System for manufacturing woven fiberglass mesh, method for manufacturing woven fiberglass mesh, and woven fiberglass mesh

Abstract

The present invention provides a method for producing a pultruded mesh, wherein a plurality of fiberglass filaments is introduced into a continuous process for producing reinforced longitudinal fiberglass rods that are impregnated with resin, and wherein a transverse rod, previously impregnated with resin, is introduced transversely, said transverse rod being wrapped in pairs of filaments, each pair of filaments being spaced apart from a second pair of filaments by a predetermined distance, so as to form a mesh. Said mesh of fibers impregnated with resin is then subjected to a resin curing process, thus forming a pultruded woven mesh.

Description

[0001] SYSTEM FOR MANUFACTURING WOVEN FIBERGLASS SCREEN, METHOD FOR MANUFACTURING WOVEN FIBERGLASS SCREEN AND WOVEN FIBERGLASS SCREEN FIELD OF THE INVENTION

[0002]

[0001] The present invention relates generally to the field of screen manufacturing, specifically the manufacture of woven fiberglass screens. Said screens are reinforced with resin, such as epoxy resin, with or without nanoparticles. In some embodiments, the screen of the present invention can be manufactured with a composition of resin and graphene nanoparticles. In one embodiment, a system for manufacturing customized fiberglass screens according to customer needs is presented, a method for manufacturing resin-reinforced coated fiberglass screens, and finally, the product, resin-reinforced fiberglass screen. Such screens manufactured according to the system and method of the present invention have improved strength and can be used in various fields, such as construction, security, agribusiness, etc.

[0003] BACKGROUND OF THE INVENTION

[0004]

[0002] Several types of polymer bars used for structural reinforcement are known in the art, particularly for use in the field of civil construction. In particular, long structures, such as polymer support bars, produced from fiber and coated with thermosetting resins, such as polyester, vinyl ester and epoxy, are known and widely used by those skilled in the art.

[0005]

[0003] In general, fiber-reinforced polymers (FRP) are produced from structural resins, such as polyester, vinyl ester, and epoxy resins, which cover flexible, continuous, and solid reinforcing fibers with small cross-sections relative to their length. Glass fibers are obtained from the melting of inorganic glass; basalt fibers are obtained by melting basaltic rock; carbon fibers are generated by the pyrolysis of precursor organic fibers containing at least 90% carbon by mass; and aramid fibers are generated from linear fiber-forming polyamides in which at least 85% of the amide groups are directly connected to two aromatic rings.

[0006]

[0004] US patent application 20190070802A1, entitled “Smooth textile reinforcement for pultrusion, method and device for producing the same, and use thereof in the manufacture of components using pultrusion,” discloses a type of pultrusion-reinforced fabric comprising a textile reinforcement that can be used for the creation of composite components by pultrusion, comprising a reinforcement layer having randomly oriented glass fiber lengths coated in a polyester binder.

[0007]

[0005] US patent 6556779B1 entitled “Pultrusion process to form specially shaped pieces for transforming electric current into diffused heat” discloses a process for producing molded tubular pieces of low rectangular cross-section, for transforming electric current into diffused heat, by means of pultrusion, with continuous forming, adding to known reinforcing materials, such as Roving and fiberglass mats, on a wide side of the molded piece, one or more parallel networks of a woven fabric made of a continuous yarn of highly conductive material coated with insulating material, connected at defined intervals to electrical socket devices incorporated in the plastic material so that, when the molded piece is cut at the position of the devices to form electrical sockets, and filling the panels with insulating foam material, oblong panels are obtained usable for numerous purposes.

[0008] SUMMARY OF THE INVENTION

[0009]

[0006] The present invention aims to provide a manufacturing system for resin-reinforced fiberglass screens, said system comprising a Fiberglass Reinforced Screen Manufacturing Module and a Rebar Manufacturing Module.

[0010]

[0007] In a second aspect, the present invention provides a method for manufacturing screens comprising cross-reinforced fiberglass rods of a given dimension.

[0011]

[0008] In a third aspect, a fiberglass rebar screen is provided according to an embodiment of the present invention.

