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WO1998036897A1 - Composite structures - Google Patents

Composite structures Download PDF

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Publication number
WO1998036897A1
WO1998036897A1 PCT/GB1998/000565 GB9800565W WO9836897A1 WO 1998036897 A1 WO1998036897 A1 WO 1998036897A1 GB 9800565 W GB9800565 W GB 9800565W WO 9836897 A1 WO9836897 A1 WO 9836897A1
Authority
WO
WIPO (PCT)
Prior art keywords
resin
composite material
core layer
layers
preformed
Prior art date
Application number
PCT/GB1998/000565
Other languages
French (fr)
Inventor
Peter James Boatman
Original Assignee
Peter James Boatman
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Peter James Boatman filed Critical Peter James Boatman
Priority to AU63017/98A priority Critical patent/AU6301798A/en
Publication of WO1998036897A1 publication Critical patent/WO1998036897A1/en

Links

Classifications

    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C67/00Shaping techniques not covered by groups B29C39/00 - B29C65/00, B29C70/00 or B29C73/00
    • B29C67/24Shaping techniques not covered by groups B29C39/00 - B29C65/00, B29C70/00 or B29C73/00 characterised by the choice of material
    • B29C67/242Moulding mineral aggregates bonded with resin, e.g. resin concrete
    • B29C67/243Moulding mineral aggregates bonded with resin, e.g. resin concrete for making articles of definite length

Definitions

  • This invention relates to a composite material, a structure including such a material, particularly a structure adapted for use where there is a requirement for the structure to be suitable for use in a corrosive environment, and a method of manufacturing the structure.
  • Laminates made of synthetic resin or plastics combined with reinforcement to provide strength e.g. GRP (Glass Reinforced Plastics), FRP (Fibre Reinforced Plastics) or Fibrcglass, have been known for many years as suitable for use in corrosive areas.
  • GRP Glass Reinforced Plastics
  • FRP Fibre Reinforced Plastics
  • Fibrcglass Fiber Reinforced Plastics
  • Such laminates have very high tensile strength but low stiffness/rigidity.
  • use of a very thick laminate is required, which then has much more tensile strength and corrosion resistance than is needed.
  • the structure is expensive when compared to other conventional materials such as stainless steel, aluminium or painted steel.
  • sandwich construction laminate i.e. where two layers of laminate are applied or bonded to a low cost core material.
  • core material such as synthetic foam, honeycomb in paper and aluminium, wood, balsa and paper.
  • the manufacturing procedure is generally to produce one laminate, then position the core material, and then build up or bond the second laminate on top of the core material to form the sandwich construction. With such a procedure, it is difficult to produce complex shapes or to change the thickness of the core to suit variable strength requirements in the same structure.
  • Another disadvantage of such a manufacturing procedure is in the strength and cost of the core material.
  • the two laminates need to be spaced further apart, with the result that the core material itself needs to be stronger. This increases its cost, and if stronger core materials are used such as honeycomb, balsa or dense synthetic foams they in turn become more expensive.
  • the time taken in positioning and bonding the core to the first laminate can be disadvantageous, and the bond between the laminates and core material can be a problem.
  • a composite material formed by a coalescence of materials in a mould, including an aggregate of materials providing strength and rigidity and a bonding agent.
  • the composite material so formed is hereinafter referred to as a "plastic concrete”.
  • the bonding agent is a thermosetting resin, for example polyester, epoxy, acrylic, vinylestcr, polyurcthane or phenolic, or can be a thermoplastic resin, for example polyvinylchloride, polypropylene or polyurcthane.
  • the aggregate can be an inorganic material, for example any of silica sand, silica powder, calcium powder, gravel, stone chippings, ceramic powder or ceramic chippings, or any combination thereof.
  • the plastic concrete may further include glass, metal or plastic fibres.
  • the present invention also provides a structure comprising a plurality of material layers, a core layer being formed of plastic concrete as hereinbefore defined, and outer layers being formed on respective sides of the core layer, each of the outer layers being formed of a plastics material.
  • the present invention further provides a method of manufacturing a structure, the method comprising forming a pair of material layers from a plastics material, positioning the material layers in a spaced apart relation, and forming a core layer between the preformed material layers.
  • the core layer may be formed of plastic concrete as hereinbefore defined and may be introduced in a flowable state between the preformed material layers to be moulded therein.
  • the preformed material layers provide formwork for the moulding.
  • the preformed material layers are moulded and are retained in their moulds to provide the formwork for moulding of the core layer.
  • the same synthetic resin may be used for the preformed material layers and the plastic concrete.
  • the plastic concrete may also include glass, metal or plastic fibres.
  • a structure is formed by producing a sandwich construction in the form of two preformed laminates on respective sides of a core material.
  • the laminates may each be formed from a synthetic resin and the core may be a composite material formed from a plastic concrete as hereinbefore defined, the plastic concrete providing the required stiffness and strength to the structure.
  • the laminates are moulded to a desired shape and, remaining within their moulds, are then used, in a spaced apart relation, as part of the formwork for the core material.
  • the plastic concrete is poured into the formwork and bonds to the preformed laminates to define the required composite structure.
  • the core material can be poured into a mould defined by the preformed laminates so as to bond thereto while setting, there is a saving in manufacturing time, and there is no restriction on changing the thickness of the core in the same structure or changing the shape of the finished structure.
  • Complex shapes can be manufactured, and by using different thicknesses of plastic concrete, the strength can be varied in different areas of the same structure.
  • the plastic concrete bonding agent may be a synthetic resin such as thermosetting resin, for example polyester, epoxy, acrylic, vinylester, polyurcthane or phenolic, or a thermoplastic resin, for example polyvinyl chloride, polypropylene or polyurethane.
  • the aggregate can be an organic material, for example any of silica sand, silica powder, calcium powder, gravel, stone chippings, ceramic powder or ceramic chippings, or any combination thereof.
  • other types of reinforcement can be included in the plastic concrete, such as glass, metal or plastic fibres.
  • the core material is low cost because the most expensive material is the synthetic resin which can be as little as 8>% of the total weight of the core.
  • the structure can be used to produce many different structures including pipes, boats, tanks, bridge decks, floor sections, structural beams, manholes, manhole covers and tank covers.

