Reinforced composite materials, and methods of making the same
Embodiments of the disclosure provide a reinforced composite material including a composite material forming a geometric body, and a reinforcement member disposed in the composite material. In some embodiments, the reinforcement member includes (i) at least one elongate metal wire extending at least partially through the composite material, and (ii) at least one barb that extends from the elongate metal wire in a transverse direction to the elongate metal wire.
1 . A reinforced cementitious material comprising:
a cementitious material forming a geometric body comprising a plurality of printed filaments, including a first filament and a second filament that is directly bonded with the first filament such that the second filament is conformed with the first filament,
a reinforcement member disposed in the cementitious material between the first filament and the second filament when in the flowable state, the reinforcement member comprising:
(i) at least one elongate metal wire extending at least partially embedded in and extending along at least one of the first filament and the second filament, and
(ii) a plurality of barbs extending from the elongate metal wire in a transverse direction to the elongate metal wire so that a first barb of the plurality of barbs extends into the first filament and a second barb of the plurality of barbs extends into the second filament;
wherein the tensile bond strength is at least 500 MPa.
2 . The reinforced cementitious material of claim 1 , wherein the cementitious material comprises a cement binder, an aggregate, at least one pozzolanic additive, an accelerator, water, and nanoclay.
3 . The reinforced cementitious material of claim 1 , wherein the reinforcement member comprises a plurality of barbs along the length of the at least one elongate metal wire.
4 . The reinforced cementitious material of claim 3 , wherein the reinforcement member is disposed between a first printed filament and a second printed filament in the cementitious material, wherein the second printed filament is configured adjacent to the first printed filament, and wherein at least a portion of the plurality of barbs extend from the elongate metal wire to project into the second printed filament, and at least a portion of the plurality of barbs extend into the first printed filament.
5 . The reinforced cementitious material of claim 3 , wherein the barbs have a barb spacing from 1 cm to 50 cm.
6 . The reinforced cementitious material of claim 1 , wherein the barbs at least partially wrap around the at least one elongate metal wire.
7 . The reinforced cementitious material of claim 1 , wherein the reinforcement member comprises at least two elongate metal wires helically twisted along the length of the elongate metal wires.
8 . The reinforced cementitious material of claim 7 , wherein the at least two elongate metal wires comprise from 2 to 50 nodes between the barbs.
9 . The reinforced cementitious material of claim 7 , wherein some or all the barbs wrap between the at least two elongate metal wires.
10 . The reinforced cementitious material of claim 7 , wherein some or all the barbs wrap around the at least two elongate metal wires.
11 . The reinforced cementitious material of claim 1 , wherein the cementitious material completely surrounds the at least one elongate metal wire and at least one barb.
12 . The reinforced cementitious material of claim 1 , wherein the cementitious material comprises a plurality of the reinforcement members disposed therein.
13 . The reinforced cementitious material of claim 1 , wherein the reinforcement member comprises a curved structure within the cementitious material.
14 . The reinforced cementitious material of claim 1 having one or more configuration selected from:
(i) from 2 to 500 rows of reinforcement members disposed within the composite material; or
(ii) from 2 to 500 columns of reinforcement members disposed within the composite material.
15 . The reinforced cementitious material of claim 14 , wherein the reinforcement members in the rows or columns are discontinuous as the reinforcements members extend along the length of the composite material.
16 . The reinforced cementitious material of claim 1 , wherein the tensile bond strength is at least 1100 MPa.
17 . The reinforced cementitious material of claim 1 , wherein the cementitious material has a final set time less than 300 minutes.
18 . The reinforced cementitious material of claim 1 , wherein the cementitious material has from 3 wt % to 20 wt % of at least one pozzolanic additive.
19 . The reinforced cementitious material of claim 1 , wherein the reinforced cementitious material has a 2-day tensile bond strength of at least 10 MPaS.
20 . The reinforced cementitious material of claim 1 , wherein the reinforced cementitious-material has a modulus of rupture of at least 1 MPa.