Load-carrying structures comprising bamboo fibers and polymers

Abstract

Shaped load-carrying structures are fabricated using bamboo linear fibers with a compatible bonding material and synthetic polymers such as polyesters, epoxies, and polyolefins. The structures are manufactured by coating at least one of bamboo culms, split bamboo culms, bamboo fiber tape, or prepared bamboo fibers with a bonding material to produce a core. The core is then combined with a polymer matrix and extruded or molded to form a structure having the desired shape. The structures compare favorably with wood, steel, and concrete regarding strength, longevity, price and ability to withstand earthquakes. The structures may be used as beams, columns, telephone poles, marine piles and pallets.

1 . A shaped load-carrying structure comprising a plurality of linear bamboo fibers covered with at least one binder and surrounded by a synthetic polymer plastic material.  
     
     
         2 . The structure of  claim 1 , wherein binder is at least one member selected from the group consisting of maleated polypropylene, maleated polyethylene, maleic anyhdride, hydroxyl methacrylate, silane compounds, N-vinyl pyridine, N-vinyl caprolactam, N-vinyl carbazole, methacrylic acid, ethyl methacrylate, isobutyl methacrylate, sodium styrene sulfonate, bis-vinyl phosphate, divinyl ether-ethylene glycol, vinyl acetate, vinyl toluene, vinylidene chloride, chloroprene, isoprene, dimethylaminoethyl methacrylate, isocetylvinyl ether, acrylonitrile, glycidyl methacrylate, N-vinyl pyrrolidone, acrylic acid, ethyl acrylate, itaconic acid, methyl acrylate, sodium vinyl sulfonate, cetyl vinyl ether, divinyl ether-butanediol, and octadecyl vinyl acetate.  
     
     
         3 . The structure of  claim 1  wherein the synthetic polymer is selected from the group comprising a thermoplastic resin and a thermosetting resin.  
     
     
         4 . The structure of  claim 1  wherein the bamboo is selected from the group comprising Gradua and Tonkin cane.  
     
     
         5 . The structure of  claim 1  wherein the bonding material is acrylic acid.  
     
     
         6 . The structure of  claim 1  wherein the synthetic polymer is polyethylene.  
     
     
         7 . The structure of  claim 1  wherein the bamboo fibers are in the form of split bamboo culms.  
     
     
         8 . The structure of  claim 1  wherein the bamboo fibers are in the form of a tape.  
     
     
         9 . The structure of  claim 1  wherein the structure is a beam.  
     
     
         10 . The structure of  claim 1  wherein the structure is a column.  
     
     
         11 . The structure of  claim 1  wherein the structure is a telephone pole.  
     
     
         12 . The structure of  claim 1  wherein the structure comprises a pallet.  
     
     
         13 . The structure of  claim 12  wherein the pallet comprises a top panel, a bottom panel and a plurality of spacers connecting the top panel to the bottom panel and defining an opening therebetween for receiving forks of a transport apparatus.  
     
     
         14 . The structure of  claim 13  wherein the top panel comprises a solid plate having an exposed load bearing surface, the top panel being formed of a plurality of elongate bamboo fibers arranged in overlapping, transverse layers adhesively bonded together within a molded plastic encapsulation.  
     
     
         15 . The structure of  claim 14  wherein the load bearing surface is formed with a plurality of raised ribs to minimize load slippage.  
     
     
         16 . The structure of  claim 13  wherein the spacers each comprise a molded plastic block filled with bamboo fibers.  
     
     
         17 . The structure of  claim 16  wherein the bamboo fibers comprise pellets of bamboo fibers cut into relatively short lengths compared to the extent of the spacers and with each pellet having a polymeric plastic coating.  
     
     
         18 . The structure of  claim 16  wherein the spacers each comprise a cut-off segment of an extruded column of linear bamboo fibers encased in an outer polymeric plastic coating.  
     
     
         19 . The structure of  claim 13  wherein the bottom panel comprises a peripheral support and a cross-shaped central support, each of said supports comprising a plurality of linear bamboo fibers encased in an outer polymeric plastic coating.  
     
     
         20 . The structure of  claim 13  wherein the top panel comprises a plurality of stacked woven mats of-bamboo fiber adhesively bonded together and encased in a polymeric plastic coating.