Non-metallic structural member and method of installing

Abstract

The application includes 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 resin at least partially encased in a film. The non-metallic structural member has a textured outer surface. The method includes positioning the non-metallic structural member in a desired location, and then at least partially surrounding the film of the non-metallic structure member with concrete. The film is configured to bond to the resin. The method further includes curing the concrete around the non-metallic structural member, and while the concrete is curing, forming a bond between the film of the non-metallic structural member and the concrete.

Description

Attorney Docket No.206962-9012-WO01 NON-METALLIC STRUCTURAL MEMBER AND METHOD OF INSTALLING CROSS REFERENCE TO RELATED APPLICATIONS

[0001] The present application claims priority to U.S. Provisional Patent Application Number 63 / 600,992, filed November 20, 2023, and claims priority to U.S. Provisional Patent Application Number 63 / 605,979, filed December 4, 2023, the entire contents of both of which are herein incorporated by reference. FIELD OF THE DISCLOSURE

[0002] The present disclosure relates to a method of manufacturing composite materials, and more particularly to a method of manufacturing fiber reinforced polymer materials. BACKGROUND

[0003] Fiber reinforced polymers include a fiber material bound by a matrix, typically provided by a binder, such as a resin. Fiber reinforced polymers are conventionally manufactured using a pultrusion process, an example of which is illustrated in FIG. 1.

[0004] In the pultrusion process, incoming fiber 5 is pulled through a production line 10 by a pulling mechanism 15, such as a pair of driven rollers 20. The fiber 5 is drawn into a bath 25 containing one of a variety of binders. Once wetted, the fiber 5 is drawn through a static die 30 that may have one or more heating zones to initiate curing of the binder. In the pultrusion process, the die 30 serves several functions. It creates pressure to promote wetting of the fiber 5, heats the binder and the fiber 5, controls curing of the binder, and controls the final shape of pultruded product.

[0005] Binders have curing profiles that are dictated by chemical reactions (curing, crosslinking, drying, etc.). These curing profiles are functions of the chemical reactivity of the binder, process temperature, and dwell time at the process temperature. As production speeds increase, it becomes increasingly difficult to ensure proper curing of the binder.

[0006] The conventional pultrusion process illustrated in FIG. 1 has inherent constraints that severely hinder the speed of the process. The length of the die 30 is the primary constraint on theAttorney Docket No.206962-9012-WO01 speed of the process, with process temperature, process friction, and process gas removal providing other limiting constraints. The binder bath 25 presents its own drawbacks, including difficulty mixing and maintaining multi-part, reactive binders, undue amounts of waste, and high operating costs due to the typically large volume of binder needed to fill the bath 25. It has previously not been cost-effective to manufacture fiber reinforced products, especially if one or more fast-curing thermosetting polymers and / or a multi-component thermosetting polymer are utilized as a portion of the binder, for at least the reasons listed above. SUMMARY

[0007] In some embodiments, the disclosure provides a method of installing a non-metallic structural member in concrete. The non-metallic structural member includes a plurality of fibers and resin at least partially encased in a film. The non-metallic structural member has a textured outer surface. The method of installing the non-metallic structural member includes positioning the non-metallic structural member in a desired location, and then at least partially surrounding the film of the non-metallic structure member with concrete. The film is configured to bond to the resin. The method further includes curing the concrete around the non-metallic structural member, and while the concrete is curing, forming a bond between the film of the non-metallic structural member and the concrete.

[0008] In some embodiments, the disclosure provides the non-metallic structural member used in the method of installing the non-metallic structural member in concrete.

[0009] In some embodiments, the disclosure includes a non-metallic structural member configured to be positioned in concrete. The non-metallic structural member includes a plurality of fibers and resin, and a film at least partially encasing the plurality of fibers and resin. The film is chemically bonded to the resin. The non-metallic structural member is positioned in a desired location and is at least partially surrounded with concrete after being positioned in the desired location. The non-metallic structural member remains in the concrete while the concrete cures. The film of the non-metallic structural member forms a bond with the concrete while the concrete is curing.

[0010] In some embodiments, the film is a polymeric compound that includes at least some polypropylene and / or polyethylene, such that the polymeric compound is configured toAttorney Docket No.206962-9012-WO01 chemically bond with the concrete while the concrete is curing. Some possible examples of polymeric compounds include biaxially oriented polypropylene, biweight midcorrelation oriented polypropylene, impact modified polypropylene, biaxially oriented polyethylene, biweight midcorrelation oriented polyethylene, and / or impact modified polyethylene.

[0011] In some embodiments, the method and apparatus include at least partially containing the fibers and resin in the film to thereby reduce the odors emitted by the resin during curing. Optionally, the method and apparatus include shrinking the film around the resin and fibers after at least partially surrounding the resin and fibers and prior to 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 prior to at least partially encasing the fibers and the resin with the film, such that the Portland cement and lime form a bond with the concrete after the film is at least partially dissolved.

[0013] In some embodiments, the film includes water-soluble paper that dissolves in the concrete while the concrete is curing to permit the resin to form a bond with the concrete, and wherein the water-soluble paper includes indica printed with an acid-based ink thereon, wherein the acid-based ink reacts with the concrete to cause the water-soluble paper to dissolve.

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

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

[0016] In some embodiments, prior to the film being chemically bonded to the resin, the fibers and resin are at least partially encased in the film, then, one portion of the film is ultrasonically welded to another portion of the film around the plurality of fibers and resin.

[0017] In some embodiments, prior to the film being chemically bonded to the resin, the method further includes bending the non-metallic structural member into a non-linear shape,Attorney Docket No.206962-9012-WO01 stretching the film and sliding the fibers with respect to one or more adjacent fibers in response to bending, curing the resin after stretching the film and sliding the fibers, retaining the non- metallic structural member in the non-linear shape. This embodiment optionally includes sliding the fibers with respect to the film in response to bending.

[0018] In some embodiments, the apparatus and method include positioning a plurality of particles between the film and bundle of fibers and resin, and a film melting point is within 15 degrees Celsius of a particles melting point. Optionally, the film melting point is between zero and five degrees Celsius of the particles melting point.

[0019] In some embodiments, the particles include phenolic open cell foam particles and / or polymeric grit particles.

[0020] Other features and aspects of the disclosure will become apparent by consideration of the following detailed description and accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0021] FIG.1 is a schematic representation of a typical pultrusion process.

[0022] FIG.2 is a schematic representation of an assembly line according to some embodiments of the disclosure.

[0023] FIG.3 is a perspective view of a portion of the assembly line of FIG.2.

[0024] FIG.4 is a perspective view of a portion of the assembly line of FIG.2.

[0025] FIG.5 illustrates a binder application assembly according to one embodiment for use in the assembly line of FIG. 2.

[0026] FIGS.6 and 7 illustrate a binder application assembly according to some embodiments for use in the assembly line of FIG. 2.

