BEAMS MADE OF STONE AND TENSIONABLE MATERIAL

Description

[0001] The present invention relates to the development of a standard profile commonly used in the construction industry, which is now usually made of steel material, known as a T-beam or double-T-beam.

[0002] Such a beam consists of three elongated plates connected longitudinally and arranged at right angles to each other. It has a compression-resistant top flange and a tension-resistant bottom flange, also called a flange, as well as a web connecting the top and bottom flanges, which is typically arranged symmetrically in the center of the flanges. There are also U-profiles with a web on one side, or box sections with two webs on the sides.

[0003] The invention also relates to such or similar and other profiles, such as: P-profile with parallel inner surfaces of the flanges, also known as "Peiner" or Peiner beam; U-profile with inclined inner surfaces of the flanges; U-profile with parallel inner surfaces of the flanges; T-profile, equal-leg; L-profile (also Angle iron, angle profile or Angle bracket ) as well as all possible variations of box profiles and V-profiles, and combinations of these profiles

[0004] Such profiles achieve an optimal load-bearing capacity for the respective application in relation to the mass of the material used and thus its weight.

[0005] In I-beams, the height of the central web essentially determines the beam's stiffness. Secondary measures for increasing stiffness include specifically increasing the tensile strength of the bottom chord and the compressive stiffness of the top chord. Since such beams are made of hot-rolled steel, the top and bottom chords are, for the sake of simplicity, identical.

[0006] The advantage of steel beams of this type is their low cost and ability to be manufactured in large quantities, as well as their reliable load-bearing capacity. Defects are rare in such profiles and can be disregarded in practical use. Furthermore, additional steel components for connecting beams to other load-bearing elements can easily be welded on-site as needed, at any time and at any point.

[0007] The disadvantage is steel's extremely high specific gravity of 7.8 g / cm³ and the fact that steel production is associated with large amounts of energy and high CO₂ emissions. Currently, only aluminum beams are available as a replacement for steel; while lighter, they have an even larger ecological footprint than steel. For this reason, the quantities of mass-produced steel required cannot be achieved with aluminum.

[0008] For this reason, steel is generally considered an indispensable building material, which is seemingly irreplaceable even from a climate protection perspective, which is why work is being done on reducing steel through hydrogen, although this makes steel production even more energy-intensive.

[0009] However, recent reports by SITRA, commissioned by the Finnish government, make it clear that today's quantities of steel, aluminum, and cement alone will account for the remaining CO2 emissions until 2100 if the 2°C target of the Paris Climate Agreement is to be met. This fact strongly suggests that the paradigm of steel and other metals as indispensable must first be reconsidered.

[0010] EP 106 20 92 and EP 273 94 71 describe how steel and aluminum can be replaced by a combination of stone and carbon fiber laminate (CFRP - carbon fiber composite) if the stone's lack of tensile strength is compensated for by the extremely high tensile strength of the carbon fiber. The bond between the stone and the fiber is created using resins, such as oxide resins or high-temperature-resistant binders based on water glass and silicone, which are capable of crosslinking or bonding with the carbon material. Under certain conditions, these bonds also create a prestress that can be permanently incorporated during or through the bonding process.

[0011] The DE 20 2006 009793 This describes how rectangular stone rods help keep stone slabs flat and straight, protecting them from breakage, by using layers of carbon fiber and stone. The stabilizing stone slabs, which meet orthogonally, can be coated on one or both sides to stabilize each other through their interlocking arrangement. What's missing here is a penetration of the stabilizing fiber layer; they simply meet.

[0012] The FR 2 422 001 A1 It describes how bundled fiber strands are inserted into a "tunnel" in the stone to stabilize it, and how stone sections pre-stabilized in this way are extended and assembled into rigid, box-shaped components. The fiber ends of orthogonally arranged stone slabs can touch each other, or rather, they merely meet without overlapping. The stabilizing fiber is not inserted as a layer.

[0013] The EP 4 025 744 The system utilizes fiber-reinforced concrete slabs connected to columns and support plates through interlocking geometry. These are rigid concrete slabs, not profiles intended to replace steel. Here, the fiber is not incorporated as a layer of long fibers in the typical orientation of CFRP matrices, but rather as unoriented short fibers homogeneously distributed within the compression-resistant concrete material.