[0012] TECHNICAL PROBLEM

[0013]

[0009] Despite numerous technologies, such as those described above for the state of the art, offering solutions that reinforce polymer profiles with glass fibers, the need persists for the production of mesh or net profiles that exhibit high quality, high strength, and low manufacturing cost. High value-added resins, such as epoxy resins, are commonly used in the field of the art.

[0014]

[0010] As seen in the prior art presented in the previous item, the state of the art does not include the continuous manufacturing of pultruded screens.

[0015] ADVANTAGES OF THE INVENTION

[0016] The present invention provides a method for producing a pultruded screen, in which a plurality of fiberglass filaments is inserted into a continuous process for producing reinforced fiberglass longitudinal bars that are coated with resin, and in which a transverse bar, previously coated in resin, is inserted, said transverse bar being wrapped by pairs of filaments, each pair of filaments spaced from a second pair of filaments by a certain distance, so as to form a screen. Said resin-bonded fiber screen then undergoes a resin curing process, thus forming a pultruded braided screen. The main advantage of the invention therefore lies in the manufacture of a pultruded braided screen that cannot be disassembled, since both its longitudinal and transverse bars are braided together and subsequently cured into a screen shape.

[0017] BRIEF DESCRIPTION OF THE DRAWINGS

[0018]

[0011] The features of various aspects are presented in detail in the appended claims. The various aspects, however, with regard to both organization and methods of operation, together with additional objects and advantages thereof, can be better understood by reference to the description presented below, considered in conjunction with the attached drawings, as follows.

[0019]

[0012] Figure 1 schematically shows the Reinforced Fiberglass Screen Manufacturing System, according to a first embodiment of the invention.

[0020]

[0013] Figure 2a schematically shows a Fiberglass Reinforced Screen Manufacturing Module.

[0021]

[0014] Figure 2b schematically shows a Rebar Manufacturing Module to be used in conjunction with the Fiberglass Reinforced Mesh Manufacturing Module.

[0015] Figure 3a schematically shows a Roving wire rack according to an embodiment of the present invention.

[0022]

[0016] Figure 3b shows a set of Roving wire shelves in use according to an embodiment of the present invention.

[0023]

[0017] Figure 4a schematically shows an immersion bath for impregnating resin into the fiberglass of the screen.

[0024]

[0018] Figure 4b shows the immersion bath with the wires from the Roving Wire Shelf being immersed in resin, according to one embodiment of the present invention.

[0025]

[0019] Figure 5a shows schematically the screen braiding assembly, in which the threads from the immersion bath are inserted separately into the thread guides to be braided.

[0026]

[0020] Figure 5b shows the Wire Braiding Assembly, which presents the wire guides in a front view.

[0027]

[0021] Figure 5c shows a rear view of the Wire Braiding Assembly featuring unitary braiding discs along its length.

[0028]

[0022] Figure 5d shows a schematic view of the entire wire braiding assembly, showing the transverse wire feed assembly on the left end and the gear assembly responsible for braiding the wire transverse to the longitudinal wires on the right end of said figure.

[0029]

[0023] Figure 5e is an enlargement of the transverse rebar feed assembly of Figure 5d, comprising a motor, a pneumatic cylinder and the rebar feed roller.

[0024] Figure 5f shows an exploded view of one of the plurality of braiding discs of the rebar braiding assembly called the geared locking assembly.

[0030]

[0025] Figure 5g shows a lower platform (5gi) with channels (5g3) that guide the transverse rebar, as the lower platform approaches and moves away from the upper platform (5g2) of the rebar braiding system.

[0031]

[0026] Figure 6a shows a Curing Oven in which prefabricated screens are inserted for curing the reinforcing coating.

[0032]

[0027] Figure 7a represents an optional cooling module that can be used in one embodiment of the invention.

[0033]

[0028] Figure 8a shows the corrugation and cutting module for manufacturing screens according to the present invention.

[0034]

[0029] Figure 9a represents an optional screen positioning module that can be used in an embodiment of the invention.

