Composite structural tie

Abstract

A structural tie 10 is made from at least one layer of composite material 20. The composite material has a polymer matrix filled with at least one reinforcing material. In one embodiment, the matrix is a thermoplastic and the reinforcing material is fibers encapsulated by the thermoplastic. A structural tie 10 may be selectively formable, in situ, by applying heat to cause the matrix material to soften. Once softened, the structural tie can be conformed to an adjacent surface. The structural tie may include layers 20, 22 of composite material bonded to one another. Optionally, the structural tie is a hybrid of a composite material and a metallic material bonded together. A structural tie may be heat-bondable to a structural member 24.

1 . A structural tie comprising:
 at least one layer of composite material, said composite material having a polymeric matrix material filled with at least one reinforcing material.   
   
   
       2 . A structural tie as defined by  claim 1  wherein the polymeric matrix material is a thermoplastic. 
   
   
       3 . A structural tie as defined by  claim 1  wherein said polymeric matrix material is a thermoset material. 
   
   
       4 . A structural tie as defined by  claim 1  wherein said reinforcing material is in the form of a plurality of continuous fibers oriented approximately parallel to one another. 
   
   
       5 . A structural tie as defined by  claim 1  wherein said reinforcing material comprises a plurality of randomly oriented fibers. 
   
   
       6 . A structural tie as defined by  claim 5  wherein said fibers are at least one of continuous and chopped. 
   
   
       7 . A structural tie as defined by  claim 2  wherein:
 said reinforcing material is in the form of a plurality of continuous fibers oriented approximately parallel to one another and following the shape of and any contours defined by said structural tie.   
   
   
       8 . A structural tie as defined by  claim 7  wherein said structural tie is selectively formable, in situ, by selectively applying heat to said structural tie thereby causing said matrix material o soften, allowing portions of said tie to be moved so as to conform to a shape defined by an adjacent surface upon cooling of said structural tie. 
   
   
       9 . A structural tie as defined by  claim 8  wherein said at least one layer of composite material includes a plurality of layers of composite material bonded to one another to form a laminated structure. 
   
   
       10 . A structural tie as defined by  claim 9  wherein at least one of said layers is oriented at an angle different from an angle that at least one of the remaining layers is oriented at. 
   
   
       11 . A structural tie as defined by  claim 1  wherein:
 said composite material includes at least, one first composite material having a first polymeric matrix material and a first reinforcing material and at least one second layer of composite material having a second polymeric matrix material and a second reinforcing material;   at least a portion of said first and second layers of composite material being bonded to one another; and wherein   said first and second polymeric matrix materials are different from one another.   
   
   
       12 . A structural tie as defined by  claim 11  wherein said first polymeric matrix material is a thermoplastic polymer and said second polymeric matrix material in a thermosetting polymer. 
   
   
       13 . A structural tie as defined by  claim 2  wherein at least a portion of said thermoplastic matrix material is heat-bondable to a structural member. 
   
   
       14 . A structural tie as defined by  claim 12  wherein at least a portion of said thermoplastic matrix material is heat-bondable to a structural member. 
   
   
       15 . A structural tie as defined by  claim 11  wherein said first reinforcing material is different from said second reinforcing material. 
   
   
       16 . A structural tie as defined by  claim 15  wherein said first reinforcing material comprises randomly oriented fibers and said second reinforcing material comprises oriented fibers whereby the fibers are substantially parallel to one another. 
   
   
       17 . A structural tie as defined by  claim 15  wherein said first and second reinforcing material each comprise continuous fibers, said continuous fibers forming part of said first composite material being oriented substantially parallel to one another, and said continuous fibers of said second composite material being oriented substantially parallel to one another. 
   
   
       18 . A structural tie as defined by  claim 12  wherein one of said first and second reinforcing materials is E-glass and the other of said first and second composite materials is S-glass. 
   
   
       19 . A structural tie as defined by  claim 12  wherein:
 said first and second composite materials each comprise laminates composed of layers of composite material stacked one-on-top-of the other and bonded together.   
   
   
       20 . A structural tie as defined by  claim 19  wherein at least one of said first and second reinforcing materials is comprised of continuous fibers oriented approximately parallel to one another with at least a portion of said layers being oriented relative to adjacent layers such that said fibers in adjacent layers are oriented at different angles relative to one another. 
   
   
       21 . A structural tie as defined by  claim 1  further comprising at least one layer of metallic material bonded to said composite material. 
   
   
       22 . A structural tie as defined by  claim 21  wherein said metallic layer is encapsulated by a polymeric material and said polymeric material is bonded to said composite material. 
   
   
       23 . A structural tie as defined by  claim 21  wherein said metallic layer of material is encapsulated by said composite layer of material. 
   
   
       24 . A structural tie as defined by  claim 21  wherein said composite material is heat-bondable to a structural member. 
   
   
       25 . A structural tie as defined by  claim 21  wherein said reinforcing material comprises elongated fibers selectively oriented to enhance the strength of said structural tie in desired locations and the ductility of said structural tie in desired locations. 
   
   
       26 . A method of making a structural tie, comprising:
 establishing a desired orientation between at least two structural members;   heating a thermoplastic composite to soften it and facilitate changing its configuration,   forming the thermoplastic composite into a customized structural tie that conforms to the structural members in the desired orientation;   cooling the thermoplastic composite in the conformed configuration; and   securing the structural tie to the structural members.   
   
   
       27 . A method of conforming a structural tie to structural members to be connected by the structural tie, comprising:
 establishing a desired orientation between the structural members;   heating the structural tie to soften it and facilitate changing its configuration;   custom-fitting the structural tie to the structural members in the desired configuration; and   cooling the structural tie.   
   
   
       28 . A method of interconnecting structural members, comprising:
 establishing a desired orientation between the structural members;   heating the structural tie to soften it and facilitate changing its configuration;   custom-fitting the structural tie to the structural members in the desired configuration to establish a custom configuration for the structural tie;   cooling the structural tie in the custom configuration; and securing the structural tie to the structural members.