# Patent

## Title
Reinforcing fiber and material formed therewith

## Abstract

A reinforcing fiber and reinforced material, which includes a fiber having a first radical wave therein, wherein said first radical wave includes an amplitude of between about 0.5 to 1 cm and a wave run width of about 0.05 to about 0.3 cm, and a leading run and trailing run of at least about 0.75.

## Background
BACKGROUND OF THE INVENTION
Field of Invention
The invention relates to a reinforcing fibers for use in concrete. Particularly, the invention relates to improvements in concrete through use of the specific geometric reinforcing fiber.
Prior Art
There are various wire designs for mixing in concrete material. Such wire designs are for the reinforcement of synthetic resins, plastics, rubber and other materials, especially mortar and concrete, which only offer a small resistance to a tensile force. These typically employ pieces of wire, made of steel, glass fiber or another synthetic material of high tensile strength which, when mixed up in a material with enhanced strength.
In order to improve the strength characteristics for a given weight of wire material, it has been previously proposed to increase the concentration of wires in the mass by a greater subdivision of finer wires. Various length and diameter ratios have been tried to enhance grip of the wire on the material. In addition, corrugations, helicoidal or ring shaped wires have been tried to improve strength and hold.
The prior use of polymeric fibers (especially polypropylene) has to date remained limited to control of plastic shrinkage cracking in freshly placed concrete resulting from loss of mix and bleed water through evaporation. Given their non structural purpose, the volume fractions of fibers used in these applications have also remained low (approximately 0.1%). The load carrying capacity of plain concrete without fiber reinforcement or that of concrete carrying a minimal amount of polypropylene fiber reinforcement (approximately 0.1% by volume) beyond matrix cracking is essentially zero. There have been some attempts to introduce greater volume fractions (about 1%) of larger diameter polypropylene fiber into concrete. These fibers have brought polymeric materials into the category of “structural” fibers Where the purpose is not so much to control plastic shrinkage cracking, but also to improve the toughness, energy absorption capability and the load carrying capacity of concrete beyond first matrix cracking.
The prior “structural” polypropylene fibers develop a poor bond with the surrounding matrix and are not very efficient. What is not known to-date, however, is what constitutes an optimal deformation for a low modulus material as polypropylene. One attempt used a sinusoidally configured fibers for reinforcing concrete and like materials.
One of the complications in adding such wires is the inability to mix these in a manner which disperses them to a degree which meet the goals of enhanced strength. If the wires for fibers tend to cluster then there is created a weak spot in the resultant material. There is a continued need to find the best geometric solution and composition for enhancing the strength such materials.
The instant invention is believed to address the needs of finding and improved a geometric design for a fiber which also meets acceptable new mix-ability.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide and improved geometric fiber design for use in enhancing material strength.
Another object invention, is to provide a fiber of a geometric design which lends itself to greater mix-ability.
Accordingly, the invention is directed to an improved fiber for reinforcing construction materials. The fiber preferably is made of a polymer having a wave therein, wherein the wave includes an amplitude of between about 0.5 to 1 cm and a wave run width of about 0.05 to about 0.3 cm, a leading run and trailing run of at least about 0.75 to about 1 cm long. A preferred fiber length is about 5 cm. In a preferred embodiment, the wave includes a leading edge and a trailing edge which are generally normal to the leading and trailing run and form part of generally square wave. A preferred fiber cross-sectional width can preferably be between 0.2 to 0.3 cm. and a linear density between about 2500 to 4500 Denier. Additionally, another aspect of the invention is to provide the fibers in a manner to interconnect the same.
By using the above fiber structure, there is provided an improved fiber which is exceptional for increased strength as well as mix-ability. Various objects, features and advantages will clearly appear from the detailed description given below taken in connection with the accompanying drawings which form part of this specification and illustrate merely by way of examples embodiments of the invention.



