain the desired rope length. The rotatable mandrel then rotates a set number of turns, thus forming a rope as shown... Figure 21B and 21C The image shows a straight fiber segment with loop structures at both ends. In some cases, a small servo motor can be installed at the drive end of the rope to generate the desired twist by winding and twisting the original rope.

[0115] To create various non-linear shapes, the rope is guided around adjustable corners, such as... Figure 21DThe corner of the XYZ stage is shown. This process can quickly form the desired shape without deformation of the corner. By using multiple stages driven by an automated system, the equipment can operate in an intermittent continuous mode, minimizing cycle time and eliminating the need for cleaning. The fibers are shaped into a non-linear form before the resin begins to harden.

[0116] Furthermore, twisting the impregnated fibers while maintaining tension can enhance the impregnation effect and form ridges on the outer surface, making it possible for finished parts to be used directly without secondary processing.

[0117] The features of this disclosure are set forth in the following claims.

Claims

1. A method for installing a non-metallic structural member in concrete, the non-metallic structural member comprising a plurality of fibers and resin at least partially wrapped with a membrane; The film chemically bonds with the resin; the method includes: Position the non-metallic structural component at a predetermined location; After the non-metallic structural member is positioned at the predetermined location, it is at least partially encased in concrete. Harden the concrete surrounding the non-metallic structural member; and During the hardening of the concrete, a bond is formed between the membrane of the non-metallic structural member and the concrete.

2. The method of claim 1, wherein the film comprises a polymer compound comprising at least a portion of polypropylene and / or polyethylene, such that the polymer compound is capable of chemically bonding with the concrete during the hardening of the concrete.

3. The method of claim 2, wherein the film comprises at least one of the following materials: biaxially oriented polypropylene, dual-weighted median-correlated oriented polypropylene, or impact-modified polypropylene.

4. The method of claim 2, wherein the film comprises at least one of the following materials: biaxially oriented polyethylene, dual-weighted median-correlated oriented polyethylene, or impact-modified polyethylene.

5. The method of claim 1, further comprising encapsulating the fiber and resin at least partially within the film to reduce odors released by the resin during curing.

6. The method of claim 1, further comprising mixing Portland cement and lime with the resin before at least partially coating the fibers and resin with the film, such that the Portland cement and lime are configured to bond with the concrete after the film has at least partially dissolved.

7. The method of claim 1, wherein the film comprises a water-soluble paper configured to dissolve in the concrete during the hardening of the concrete to allow the resin to bond with the concrete; and the water-soluble paper comprises printed paper printed with acidic ink, wherein the acidic ink is configured to react with the concrete, thereby causing the water-soluble paper to dissolve.

8. The method of claim 1, wherein a mechanical bond is formed between the film and the concrete through contact between the concrete and one or more embossed features of the film.

9. The method according to claim 1, wherein the bonding between the non-metallic structural member and the concrete is enhanced by contact between the concrete and the textured outer surface of the non-metallic structural member.

10. The method of claim 1, wherein the method comprises shrinking the film surrounding the resin and fibers after at least partially covering the resin and fibers with concrete and before at least partially covering the non-metallic structural member.

11. The method of claim 1, wherein the resin comprises at least one of the group consisting of dicyclopentadiene and tricyclopentadiene.

12. The method of claim 1, wherein the plurality of fibers and resin are at least partially encapsulated in the film before the film is chemically bonded to the resin; subsequently, a portion of the film is ultrasonically welded to another portion of the film around the plurality of fibers and resin.

13. The method of claim 1, wherein before the film chemically bonds with the resin, the method further comprises: The non-metallic structural component is bent into a non-linear shape; In response to bending, the film is stretched, and the fibers slide relative to one or more adjacent fibers; The resin is hardened after the film is stretched and the fibers are slidable, and The non-metallic structural component is held in the non-linear shape.

14. The method of claim 13, wherein prior to chemical bonding of the film with the resin, the method comprises sliding the fibers relative to the film.

15. The method of claim 1, wherein the resin and the fiber form a bundle, and the method further comprises positioning a plurality of particles between the film and the bundle, wherein the melting point of the film differs from the melting point of the particles by no more than 15 degrees Celsius.