Landscapes

  • Engineering & Computer Science (AREA)
  • Ceramic Engineering (AREA)
  • Structural Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Laminated Bodies (AREA)

Abstract

A sandwich construction comprises two preformed laminates on respective sides of a core material. The laminates are each formed from a synthetic resin and the core material is formed from an inorganic aggregate and a bonding agent, the latter being the same synthetic resin as the preformed laminates. The laminates are moulded to a desired shape and are then used as part of the formwork for moulding of the core material. A strong bond is formed between the laminates and the core material by the use of the same resin, and the method of manufature provides a saving in manufacturing time and no restriction on varying the thickness of the core material.

Description

Composite Structures
This invention relates to a composite material, a structure including such a material, particularly a structure adapted for use where there is a requirement for the structure to be suitable for use in a corrosive environment, and a method of manufacturing the structure.
Laminates made of synthetic resin or plastics combined with reinforcement to provide strength, e.g. GRP (Glass Reinforced Plastics), FRP (Fibre Reinforced Plastics) or Fibrcglass, have been known for many years as suitable for use in corrosive areas. Such laminates have very high tensile strength but low stiffness/rigidity. To overcome this and provide a rigid structure, use of a very thick laminate is required, which then has much more tensile strength and corrosion resistance than is needed. As a consequence the structure is expensive when compared to other conventional materials such as stainless steel, aluminium or painted steel.
It has been known that one way to overcome this lack of stiffness is to produce a sandwich construction laminate, i.e. where two layers of laminate are applied or bonded to a low cost core material. Many different materials have been used as the core, such as synthetic foam, honeycomb in paper and aluminium, wood, balsa and paper. The manufacturing procedure is generally to produce one laminate, then position the core material, and then build up or bond the second laminate on top of the core material to form the sandwich construction. With such a procedure, it is difficult to produce complex shapes or to change the thickness of the core to suit variable strength requirements in the same structure.
Another disadvantage of such a manufacturing procedure is in the strength and cost of the core material. To obtain maximum stiffness, the two laminates need to be spaced further apart, with the result that the core material itself needs to be stronger. This increases its cost, and if stronger core materials are used such as honeycomb, balsa or dense synthetic foams they in turn become more expensive. The time taken in positioning and bonding the core to the first laminate can be disadvantageous, and the bond between the laminates and core material can be a problem.
According to the present invention there is provided a composite material formed by a coalescence of materials in a mould, including an aggregate of materials providing strength and rigidity and a bonding agent. The composite material so formed is hereinafter referred to as a "plastic concrete".
The bonding agent is a thermosetting resin, for example polyester, epoxy, acrylic, vinylestcr, polyurcthane or phenolic, or can be a thermoplastic resin, for example polyvinylchloride, polypropylene or polyurcthane. The aggregate can be an inorganic material, for example any of silica sand, silica powder, calcium powder, gravel, stone chippings, ceramic powder or ceramic chippings, or any combination thereof. The plastic concrete may further include glass, metal or plastic fibres.
The present invention also provides a structure comprising a plurality of material layers, a core layer being formed of plastic concrete as hereinbefore defined, and outer layers being formed on respective sides of the core layer, each of the outer layers being formed of a plastics material.
The present invention further provides a method of manufacturing a structure, the method comprising forming a pair of material layers from a plastics material, positioning the material layers in a spaced apart relation, and forming a core layer between the preformed material layers.
The core layer may be formed of plastic concrete as hereinbefore defined and may be introduced in a flowable state between the preformed material layers to be moulded therein. The preformed material layers provide formwork for the moulding. The preformed material layers are moulded and are retained in their moulds to provide the formwork for moulding of the core layer.
The same synthetic resin may be used for the preformed material layers and the plastic concrete. The plastic concrete may also include glass, metal or plastic fibres.
An embodiment of the present invention will now be described by way of example only.
A structure is formed by producing a sandwich construction in the form of two preformed laminates on respective sides of a core material. The laminates may each be formed from a synthetic resin and the core may be a composite material formed from a plastic concrete as hereinbefore defined, the plastic concrete providing the required stiffness and strength to the structure.
The laminates are moulded to a desired shape and, remaining within their moulds, are then used, in a spaced apart relation, as part of the formwork for the core material. The plastic concrete is poured into the formwork and bonds to the preformed laminates to define the required composite structure.
As the core material can be poured into a mould defined by the preformed laminates so as to bond thereto while setting, there is a saving in manufacturing time, and there is no restriction on changing the thickness of the core in the same structure or changing the shape of the finished structure. Complex shapes can be manufactured, and by using different thicknesses of plastic concrete, the strength can be varied in different areas of the same structure.
The plastic concrete bonding agent may be a synthetic resin such as thermosetting resin, for example polyester, epoxy, acrylic, vinylester, polyurcthane or phenolic, or a thermoplastic resin, for example polyvinyl chloride, polypropylene or polyurethane. The aggregate can be an organic material, for example any of silica sand, silica powder, calcium powder, gravel, stone chippings, ceramic powder or ceramic chippings, or any combination thereof. To provide further strength, other types of reinforcement can be included in the plastic concrete, such as glass, metal or plastic fibres. By using the same synthetic resin in forming the laminates and the core, the bond between the laminates and the core can be improved and the core becomes more of an integral part of the laminates.
The core material is low cost because the most expensive material is the synthetic resin which can be as little as 8>% of the total weight of the core.
The structure can be used to produce many different structures including pipes, boats, tanks, bridge decks, floor sections, structural beams, manholes, manhole covers and tank covers.
Various modifications may be made without departing from the invention.

