HIGH-PERFORMANCE GRAPHENE-REINFORCED COMPOSITE BEAMS FOR STRUCTURAL APPLICATIONS

Abstract

7. ABSTRACT The present invention discloses the mechanical behaviour of graphene-reinforced composite beams (100) for structural applications. Graphene (102), a two-dimensional carbon allotrope with exceptional mechanical properties, is incorporated into a polymer matrix (102) to enhance the strength, stiffness, and toughness of the resulting composite material. The effects of graphene concentration, distribution, and interfacial bonding on the mechanical properties of the composite beams are studied through experimental testing and finite element modeling. The results demonstrate that graphene-reinforced composite beams (100) exhibit significantly improved mechanical performance compared to conventional composite beams. These findings have implications for the development of lightweight and high-performance structural components in various industries, including aerospace, automotive, and civil engineering. The figure associated with abstract is Fig. 1.

Specification

Description:4. DESCRIPTION
Technical Field of the Invention

The present invention related to civil engineering and structural composites. More particularly, focusing on advanced composite beams reinforced with graphene. This innovation aims to enhance structural performance, durability, and load-bearing capacity for applications.
Background of the Invention

In civil engineering, structural beams are integral to the construction of various infrastructures, including bridges, buildings, and industrial frameworks. Traditional structural materials, such as steel, concrete, and polymer composites, have served these purposes for decades. However, as the demands on infrastructure increase, especially in high-stress or environmentally challenging locations, conventional materials face significant limitations. Steel beams, while strong, are prone to corrosion, particularly in humid or marine environments, leading to frequent maintenance and repairs. Concrete beams are heavy, limiting transportation efficiency and increasing costs, while polymer-based composites, though lightweight, often lack the mechanical strength required for high-load applications.

In recent years, composite materials that combine a polymer matrix with reinforcing fillers have been explored to address some of these challenges. However, the typical fillers, such as carbon fibers or glass fibers, present limitations in terms of tensile strength, environmental durability, and weight-to-strength ratios. While these composites have improved structural properties over concrete alone, they still suffer from degradation under cyclic loading conditions, making them less suitable for applications where repeated stress is common, such as in bridges or high-rise buildings.

Graphene, a carbon-based nanomaterial with exceptional strength, flexibility, and conductivity, has emerged as a potential reinforcement agent for composites. However, integrating graphene into construction materials has been challenging due to issues with even dispersion within the matrix and difficulties in scaling production. Despite these obstacles, the unique properties of graphene, particularly its strength-to-weight ratio and resistance to environmental degradation, make it a promising solution for enhancing composite materials for infrastructure.

This invention addresses these challenges by creating a graphene-reinforced composite beam that leverages graphene's nanoscale strength and durability. By embedding graphene within a polymer or concrete matrix, the invention achieves significantly higher load-bearing capacity and resistance to environmental stressors. Unlike traditional materials, which are often bulky and susceptible to environmental wear, the graphene-reinforced beam is designed to be lightweight, durable, and fatigue-resistant, enhancing the longevity and reliability of structures in harsh conditions.

Furthermore, this new composite beam overcomes the limitations of previous materials by providing improved resistance to cyclic loading, meaning it can endure repeated stresses without structural fatigue. This property is particularly advantageous for civil engineering applications that experience constant dynamic loads, such as bridges or high-traffic areas. The graphene reinforcement acts as a barrier to crack propagation, which mitigates material failure and extends the lifespan of the structure, reducing maintenance costs over time.

This invention represents a substantial advancement over traditional materials by providing a lightweight yet robust solution for structural beams. Its enhanced resistance to environmental factors, fatigue, and cyclic loading, along with the scalability of graphene integration, makes it highly suitable for modern infrastructure demands. The graphene-reinforced composite beams offer civil engineers a versatile, sustainable, and economically beneficial material option, addressing the key drawbacks of conventional construction materials and setting a new standard for structural resilience in high-stress applications.

Brief Summary of the Invention

The following presents a simplified summary of the disclosure in order to provide a basic understanding to the reader. This summary is not an extensive overview of the disclosure and it does not identify key/critical elements of the invention or delineate the scope of the invention. Its sole purpose is to present some concepts disclosed herein in a simplified form as a prelude to the more detailed description that is presented later.