[0014] A composition is not described. of stone partsto load profiles with layered structures that are explicitly designed to carry loads exceeding the entire to transfer the force over the length of the component, as in the example of a double-T beam, which must elastically absorb very high loads and bending forces in the middle and still withstand these loads without breaking or sustaining damage, which is not possible without a spatially complete force transmission between orthogonally arranged and interlocking structures made of tensile-strength fiber-stone layers over the entire length of the component, since the component must not fail at a single point in its application in the construction sector, which would lead to the overall failure of the beam if it is bent.

[0015] The invention describes a way in which such a double-T beam can be constructed. for exampleIt can be designed to transfer the use of the CFRP-stone composite (CFS - CarbonFiberStone) to practical and optimized structures or geometries, as known in the construction industry. The technical implementation is shown in Figures 1 to 8. for example This is illustrated for a double-T beam and a single T-beam. The main challenge is to force-fit the perpendicular surfaces together without local stress concentrations causing premature local failure and ultimately leading to complete failure of the geometry. The force-fit between the surfaces is achieved primarily using adhesives. This applies to the fabrication of the CFRP-block composite (CFS) as well as to the joining of the CFS components themselves. For this purpose, the base plate material is first cut into Figure 1 manufactured which arranges the carbon layer (4) exemplarily (previous claim 2) centrally between two stone slabs or exemplarily also provides a configuration with stone in the middle between two fiber layers (previous claim 3), or which tensile-stabilized the stone slabs with at least one tensile-stable layer (previous claim 1) or is arranged in a multi-layered structure of stone and fiber layers (previous claim 4).

[0016] The parts to be joined are then dovetailed, just as in carpentry, wooden panels are prepared with dovetails to optimize the orthogonal connection of wooden panels. In wood, too, the effect is ultimately utilized that orthogonally meeting fiber layers are joined together in an overlapping or overlapping manner, since butt joints without geometric overlap would rely solely on the adhesive's force-fit, which would ultimately fail quickly due to its insufficient tensile strength. By dovetailing the transitions, the force transfer from one tensile-resistant plane to the orthogonally positioned tensile-resistant plane is almost completely achieved when the two tensile-resistant planes—in our example, the carbon layers arranged in the stone layer shown in Figures 1 to 8—intersect spatially in cross-section.

[0017] Fracture tests have demonstrated that a double-T beam made of CFS panels can bear similarly high loads as a comparable steel beam. However, the CFS beam is significantly lighter, as stone, with a specific gravity of 2.8 g / cm³, is considerably lighter than steel. Furthermore, stone and carbon together produce significantly fewer CO₂ emissions during manufacturing than steel. Savings of 30–50% can be expected. The overall structure exhibits elasticity in fracture tests, without the zinc bond failing when the beam deflects.

[0018] To ensure sufficient tensile strength in the bottom chord, only relatively thin and lightweight layers of carbon are needed, which further reduces the overall weight relative to the total volume. Compressive stiffness in the top chord and web is achieved through the stone component. Besides carbon, many other fiber materials can be used that have a significantly smaller ecological footprint than carbon fibers. Depending on the application, glass fibers, basalt fibers, stone fibers, steel fibers, and flax fibers are also suitable examples. However, carbon fiber is of particular importance from a technical perspective because, unlike most other fibers, it possesses a significantly higher tensile stiffness. This is especially true for graphene-based structures, which, while not technically a fiber, is a potential reinforcement material for the future.

[0019] Another effective measure to further reduce the carbon footprint is the production of carbon and graphene from sustainable resources, for example, from algal oil or other plant-based oils from algae or yeast, carbon fibers from lignin (i.e., from wood waste from paper production), or carbon fibers from synthetically produced methanol using the extended Fischer-Tropsch synthesis and water-gas shift reaction. Graphene can also be produced directly from CO₂ using electrical energy. In these cases, a portion of the building material—in the case of a tensile-strength layer made of carbon fibers or graphene—originates primarily from CO₂ sources, with the carbon, previously harmful to the climate in the form of CO₂, now permanently bound in the fiber and thus also in the building material in solid form. This is another reason why carbon fiber is of particular importance as a tensile-strength material.