[0027] FIG.8 is a perspective view of another portion of the assembly line of FIG.2, illustrating a die being curled around a length of wetted fibers.Attorney Docket No.206962-9012-WO01

[0028] FIG.9 is a perspective representation of the die being curled around the length of wetted fibers.

[0029] FIG.10 is an end view of a shaping station of the assembly line of FIG.2.

[0030] FIG.11 is a schematic representation of a shaping station according to some embodiments.

[0031] FIG.12 is a schematic representation of a shaping station according to some embodiments.

[0032] FIG.13 is a schematic representation of a shaping station according to some embodiments.

[0033] FIG.14 is a schematic representation of a shaping station according to some embodiments.

[0034] FIG.15 is a schematic representation of a shaping station according to some embodiments.

[0001] FIG.16 is a schematic representation of a shaping station according to some embodiments.

[0002] FIG.17 is a representative cross-sectional view of a structural member including a plurality of fibers and traction agents.

[0003] FIG.18 shows one embodiment of traction agent particles as seen through a microscope.

[0004] FIG.19 shows another embodiment of traction agent particles as seen through a microscope.

[0035] FIGS.20A through 20D illustrate various possible bend shapes.

[0036] FIGS.21A through 21D illustrate various steps of a bend making process.Attorney Docket No.206962-9012-WO01

[0037] FIGS.22A and 22B are perspective views of an embossed film for a non-metallic structural member.

[0038] Before any embodiments of the disclosure are explained in detail, it is to be understood that the disclosure is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The disclosure is capable of other embodiments and of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. DETAILED DESCRIPTION

[0039] FIGS.2 and 3 illustrate an assembly line 100 for manufacturing fiber-reinforced polymer (FRP) structural composites (i.e. matrix composites). The structural composites may form a wide variety of structural members, such as rebar, I-beams, C-channels, tubes, structural laminates, and the like. The illustrated assembly line 100 includes a roving station 105, a binder application station 110, and a plurality of shaping stations 115. In some embodiments, additional or alternative stations may be included in the assembly line 100. The assembly line 100 is generally linear and defines a central axis 120 along which the structural composite is produced (FIG.3). As described in greater detail herein, the assembly line 100 enables FRP structural composites to be continuously manufactured at high speed.

[0040] The roving station 105 includes a plurality of spools or bobbins 125 that support and dispense strands or rovings of fiber 130 to be included in the structural composite. In the illustrated embodiment, the fiber 130 includes basalt; however, the fiber 130 may include glass, aramid, carbon, or any other desired fiber material. The bobbins 125 may be coupled to a power drive system that controls the fiber feed rate. In such embodiments, dancers or other automatic tensioning devices (not shown) may be provided to maintain a consistent tension on the fibers 130.

[0041] After being dispensed from the bobbins 125, the fibers 130 pass through a guide assembly 135 that arranges the fibers 130 for wetting at the binder application station 110 (FIGS. 3 and 4). In some embodiments, the guide assembly 135 may arrange the fibers 130 in a plane to provide a relatively large, rectangular surface area for wetting. Alternatively, the guide assemblyAttorney Docket No.206962-9012-WO01 135 may arrange the fibers 130 into other patterns, such as linear, cylindrical, tubular, or spiral patterns.

[0042] In some embodiments, the roving station 105 includes one or more heating elements (not shown) to preheat the fibers 130 to a desired temperature before they are dispensed to the binder application station 110. The heating elements may be located internally within the bobbins 125, or may be external to the bobbins 125. For example, heated air may be directed over the fibers 130 as they leave the roving station 105. Preheating the fibers 130 may reduce the energy input required at the binder application station 110 and may help stabilize the binder curing process, described in greater detail below.

[0043] Due to the relatively small diameter of the fibers (when compared to the diameter of the grouped fibers in the die and shaping stations), less time and / or energy is required to preheat the individual fibers than would be required to heat the grouped fibers in one or more of the shaping stations. The shaping stations are operable to maintain the elevated temperature of the preheated fibers. In some embodiments, the binder is heated prior to being applied to the fibers 130.

[0044] With reference to FIGS.2 and 3, the binder application station 110 is located downstream of the roving station 105 such that fibers 130 exiting the guide assembly 135 are drawn into the binder application station 110 to be wetted with a binder, such as a resin. In some embodiments, the binder is an extremely low viscosity short chain length monomer or combination of monomers, such as Dicyclopentadiene (DCPD) or Tricyclopentadiene (TCPD). In some embodiments, the binder includes one or more low viscosity polyurethane polymers and systems, such as a two component mDI-based elastomer. In other embodiments a thermosetting polymer such as a phenolic resin or an epoxy resin. In other embodiments, the binder may include polyester, vinyl ester, Portland cement, or any other suitable binder.

[0045] The binder has a viscosity that is less than 25 centipoise (cP) at temperatures in the range of 20°C to 55°C. In some embodiments, the binder has a viscosity less than 20 centipoise at 20°C to 55°C. In some embodiments, the binder has a viscosity less than 15 centipoise at 20°C to 55°C. In some embodiments, the binder has a viscosity less than 10 centipoise at 20°C to 55°C.Attorney Docket No.206962-9012-WO01

[0046] Extremely low viscosity binders quickly spread between the fibers 130 and move together with the fibers 130 through the assembly line 100 at high speeds without requiring a traction agent. This results in a consistent end product even at very high speeds.

[0047] The binder application station 110 is operable to apply a desired amount of binder to the fibers in a precisely metered manner. Specifically, depending upon the desired ratio of binder to fibers, the appropriate amount of binder can be applied directly to the fibers. This is in direct contrast to the binder bath shown in FIG.1 which does not control the amount of binder that is applied to the fibers. The excess binder must be removed and thus, more waste is created. Also, the entire binder bath must be maintained at the appropriate temperature which is a waste of energy to heat the extra binder, especially when some of the heated binder is removed from the fibers. Also, the product produced with the binder bath can be inconsistent because the ratio of fibers to binder is not controlled. In the present disclosure, the quantity of binder applied to the fibers can be controlled to assure the desired quality and consistency of the product produced.

[0048] FIGS.3-5 illustrate one embodiment of the binder application station 110. In the illustrated embodiment, the binder application station 110 includes a pressurized well 140. The pressurized well 140 receives the binder from a binder source 145, such as a hopper or storage vessel (FIG.2). The well 140 includes an end plate 150 having an inlet opening 155 through which the binder may be injected (FIG.5). The binder is then extruded under pressure through a plurality of channels 160 extending radially-outwardly from the inlet opening 155. The channels 160 communicate with wetting regions 165 located at an outer periphery of the end plate 150.

