High strength, light weight structural composite and method of preparing same
AssigneeUtilities Products International Inc.
InventorsNorton S. Beckerman, Tom Endres, Peter Bowthorpe
Life of this patent
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Abstract
A light weight structural composite comprised of a cellular core having high dynamic load-bearing properties and a fiber reinforced resinous skin, the panel further comprised of an internally disposed elastomeric membrane which covers the core and acts to disperse shock waves created from impact loads.
Claims25
A structural composite panel, which comprises:
- (a) a substantially flat lower skin layer;
- (b) an upper skin layer which is spaced from said lower skin layer and which extends substantially parallel thereto;
- and
- (c) at least one core structure disposed between said skin layers and integrally bonded thereto such that said upper and lower skin layers and said core structure define a substantially monolithic composite panel, said core structure comprising:
- (i) a plurality of cellular core members arranged adjacent to each other and extending along the length of said panel substantially parallel to said upper and lower skin layers thereof,
- (ii) frame means integrally bonded to said cellular core members,
- (iii) skin means integrally bonded to and completely encasing said cellular members and said frame means, and
- (iv) an elastomeric membrane layer integrally bonded to and completely covering said skin means;
- wherein said upper and lower skin layers and said skin means of said core structure comprise a fiber reinforced resin matrix;
- wherein said cellular core members and said frame means are integrally bonded to each other and to said skin means;
- and
- wherein said upper skin and lower skin layers are integrally bonded to said core structure so as to form a substantially air bubble-free, monolithic composite panel having an internally disposed shock absorbing elastomeric membrane and having an ability to carry a static axle load of 32,000 pounds and an impact load of 41,600 pounds with a 3:1 safety factor even when said panel is supported only on two sides while spanning a ground opening.
A process for preparing a substantially monolithic composite structural panel which is capable of carrying a static axle load of 32,000 pounds and an impact load of 41,600 pounds with a 3:1 safety factor even when said panel is supported only on two sides while spanning a ground opening, which comprises the steps of:
- applying a release coating to the inner bottom surface of a mold;
- applying a gel coat on said release coating;
- applying one or more first layers of resin impregnated fibrous reinforcing material on the gel coat in said mold;
- curing said gel coat and said first resin impegnated fibrous reinforcing material to form a hardened first skin layer on said release coating;
- coating a first portion of the exposed surface of said first skin layer with an elastomeric composition;
- positioning a core structure on said elastomeric composition in such a manner as to exclude the formation of voids or occluded air between said elastomeric composition and said core structure;
- coating the entire exposed surface of said core structure with an elastomeric composition;
- applying one or more second layers of resin impregnated fibrous reinforcing material over the elastomeric material-coated core structure and over all remaining exposed portions of said first skin layer, in such a manner as to exclude the formation of voids or occluded air;
- and
- curing said second layers of resin impregnated fibrous reinforcing material to form a second skin layer and to integrally bond said first skin layer, said elastomeric composition, said core structure and said second skin layer into a substantially monolithic composite panel having a hardened central core and a hardened exterior surface which are interfaced with an impact absorbant elastomeric membrane.
Dependencies are inferred from the claim text.