Composite Rebar Technologies, Inc.

Composite Rebat Technologies, Inc.

Robert C Gibson

Matthew H Noble

Trent J Garber

Thomas S Ohnstad

Thomas A Hershberger

John R Hillman

Sean Walsh

Gregory A Zjaba

Richard A Schulte

A method for making a plural-component, composite-material, highway dowel-bar including (1) preparing an elongate core train possessing endo-abutting, longitudinally alternating, (a) elongate, high-shear-strength, cylindrical cores having a common cross section, and (b) elongate, but shorter, cylindrical, fibre-reinforced plastic-resin end-plug blanks having opposite ends, and each having a cross section matching the cross section of the cores, (2) using the core train as a longitudinally moving mandrel, pultrusion-forming a fibre-reinforced plastic-resin sleeve continuously and bondedly around the core train so as to produce a pultrusion-result, intermediate, dowel-bar product, and (3) following pultrusion-forming, cross-cutting the intermediate, dowel-bar product at each longitudinal location therein which is intermediate the opposite ends of the end-plug blanks, thereby to form completed dowel bars.

Plural-component, composite-material highway dowel bar fabrication methodology

A rebar structure for concrete reinforcement may include an elongate tubular central wall portion having an inside surface and an outside surface. The central wall portion may be formed circumferentially around a core axis and may include glass or carbon fibers mostly being oriented longitudinally parallel to the core axis. The rebar structure may include an inner wall portion bonded to the inside surface of the central wall portion. The inner wall portion may include glass or carbon fibers and may have a higher percentage of fibers oriented non-parallel to the core axis as compared to the central wall portion.

Hollow, composite rebar structure, associated fabrication methodology, and apparatus

A method for making a plural-component, composite-material, highway dowel-bar including (1) preparing an elongate core train possessing endo-abutting, longitudinally alternating, (a) elongate, high-shear-strength, cylindrical cores having a common cross section, and (b) elongate, but shorter, cylindrical, fiber-reinforced plastic-resin end-plug blanks having opposite ends, and each having a cross section matching the cross section of the cores, (2) using the core train as a longitudinally moving mandrel, pultrusion-forming a fiber-reinforced plastic-resin sleeve continuously and bondedly around the core train so as to produce a pultrusion-result, intermediate, dowel-bar product, and (3) following pultrusion-forming, cross-cutting the intermediate, dowel-bar product at each longitudinal location therein which is intermediate the opposite ends of the end-plug blanks, thereby to form completed dowel bars.

Elongate, composite-material, hollow rebar structure, along with associated components, related fabrication apparatus, and apparatus-implemented, rebar-structure-making methodology. The rebar structure has a long axis, and includes (a) an elongate, hollow core centered on that long axis, (b) an elongate, hollow sleeve having inner and outer surfaces, circumsurrounding the core along the core's length, with the sleeve's inner surface bonded to the core's outer surface along the length thereof, and (c) longitudinally distributed, radial-dimensionality, external-purchase-enhancing structure formed unitarily with the sleeve's outer surface along the length thereof. The bond existing between the core and the sleeve takes the form of a single-cure, reverse-temperature-gradient-cure, plastic-material, molecular bond.

Hollow, composite-material rebar structure, associated components, and fabrication apparatus and methodology

Apparatus possessing elongate, long-axially aligned componentry for making hollow, composite-material rebar including (a) a hollow mandrel disposed upstream in the apparatus, (b) a hollow pultrusion die circumsurrounding the mandrel for forming a composite-material hollow core in the space between it and the mandrel, and (c) a hollow, continuous-transfer-molding die spaced downstream from the pultrusion die, having a central long axis about which it is rotatable, operable to form, along the length of a core which has been formed in the pultrusion die, (1) an elongate, composite-material, core-circumsurrounding, hollow sleeve having an outer surface, and (2), unitarily with the sleeve, and in a manner distributed along the length of the sleeve's outer surface, an external-purchase-enhancing structure possessing radial-dimensionality.

Hollow, composite-material rebar fabrication apparatus

A method of making an elongate, composite-material, hollow rebar structure including (a) forming an elongate, composite-material, hollow core, (b) in association with such forming, preparing along the core's length an elongate, composite-material, core-circumsurrounding, hollow sleeve having inner and outer surfaces, (c) in association with such preparing, creating, unitarily with the sleeve, and in a manner distributed along the length of the sleeve's outer surface, an external-purchase-enhancing structure possessing radial-dimensionality, and (d) bonding the inner surface of the sleeve to the outer surface of the core.

Hollow, composite-material rebar fabrication methodology

A plural-component, composite-material highway dowel bar and an associated fabrication methodology. The dowel bar includes an elongate, solid-cylindrical, high-shear-strength core bar, preferably steel, and an elongate, fiber-reinforced plastic-resin jacket, including an elongate, pultrusion-formed, tubular sleeve, and sleeve-received, opposite-end, end-well sleeve end plugs, fully surrounding and protectively covering the core bar.

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Madison, WI, United States of America

Robert C Gibson