[0049] During operation, the binder is continuously extruded through the channels 160 and into the wetting regions 165. The fibers 130 pass through the wetting regions 165 to be wetted with the binder, beginning the formation of the matrix composite. In the illustrated embodiment, the end plate 150 includes two wetting regions 165 offset from each other by about 180 degrees. Thus, the fibers 130 may be arranged along two paths that are wet simultaneously. The fibers 130 are spaced apart while traveling through the wetting regions 165 to promote thorough coating of the fibers 130 with the binder. In other embodiments, the end plate 150 may include any number of wetting regions. The operating pressure of the well 140 and the number and size of the channels 160 may be variable to provide a desired wetting rate.Attorney Docket No.206962-9012-WO01

[0050] FIGS.6 and 7 illustrate portions of a binder application station 110a according to another embodiment. The binder application station 110a can be utilized with any of the embodiments described herein. In some embodiments, the binder application station 110a is utilized in addition to the binder application station illustrated and described in other embodiments, whereas in other embodiments, the binder application station 110a is utilized in the place of the binder application station illustrated and described in other embodiments. In the illustrated embodiment, the binder application station 110a includes a die 170 that guides the incoming fibers 130 into a generally tapered or conical arrangement. The die 170 can be capable of moving in a longitudinal direction (i.e. along the central axis 120). This movement may facilitate formation of the incoming fibers 130 into a generally continuous wall or sheet. The binder application station 110a includes a spray nozzle 175 that receives binder from the binder source 145 (FIG. 2) and is operable to spray a stream of binder against the incoming fibers 130. The position of the nozzle 175 may be modified in the longitudinal direction to adjust the binder spray characteristics.

[0051] In yet another alternative embodiment, the binder application station may include a binder bath. After passing through the bath, the fibers 130 may be routed through a series of parallel rollers to mechanically agitate and physically force the binder into the passing fibers. The binder content of the impregnated fibers may be controlled using wipers and / or rollers. In addition, the binder content may be controlled by directing some of the fibers 130 to bypass the binder bath.

[0052] In this alternative embodiment, the assembly line 100 may further include an oven buncher station between the binder application station and the one or more shaping stations 115 to heat the binder impregnated fiber 130, finish the wetting process, begin the curing process, and roughly form the wetted fibers. In addition, the oven buncher station may include one or more drive rollers to pull the fibers from the roving station 105 and through the binder application station.

[0053] With reference to FIG.2, in some embodiments, the illustrated assembly line 100 includes two separate traction agent sources 177a, 177b that supply a traction agent to be applied to the fibers 130. Either or both of the traction agent sources 177a, 177b can be utilized with any of the embodiments described herein. In some embodiments, the traction agent increases frictionAttorney Docket No.206962-9012-WO01 between adjacent fibers 130 to inhibit the fibers 130 from slipping relative to each other during processing on the assembly line 100. In some embodiments, the traction agent increases friction between the fibers 130 and the die 180. The traction agent preferably includes a non-metallic powder, such as diatomaceous earth. In other embodiments, the traction agent can include talc, mica, pearlite, calcium carbonate, fumed silica, quartz, aluminum oxide, silicon carbide, polymeric grit, carbon black, carbon nano-tubes, and the like.

[0054] With reference to FIG.17, the traction agent includes particles 178a, 178b that are smaller in diameter than the fibers 130. The traction agent particles 178a can be interspersed among the fibers 130 and can fill voids between adjacent fibers 130. In some embodiments, the traction agent particles 178a have an average diameter less than about 17 microns. In other embodiments, the traction agent particles 178a have an average diameter less than about 15 microns. In other embodiments, the traction agent particles 178a have an average diameter of about 13 microns. In other embodiments, the traction agent particles 178a have an average diameter between about 5 microns and about 20 microns. In other embodiments, the traction agent particles 178a have an average diameter between about 20% of an average diameter of the fibers 130 and about 90% of the average diameter of the fibers 130. In other embodiments, the traction agent particles 178a have an average diameter that is about 75% of an average diameter of the fibers 130.

[0055] The traction agent is preferably softer than the fibers 130. In some embodiments, the traction agent particles 178a have a Mohs hardness of about 6 or less. In other embodiments, the traction agent particles 178a have a Mohs hardness of about 4 or less. In other embodiments, the traction agent particles 178a have a Mohs hardness of about 2 or less. In other embodiments, the traction agent particles 178a have a Mohs hardness between about 0.5 and about 2. In some embodiments, the traction agent particles 178a have a hardness between about 10% of a hardness of the fibers 130 and about 50% of a hardness of the fibers 130.

[0056] In some embodiments, the traction agent particles 178a have a rounded shape, generally free of sharp edges, corners, or points. In some embodiments, the traction agent particles 178a also include a plurality of surface pores. The surface pores can provide increased contact between the traction agent particles 178a and the fibers 130 as well as improved resin retention and penetration. The particles 178a may also interact with the resin to create aAttorney Docket No.206962-9012-WO01 thixotropic or gelling effect, helping to maintain the wetted fibers 130 in a desired shape until the resin is cured.

[0057] Referring to FIG. 2, the traction agent source 177a is positioned to introduce the traction agent particles 178a into the binder source 145. The traction agent mixes with the binder to form a binder mixture in which the traction agent particles 178a are suspended. In some embodiments, the traction agent source 177a and the binder source 145 can respectively dispense the traction agent and the binder into a mixing chamber where the traction agent and the binder are combined to form the binder mixture. The binder mixture is then supplied to the binder application station 110 where it is applied to the fibers 130. In embodiments utilizing a low viscosity resin, the traction agent particles 178a are optional and can be omitted.

[0058] With continued reference to FIG.2, the traction agent source 177b is positioned to introduce the traction agent particles 178b to the wetted fibers 130 as the fibers 130 leave the binder application station 110. In some embodiments, the traction agent source 177b is positioned above the fibers 130, and one or more shakers or other agitators is provided to facilitate dispensing a desired amount of the traction agent particles 178b on to the fibers 130 under the influence of gravity. In other embodiments, the traction agent particles 178b can be entrained in a compressed gas stream and sprayed on to the fibers 130. In yet other embodiments, the traction agent particles 178b can be mixed with a liquid and sprayed on to the fibers 130.

[0059] In some embodiments, the traction agent particles 178b are sized between 54 grit (0.012 inches) and 220 grit (0.0012 inches). The traction agent particles 178b are applied to the fibers 130 at a rate that corresponds to the process speed.

[0060] The traction agent particles 178a and 178b are applied to the fibers 130 and the binder before the binder is cured. The traction agent sources 177a, 177b can be incorporated into the assembly line 100 individually or in combination. For example, in one embodiment, the assembly line 100 includes only the traction agent source 177a such that the traction agent particles 178a are applied to the fibers 130 only via the resin mixture. In another embodiment, the assembly line 100 includes only the traction agent source 177b such that the traction agent particles 178b are applied only to the wetted fibers 130. In another embodiment, the assembly line 100 includes both traction agent sources 177a, 177b such that the traction agent particlesAttorney Docket No.206962-9012-WO01 178a are applied to the fibers 130 as part of the resin mixture and the traction agent particles 178b are applied to the wetted fibers 130 as the fibers 130 leave the binder application station 110.