BRIEF DESCRIPTION OF THE DRAWINGS
In the following description and in the claims, parts will be identified by specific names for convenience, but such names are intended to be as generic in their application to similar parts as the art will permit. Like reference characters denote like parts in the several figures of the drawings in which:
FIG. 1A is a perspective illustration of a reinforcing fiber geometry according to the invention;
FIG. 1B is a perspective illustration of another embodiment of reinforcing fiber geometry according to the invention;
FIG. 2 illustrates another aspect of a reinforcing fiber according to the invention;
FIG. 3 illustrates comparative examples of fibers tested according to the invention;
FIG. 4 shows a top view comparative example of fibers tested according to the invention;
FIG. 5 is an illustration of a method used to hold a fiber for purposes of analyzing.
FIG. 6 is an illustration of a fiber of the invention embedded in a mortar block for purposes of analyzing.
FIG. 7 shows an image of a comparative test fiber having a nob end.
FIG. 8 shows fibers tested in accordance with those in FIG. 3.



DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Referring now to the drawings, the reinforcing fiber of the instant invention is generally designated by the numeral 100. The term “reinforcing” as used herein refers to a fiber with increased strength as well as mix-ability. The reinforcing fiber 100 preferably is made of a polymer having a wave 102 therein. The wave 102 includes an amplitude A of between about 0.5 to 1 cm and a wave width W of about 0.05 to about 0.3 cm, a leading run LR and trailing run TR of at least about 0.75 to about 1 cm long. A preferred length of fiber 100 is about 5 cm with distance between two peaks of radical waves 102 separated by at least about 1.5 to 3 cm, and preferably 3.
In a preferred embodiment, the wave 102 includes a leading edge 104 and a trailing edge 106 which are generally normal to the leading run LR and trailing run TR and and include a peak run 108 form part of generally square wave. This is represented in FIG. 1A and FIG. 1B. A preferred fiber cross-sectional width CS can preferably be between 0.2 to 0.3 cm. and a linear density between about 2500 to 4500 Denier.
Tests were provided on seven different fiber materials, specifications of each fiber material can be seen in Table 1 and photos of the fibers are shown in FIG. 4. All seven fibers were used in the single fiber pullout tests. Only type 1 seen in FIG. 4 was used for the study of end anchoring mechanisms.
The fibers were cast in 2′′×2′′×2′′ mortar cubes. A jig was used to ensure the fibers were vertical during curing. After the mortar was set, the cubes were placed in an environmental room for further curing. The mortar mix was designed with the proportions shown in Table 2 with the procedures summarized in Table 3. After seven days, the strength of the mortar was tested and found to have strength in excess of 4000 psi.
The cubes were cured in the lab for one day, and then removed from the molds and placed in an environmental room (62 degrees Fahrenheit, 100% humidity) until the age of 7 days. Testing was conducted at the age of 7 days.







TABLE 1







Fiber Material Specifications












Material


Cross Sectional Area



Number
Denier
Crimp Pattern
(mm2)