[0035]

[0030] Figure 10a schematically represents a screen winding device according to an embodiment of the invention.

[0036]

[0031] Figure 10b represents a three-dimensional view of the screen winding device showing the parts that make it up.

[0037]

[0032] Figure 10c represents the screen winding device with the reinforced screen of the invention.

[0038] DETAILED DESCRIPTION OF THE INVENTION

[0039]

[0033] Figure 1 schematically shows a Fiberglass Reinforced Screen Manufacturing System, comprising a rebar manufacturing device (A) and a rebar screen assembly device (B).

[0040]

[0034] The rebar manufacturing device (A) comprises, in a manufacturing sequence, shelves of Roving yarns (A12) where fiber yarns, for example fiberglass, are placed, which will serve as the base for the rebar, according to one embodiment of the invention. Subsequently, these Roving yarns (A12F) are pulled separately from each other into an impregnation bath (A13), at a specific speed, typically between 1.0 and 1.5 m / min. The impregnation bath (A13) contains impregnation resin, such as an epoxy resin, which provides the yarn with alkaline resistance properties, improved tensile strength and modulus of elasticity. In the said impregnation bath (A13), the resin adheres to each Roving strand (A13R) in this process, which results in a final product with 50 to 90%, preferably 80% fiberglass and 10 to 50%, preferably 20% resin.The said resin is any resin known in the art that can be impregnated into glass fibers by pultrusion processes. In an optional embodiment, the impregnated strands are separated from each other by a distance of 1.0 to 50.0 cm. Several roving strands can be used at the same time and the present invention does not aim to restrict this number. In an exemplary embodiment of Figure 3B, 24 roving strands are immersed simultaneously in the impregnation bath (13). In a preferred embodiment, the resin inside the impregnation bath (13B) is heated to a temperature between 10. S C and 80 S C, preferably between 30 and 40 S C through an electrical resistance.

[0041]

[0035] Figure 2a schematically shows a Fiberglass Reinforced Screen Manufacturing Module.

[0042]

[0036] Figure 2b schematically shows a Rebar Manufacturing Module to be used in conjunction with the Fiberglass Reinforced Mesh Manufacturing Module.

[0037] Figure 3a schematically shows a Roving wire rack according to an embodiment of the present invention.

[0043]

[0038] Figure 3b shows a set of Roving wire shelves in use according to an embodiment of the present invention.

[0044]

[0039] Figure 4a represents a schematic view of the impregnation bath (13B). Figure 4b represents two pieces of equipment installed side by side where the Roving wires (13F1) are aligned to subsequently enter the impregnation bath.

[0045]

[0040] It can be seen in Figures 4a and 4b that the Roving yarns (13F1), normally made from fiberglass, enter the impregnation bath through Roving entry holes (1301), normally with a diameter between 1 and 12 cm, preferably between 3 and 8 cm, pass through a first upper roller (13R1) to be pulled to a height slightly higher than the height of the entry holes (for example, between 1 and 50 cm above the Roving yarn entry hole (1301), and then said Roving yarns are directed to a second lower roller (13R2), where the Roving yarns are impregnated with a resin that gives specific properties to said yarns.Subsequently, the resin-impregnated yarn (A13F1) exits the bath towards a third upper roller (13R3), located approximately at the same height as the first upper roller (13R1). The impregnated yarns then proceed to a fourth upper roller (13R4), finally exiting through outlet holes (13O2) for resin-impregnated exit yarns (A13F1). Optionally, the impregnation bath (13B) comprises, after the second lower roller (13R2), a longitudinal bar with spaced pins which, when the resin-impregnated yarns (13F1) pass through them, remove the excess resin from each impregnated yarn. It is understood that in the exemplary embodiment, four rollers are presented to guide the roving yarn through the impregnation bath (13B), but a greater or lesser number of guide rollers could also be used to achieve the same result, and this modification is also included in the scope of the present invention.

[0046]

[0041] The resin-impregnated wires (A13FÍ) exit the impregnation bath (A13) through the outlet holes (1302) towards a rebar screen braiding device (B).