It is a primary objective of the invention is to enhance the structural strength of composite beams through graphene reinforcement, providing higher load-bearing capacity compared to traditional materials without compromising on weight.

It is yet another object of the invention to improve the environmental durability of composite beams, making them resistant to corrosion, moisture, and temperature fluctuations, thereby reducing the need for frequent maintenance.

It is yet another object of the invention to increase the fatigue resistance of composite beams, enabling them to withstand cyclic loading conditions and repetitive stress without structural degradation, ideal for bridges and high-rise applications.

It is yet another object of the invention to reduce the overall weight of structural beams by incorporating lightweight graphene, facilitating easier transport, handling, and reduced construction costs without sacrificing strength.

It is yet another object of the invention to support sustainable engineering practices by providing a long-lasting, resilient composite material that lowers material waste and energy consumption over the lifespan of civil engineering projects.
According to an aspect of the present invention, a high-performance composite beam for civil engineering applications is disclosed. The system comprising a polymer or concrete matrix, graphene, nanofillers, environmental resistance, fatigue resistance, and lightweight design.

In accordance with the aspect of the present invention, the invention introduces a novel type of high-performance composite beam designed for civil engineering applications. By incorporating graphene as a reinforcing material within a conventional polymer or concrete matrix, these composite beams significantly enhance structural strength, stiffness, and durability. This advancement addresses the growing demand for materials that can withstand higher loads while being lightweight, making them ideal for a variety of construction projects.

In accordance with the aspect of the present invention, the graphene-reinforced composite beams offer exceptional mechanical properties, including increased load-bearing capacity and superior flexural strength. The incorporation of graphene, known for its outstanding strength-to-weight ratio, provides a reliable solution for building durable structures. This improvement not only extends the lifespan of civil engineering projects but also reduces maintenance costs associated with traditional materials.

In accordance with the aspect of the present invention, these composite beams demonstrate enhanced environmental durability, showcasing excellent resistance to moisture, corrosion, and temperature fluctuations. This characteristic makes the beams suitable for outdoor applications, where traditional materials often succumb to environmental degradation. The graphene reinforcement ensures that the beams maintain their structural integrity over time, contributing to more sustainable construction practices.

In accordance with the aspect of the present invention, the invention also focuses on improving fatigue resistance, allowing the composite beams to endure cyclic loading and repetitive stress without compromising their structural performance. This quality is particularly beneficial for infrastructure projects, such as bridges and high-rise buildings, which experience dynamic loads during their operational life. As a result, these beams provide a safer and more reliable option for engineers and builders.

In accordance with the aspect of the present invention, the lightweight design of the graphene-reinforced composite beams facilitates efficient transport and handling during construction, leading to reduced overall project costs. By promoting sustainable engineering practices and minimizing material waste, this invention represents a significant advancement in the field of civil engineering, offering a versatile solution for a wide range of structural applications.

Applications:
• Bridges and Overpasses: These beams provide the necessary strength for bridges while being lightweight, which reduces stress on foundational structures.
• High-Rise Buildings: Enhanced load-bearing capacity and durability make them ideal for high-rise construction.
• Industrial Structures: Suitable for environments with fluctuating temperatures and exposure to chemicals or humidity.
• Seismic Zones: Their improved fatigue resistance and durability make them viable for structures in earthquake-prone areas.

Further scope of applicability of the present invention will become apparent from the detailed description given hereinafter. However, the detailed description and specific examples, while indicating preferred embodiments of the invention, will be given by way of illustration along with complete specification.

Brief Summary of the Drawings

The invention will be further understood from the following detailed description of a preferred embodiment taken in conjunction with an appended drawing, in which:

Fig. 1 (100) illustrates the block diagram of features of a high-performance composite beam, in accordance with the exemplary embodiment of the present invention.

Fig. 2 illustrates the diagram of experimental setup of producing a high-performance composite beam, in accordance with the exemplary embodiment of the present invention.

Fig. 3 illustrates the graph of relationship between applied load (in kilonewtons, kN) and resulting deflection, in accordance with the exemplary embodiment of the present invention.

Fig. 4 illustrates the graph of relationship between applied load (in kilonewtons, kN) and resulting deflection (in millimetres, mm), in accordance with the exemplary embodiment of the present invention.

Fig. 5 illustrates the diagram of results of a Scanning Electron Microscopy (SEM) analysis, in accordance with the exemplary embodiment of the present invention.