 1
4500
18
0.709



 2
TBD
Indented
0.482



11
2500
18
0.558



12
2500
6.5
0.455



14
2500
22
0.512



15
2500
6.5
0.483



16
4500
6.5 hi amplitude 
0.717
















TABLE 2





Ratio


















Water:Cement
.42



Sand:Cement
2.33


















TABLE 3






Time (seconds)
Instructions


















0
Mix concrete and water on low speed



30
Add sand



90
Stop mixing



150
Mix at medium speed



240
Mixing is complete









Tests were performed to explore the effects of various crimping patterns on the hold of a fiber placed in a cube of mortar. The goal of the testing was to draw both comparative and overall conclusions from the results. The tests also explored end anchoring mechanisms implemented on the fibers and their effect on the overall hold of the fiber in cube of mortar.
Procedure
An Instron 4502 universal test machine was used to provide consistent force and displacement data when performing the test. Each fiber and cube was mounted in the test machine. The fibers were mounted in a manner that limited slippage using vise fixtures. The fiber was compressed in a grip that used wood spacers that were secured by the vise fixtures (FIG. 3). Two wooden spacers (3 mm thick) were used to protect the fiber from the sharp grooves of the vice and increase friction while preventing the fibers from being over compressed (FIG. 4). Preliminary tests showed that an overly tight grip led to failure of fibers within the grip zone, and the grip tightness was set appropriately during the actual tests.
Mortar cubes, such as seen in FIG. 6, were installed in a test machine having fiber 100 there with a free fiber end 110 extending outside the block. The free end 110 was gripped by of the test machine. This fixture ensured that the mortar cubes were secure and level.
Each fiber sample was installed with an exposed fiber length of 30 cm between the cube and a vise used to grip the fiber. The fiber 10 was manually loaded to 10 N to remove slack. Then, the test proceeded under displacement control to elongate the fiber at a rate of 20 mm/min until failure. Data collection of load and position was recorded at the rate of 1 hz.
End Anchorage Methods
An end anchorage method is a unique shape or “radical wave” created at the end of a fiber 100 to provide a mechanical hold beyond the crimp pattern of the fiber 100. There were four anchorage methods tested.
End Anchorage Example 1: Nub
This method created a nub 51 at the end of the fiber 50. This nub 51 was produced by melting the end of a normal fiber 50. When there was a small collection of molten polypropylene, the nub 51 was shaped by using pliers to compress the fiber 10 as seen in FIG. 7.
Other end anchorage methods employed examples 2, 3, and 4 are all founded in the idea of creating a large disparity (wave 102) at the end of the fiber 100. A radical wave is a relatively large feature that is superimposed over a normal crimp pattern of the fiber 100. The end anchorage methods employ examples 2, 3, and 4 which are all radical waves, each method consists of a different radical wave shape, generally represented as shown in FIG. 8 (wherein radical ave of end anchorage in examples 2, 3 and 4 are shown in a scale of centimeters. The observed breakage is as follows:
Splayed Fiber
The fiber 100 is pulled out of the mortar cube with great damage to the fiber end 110. The fibrils within the fiber 100 are splayed and separated during the failure. The splaying can be isolated at the fiber end 110 or it may be observed along the full exposed length of the fiber 100, from block to grip.
Break at Nub
End anchorage example 1 involves melting the fiber 50 to create a nub 51 at the fiber end. The fiber 50 has a tendency to break at the end nub 51. The melting evidently weakens the fiber 50 and creates a vulnerability to failure.
Cut Fiber
In anchorage examples 2, 3, and 4, there is a point at the apex 108 of the curve in the fiber 100 where the mortar binds the fiber 100 and may create a cutting edge that fails the fiber 100 when the tensile load becomes high. This was the most common failure mechanisms observed for anchorage examples 3 and 4 due to the small run width at the apex of the wave 102. In anchorage example 2, there is a wider run width, of about 0.2-0.3 cm at the apex, creating a square wave shape and the mortar is noted less likely to create a sharp edge.
Results
Single Fiber Pull Out Results
Three replicates were tested for each fiber material. Each fiber had an implanted depth of 20 millimeters into the cube of mortar. The average results can be seen in Table 4.







TABLE 4







Average Results for Single Fiber Pull Out Tests












Load at
Cross
Fiber Tensile



Fiber
Failure
Sectional
Stress at
Mode of


Material
(N)
Area (mm2)
Failure (ksi)
Failure














1
156
0.709
31.9
Clean pullout


2
96.7
0.482
29.1
Clean pullout


11
120.3
0.558
31.3
Clean pullout


12
110.7
0.455
35.3
Clean pullout


14
148.3
0.512
42
Splayed fiber


15
90.7
0.483
27.2
Clean pullout


16
200.7
0.717
40.6
Splayed fiber









End Anchorage Results

Three replicates were tested for each end anchorage method. All tests used fiber material 1. The result of fiber material 1 from the single fiber pull out test without end anchorage is included as reference value in Table 5.