[0061] FIG.18 illustrates one possible embodiment of traction agent particles 278 that can be applied to the outside of the resin-coated fibers 130 in place of the traction agent particles178b. The die 180 can capture the traction agent particles 278 and apply the traction agent particles 278 around the circumference of the resin-coated fibers 130. In some embodiments, the 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 fibers.

[0062] It took a significant amount of research and testing to determine viable options for traction agents for use with a low viscosity resin. During the research and testing, one of the desirable parameters includes limited abrasiveness to metal, such as a polymeric material. Some of the traction agents tested created significant wear on the tooling, which is undesirable. Another desirable parameter is a sharp and angular overall shape. This provides greater surface area and increased friction between the fibers 130 and the die 180. Yet another desirable parameter is a material that is friable, crushable and brittle, so that the material does not expand after being compressed between the fibers 130 and the die 180. Optionally, it would be beneficial if the material can be low cost and readily available, potentially as a waste product.

[0063] The illustrated traction agent particles 278 are sharp, irregular and angular in shape. Each of the individual particles 278 often have multiple irregular angles in one particle. In some embodiments, the traction agent particles 278 have a significant aspect ratio between the average length and average width of the particles 278. For example, often the aspect ratio is at least 10:1. The traction agent particles 278 do not cause significant wear on the tooling. The traction agent particles 278 are friable and do not expand after being compressed. The material shown in FIG. 17 includes phenolic open cell foam particles.

[0064] FIG.19 illustrates another possible embodiment of traction agent particles 378 that can be applied to the outside of the resin-coated fibers 130, along with the traction agent particles 278, in place of the traction agent particles 178b. The die 180 can capture the traction agent particles 278, 378 and apply the traction agent particles 278, 378 around the circumference of the resin-coated fibers 130. In some embodiments, the traction agent particles 178a are omittedAttorney Docket No.206962-9012-WO01 entirely, such that the traction agent particles 278, 378 are not mixed with the resin before the resin is applied to the fibers.

[0065] The illustrated traction agent particles 378 are sharp and elongate in shape. Each of the individual particles 378 often have multiple irregular angles in one particle. The traction agent particles 278, 378 do not cause significant wear on the tooling. The material shown in FIG.19 includes phenolic open cell foam particles 278 as well as relatively larger (60-80 grit) polymeric grit particles 378. Phenolic open cell foam particles and polymeric grit particles can be found as waste products and be obtained for a very low cost.

[0066] With reference to FIGS.2, 4, 8, and 9, the assembly line 100 further includes a continuously-conformable translating die 180 that is wrapped around the wetted fibers 130 as they exit the binder application station 110. The illustrated die 180 is a strip of paper fed from a roll 185 (FIG.4). The paper die 180 travels along the central axis 120 adjacent the wetted fibers 130, and a series of Teflon guide plates 190 gradually curls the die 180 around the wetted fibers 130 until the die completely surrounds and encases the wetted fibers 130 (FIGS.8 and 9). As the wetted fibers 130 enter a first portion or entrance 195 of the die 180, the fibers 130 are compressed from the relatively large, rectangular area into a smaller generally circular area corresponding with the diameter of the die at the entrance 195.

[0067] The die 180 travels with the wetted fibers 130 through the remainder of the assembly line 100. As described in greater detail below, the die 180 facilitates travel of the wetted fibers 130 through the shaping stations 115 by inhibiting the wetted fibers 130 from sticking to the shaping stations 115. In addition, the die 180 constrains the wetted fibers 130 during curing, facilitates mixing of the binder and the fibers 130 to ensure thorough wetting, and helps to maintain a consistent curing pressure and temperature.

[0068] The process speed or product output rate of the assembly line 100 and any other continuous FRP manufacturing process is governed by the following equation:

[0069] Because the continuously-conformable translating die 180 moves with the wetted fibers 130, it can be many times longer than the static die 30 employed in the typical pultrusionAttorney Docket No.206962-9012-WO01 process (FIG.1). Accordingly, the assembly line 100 may operate at a process speed many times greater than that of the typical pultrusion process. For example, if the translating die has a length of 2,000 feet, and the binder requires 2 minutes to cure, the assembly line 100 will have a potential process speed of 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 between about 20 feet per minute and about 50 feet per minute. In other embodiments, the assembly line 100 is configured to have a process speed between about 50 feet per minute and about 100 feet per minute. In other embodiments, the assembly line 100 is configured to have a process speed between about 100 feet per minute and about 250 feet per minute. In other embodiments, the assembly line 100 is configured to have a process speed between about 100 feet per minute and about 500 feet per minute. In other embodiments, the assembly line 100 is configured to have a process speed between about 100 feet per minute and about 1000 feet per minute. In other embodiments, the assembly line 100 is configured to have a process speed between about 20 feet per minute and about 100 feet per minute. In other embodiments, the assembly line 100 is configured to have a process speed between about 20 feet per minute and about 1,000 feet per minute. In other embodiments, the assembly line 100 is configured to have a process speed between about 100 feet per minute and about 1,000 feet per minute.

[0070] The paper die 180 may be coated with a release agent, such as silicone, to facilitate removal of the die 180 from the finished structural composite. In addition, the paper die 180 may be relatively porous to permit gas and vapor to be released through the die 180. Alternatively, the die 180 may be substantially air tight.

[0071] In some embodiments the paper die 180 includes water-soluble paper that dissolves in the concrete while the concrete is curing to permit the resin to form a bond with the concrete. In some embodiments, the water-soluble paper includes indica printed with an acid-based ink that reacts with the concrete to cause the water-soluble paper to dissolve.

[0072] The die 180 may include other substrate materials or combinations of materials applied to the wetted fibers 130 in various ways. For example, in some embodiments the die 180 may include a powder or a liquid (e.g., molten wax) that is applied to the wetted fibers 130 and subsequently hardened or cured using UV light, temperature, a chemical reactant, or otherAttorney Docket No.206962-9012-WO01 suitable means. In other embodiments, the die 180 may include a vapor releasing micro-porous membrane such as GORE-TEX. In other embodiments, the die 180 may include a macro-porous material such as a woven fabric or fiber mat. In yet other embodiments, the die 180 may include one or more metal films, such as non-sacrificial stainless steel, carbon steel cover, or copper etc. In some embodiments, the die 180 encases a mixture of Portland cement and lime around the fibers and the resin. The die 180 is designed to at least partially dissolve in the concrete, to permit the Portland cement and lime to form a bond with the concrete after the film is at least partially dissolved.

