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 method of making a structural tie, comprising:
 establishing a desired orientation between at least two structural members;   heating a composite material to soften the composite material and facilitate changing a configuration of the composite material;   forming the composite material into a customized structural tie that conforms to the structural members in the desired orientation; and   cooling the composite material in the conformed configuration to make the structural tie.   
     
     
         2 . A method according to  claim 1 , wherein the composite material comprises a polymeric matrix material and at least one reinforcing material. 
     
     
         3 . A method according to  claim 2 , wherein the polymeric matrix material is a thermoplastic. 
     
     
         4 . A method according to  claim 2 , wherein the at least one reinforcing material comprises continuous fibers oriented approximately parallel to one another. 
     
     
         5 . A method according to  claim 2 , wherein the at least one reinforcing material comprises a plurality of randomly oriented fibers. 
     
     
         6 . A method according to  claim 1 , wherein at least one layer of metallic material is adjacent to the composite material, the metallic material comprising steel or aluminum. 
     
     
         7 . A method according to  claim 1 , further comprising:
 securing the structural tie to the structural members   
     
     
         8 . A method of conforming a structural tie to structural members to be connected by the structural tie, the method 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.   
     
     
         9 . A method according to  claim 8 , wherein the structural tie comprises at least one layer of composite material. 
     
     
         10 . A method according to  claim 9 , wherein the structural tie further comprises at least one layer of metallic material adjacent to the at least one layer of composite material, the metallic material comprising steel or aluminum. 
     
     
         11 . A method according to  claim 9 , wherein the composite material comprises a polymeric matrix material and at least one reinforcing material. 
     
     
         12 . A method according to  claim 11 , wherein the polymeric matrix material is a thermoplastic. 
     
     
         13 . A method according to  claim 11 , wherein the at least one reinforcing material comprises continuous fibers oriented approximately parallel to one another. 
     
     
         14 . A method according to  claim 11 , wherein the at least one reinforcing material comprises a plurality of randomly oriented fibers. 
     
     
         15 . A method according to  claim 8 , wherein the structural tie comprises:
 a first layer of composite material having a first polymeric matrix and a first reinforcing material; and   a second layer of composite material having a second polymeric matrix material and a second reinforcing material.   
     
     
         16 . A method according to  claim 15 , wherein the first polymeric matrix material is different from the second polymeric matrix material. 
     
     
         17 . A method of interconnecting structural members, comprising:
 establishing a desired orientation between the structural members;   heating a structural tie to soften the structural ties and facilitate changing a configuration of the structural tie;   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.   
     
     
         18 . A method according to  claim 17 , wherein the structural tie comprises at least one layer of composite material. 
     
     
         19 . A method according to  claim 18 , wherein the structural tie further comprises at least one layer of metallic material adjacent to the at least one layer of composite material, the metallic material comprising steel or aluminum. 
     
     
         20 . A method according to  claim 18 , wherein the composite material comprises a polymeric matrix material and at least one reinforcing material. 
     
     
         21 . A method according to  claim 20 , wherein the polymeric matrix material is a thermoplastic. 
     
     
         22 . A method according to  claim 20 , wherein the at least one reinforcing material comprises continuous fibers oriented approximately parallel to one another. 
     
     
         23 . A method according to  claim 20 , wherein the at least one reinforcing material comprises a plurality of randomly oriented fibers.