TABLE 5







Average Results for End Anchorage Method Tests











End
Load at
Cross
Fiber Tensile



Anchorage
Failure
Sectional
Strength at
Mode of


Method
(N)
Area (mm2)
Failure (ksi)
Failure














Reference:
156
0.709
31.9
Clean pullout


Fiber 1 w/o end






anchorage






1
158.3
0.675
34
Break at Nub


2
266.7
0.661
58.5
Splayed fiber


3
229.7
0.677
49.2
Clean pullout


4
252.3
0.712
51.4
Cut fiber









CONCLUSIONS
1. Fiber types 1, 14 and 16 developed highest pullout load. Taking the cross-sectional area into account, fiber types 14 and 16 developed the highest tensile stress at failure, suggesting that these crimp patterns are the best performers in simple pullout tests.

2. The best performance was associated with crimp patterns with large amplitude and “kinky” rather than “smooth wave” texture. These shape characteristics contribute to secure bond of the fiber in mortar.

3. The end anchorage tests were very encouraging with pullout loads much greater than for fibers without the end anchorage.

4. The nubs created by melting the end of fibers led to breakage at the nub, suggesting this option may not be attractive.

5. All the “radical wave” fibers showed excellent performance. Pullout loads with “radical wave” designs were more than 50% greater than fibers without wave example end anchorage. End anchorage example 2 performed the best out of the “radical wave” designs.