Detailed Description of the Invention

The present disclosure emphasises that its application is not restricted to specific details of construction and component arrangement, as illustrated in the drawings. It is adaptable to various embodiments and implementations. The phraseology and terminology used should be regarded for descriptive purposes, not as limitations.

The terms "including," "comprising," or "having" and variations thereof are meant to encompass listed items and their equivalents, as well as additional items. The terms "a" and "an" do not denote quantity limitations but signify the presence of at least one of the referenced items. Terms like "first," "second," and "third" are used to distinguish elements without implying order, quantity, or importance.

According to the exemplary embodiment of the present invention, a high-performance composite beam for civil engineering applications comprising a polymer or concrete matrix (102), graphene (104), nanofillers (106), environmental resistance (108), fatigue resistance (110), and lightweight design (112).

In accordance with the exemplary embodiment of the present invention, the composite beam is fabricated using a precise mixing process where graphene (104) is uniformly dispersed within the polymer matrix. The incorporation of graphene nanofillers (106) occurs in a concentration range of 0.1% to 10% by weight, optimizing the mechanical properties of the composite without compromising workability. This method ensures a homogeneous distribution of graphene throughout the matrix, facilitating effective load transfer and enhanced structural performance.

In accordance with the exemplary embodiment of the present invention, the polymer matrix (102) used in the composite beam can be selected from various materials, including thermosetting resins such as epoxy or polyester, and thermoplastic materials like polyvinyl chloride (PVC). These materials are chosen for their compatibility with graphene and their inherent properties that contribute to the overall durability and performance of the beam. This selection allows for customization based on specific application requirements in civil engineering projects.

In accordance with the exemplary embodiment of the present invention, the composite beam is designed to exhibit superior mechanical properties, with a flexural strength greater than 80 MPa. This makes the beam suitable for heavy load-bearing applications, such as bridges, high-rise buildings, and other structural frameworks. Furthermore, the enhanced fatigue resistance of the graphene-reinforced composite ensures that the beam can withstand cyclic loading, thereby maintaining structural integrity over time, even under varying loads.

In accordance with the exemplary embodiment of the present invention, additional features may include a protective coating applied to the surface of the composite beam. This coating enhances resistance to environmental factors such as moisture, corrosion, and temperature fluctuations, thereby prolonging the lifespan of the structure. Furthermore, the composite beam can be equipped with embedded sensors that facilitate real-time monitoring of structural integrity and environmental conditions, ensuring proactive maintenance and safety.

In accordance with the exemplary embodiment of the present invention, the innovation aligns with sustainable engineering practices. The use of graphene-reinforced composites contributes to longer-lasting structures, reducing the need for repairs and replacements over time. This not only minimizes material waste but also enhances energy efficiency during construction, making the invention a valuable advancement in the field of civil engineering.

Now referring to figures, Fig. 1 illustrates the high-performance composite beam construction with a polymer or concrete matrix (102) as its main structural base. Within this matrix, graphene (104) is incorporated as a reinforcing fatigue material (110) to enhance the beam's strength, stiffness, and durability. The beam includes a network of graphene nanofillers (106) that is carefully dispersed throughout, boosting its load-bearing capacity and toughness. Additionally, the beam has environmental resistance features (108), protecting it against moisture, corrosion, and temperature fluctuations. The composite design also incorporates fatigue resistance, which allows the beam to maintain its structure even under repetitive loads. Finally, its lightweight (112) construction makes it easy to transport and handle during construction, helping to reduce overall project costs.