Claims

1. A composite material formed by a coalescence of materials in a mould, including an aggregate of materials providing strength and rigidity and a bonding agent.
2. A composite material according to Claim 1 , wherein the bonding agent is a thermosetting resin.
3. A composite material according to Claim 2, wherein the thermosetting resin is selected from polyester, epoxy, acrylic, vinylester, polyurcthane or phenolic.
4. A composite material according to Claim 1, wherein the resin is a thermoplastic resin.
5. A composite material according to Claim 4, wherein the thermoplastic resin is selected from polyvinylchloridc, polypropylene or polyurethanc.
6. A composite material according to any of the preceding Claims, wherein the aggregate is an inorganic material.
7. A composite material according to Claim 6, wherein the aggregate is selected from silica sand, silica powder, calcium powder, gravel, stone chippings, ceramic powder or ceramic chippings, or any combination thereof.
8. A composite material according to any of the preceding Claims, including a material selected from glass, metal or plastic fibres.
9. A structure comprising a plurality of material layers, a core layer being formed of a composite material according to any of the preceding Claims, and outer layers being formed on respective sides of the core layer, each of the outer layers being formed of a plastics material.
10. A structure according to Claim 9, wherein each of the outer layers is formed of a resin.
11. A method of manufacturing a structure, the method comprising forming a pair of material layers from a plastics material, positioning the material layers in a spaced apart relation, and forming a core layer between the preformed material layers.
12. A method according to Claim 11, wherein the core layer is introduced in a flowable state between the preformed material layers to be moulded therein.
13. A method according to Claim 12, wherein the preformed material layers provide formwork for the moulding of the core layer.
14. A method according to Claim 13, wherein the preformed material layers are moulded and are retained in their moulds to provide the formwork for moulding of the core layer.
15. A method according to any of Claims 11 to 14, wherein the core layer includes an aggregate of materials providing strength and rigidity and a bonding agent formed of a resin, and the preformed material layers are formed of the bonding agent resin.
16. A method according to Claim 15, wherein the resin is a thermosetting resin selected from polyester, epoxy, acrylic, vinylester, polyurethane or phenolic.
17. A method according to Claim 15, wherein the resin is a thermoplastic resin selected from polyvinylchloride, polypropylene or polyurethane.
18. A method according to any of Claims 15 to 17, wherein the aggregate is an inorganic material selected from silica sand, silica powder, calcium powder, gravel, stone chippings, ceramic powder or ceramic chippings, or any combination thereof.
19. A method according to any of Claims 1 5 to 18, wherein the core layer includes a material selected from glass, metal or plastic fibres.
20. A composite material substantially as hereinbefore described.
2 1. A structure comprising a plurality of material layers substantially as hereinbefore described.
22. A method of manufacturing a structure substantially as hereinbefore described.
23. Any novel subject matter or combination including novel subject matter disclosed herein, whether or not within the scope of or relating to the same invention as any of the preceding claims.
PCT/GB1998/000565 1997-02-21 1998-02-23 Composite structures WO1998036897A1 (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
AU63017/98A AU6301798A (en) 1997-02-21 1998-02-23 Composite structures