[0047]

[0042] Figure 5a shows schematically the screen braiding assembly, in which the threads from the immersion bath are inserted separately into the thread guides to be braided.

[0048]

[0043] Figure 5b shows the Wire Braiding Assembly, which presents the wire guides in a front view.

[0049]

[0044] Figure 5c shows a rear view of the Wire Braiding Assembly featuring unitary braiding discs along its length.

[0050]

[0045] Figure 5d shows a schematic view of the entire wire braiding assembly, showing on the left end the transverse wire feed assembly (5d1) and on the right end of said figure the gear assembly responsible for braiding the transverse wire to the longitudinal wires (5d2, 5d3). Each braiding disc rotates to twist both longitudinal wires (5d2, 5d3). At the exit of the braiding disc there is a spacing between the 2 longitudinal wires (5d2, 5d3), through which the transverse rebar (which determines the width of the screen) is inserted and pulled to the end of the equipment (5f7). After insertion, the screen is pulled and a new transverse rebar is inserted, thus forming the screen.

[0046] Figure 5e is an enlargement of the transverse rebar feeding assembly of Figure 5d, which comprises a motor (5e3), a pneumatic cylinder (5e1) and the rebar feed roller, called the rebar bushing assembly.In this enlargement, it can be seen that each set of longitudinal wires (5d2, 5d3) is braided onto a transverse rod (5d1), forming the said screen which will then go to the ovens for curing.

[0051]

[0047] Figure 5f shows an exploded view of one of the plurality of braiding discs of the rebar braiding assembly called the interlocking gear assembly.

[0052]

[0048] Figure 5g shows a lower platform (5gi) with channels (5g3) that guide the transverse rebar, while the lower platform approaches and moves away from the upper platform (5g2) of the rebar braiding system. The movement of the lower platform (5gi) is carried out by one or more pneumatic cylinders (5f4) that ensure the synchronicity of the up and down movement towards the upper platform (5gs). An inverted T-shaped plate and a fixing plate are shown in the figure, whose guiding assembly (5f1) marks the movement of the plurality of discs. In an exemplary embodiment of the present invention, the upper platform comprises 29 geared rotation-braiding assemblies (5f3) that are fitted into holes in the upper platform.At the furthest end of the transverse rebar feed there is also a chain-tensioner guide assembly (5f3), through which a transmission chain passes and is driven by a rotary motor (5f6). Also visible in this image is the transverse rebar wire guide structure (5f7) which is fixed below each disc (5f2). In this configuration, the rotary motor causes the discs (5f2) to perform braiding movements of the longitudinal wire assemblies, so that each transverse rebar is braided between each pair of longitudinal wires.

[0053]

[0049] Figure 6a shows a curing oven in which prefabricated screens are inserted for curing the reinforcing coating. Depending on the resin that will be impregnated into the rebar, the curing temperatures will be adjusted as known to one skilled in the art.

[0054]

[0050] Figure 7a represents an optional cooling module that can be used in one embodiment of the invention. The

[0055]

[0051] Figure 8a shows the corrugation and cutting module for manufacturing screens according to the present invention.

[0056]

[0052] Figure 9a represents an optional screen positioning module that can be used in an embodiment of the invention.

[0057]

[0053] Figure 10a schematically represents a screen winding device according to one embodiment of the invention.

[0058]

[0054] Figure 10b represents a three-dimensional view of the screen winding device showing the parts that make it up.

[0059]

[0055] Figure 10c represents the screen winding device with the reinforced screen of the invention.

[0060]

[0056] The rebar mesh braiding device (B) can be considered the most critical point of the present invention. This rebar mesh braiding device (B) is responsible for producing a continuous rebar mesh, which has a width determined (LT) by the width of the mesh width dimensioning device (B14). The mesh width dimensioning device (B14) can have any dimension determined by the operator or customer. For example, wider meshes can be obtained by using the entire length of the impregnated wire entry holes (1401) arranged in the mesh width dimensioning device (B14), and shorter meshes can be obtained by using a number less than the total number of impregnated wire entry holes (1401). In an exemplary embodiment, the impregnated wire entry holes (1401) have an approximate diameter between 1 and 10 cm.In one construction method, the wire mold has a dimension between 1 and 4 meters, particularly between 1.5 and 3.5 meters, and even more particularly between 2 and 3 meters.

