초록 ▼

An inflatable mold assembly for forming a hollow composite construction member that is suitable for use as a building material has a longitudinal axis. The mold assembly further has a flexible, substantially tubular bladder wall defining an elongated inflatable cavity. A reinforcing fabric is positi

An inflatable mold assembly for forming a hollow composite construction member that is suitable for use as a building material has a longitudinal axis. The mold assembly further has a flexible, substantially tubular bladder wall defining an elongated inflatable cavity. A reinforcing fabric is positioned concentrically around the flexible bladder wall. A flexible air-impervious outer layer is positioned concentrically around the fabric, with the bladder wall and the outer layer defining an elongated annular space, and with the fabric being positioned within the elongated annular space.

대표청구항 ▼

1. An inflatable mold assembly for forming a hollow composite construction member suitable for use as a building material, the mold assembly having a longitudinal axis, and further having: a flexible, substantially tubular bladder wall defining an elongated inflatable cavity;reinforcing fabric posit

1. An inflatable mold assembly for forming a hollow composite construction member suitable for use as a building material, the mold assembly having a longitudinal axis, and further having: a flexible, substantially tubular bladder wall defining an elongated inflatable cavity;reinforcing fabric positioned concentrically around the flexible bladder wall;a flexible air-impervious tubular membrane positioned concentrically around the fabric, with the bladder wall and the outer layer defining an elongated annular space, with the fabric being positioned within the space; anda shear transfer layer positioned concentrically within the elongated annular space between the reinforcing fabric and the tubular bladder. 2. The inflatable mold assembly of claim 1 in which the mold is structured to be bent into a curved shape after inflation to any one of many different curvatures, and in which the fabric is structured so that when tension is applied to the fabric before bending the mold, the fibers of the fabric will remain in tension even after the mold is bent into the curved shape. 3. The inflatable mold assembly of claim 1 in which the fabric comprises a plurality of fibers, some of which are oriented in an off-hoop direction that is at an angle greater than or equal to 30 degrees to the hoop direction, and in which the fabric is structured so that when tension is applied to the fabric, the off-hoop direction fibers are prevented from buckling when curvature is applied to the mold assembly resulting in superior structural properties relative to fabric to which tensioning was not applied. 4. The inflatable mold assembly of claim 1 in which the elongated inflatable mold includes a mechanical grip at each end, with the mechanical grips being connected to the fabric and being configured to apply tension to the fabric. 5. The inflatable mold assembly of claim 1 in which the elongated inflatable cavity, when inflated, has a cross-sectional dimension that varies along the longitudinal axis of the elongated inflatable mold. 6. The inflatable mold assembly of claim 1 including a gripping system at each end of the elongated inflatable mold. 7. The inflatable mold assembly of claim 6 including a vacuum inlet positioned outside of the gripping systems. 8. A hollow composite construction member suitable for use as a building material comprising: an arched tubular primary reinforcement member having a hollow interior and formed from a fiber reinforced polymer;a flexible, tubular shear transfer member bonded to an inside surface of the arched tubular primary reinforcement member; anda secondary reinforcement material different from the fiber reinforced polymer and at least partially filling the hollow interior of the tubular primary reinforcement member. 9. The hollow composite construction member of claim 8 wherein the secondary reinforcement material is selected from the group consisting of non-shrink concrete, expansive concrete, non-shrink grout, expansive grout, foam, and sand. 10. The hollow composite construction member according to claim 8, wherein the shear transfer member includes a body formed as an array of elongated members and spaces between the elongated members. 11. The hollow composite construction member according to claim 10, wherein the array of elongated members and spaces define a repeating pattern of geometric shapes. 12. The hollow composite construction member according to claim 10, wherein the array of elongated members and spaces define an irregular array of dissimilar shapes. 13. The hollow composite construction member according to claim 10, wherein radially inwardly facing surfaces of the elongated members have a rounded shape. 14. The hollow composite construction member according to claim 8, wherein the shear transfer member is formed from one of polyethylene, polyester, and polyoxymethylene. 15. A hollow composite construction member suitable for use as a building material comprising: an arched tubular primary reinforcement member having a hollow interior and formed from a fiber reinforced polymer, wherein one of an array of grooves and ridges is formed on an inside surface of the tubular primary reinforcement member, the array defining a shear transfer member; anda secondary reinforcement material different from the first material and at least partially filling the hollow interior of the tubular primary reinforcement member. 16. The hollow composite construction member of claim 15 wherein the secondary reinforcement material is selected from the group consisting of non-shrink concrete, expansive concrete, non-shrink grout, expansive grout, foam, and sand. 17. The hollow composite construction member according to claim 15, wherein the one of an array of grooves and spaces ridges define a repeating pattern of geometric shapes. 18. The hollow composite construction member according to claim 15, wherein the one of an array of grooves and ridges define an irregular array of dissimilar shapes. 19. The inflatable mold assembly of claim 1 wherein the intermediate shear transfer layer positioned concentrically within the elongated annular space between the reinforcing fabric and the tubular bladder comprises a layer having a pattern of alternating protrusions with spaces between the protrusions. 20. The inflatable mold assembly of claim 19 wherein the pattern of alternating protrusions with spaces between the protrusions forms a pattern of repeating hexagons. 21. The hollow composite construction member according to claim 8 wherein the flexible, tubular shear transfer member extends a substantial portion of a length of the arched tubular primary reinforcement member. 22. The hollow composite construction member according to claim 15, wherein the array of grooves includes a pattern of elongated grooves extending radially into the inside surface of the tubular primary reinforcement member; and wherein the array of ridges includes a pattern of elongated protrusions extending radially from of the inside surface and into the hollow interior of the arched tubular primary reinforcement member. 23. The hollow composite construction member according to claim 22 wherein the one of an array of grooves and ridges extends a substantial portion of a length of the arched tubular primary reinforcement member. 24. The hollow composite construction member according to claim 15 wherein the one of an array of grooves and ridges extends a substantial portion of a length of the arched tubular primary reinforcement member. 25. The hollow composite construction member according to claim 8 wherein fibers of the fiber reinforced polymer are aligned such that wrinkling and buckling of the fibers is substantially eliminated. 26. The hollow composite construction member according to claim 15 wherein fibers of the fiber reinforced polymer are aligned such that wrinkling and buckling of the fibers is substantially eliminated.