16. The method of claim 15, wherein the melting point of the film differs from the melting point of the particles by no more than 5 degrees Celsius.

17. The method of claim 15, wherein the particles comprise one or more of the following: phenolic open-cell foam particles, or polymer abrasive particles.

18. A non-metallic structural component used in the method of claim 1.

19. A non-metallic structural member configured to be placed in concrete, the non-metallic structural member comprising: Multiple fibers and resins; A film that at least partially covers the plurality of fibers and resin, the film being chemically bonded to the resin; The non-metallic structural member is configured to be placed in a predetermined position; The non-metallic structural member is configured to be at least partially surrounded by concrete after being positioned at the predetermined location; The non-metallic structural member is configured to remain in the concrete during the hardening process of the concrete; as well as The membrane of the non-metallic structural member is configured to bond with the concrete during the hardening process of the concrete.

20. The non-metallic structural member of claim 19, wherein the film is configured to at least partially cover the plurality of fibers and resin before the film is chemically bonded to the resin; subsequently, a portion of the film is configured to be ultrasonically welded around the plurality of fibers and resin to another portion of the film.

21. The non-metallic structural member of claim 19, wherein the film comprises a polymer compound comprising at least a portion of polypropylene and / or polyethylene, such that the polymer compound is capable of chemically bonding with the concrete during the hardening of the concrete.

22. The non-metallic structural member of claim 19, wherein the film comprises at least one of the following materials: biaxially oriented polypropylene, dual-weighted median-correlated oriented polypropylene, or impact-modified polypropylene.

23. The non-metallic structural member of claim 19, wherein the film comprises at least one of the following materials: biaxially oriented polyethylene, dual-weighted median-correlated oriented polyethylene, or impact-modified polyethylene.

24. The non-metallic structural member of claim 19, wherein the film comprises a water-soluble paper configured to dissolve in the concrete during the hardening of the concrete to allow the resin to bond with the concrete; and the water-soluble paper comprises printed paper printed with acidic ink, wherein the acidic ink is configured to react with the concrete, thereby causing the water-soluble paper to dissolve.

25. The non-metallic structural member of claim 19, further comprising mixing Portland cement and lime with the resin before at least partially coating the fibers and resin with the film, such that the Portland cement and lime are configured to bond with the concrete after at least partially dissolving the film.

26. The non-metallic structural member of claim 19, wherein the film at least partially encapsulates the fiber and resin, thereby reducing the odor released by the resin during the curing process.

27. The non-metallic structural member of claim 19, wherein the non-metallic structural member has a textured outer surface for bonding with the concrete, thereby enhancing the bond between the non-metallic structural member and the concrete.

28. The non-metallic structural member according to claim 19, wherein the resin comprises at least one of the group consisting of dicyclopentadiene or tricyclopentadiene.

29. The non-metallic structural member according to claim 19, wherein, The film is configured to shrink around the resin and fibers after the film has at least partially surrounded the resin and fibers and before the non-metallic structural member has at least partially surrounded by the concrete.

30. The non-metallic structural member according to claim 19, wherein before the film chemically bonds with the resin, The non-metallic structural member is configured to be bent into a non-linear shape; In response to bending, the film is configured to stretch, and the fibers are configured to slide relative to one or more adjacent fibers and / or relative to the film; The resin is configured to harden after the film is stretched and the fibers slide, and The non-metallic structural member is configured to remain in the non-linear shape after the resin has hardened.

31. The non-metallic structural component according to claim 19, wherein the resin and fiber form a bundle, and further comprises a plurality of particles located between the film and the bundle, wherein the melting point of the film differs from the melting point of the particles by no more than 15 degrees Celsius.

32. The non-metallic structural component according to claim 31, wherein the melting point of the film differs from the melting point of the particles by no more than 5 degrees Celsius.

33. The non-metallic structural component according to claim 31, wherein the particles include one or more of the following: phenolic open-cell foam particles, or polymer abrasive particles.

34. The non-metallic structural member of claim 19, wherein the film includes one or more embossed features for bonding with the concrete, thereby enhancing the bond between the film and the concrete.

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