Fig. 2 illustrates (left side) a simplified representation of the experimental setup, focusing on the key dimensions of the sample and loading configuration.
• Sample Dimensions: The rectangular sample is depicted with the following dimensions:
Length: 25 mm
Width: 5 mm
Height (or thickness): 10 mm
• Loading: A vertical load denoted by 'W' is applied to the top surface of the sample.
• Supports: The sample is supported at its two ends. The total span between the supports is 35 mm.
•
This other side (right) offers a visual representation of the actual experimental setup, allowing us to contextualize the schematic diagram. We can observe:
• Sample: The rectangular sample, likely the one depicted in the schematic, is visible within the loading frame.
• Loading Frame: The frame is responsible for applying the load 'W' to the sample.
• Support: The frame also provides the necessary support to the sample at its ends.
Overall Interpretation:
Based on the diagram and photograph, it is evident that this setup is designed for a compression test. The objective of this test is to evaluate the material's behavior under compressive forces. The load 'W' is gradually increased until the sample fails, and the corresponding stress and strain values are recorded.
Key Considerations:
Sample Dimensions: The dimensions of the sample play a crucial role in determining the stress and strain calculations. The length-to-width ratio, in particular, can influence the failure mode of the sample.
Loading Rate: The rate at which the load is applied is another important factor. A slower loading rate can allow for more accurate measurement of the material's response.
Type of Loading: The type of loading, whether constant strain rate or constant stress rate, can also affect the test results.
Support Conditions: The support conditions, such as pinned or roller supports, can impact the stress distribution within the sample.
Now referring to figures, Fig. 3 illustrates relationship between applied load (in kilonewtons, kN) and resulting deflection (in millimeters, mm) for a specific material or structural component. It likely represents a compression test, where a specimen is subjected to increasing compressive forces, and its deformation is measured.
Key Observations
1.Non-Linear Relationship: The graph demonstrates a non-linear relationship between load and deflection. This means that as the load increases, the deflection doesn't increase proportionally. The rate of deflection tends to accelerate with higher loads.
2.Initial Linear Region: The graph might exhibit a small initial linear region at lower loads. This indicates that within this range, the material behaves elastically, meaning it returns to its original shape when the load is removed.
3.Yield Point (Approximate): The point where the graph starts to deviate significantly from linearity is often referred to as the yield point. This is where the material transitions from elastic to plastic behavior, meaning it undergoes permanent deformation.
4.Ultimate Load: The maximum load the specimen can withstand before failure is indicated by the peak of the curve. This point is crucial for determining the material's strength.
5.Failure Point: The point where the curve drops sharply after the peak represents the failure of the specimen.

Fig. 3 shows a graph that illustrates the relationship between applied load (in kilonewtons, kN) and resulting deflection (in millimeters, mm) for a specific material or structural component. It likely represents a compression test, where a specimen is subjected to increasing compressive forces, and its deformation is measured.

Key Observations
1.Non-Linear Relationship: The graph demonstrates a non-linear relationship between load and deflection. This means that as the load increases, the deflection doesn't increase proportionally. The rate of deflection tends to accelerate with higher loads.
2.Initial Linear Region: The graph might exhibit a small initial linear region at lower loads. This indicates that within this range, the material behaves elastically, meaning it returns to its original shape when the load is removed.
3.Yield Point (Approximate): The point where the graph starts to deviate significantly from linearity is often referred to as the yield point. This is where the material transitions from elastic to plastic behavior, meaning it undergoes permanent deformation.
4.Ultimate Load: The maximum load the specimen can withstand before failure is indicated by the peak of the curve. This point is crucial for determining the material's strength.
5.Failure Point: The point where the curve drops sharply after the peak represents the failure of the specimen.

Fig. 5 is a image presents the results of a Scanning Electron Microscopy (SEM) analysis coupled with Energy-Dispersive X-ray Spectroscopy (EDS). This combined technique offers a comprehensive view of a sample's surface morphology and elemental composition.
SEM Image
• Scale: The scale bar indicates that the image covers a field of view of 20 micrometers (μm).
• Surface Features: The image reveals a textured surface with varying shades of gray. This suggests differences in material composition or surface topography. The presence of pores or voids might also be visible, which can impact the material's properties.

EDS Spectrum
• X-Axis: The horizontal axis represents the energy of X-rays in kiloelectronvolts (keV).
• Y-Axis: The vertical axis represents the intensity of detected X-rays at each energy level.
• Peaks: The peaks in the spectrum correspond to the characteristic X-rays emitted by elements present in the sample when excited by the electron beam.
• Element Identification: By comparing the peak positions to known X-ray emission spectra, it's possible to identify the elements present in the sample. In this case, the peaks likely correspond to elements like carbon, oxygen, silicon, and potentially others, depending on the sample's composition.