[0073] In some embodiments, the die 108 is a film that bonds with the binder. In some embodiments, the film is polymeric and includes at least some polypropylene and / or polyethylene. Some possible polymeric compounds include biaxially oriented polypropylene, biaxially oriented polyethylene, biweight midcorrelation oriented polypropylene, biweight midcorrelation oriented polyethylene, impact modified polypropylene and / or impact modified polyethylene.

[0074] In some embodiments, the die 180 is a film that includes a film additive that allows the resin to bond to an otherwise difficult to bond to resin. This film allows the near complete, or in some cases complete, covering of the rebar through the manufacturing process and enables it to be integrated into the final product. This non-sacrificial die eliminates most of the odor emitted during manufacturing by sealing and almost fully encasing of the completed product. In some embodiments, the ends of the product are uncovered, but in other embodiments, the ends of the product are at least partially covered. The final product is covered along almost or all of the length of the product, thereby enabling the capture of almost all of potential emissions during curing. This is a substantial advantage for a manufacturer utilizing DCPD, TCPD or any volatile organic compound (“VOC”) producing resin.

[0075] The non-sacrificial die is a stiff low-stretch film developed to bond to the DCPD and / or TCPD resin while providing the flexural modulus necessary to pressurize the wetted fiber bundle. This non-sacrificial die is pulled tight around the wetted fiber bundle and welded closed using rotating ultrasonic welding technologies creating an airtight pressurized continuous conformable die.Attorney Docket No.206962-9012-WO01

[0076] Further, this non-sacrificial die can be embossed in a configuration that maximizes mechanical adherence to the wetted fiber bundle on the interior and concrete on the exterior to improve processability. One example of an embossed non-sacrificial film die surrounding a cured bundle of resin and fibers is shown in FIGS.22A and 22B. FIGS. 22A and 22B illustrate an embossed non-sacrificial film die 180a. In the illustrated embodiment, the die 180a is a non- sacrificial film that remains on the bundle of resin and fibers during installation. The die 180a includes a plurality of protruding elements 196a and a plurality of recessed regions 196b that form a textured pattern. The illustrated protruding elements 196a form the outlines of diamond shapes with recessed regions 196b within the diamonds. Essentially the protruding elements 196a are adjacent spirals extending in opposite directions around the perimeter of the cylindrical shape. Other patterns and configurations of embossed features can be utilized, and the diamond outlines are shown by way of example only. This embossed outer surface forms a mechanical bond with the concrete, as well as a chemical bond, to thereby increases the bond between the die 180a and the concrete. In some embodiments, the traction agent particles 178b positioned under the film cause the film to have a textured outer surface. This textured outer surface also increases the bond between the film and the concrete.

[0077] The illustrated die 180a has been ultrasonically welded together around the bundle. Namely, one portion of the die 180a has been welded to another portion of the die 180a to thereby secure the die 180a around the bundle. The ends of the die 180a that are joined together and welded form a seam 197a that extends in the elongate direction of the die 180a. Other methods for joining opposing ends of the die 180a together can be utilized in place of ultrasonic welding.

[0078] This non-sacrificial die addresses global climate and air pollution concerns by essentially eliminating the need for expensive and cumbersome VOC capture, air cleaning protocols and air cleaning media waste in activated carbon or energy to burn the waste. The non- sacrificial die also reduces process waste thereby enabling production facility placement globally without minimal concerns for air pollution controls.

[0079] In some embodiments, the melting point of the traction agent particles 178a, 178b, 278, 378 and the melting point of the die 180 are reasonably similar. This is particularly beneficial for embodiments that utilize ultrasonic welding to secure the die 180 around the fibers.Attorney Docket No.206962-9012-WO01 For example, in some embodiments, the melting point of the traction agent particles 178a, 178b, 2678, 378 is less than 15 degrees Celsius from the melting point of the die 180. In some embodiments, the melting point of the traction agent particles 178a, 178b, 2678, 378 is less than 10 degrees Celsius from the melting point of the die 180. In some embodiments, the melting point of the traction agent particles 178a, 178b, 2678, 378 is less than 5 degrees Celsius from the melting point of the die 180. In some embodiments, the melting point of the traction agent particles 178a, 178b, 2678, 378 is less than 2 degrees Celsius from the melting point of the die 180.

[0080] In some embodiments the die 180 may be wetted by the binder to bind the die 180 to the matrix composite, thereby creating an integrated construction that includes all or a portion of the die 180. Thus, the die material may be chosen to provide the produced structural composite with additional desired properties. For example, the die 180 may include an electrically- conductive material to provide electrical conductivity to an otherwise non-conducting composite. The die material may have an affinity to an external binding compound (e.g., Portland cement) to facilitate integration of the structural composite (e.g., rebar) into its particular application (e.g., reinforced concrete).

[0081] Now referring to FIGS.2-4, the shaping stations 115 are located downstream of the binder application station 110. In the illustrated embodiment, the assembly line 100 includes first, second, and third shaping stations 115 that are spaced from one another along the central axis 120 (FIG.2). In other embodiments, the assembly line 100 may include any number of shaping stations 115.

[0082] The shaping stations 115 each include at least one guide that contacts and shapes the fibers 130. In some embodiments, the guide can include one or more rollers with one or more slots sized to receive and shape the fibers 130. In some embodiments, the guide can include one or more stationary or rotating dies that have one or more openings sized to receive and shape the fibers 130. The slots in the rollers and the openings in the stationary dies can each have different shapes and sizes to mold the fibers 130 into different shapes and sizes.

[0083] Each of the illustrated shaping stations 115 includes a plurality of rollers 200. The rollers 200 are arranged in pairs, and each includes a groove 205 through which the die-wrapped fibers 130 are rolled and shaped (FIG.10). In some embodiments, pairs of rollers 200 may beAttorney Docket No.206962-9012-WO01 positioned in different orientations. For example, pairs of rollers 200 may alternate between horizontal and vertical orientations. Some or all of the rollers 200 may be driven using variable speed drive motors to draw the die 180 and fibers 130 through the assembly line 100.

[0084] Referring again to FIGS.2 and 3, each shaping station 115 can further include thermal transfer panels (not shown) to allow precise control of the process temperature. For example, each shaping station 115 may be controlled to maintain the wetted fibers 130 at a stable, controlled temperature that cures the binder at a rate of speed that corresponds to the process speed. The specific temperature is dependent upon the type of binder used and the process speed of the assembly line. In some embodiments, a phenolic resin is used as the binder and the fibers are maintained at a temperature of about 160 degrees Celsius. In some embodiments, an epoxy resin is used as the binder and the fibers are maintained at a temperature of between about 50 and about 90 degrees Celsius. In embodiments that utilize low viscosity resins, such as DCPD and / or TCPD, preheating may not be necessary. However, in some cases, preheating the fibers to a temperature of between about 25 degrees Celsius and about 105 degrees Celsius can be manufactured at a somewhat faster process speed. Accordingly, the binder curing process may be completed while the shaped, wetted fibers 130 are traveling through the shaping stations 115. Alternatively, the wrapped fibers may be cut to length, removed from the shaping stations 115, and then set in a designated location to cure for a set time period. In some configurations, the designated location is heated to enhance curing.