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
GBGB9703609.9A GB9703609D0 (en) 1997-02-21 1997-02-21 Composite structures
GB9703609.9 1997-02-21

Publications (1)

Publication Number Publication Date
WO1998036897A1 true WO1998036897A1 (en) 1998-08-27

Family

ID=10808064

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/GB1998/000565 WO1998036897A1 (en) 1997-02-21 1998-02-23 Composite structures

Country Status (3)

Country Link
AU (1) AU6301798A (en)
GB (1) GB9703609D0 (en)
WO (1) WO1998036897A1 (en)

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2000035664A1 (en) * 1998-12-12 2000-06-22 Peter James Boatman Improvements in or relating to pipes
WO2001039955A1 (en) * 1999-11-30 2001-06-07 Lupke Manfred Arno Alfred Pipe with composite wall construction and method of making same
BE1019929A5 (en) * 2011-12-22 2013-02-05 Polysto WALL OR WALL CLADDING ELEMENTS AND THEIR PRODUCTION.

Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4207373A (en) * 1973-04-25 1980-06-10 Allied Chemical Corporation Highly filled polyolefin compositions
EP0034678A2 (en) * 1980-02-21 1981-09-02 Inax Corporation Lightweight and dimensionally accurate resin concrete molded products, and a method of making the same
FR2538303A1 (en) * 1982-12-27 1984-06-29 Gigon Michel Process for producing a composite product provided with a surface layer made from polyester resin and product obtained thereby
EP0124403A1 (en) * 1983-03-31 1984-11-07 Societe D'exploitation Des Procedes Plastrex-Manurhin Sepma Process for producing high-pressure collar flanges from composite material, and product obtained
EP0412903A1 (en) * 1989-08-07 1991-02-13 Electricite De France Composite panel of fireproof, impact-resistant, watertight and sound-absorbant material and its method of manufacture
EP0508950A1 (en) * 1991-04-10 1992-10-14 Alusuisse-Lonza Services Ag Method and apparatus for producing a composite panel which is barely inflammable to unburnable
JPH0516288A (en) * 1991-07-10 1993-01-26 Matsushita Electric Ind Co Ltd Molded body with pattern composed of laminate structure

Patent Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4207373A (en) * 1973-04-25 1980-06-10 Allied Chemical Corporation Highly filled polyolefin compositions
EP0034678A2 (en) * 1980-02-21 1981-09-02 Inax Corporation Lightweight and dimensionally accurate resin concrete molded products, and a method of making the same
FR2538303A1 (en) * 1982-12-27 1984-06-29 Gigon Michel Process for producing a composite product provided with a surface layer made from polyester resin and product obtained thereby
EP0124403A1 (en) * 1983-03-31 1984-11-07 Societe D'exploitation Des Procedes Plastrex-Manurhin Sepma Process for producing high-pressure collar flanges from composite material, and product obtained
EP0412903A1 (en) * 1989-08-07 1991-02-13 Electricite De France Composite panel of fireproof, impact-resistant, watertight and sound-absorbant material and its method of manufacture
EP0508950A1 (en) * 1991-04-10 1992-10-14 Alusuisse-Lonza Services Ag Method and apparatus for producing a composite panel which is barely inflammable to unburnable
JPH0516288A (en) * 1991-07-10 1993-01-26 Matsushita Electric Ind Co Ltd Molded body with pattern composed of laminate structure

Non-Patent Citations (1)

* Cited by examiner, † Cited by third party
Title
DATABASE WPI Derwent World Patents Index; AN 93-070632, XP002066148 *

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2000035664A1 (en) * 1998-12-12 2000-06-22 Peter James Boatman Improvements in or relating to pipes
WO2001039955A1 (en) * 1999-11-30 2001-06-07 Lupke Manfred Arno Alfred Pipe with composite wall construction and method of making same
BE1019929A5 (en) * 2011-12-22 2013-02-05 Polysto WALL OR WALL CLADDING ELEMENTS AND THEIR PRODUCTION.

Also Published As

Publication number Publication date
GB9703609D0 (en) 1997-04-09
AU6301798A (en) 1998-09-09

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