[0020] One of the many possible embodiments of the invention describes in Figure 1 and Figure 2 a CFS plate (1) as top chord and a second stabilizing CFS plate (2) underneath as bottom chord, each with an internal carbon layer (4) in the plates, wherein a web (3) made of CFS, also with an internal carbon layer, is arranged perpendicular to the plates (1) and (2), stiffening the overall arrangement. The Figure (1 ) shows the galvanizing with the projections (5) and cutouts (6) of all plates These features allow the plates to have interlocking structures that ensure a force-fit connection across the plates when they are bonded together using adhesives. The optimization of the components is achieved by giving the top chord a higher proportion of stone than the bottom chord, and vice versa. This also optimizes the carbon footprint.

[0021] Figures 3 and 4 show the structure of the Fig. 2in cross-section (FF) and (GG), with which the two plates (1) and (2) are connected using from galvanizing mechanically force-fit connected via the CFS plate (3).

[0022] For example, in the Figures 5 to 8 The same is shown for a T-beam. The two designs are representative of the principle of connecting the CFS panels using dovetail joints on the adhesive edges, in order to connect all possible other structures at right angles or oblique angles and with a force-fit connection by ensuring that the tensile-stabilized stone panels overlap in a cross-sectional line.

Claims

1. A profile carrier comprising two (1,3) or more plates (1,2,3) made of natural stone or mineral-bound stone powders, glass, or ceramic-hereinafter stone plates-wherein each stone plate is mechanically tensile-stabilized by at least one or two tensile-stable fiber layers (4), or wherein each stone plate consists of two or more stone layers which are tensile-stabilized by a fiber layer or by a different sequence of multiple fiber layers (4) alternating with stone layers, characterized in that the fiber-stabilized stone plates arranged at angles to one another are connected without overlapping or continuous fiber layers, that all plates have precisely matching recesses (6) over their entire length, and that all projections (5) and recesses (6) are configured such that the fiber-stabilized stone plates are connected without penetration of the tensile-stable fiber layers (4), and that the tensile-stable fiber layers (4) of one stone plate completely overlap the tensile-stable fiber layers (4) of the other stone plates in one of their mutually perpendicular planes and are connected in a force-locked manner.

2. The profile carrier according to claim 1, characterized in that the fibers are steel fibers, glass fibers, stone fibers, carbon fibers, aramid fibers, bamboo fibers, wood fibers, flax fibers, or a mixture thereof.

3. The profile carrier according to claims 1 or 2, characterized in that the binding matrix of the carrier is based on epoxy resin, polyester resin, phenolic resin, polyimide resin, cyanate ester resin, vinyl ester resin, polymethane resin, silicone resin, or water-based binders (page 3, line 3), or a mixture of these resins, which preferably have shrinkage properties.

4. The profile carrier according to claims 2 and 3, characterized in that the carbon fibers originate from fossil sources or from renewable sources.

5. The profile carrier according to claims 2 and 3, characterized in that the raw materials for the carbon fibers, the resins, and the adhesives are derived from plants, algae, yeast oils, lignin, or other plant-based raw materials or algal substances.

6. The profile carrier according to claims 2 and 3, characterized in that the raw materials for the carbon fibers, the resins, and the adhesives are derived from plants, algae, yeast oils, lignin, or other plant-based raw materials, which supply PAN-based carbon fibers, graphene, resins, and binders using fermentations, yeast, or biogenic production methods.

7. The profile carrier according to claim 6, characterized in that PAN-based carbon fibers and / or resins and binders are produced synthetically from CO2.

8. The profile carrier according to claim 7, characterized in that the carbon fibers, resins, and adhesives are produced from CO2 using the water-gas shift reaction and the Fischer-Tropsch synthesis.

9. The profile carrier according to claims 1 to 8, characterized in that, in the case of resin- or mineral-bound stone powders, the binder consists of a mixture of resin and mineral adhesion additives having the highest possible temperature stability.

10. The profile carrier according to claims 1 to 9, characterized in that the tensile-stable material is prestressed relative to the compression-stable material or at least a part thereof.