[0061]

[0057] The impregnated yarns (1401) that are inserted into the screen width sizing device (B14) may originate from one or more impregnation baths (13B). In an exemplary embodiment, a plurality of Roving Yarn shelves (A12) pass their Roving yarns through a plurality of impregnation baths (A13) to obtain resin-impregnated yarns (A13Fi) that are directed to the screen width sizing device (14). The screen width sizing device (B14) comprises a single input die (14M) of impregnated yarns (1401) of maximum width (Lmax). In a specific embodiment, this single input die has a length ranging from 1 to 5 meters. In an exemplary embodiment - the maximum screen width (Lmax) comprises a plurality of upper entry holes (1401 s) of impregnated wires (1401 ) with spacing determined by the manufacturer's requirement (e).Immediately below each upper entry hole (1401 s), at a determined height between holes (h), there is a lower entry hole (1401 i), in which an upper impregnated filament (B14Fs) and a lower impregnated wire (B14Fs) are arranged so that they are braided together, forming a braided rod (VT).

[0062]

[0058] The braiding of the upper impregnated filament (B14Fs) to the lower impregnated filament (B14Fs) in the rebar screen mounting device (B) is done as follows:

[0063] • Both the upper (B14Fs) and lower (B14F1) filaments are inserted into a braiding disc (B14Ox);

[0064] • The said braiding disc (B14Ox) is pivotable in relation to its axis, so that when rotating, it braids the upper (B14Fs) and lower (B14FÍ) filaments before entering the braiding disc.

[0065] • After the said braiding disc (B14Ox), a transverse filament from the rebar manufacturing device (A) is inserted transversely to the resin-bonded braided rebars, so close to the exit of the upper and lower filaments that it is inserted between each pair of upper and lower filaments;

[0066] • After this insertion, the screen traction is activated longitudinally to move the assembly formed by the braiding of the upper and lower longitudinal filaments with the transverse filament, causing the braiding disc (B14Ox) to pivot around its axis to form another sequence of screen grids.

[0067]

[0059] For example, each upper hole (for example, with a diameter between 0.5 and 50 cm) is spaced from the other upper hole by a predetermined distance, for example 1 cm to 50 cm, more specifically. Similarly, each lower hole (for example, with a diameter between 0.5 and 50 cm) is spaced from the other lower hole by a predetermined distance, for example 1 cm to 10 cm, more specifically.

[0068]

[0060] The longitudinally braided rebar (VTL) then exits the screen width dimensioning device (B14) through the braiding disc (B14Ox), and proceeds to the screen curing oven (B16)

[0069]

[0061] The set of braided rods (VTL) that then come out of the screen width dimensioning device (B14), dimension the total width of the screen that will be manufactured according to an embodiment of the invention.

[0070]

[0062] Right at the exit of the plurality of braided longitudinal rebars (VTL) that go to the screen curing oven (B16), a transverse braided rebar (VTT) is supplied, which is inserted between both the upper impregnated filament (B14Fs) and the lower impregnated filament (B14Fs)).

[0071]

[0063] After the insertion of the transverse braided rebar (VTT) between the upper impregnated filament (B14Fs) and the lower impregnated filament (B14Fs), the disc pivots again to form the braiding of the longitudinal transverse rebar (VTL).

[0072]

[0064] The cross rebar feeder (C1) is a feeder that holds the fiberglass rebar roll coming from a rebar manufacturing machine (e.g., manufactured by KORTH FIBER®).

[0073]

[0065] The transverse braided rebar (VTT) is manually fed transversely after the screen exits the screen width sizing device (B14). As an example, it is suggested that the transverse rebar feeder (C1) contain at least 400 meters of rebar so that the system's handling time is reduced and the screen production speed is increased. This feeder unwinds the transverse rebar directly from the screen width sizing device (B14).