Single Fiber Pull Out Test Results















Cross






Thick-
Sectional
Load at
Tensile



Width
ness
Area
Failure
Strength


Code
(mm)
(mm)
(mm2)
(N)
N/mm{circumflex over ( )}2















SF-20-0101
1.5 
0.45
0.675
184
272.5925926


SF-20-0102
1.62
0.45
0.729
151
207.133059 


SF-20-0103
1.57
0.46
0.7222
133
184.1595126


SF-20-0201
1.09
0.45
0.4905
116
236.4933741


SF-20-0202
1.09
0.4
0.436
 87
199.5412844


SF-20-0203
1.06
0.49
0.5194
 87
167.5009626


SF-20-1101
1.61
0.34
0.5474
 91
166.2404092


SF-20-1102
1.53
0.3
0.459
114
248.3660131


SF-20-1103
1.63
0.41
0.6683
156
233.4281012


SF-20-1201
1.42
0.34
0.4828
136
281.6901408


SF-20-1202
1.16
0.29
0.3364
 93
276.4565993


SF-20-1203
1.44
0.38
0.5472
103
188.2309942


SF-20-1401
1.41
0.34
0.4794
148
308.7192324


SF-20-1402
1.35
0.32
0.432
111
256.9444444


SF-20-1403
1.6 
0.39
0.624
186
298.0769231


SF-20-1501
1.28
0.32
0.4096
116
283.203125 


SF-20-1502
1.54
0.37
0.5698
 63
110.5651106


SF-20-1503
1.34
0.35
0.469
 93
198.2942431


SF-20-1601
1.82
0.47
0.8554
207
241.9920505


SF-20-1602
1.63
0.42
0.6846
190
277.5343266


SF-20-1603
1.53
0.4
0.612
205
334.9673203



















End Anchorage Examples















Cross






Thick-
Sectional
Load at
Tensile



Width
ness
Area
Failure
Strength


Code
(mm)
(mm)
(mm2)
(N)
N/mm{circumflex over ( )}2





EA01-20-0101
1.49
0.44
0.6556
147
224.2220866


EA01-20-0102
1.59
0.44
0.6996
109
155.8033162


EA01-20-0103
1.52
0.44
0.6688
219
327.4521531


EA02-20-0101
1.57
0.45
0.7065
290
410.4741684


EA02-20-0102
1.51
0.42
0.6342
254
400.5045727


EA02-20-0103
1.46
0.44
0.6424
256
398.505604 


EA03-20-0101
1.53
0.45
0.6885
230
334.0595497


EA03-20-0102
1.56
0.42
0.6552
245
373.9316239


EA03-20-0103
1.53
0.45
0.6885
214
310.8206245


EA04-20-0101
1.62
0.48
0.7776
270
347.2222222


EA04-20-0102
1.45
0.41
0.5945
235
395.2901598


EA04-20-0103
1.66
0.46
0.7636
252
330.015715 









Useful fibers can include thermoplastics including polyolefins, such as polyethylene and polypropylene; poly esters; polyvinyl chloride; polyvinylidene chloride; polyamides including aromatic polyamides, such as KEVLAR®; polyacrylics, and mixtures thereof. The thermoplastic fibers can be 100 percent homopolymer, they can have copolymers and polymer blends. material can be modified with coatings or filler. The material must be of a type to lend itself to addition to concrete. A fiber can be referred to by its polymeric name e.g., polypropylene, if it is at least primarily polypropylene rather than comprising 100 percent polypropylene. In other words, selection of the thermoplastic polymer does not constitute a limitation of the present invention. Practical considerations for fiber selection include creep resistance, a strong trait of polyesters, and dispersibility of the fiber in the concrete mixture, although the absence of either one of these properties should not eliminate a particular polymer invention.
In addition to the radical wave described herein, the fiber 100 can includes a plurality of conventional smaller crimps, such as a small sinusoidal configuration in addition the radical wave 102. The value of the fiber 100 as an additive to reinforce concrete is in the increased force and energy expended to pull the bonded fiber from the concrete which is limited by the ultimate tensile strength (UTS) of the fiber 100 where failure occurs and it can no longer resist the separation between previously continuous sections of concrete.
The invention is not limited to the materials which have been mentioned, nor to the forms of fiber which have been shown, so it is possible to obtain wire elements of the same form with other fibers. Those skilled in the art can vary the material and amount of the fiber 100 for particular use. While the invention has been described and illustrated with respect to certain preferred examples which give satisfactory results, it will be understood by those skilled in the art after understanding the principle of the invention, that various changes and modifications may be made without departing from the spirit of the invention.

## Claims

1. A reinforcing fiber, which includes:
a polymer fiber having a first radical wave therein, wherein said first radical wave includes an amplitude of between about 0.5 to 1 cm and a wave run width of about 0.05 to about 0.3 cm, and a leading run and trailing run of at least about 0.75 cm, wherein said wave includes a leading edge and a trailing edge which are normal to said leading run and said trailing run and form part of square wave.

2. The reinforcing fiber of claim 1, wherein said polymer fiber cross-sectional width can be between 0.2 to 0.3 cm. and a linear density between about 2500 to 4500 Denier.

3. The reinforcing fiber of claim 1, having a second radical wave therein, wherein said second radical wave includes an amplitude of between about 0.5 to 1 cm and a wave run width of about 0.05 to about 0.3 cm, and a leading run and trailing run of at least about 0.75 cm, wherein said leading run of said first radical wave interconnects said trailing run of said second radical wave.

4. The reinforcing fiber of claim 3, wherein at least of said leading run of said second radical wave and said trailing run of said first radical wave are separated by about 1.5 cm.

5. A reinforced material, which includes:
a concrete material,
a plurality of polymer fibers substantially uniformly distributed and randomly oriented in said concrete material, each said polymer fiber having a first radical wave therein, wherein said first radical wave includes an amplitude of between about 0.5 to 1 cm and a wave run width of about 0.05 to about 0.3 cm, and a leading run and trailing run of at least about 0.75 cm, wherein said wave includes a leading edge and a trailing edge which are normal to said leading run and said trailing run and form part of square wave.

6. The reinforced material of claim 5, wherein said polymer fiber cross-sectional width can be between 0.2 to 0.3 cm. and a linear density between about 2500 to 4500 Denier.

7. The reinforced material of claim 5, having a second radical wave therein, wherein said second radical wave includes an amplitude of between about 0.5 to 1 cm and a wave run width of about 0.05 to about 0.3 cm, and a leading run and trailing run of at least about 0.75 cm, wherein said leading run of said first radical wave interconnects said trailing run of said second radical wave.

8. The reinforced material of claim 7, wherein at least of said leading run of said second radical wave and said trailing run of said first radical wave are separated by about 1.5 cm.