[0085] Process temperature can be controlled in multiple zones along the length of each shaping station 115 to promote or reduce the speed of curing along the length of the die 180. The rollers 200 exert pressure on the die 180 to provide the required curing pressure. As the die 180 and fibers 130 pass between adjacent shaping stations 115, the product may be cooled if desired (either by exposure to the ambient environment between the adjacent shaping stations 115 or through controlled cooling zones), and gas or vapor byproducts may be vented through the die 180. This is not possible in a typical pultrusion process, as the static dies 30 (FIG. 1) are typically impermeable. In some embodiments, one or more of the shaping stations 115 cool the die 180 and the fibers 130 to a temperature below the glass transition temperature of the binder. Therefore, the die 180 and fibers 130 dispensed from the shaping stations 115 can maintain its shape. In other embodiments, the die 180 and fibers 130 are not cooled below the glass transition temperature until after the die 180 and fibers 130 have exited the shaping stations 115Attorney Docket No.206962-9012-WO01 to permit final manipulation of the die 180 and fibers 130 into the desired final shape and / or formation of any surface configurations (such as, for example, ribs, protrusions, recesses and / or other suitable surface configurations).

[0086] In a typical process, gaps between any stations must be minimized so that proper support is offered to the fibers along an entire length of the assembly line. In contrast, the illustrated shaping stations 115 are spaced apart a distance in the die flow direction, because the die 180 provides sufficient supports to the fibers 130 between the shaping stations 115. The space between the shaping stations 115 permits air and water to vent from the die 180 and fibers 130. Further, the spaced apart shaping stations 115 extend across a longer distance than if the shaping stations 115 were directly adjacent. The increase in the overall distance of the shaping stations 115 permits the die 180 to move through the shaping stations 115 at a faster speed while still partially or fully curing in the shaping stations 115. Therefore, by using more shaping stations 115 and spaced apart shaping stations 115, the process speed can be increased, thereby increasing productivity and profitability. The distance between the shaping stations 115 also decreases the capital cost of building and installing the assembly, when compared to an arrangement in which shaping stations are adjacent for an entire length of the shaping assembly. The shaping stations 115 can be modular, such that one or more shaping stations 115 can be added, removed or repaired without a substantial loss of production. Instead of shutting down production of the entire assembly line (as would be required for units that utilized a single, stationary die), the production would be shut down for a brief period to permit addition, removal or replacement of one or more of the shaping stations 115. The removed shaping station 115 can be repaired or stored while the assembly line is in operation.

[0087] With reference to FIGS.11-16, one or more of the shaping stations 115 may also dynamically manipulate the die 180 and the fibers 130 to promote thorough wetting and homogeneous curing. Wetting is improved through shear viscosity changes that are induced by dynamically modifying the cross-sectional area of the matrix composite. Further shear mixing of the matrix composite can be induced by selectively increasing and decreasing the mechanical pressure applied by the shaping station 115. In some embodiments, the shaping station 115 can be configured to have incomplete wet-out of the fibers 130 to improve the flexibility of the fibers 130 upon curing.Attorney Docket No.206962-9012-WO01

[0088] In some embodiments, the guides may be configured to progressively increase the applied mechanical pressure over the length of the die 180. In some embodiments, the increase in pressure is created by moving the fibers 130 through a tapered stationary die that has an opening with a decreasing diameter along the length. In other embodiments, the increase in mechanical pressure can be created by moving the fibers 130 through a series of stationary dies, each of which has progressively smaller openings. In some embodiments, the holes in the stationary dies can have different shapes and sizes of openings to dynamically alter the cross- sectional shape of the die 180 and the fibers 130.

[0089] In the embodiment illustrated in in FIG.11, the rollers 200 are configured to progressively increase the applied mechanical pressure over the length of the die 180. As such, the cross-sectional area of the die 180 may decrease through each successive pair of rollers 200. This promotes thorough wetting and compacting of the fibers 130. In other embodiments, the rollers 200 may be configured to dynamically alter the cross-sectional shape of the die 180 and the fibers 130 (FIGS.12-15). For example, the die 180 may be rolled into an oval shape that assumes different orientations at alternating roller pairs 200 to promote further shear mixing (FIG.12). Alternatively, die 180 may be rolled into a variety of other shapes, such as oval, circle, rectangle, square, triangle, etc. (see, for example, FIG. 13). In other embodiments, one or more of the shaping stations 115 may twist the die 180 and the fibers 130 about the central axis 120 (FIG. 14). In yet other embodiments, one or more of the shaping stations 115 may alternatingly increase and decrease the cross-sectional area of the die 180 (FIG. 15). In still other embodiments, the rollers 200 may be offset to create undulations in the die 180 and the fibers 130 (FIG.16). Each of the shaping stations 115 can have different arrangements and configurations of rollers 200 and / or stationary dies.

[0090] In some embodiments, the assembly line 100 may further include a burn-off station 210 to thermally abrade the cured surface of the composite structure (FIG.2). The burn-off station 210 may be employed to remove the die, to expose portions of the fiber, and / or to provide a carbonaceous char that may have an affinity for an external binding compound like Portland cement.

[0091] In some embodiments, the assembly line 100 may further include a post-cure station 215. The post-cure station 215 may include one or more heating elements to provide anyAttorney Docket No.206962-9012-WO01 necessary secondary curing time and temperature controls. In addition, the post-cure station 215 may include one or more machining devices operable to shape the structural composite into a desired final shape. For example, the structural composite may be bent or cut and folded into a C-channel shape, a spiral shape or other desirable shape.

[0092] In some embodiments, the assembly line 100 may further include a packaging station 220. The packaging station 220 may include one or more cutting devices operable to cut the structural composite into a desired length for sale and shipping. The structural composite may be marked with product information, branding information, or other indicia, and then packaged for shipping.

[0005] In operation, a plurality of fibers 130 is dispensed from the roving station 105 and moved along the assembly line 100 to the binder application station 110. The fibers 130 are generally spaced apart as they enter the binder application station 110 such that the fibers 130 extend across a first, relatively large surface area. The fibers 130 are wetted with binder or, in some embodiments, with a binder mixture including the traction agent. In some embodiments, the traction agent is applied to the wetted fibers 130 leaving the binder application station 110.

[0093] The wetted fibers 130 are then guided into the first portion 195 of the die 180 proximate the binder application station 110, and the die 180 is curved to wrap around the wetted fibers 130. As the die 180 is wrapped around the wetted fibers 130, the fibers 130 are compressed together. The wetted fibers 130, encased by the die 180, are then fed into the shaping stations 115.