This technique is widely used in various fields, including:
• Materials Science: Characterizing the microstructure and composition of materials, such as metals, ceramics, polymers, and composites.
• Geology: Identifying minerals and rocks, understanding their formation processes, and assessing their potential applications.
• Biology: Studying the elemental composition of cells and tissues, aiding in medical research and diagnostics.
• Forensic Science: Analyzing evidence for trace elements, aiding in criminal investigations.
• Semiconductor Industry: Inspecting and analyzing microelectronic devices, ensuring quality control and improving manufacturing processes.
• Environmental Science: Studying the composition of pollutants and environmental samples.
• Nanotechnology: Characterizing nanomaterials and understanding their properties.
• Limitations and Considerations
• Sample Preparation: Proper sample preparation is crucial to obtain accurate results. The sample must be conductive or coated with a conductive layer to prevent charging during electron bombardment.
• Depth of Analysis: The technique is primarily surface-sensitive, providing information about the topmost layers of the sample.
• Quantitative Analysis: While the EDS spectrum provides qualitative information about the elements present, quantitative analysis requires calibration and additional data processing.
• Beam Damage: The electron beam can damage sensitive samples, especially organic materials.
• Spatial Resolution: The spatial resolution of the analysis depends on the beam size and the sample's properties.

Further Analysis and Interpretation
To gain deeper insights into the sample, additional analyses can be performed, such as:
• Transmission Electron Microscopy (TEM): Provides high-resolution imaging of the sample's internal structure.
• Focused Ion Beam (FIB): Allows for precise sample preparation and cross-sectioning for further analysis.
• X-ray Diffraction (XRD): Provides information about the crystal structure and phase composition of the sample.

The SEM-EDS analysis is a powerful tool for characterizing the surface morphology and elemental composition of a sample. By carefully interpreting the data, researchers can gain valuable insights into the sample's properties, its potential applications, and its underlying processes.
, C , Claims:5. CLAIMS
I/We Claim:
1. A high-performance composite beam (100) for civil engineering applications, comprising:
the polymer or concrete matrix (102) serving as the primary structural framework;
the graphene (104) incorporated within the matrix as a reinforcing material, enhancing the beam's strength, stiffness, and durability;
the network of graphene nanofillers (106) dispersed throughout the matrix, providing increased load-bearing capacity and toughness;
an enhanced environmental resistance (108) features, ensuring durability against moisture, corrosion, and temperature fluctuations;
an improved fatigue resistance (110) characteristic, allowing the beam to maintain structural integrity under cyclic loading;
the lightweight design (112) that facilitates efficient transport and handling during construction, thereby reducing overall project costs.

2. The system (100) as claimed in claim 1, wherein the polymer matrix comprises a thermosetting or thermoplastic material selected from the group consisting of epoxy, polyester, and polyvinyl chloride (PVC).

3. The system (100) as claimed in claim 1, wherein the graphene is present in a concentration range of 0.1% to 10% by weight of the composite beam, optimizing the mechanical properties without compromising workability.

4. The system (100) as claimed in claim 1, further comprising a protective coating applied to the surface of the composite beam to enhance resistance to environmental degradation and improve longevity.

5. The system (100) as claimed in claim 1, wherein the graphene nanofillers form a three-dimensional network within the matrix, improving load transfer efficiency and enhancing overall structural performance.

6. The system (100) as claimed in claim 1, wherein the composite beam exhibits a flexural strength greater than 80 MPa, making it suitable for heavy load-bearing applications.

7. The system (100) as claimed in claim 1, further including embedded sensors for real-time monitoring of structural integrity and environmental conditions affecting the composite beam.

8. The system (100) as claimed in claim 1, wherein the composite beam is designed for use in applications requiring seismic resistance, ensuring stability and safety during earthquakes.

9. The system (100) as claimed in claim 1, wherein the composite beam is compatible with standard construction practices, allowing for easy integration with existing infrastructure.

10. A method for constructing a high-performance composite beam for civil engineering applications, comprising:
a. Preparing a polymer or concrete matrix to serve as the structural framework of the beam;
b. Incorporating graphene into the matrix to enhance strength, stiffness, and durability;
c. Dispersing graphene nanofillers throughout the matrix to form a reinforcing network that increases load-bearing capacity and toughness;
d. Enhancing environmental resistance of the beam by ensuring durability against moisture, corrosion, and temperature fluctuations;
e. Improving fatigue resistance by configuring the composite to withstand cyclic loading without structural degradation; and
f. Designing the beam to be lightweight, facilitating efficient transport and handling during construction and reducing overall project costs.

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