[0074]

[0066] The formed screen that comes out of the screen sizing device (B14) already with the longitudinal braided rods is then sent to a set of furnaces (B16), which in a preferred embodiment, consists of 3 furnaces.

[0075]

[0067] Optionally, after the furnace assembly (B16), the cured screen may be sent to a screen cooling device (B17), in which the screen is cooled in open air, water or by any other means known in the art. In an exemplary embodiment, the screen cooling device (B17) comprises a water pump for cooling the screen that has been heated in the furnace assembly (B16).

[0076]

[0068] After the screen has been cooled in the open air or by means of the cooling device, it then goes to the traction corrugated assembly (B18) which pulls the screen according to the programming done on the CNC and is one of the most important points in the screen manufacturing process.

[0077]

[0069] Finally, after the screen exits the corrugated traction assembly (B18), it proceeds to the cutting assembly (B19). In one embodiment, the cutting system is of the flying type, where length control is done by reading the servomotor encoder and executed as programmed by the operator.

[0078]

[0070] Optionally, after the screen is cut in the cutting unit (B19), it can proceed to a positioning / alignment table (B20).

[0071] Finally, the cut screen goes to a finished screen accumulator device (B21) which winds the cured screen around an axis to the length desired by the customer.

[0079] Embodiments of the present invention

[0080]

[0072] In a first embodiment, a pultruded woven fabric manufacturing system is provided comprising:

[0081] a. to continuously supply a plurality of longitudinal glass fiber roving filaments (A12F);

[0082] b. provide a first resin immersion bath (A13a), wherein each of the plurality of longitudinal fiberglass roving filaments is pulled into the resin immersion bath, in which said resin envelops the longitudinal fiberglass filament forming a resin-coated longitudinal rebar (A13R);

[0083] whereby the said system additionally includes:

[0084] c. a braiding module comprising

[0085] i. a vertical screen width sizing device (B14) for aligning resin-bonded longitudinal rods, comprising a set of upper holes (14O1 s) spaced apart by a hole spacing (e); each upper hole being configured to align an upper impregnated filament (B14Fs), each upper hole having below it a lower hole (14O1 i) for aligning a lower impregnated filament (B14Fi), said lower hole being spaced from the upper hole by a determined hole height (h); ii. and a second vertical support comprising a plurality of braiding discs (B14Ox), each braiding disc separated from each other by a defined distance; iii.each braiding disc (B14Ox) comprising two holes through which the first longitudinal rebar and the second resin-coated longitudinal rebar are pulled; wherein the first longitudinal rebar and the second longitudinal rebar are braided through the holes of the braiding disc (B14Ox), which operates in a pivoting manner on its axis, before and after passing through said holes of the braiding disc, forming a braided longitudinal rebar (VTL);

[0086] d. a resin-bonded crossbar feeder (C1) comprising:

[0087] i. a roll of transverse glass fiber filament. Said filament can be drawn into a second resin immersion bath (A13), in which said resin envelops the transverse glass fiber filament forming a resin-coated transverse rod (for example, with a composition of 80% glass fiber and 20% resin);

[0088] ii. a traction device capable of pushing the transverse rebar towards the longitudinal rebars, parallel to the braiding discs.

[0089] iii. a device for cutting resin-bonded crossbar, where the cut length of the crossbar defines the width of the screen produced;

[0090] Whereas when the first longitudinal rebar and second longitudinal rebar exit the braiding disc (B14Ox), before the braiding after the braiding disc (B14Ox), said transverse rebar (VTT) is inserted transversely next to the exit of the braiding disc (B14Ox), through a transverse rebar guide (VTT), so that, by pivoting the braiding disc (B14Ox) the first longitudinal rebar and second longitudinal rebar are braided around said transverse rebar, forming the structure in the shape of a mesh;

[0091] After the braiding of the first longitudinal rebar and the second longitudinal rebar together with the transverse rebar, the mesh-shaped structure is tensioned so that a new braiding of transverse rebar occurs, the distance of each tensioning delimiting the lateral edge of the mesh;

[0092] e. wire mesh curing oven (B16), in which the wire mesh woven with longitudinal and transverse rebars is inserted, forming a cured wire mesh;

[0093] f. a cured rebar mesh cooling table, in which cured mesh is cooled;

[0094] g. a CNC-operated corrugated pull-out assembly (B18) that pulls the cooled screen, directing it for cutting;

[0095] h. a screen cutting device, configured to cross-cut the screen to a predetermined screen length; i. a finished screen accumulator device (B21) that rolls the cured rebar screen around its axis to the predetermined length.