[0094] In the shaping stations 115, the die 180 and the wetted fibers 130 are compressed between the guides, such as the sets of rollers 200 or the stationary dies to mix the binder and the fibers 130, to form the product shape. The die 180 separates the wetted fibers 130 from the rollers 200 and / or the stationary dies in order to prevent the binder from sticking to the rollers 200 and / or the stationary dies. Heat is applied throughout the shaping stations 115 to promote curing of the binder. As the die 180 travels between adjacent shaping stations, the matrix may cool and / or expel gas and vapor byproducts.

[0006] During shaping, the traction agent particles 178a are interspersed among the fibers 130 and provide increased friction between adjacent fibers 130 (FIG. 17). Accordingly, theAttorney Docket No.206962-9012-WO01 traction agent can reduce interlaminar slippage to provide a more consistent and sound structural composite. The traction agent particles 178a can also fill voids between the fibers 130, facilitate resin penetration, and impart desirable thixotropic properties.

[0007] In some embodiments, the traction agent particles 178b, 278, 378 are applied to the die 180 and / or the fibers 130 before or after curing has been completed. The traction agent particles 178b, 278, 378 may be chosen to improve physical bond characteristics between the final composite of the fibers 130 and the binder and the material the final composite will be connected to, such as, for example, concrete.

[0095] Prior to curing, it may be desirable to bend the fibers 130 to form a non-linear shape, such as a curve or bend. In some embodiments, the die 180 remains around the fibers 130 while the fibers 130 are bent.

[0096] To produce a structurally sound corner with an anisotropic fiber reinforced composite material it must be understood that the lengths of the individual fibers must be different (i.e., shorter) on the inside of a radius relative to the outside of a radius. Therefore, manufacturing a component with one or more radii requires utilizing a twisted group of fibers to allow the combined group of twisted linearly aligned fibers to be bent around these radii. Alternately, if the individual fibers are allowed to slip or move relative to adjacent fibers to accommodate the shaping of the fibers around a radius, competent corners can be produced. The die 180 can be a flexible film member that contains and surrounds the fibers while permitting fibers to move linearly relative to adjacent fibers. Filament winding can produce a radius with varying length fibers.

[0097] In some embodiments, the die 180 is a sealed polymeric film that forms a skin to allow the internal fibers and resin to slip relative to the fiber immediately adjacent to it in a high- speed manufacturing process to produce commercially valuable shapes.

[0098] In some embodiments, the die 180 is a polymeric film that can be stretched greater on the exterior of the radii relative to the interior of the radii. In some embodiments, the die 180 contains a significant amount of the odors emitted by the resin, thereby enabling manufacturing in close proximity to residential areas. In some embodiments, the die 180 is a polymeric filmAttorney Docket No.206962-9012-WO01 that contains stray fibers, thereby forming a protective surface that essentially prevents slivers in a person handling the die 180 and fibers 130.

[0099] In some embodiments, the die 180 is a polymeric film, and the interface between the polymeric film and the fibers, and between adjacent fibers allows relative movement of the fibers with respect to the polymeric film and with respect to the adjacent fibers. This relative movement enables the fibers to produce a corner with limited, or in some cases zero, bunched fibers. Bunched fibers, or small openings between adjacent fibers in a bend can form a weak point. The relative movement of the fibers with respect to the polymeric film and with respect to adjacent fibers also inhibits the formation of openings between adjacent fibers, thereby maintaining the material properties of the fibers 130 even while the shape of the fiber bundle is non-linear.

[0100] In some embodiments, the finished part can be produced in a round, square, trapezoidal, hooked and other configurations. In some embodiments, the finished part can be produced in bends with various radii, angles and leg lengths.

[0101] In order to meet ASTM specifications, composite rebar bends produced from glass fiber reinforced polymer (GFRP) rebar need to be produced after the fiber is wetted with resin and before this resin has cured. This means that wetted fiber in which the resin is in the liquid form will need to be wrapped around mandrels prior to curing. To date this work after the fiber is wetted is largely done manually with limited automation. Four possible examples of complex shapes are shown in FIGS. 20A through 20D. The industry does not currently have any viable options to automate the formation of different bends and shapes of GFRP, such as the exemplary shapes shown in FIGS.20A through 20D.

[0102] The ability to produce a straight piece of wetted fiber of the appropriate diameter and bend it around a given corner while maintaining its generally round shape is hampered by the anisotropic properties of fiber of equal length when multiple strands are bent around a corner. The outside fiber will be taut while the inside fibers will be loose and consequently spread horizontally or crumpled to compensate for the unequal lengths. Rope producers (wire, hemp and polymer) have long compensated for this by twisting multiple strands of fiber around a center axis creating a supple cord that can be bent around a corner without flattening the rope. These multiple twisted strands can be twisted together to produce large diameter rope.Attorney Docket No.206962-9012-WO01

[0103] The Applicant has not observed the composite industry using this principle. It is apparent that this twisted rope concept completed after the individual glass fibers are wetted with resin but prior to cure would offer these same advantages.

[0104] The challenges to producing these bends is that the shapes are often double ended. A shape such as a circle, circle, square or hexagon is easily wound to make a robust part. Making a component such as any of the following standard shapes if difficult and is typically done manually.

[0105] The process to create a needed shape is initiated by anchoring a tow of wetted fiber to an initial point and then wrapping one end around a fixed mandrel and the other end around a rotatable mandrel as shown in FIG.21A. The rotatable mandrel is adjustably positioned to produce the needed length for the rope. Then, the rotatable mandrel is rotated a set number of rotations to form a straight length of fibers with loops at opposite ends as shown in FIGS.21B and 21C. In some instances, wrapping and twisting the original rope can be accomplished with a small servo motor on the active end of the rope to produce the twists.

[0106] In order to produce various non-linear shapes, this rope is manipulated around adjustably located corners, such as the corners of an XYZ table shown in FIG. 21D. This process will produce the required shape quickly without corners becoming deformed. By using multiple platens moved with automation the machine can operate in an intermittent continuous fashion eliminating the need for clean out by keeping the cycle times to a minimum. The fibers are formed into the non-linear shape before the resin begins to harden.

[0107] Additionally, twisting the wetted fiber and keeping it under tension will enhance wet- out and create ridges on the outer surface which will enable the finished part to potentially be used as is without a secondary finish.

[0108] Various features of the disclosure are set forth in the following claims.

Claims

Attorney Docket No.206962-9012-WO01 CLAIMS What is claimed is:

1. A method of installing a non-metallic structural member in concrete, the non-metallic structural member including a plurality of fibers and resin at least partially encased in a film, the film being chemically bonded to the resin, the method comprising: positioning the non-metallic structural member in a desired location; at least partially surrounding the non-metallic structural member with concrete after positioning the non-metallic structural member in the desired location; curing the concrete around the non-metallic structural member; and while curing the concrete, forming a bond between the film of the non-metallic structural member and the concrete.