[0096]

[0073] In an additional embodiment, the system, according to embodiment 1, has the characteristic that the resin-impregnated filaments pass through said immersion bath (A13) at a speed between 1.0 and 1.5 m / min, said impregnated filaments are spaced apart by a distance between 1.0 and 50.0 cm, and said impregnation bath is heated to a temperature between 10 S C and 80 S C, preferably between 30 and 40 S C through an electrical resistance.

[0097]

[0074] In an additional embodiment, the system, according to embodiment 1, is characterized by the resin-impregnated filaments having a composition of 50 to 90%, preferably 80%, fiberglass and 10 to 50%, preferably 20%, resin.

[0098]

[0075] In a second embodiment, a method for manufacturing a pultrusion-based mesh of woven rebar is presented, comprising:

[0099] a. provide a plurality of longitudinal glass fiber filaments;

[0100] b. to coat said longitudinal fiberglass filaments in resin, obtaining resin-coated longitudinal reinforcing bars;

[0101] c. to separate said resin-bonded longitudinal rods into pairs, causing a first longitudinal rod and a second longitudinal rod to be braided together before and after by a braiding disc, pivoting on its axis, to form a braided longitudinal rod;

[0102] d. Insert a resin-bonded transverse rebar, formed from fiberglass filaments and resin, immediately after the braiding discs, so that the transverse rebar is inserted between the first longitudinal rebars and the second longitudinal rebars secured in their respective braiding discs;

[0103] e. braid each first longitudinal rebar and each second longitudinal rebar with the transverse rebar inserted into them, forming a mesh; f. pull the mesh towards a curing oven to cure the resin and obtain the cured rebar mesh; and

[0104] g. cut the screen to a predetermined length.

[0105]

[0076] In a third embodiment, a woven rebar screen is presented which is manufactured by the pultruded screen manufacturing system as defined in embodiment 1 above or manufacturing method as defined in embodiment 2 above.

[0106]

[0077] The embodiments of the present invention have been described above in detail with reference to the drawings, but the specific configuration is not limited to these embodiments and includes, for example, an amendment to a design that falls within the scope and does not depart from the scope of the present invention.

[0107]

[0078] In general, the system offers the production of 3.2, 4.2, and 6.2 mm fiberglass screens. In an exemplary configuration, the screen length can be any length desired by the customer, for example 5 meters, more specifically 3 meters.

[0108]

[0079] Usually, the longitudinal reinforcing bars of the present invention will have a diameter of 1 to 10 mm, preferably between 2 mm and 6 mm.

[0109]

[0080] The machines can be operated by CNC control with independent speed control and central control panel.

[0110]

[0081] Various modifications are possible within the scope of an aspect of the present invention defined by the claims, and embodiments that are produced by the appropriate combination of the technical means disclosed according to different embodiments are also included in the technical scope of the present invention. Also included in the technical scope of the present invention is a configuration in which constituent elements, described in the embodiments and having mutually the same effects, are substituted for one another.

Claims

CLAIMS:

1. PULTRUTED WOVEN SCREEN MANUFACTURING SYSTEM comprising: a. to continuously supply a plurality of longitudinal glass fiber roving filaments (A12F); b. provide a first resin immersion bath (A13a), wherein each of the plurality of longitudinal fiberglass roving filaments is pulled into the resin immersion bath, in which said resin envelops the longitudinal fiberglass filament forming a resin-coated longitudinal rebar (A13R); characterized in that it additionally comprises c. a braiding module comprising i. a vertical screen width sizing device (B14) for aligning resin-bonded longitudinal rebars, comprising a set of upper holes (14O1 s) spaced apart by a hole spacing (e); each upper hole being configured to align an upper impregnated filament (B14Fs), each upper hole having below it a lower hole (14O1 i) for aligning a lower impregnated filament (B14Fi), said lower hole being spaced from the upper hole by a determined hole height (h); ii. and a second vertical support comprising a plurality of braiding discs (B140x), each braiding disc separated from each other by a defined distance; iii. each braiding disc (B14Ox) comprising two holes through which the first longitudinal rebar and the second resin-bonded longitudinal rebar are split; wherein the first longitudinal rebar and second longitudinal rebar are braided through the holes of the braiding disc (B14Ox), which operates in a pivoting manner on its axis, before and after passing through said holes of the braiding disc, forming a braided longitudinal rebar (VTL); d. a transverse rebar feeder (C1) comprising: i. a roll of transverse rebar; ii. a transverse rebar puller for positioning the transverse rebar perpendicular to the plurality of resin-bonded longitudinal rebars, after the braiding disc (B14Ox); iii. a device for cutting the resin-coated transverse rebar, wherein the cut length of the transverse rebar defines the width of the produced mesh; wherein when the first longitudinal rebar and second longitudinal rebar exit the braiding disc (B14Ox), before braiding after the braiding disc (B14Ox), said transverse rebar (VTT) is inserted transversely next to the exit of the braiding disc (B14Ox), through a transverse rebar guide (VTT), so that, by pivoting the braiding disc (B14Ox), the first longitudinal rebar and second longitudinal rebar are braided to around said transverse rebar, forming a screen-like structure; After the braiding of the first longitudinal rebar and the second longitudinal rebar together with the transverse rebar, the mesh-shaped structure is tensioned so that a new braiding of transverse rebar occurs, the distance of each tensioning delimiting the lateral edge of the mesh; e. wire mesh curing oven (B16), in which the wire mesh woven with longitudinal and transverse rebars is inserted, forming a cured wire mesh; f. a cured rebar mesh cooling table, in which cured mesh is cooled; g. a CNC-operated corrugated pull-out assembly (B18) that pulls the cooled screen, directing it for cutting; h. a screen cutting device, configured to cross-cut the screen to a predetermined screen length; i. a finished screen accumulator device (B21) that winds the cured rebar screen around its axis to the predetermined length.

2. SYSTEM, according to claim 1, characterized in that the resin-impregnated filaments pass through said immersion bath (A13) at a speed between 1.0 and 1.5 m / min, said impregnated filaments are spaced apart by a distance between 1.0 and 50.0 cm, and said impregnation bath is heated to a temperature between 10 S C and 80 S C, preferably between 30 and 40 S C through an electrical resistance.

3. SYSTEM, according to claim 1, characterized in that the resin-impregnated filaments have a composition of 50 to 90%, preferably 80%, fiberglass and 10 to 50%, preferably 20%, resin.

4. METHOD FOR MANUFACTURING BY PULTRUSION A MESH OF WOVEN REBAR, characterized in that it comprises: a. provide a plurality of longitudinal glass fiber filaments; b. to bathe said longitudinal fiberglass filaments in resin, obtaining resin-coated longitudinal reinforcing bars; c. to separate said resin-coated longitudinal reinforcing bars into pairs, causing a first longitudinal reinforcing bar and a second longitudinal reinforcing bar to be braided together before and after by a braiding disc, pivoting on its axis, to form a braided longitudinal reinforcing bar; d. Insert a resin-bonded transverse rebar, formed from fiberglass filaments and resin, immediately after the braiding discs, so that the transverse rebar is inserted between the first longitudinal rebars and the second longitudinal rebars secured in their respective braiding discs; e. braid each first longitudinal rebar and each second longitudinal rebar with the transverse rebar inserted into them, forming a mesh; f. pull the screen towards a curing oven to cure the resin and obtain cured rebar screen; and g. cut the screen to a predetermined length.

5. Woven rebar mesh, characterized by being manufactured by the pultruded mesh manufacturing system as defined in claim 1 or by the manufacturing method as defined in claim 2.

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