2. The method of claim 1, wherein the film comprises a polymeric compound that includes at least some polypropylene and / or polyethylene, such that the polymeric compound is configured to chemically bond with the concrete while the concrete is curing.

3. The method of claim 2, wherein the film includes at least one of the following group of materials: biaxially oriented polypropylene, biweight midcorrelation oriented polypropylene, or impact modified polypropylene.

4. The method of claim 2, wherein the film includes at least one of the following group of materials: biaxially oriented polyethylene, biweight midcorrelation oriented polyethylene, or impact modified polyethylene.

5. The method of claim 1, further comprising at least partially containing the fibers and resin in the film to thereby reduce the odors emitted by the resin during curing.

6. The method of claim 1, further comprising mixing Portland cement and lime with the resin prior to at least partially encasing the fibers and the resin with the film, such that the Portland cement and lime are configured to form a bond with the concrete after the film is at least partially dissolved.Attorney Docket No.206962-9012-WO01 7. The method of claim 1, wherein the film includes water-soluble paper configured to dissolve in the concrete while the concrete is curing to permit the resin to form a bond with the concrete, and wherein the water-soluble paper includes indica printed with an acid-based ink thereon, wherein the acid-based ink is configured to react with the concrete to cause the water- soluble paper to dissolve.

8. The method of claim 1, forming a mechanical bond between the film and the concrete by contact between the concrete and one or more embossed features of the film.

9. The method of claim 1, increasing a bond between the non-metallic structural member and the concrete by contact between the concrete and a textured outer surface of the non-metallic structural member.

10. The method of claim 1, the method includes shrinking the film around the resin and fibers after at least partially surrounding the resin and fibers and prior to at least partially surrounding the non-metallic structural member with concrete.

11. The method of claim 1, wherein the resin includes at least one of the following group: dicyclopentadiene and tricyclopentadiene.

12. The method of claim 1, wherein prior to the film being chemically bonded to the resin, at least partially encasing the plurality of fibers and resin in the film, then, ultrasonically welding one portion of the film to another portion of the film around the plurality of fibers and resin.

13. The method of claim 1, wherein prior to the film being chemically bonded to the resin, the method further includes bending the non-metallic structural member into a non-linear shape, stretching the film and sliding the fibers with respect to one or more adjacent fibers in response to bending, curing the resin after stretching the film and sliding the fibers, and retaining the non-metallic structural member in the non-linear shape.Attorney Docket No.206962-9012-WO01 14. The method of claim 13, wherein prior to the film being chemically bonded to the resin, the method includes sliding the fibers with respect to the film.

15. The method of claim 1, wherein the resin and fibers form a bundle, and wherein the method further includes positioning a plurality of particles between the film and bundle, wherein a film melting point is within 15 degrees Celsius of a particles melting point.

16. The method of claim 15, wherein the film melting point is within 5 degrees Celsius of the particles melting point.

17. The method of claim 15, wherein the particles include one or more particles of the following: phenolic open cell foam particles or polymeric grit particles.

18. The non-metallic structural member used in the method of claim 1.

19. A non-metallic structural member configured to be positioned in concrete, the non- metallic structural member comprising: a plurality of fibers and resin; a film at least partially encasing the plurality of fibers and resin, the film being chemically bonded to the resin; the non-metallic structural member configured to be positioned in a desired location; the non-metallic structural member configured to be at least partially surrounded with concrete after being positioned in the desired location; the non-metallic structural member configured to remain in the concrete while the concrete cures; and wherein the film of the non-metallic structural member is configured to form a bond with the concrete while the concrete is curing.

20. The non-metallic structural member of claim 19, wherein before the film is chemically bonded to the resin, the film is configured to at least partially encase the plurality of fibers and resin, and then, one portion of the film is configured to be ultrasonically welded to another portion of the film around the plurality of fibers and resin.Attorney Docket No.206962-9012-WO01 21. The non-metallic structural member of claim 19, wherein the film comprises a polymeric compound that includes at least some polypropylene and / or polyethylene, such that the polymeric compound is configured to chemically bond with the concrete while the concrete is curing.

22. The non-metallic structural member of claim 19, wherein the film includes at least one of the following group of materials: biaxially oriented polypropylene, biweight midcorrelation oriented polypropylene, or impact modified polypropylene.

23. The non-metallic structural member of claim 19, wherein the film includes at least one of the following group of materials: biaxially oriented polyethylene, biweight midcorrelation oriented polyethylene, or impact modified polyethylene.

24. The non-metallic structural member of claim 19, wherein the film includes water-soluble paper configured to dissolve in the concrete while the concrete is curing to permit the resin to form a bond with the concrete, and wherein the water-soluble paper includes indica printed with an acid-based ink thereon, wherein the acid-based ink is configured to react with the concrete to cause 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 prior to at least partially encasing the fibers and the resin with the film, such that the Portland cement and lime are configured to form a bond with the concrete after the film is at least partially dissolved.

26. The non-metallic structural member of claim 19, wherein the film at least partially contains the fibers and resin to reduce the odors emitted by the resin during curing.

27. The non-metallic structural member of claim 19, wherein the non-metallic structural member has a textured outer surface to engage the concrete and thereby strengthen the bond between the non-metallic structural member and the concrete.Attorney Docket No.206962-9012-WO01 28. The non-metallic structural member of claim 19, wherein the resin includes at least one of the following group: dicyclopentadiene or tricyclopentadiene.

29. The non-metallic structural member of claim 19, wherein the film is configured to shrink around the resin and fibers after the film at least partially surrounds the resin and fibers and prior to the non-metallic structural member being at least partially surrounded with concrete.

30. The non-metallic structural member of claim 19, wherein before the film is chemically bonded to the resin, the non-metallic structural member is configured to be bent into a non-linear shape, the film is configured to stretch, and the fibers are configured to slide with respect to one or more adjacent fibers and / or with respect to the film in response to bending, the resin is configured to cure after the film has been stretched and the fibers have slid, and the non-metallic structural member is configured to remain in the non-linear shape after the resin has cured.

31. The non-metallic structural member of claim 19, wherein the resin and fibers form a bundle, further comprising a plurality of particles positioned between the film and bundle, wherein a film melting point is within 15 degrees Celsius of a particles melting point.

32. The non-metallic structural member of claim 31, wherein the film melting point is within 5 degrees Celsius of the particles melting point.

33. The non-metallic structural member of claim 31, wherein the particles include one or more particles of the following: phenolic open cell foam particles or polymeric grit particles.

34. The non-metallic structural member of claim 19, wherein the film includes one or more embossed features to engage the concrete and thereby strengthen the bond between the film and the concrete.

Images