WO1998036897A1 - Composite structures - Google Patents
Composite structures Download PDFInfo
- 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
Links
- 239000002131 composite material Substances 0.000 title claims description 17
- 238000000034 method Methods 0.000 claims abstract description 12
- 229920005989 resin Polymers 0.000 claims abstract description 12
- 239000011347 resin Substances 0.000 claims abstract description 12
- 239000007767 bonding agent Substances 0.000 claims abstract description 8
- 238000004519 manufacturing process Methods 0.000 claims abstract description 8
- 238000009415 formwork Methods 0.000 claims abstract description 7
- 238000000465 moulding Methods 0.000 claims abstract description 5
- 239000000463 material Substances 0.000 claims description 32
- 239000010410 layer Substances 0.000 claims description 23
- 239000004033 plastic Substances 0.000 claims description 22
- 229920003023 plastic Polymers 0.000 claims description 22
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical group O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims description 20
- 239000012792 core layer Substances 0.000 claims description 13
- 239000000843 powder Substances 0.000 claims description 12
- 239000000919 ceramic Substances 0.000 claims description 8
- -1 polypropylene Polymers 0.000 claims description 8
- 239000000377 silicon dioxide Substances 0.000 claims description 8
- 239000011521 glass Substances 0.000 claims description 5
- 229910052751 metal Inorganic materials 0.000 claims description 5
- 239000002184 metal Substances 0.000 claims description 5
- 229920005992 thermoplastic resin Polymers 0.000 claims description 5
- 229920001187 thermosetting polymer Polymers 0.000 claims description 5
- OYPRJOBELJOOCE-UHFFFAOYSA-N Calcium Chemical compound [Ca] OYPRJOBELJOOCE-UHFFFAOYSA-N 0.000 claims description 4
- 239000004593 Epoxy Substances 0.000 claims description 4
- 239000004743 Polypropylene Substances 0.000 claims description 4
- NIXOWILDQLNWCW-UHFFFAOYSA-N acrylic acid group Chemical group C(C=C)(=O)O NIXOWILDQLNWCW-UHFFFAOYSA-N 0.000 claims description 4
- 229910052791 calcium Inorganic materials 0.000 claims description 4
- 239000011575 calcium Substances 0.000 claims description 4
- ISWSIDIOOBJBQZ-UHFFFAOYSA-N phenol group Chemical group C1(=CC=CC=C1)O ISWSIDIOOBJBQZ-UHFFFAOYSA-N 0.000 claims description 4
- 229920000728 polyester Polymers 0.000 claims description 4
- 229920001155 polypropylene Polymers 0.000 claims description 4
- 239000004576 sand Substances 0.000 claims description 4
- 239000004575 stone Substances 0.000 claims description 4
- 229910010272 inorganic material Inorganic materials 0.000 claims description 3
- 239000011147 inorganic material Substances 0.000 claims description 3
- 229920002635 polyurethane Polymers 0.000 claims description 3
- 239000004814 polyurethane Substances 0.000 claims description 3
- 229920000915 polyvinyl chloride Polymers 0.000 claims description 3
- 239000004800 polyvinyl chloride Substances 0.000 claims description 3
- 229920001567 vinyl ester resin Polymers 0.000 claims description 3
- 238000004581 coalescence Methods 0.000 claims description 2
- 230000009969 flowable effect Effects 0.000 claims description 2
- 230000000717 retained effect Effects 0.000 claims description 2
- 239000011162 core material Substances 0.000 abstract description 25
- 239000000057 synthetic resin Substances 0.000 abstract description 8
- 229920003002 synthetic resin Polymers 0.000 abstract description 8
- 238000010276 construction Methods 0.000 abstract description 4
- 229920002430 Fibre-reinforced plastic Polymers 0.000 description 2
- 240000007182 Ochroma pyramidale Species 0.000 description 2
- 239000004411 aluminium Substances 0.000 description 2
- 229910052782 aluminium Inorganic materials 0.000 description 2
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 2
- 239000011151 fibre-reinforced plastic Substances 0.000 description 2
- 239000011152 fibreglass Substances 0.000 description 2
- 239000006260 foam Substances 0.000 description 2
- 239000000123 paper Substances 0.000 description 2
- 230000002787 reinforcement Effects 0.000 description 2
- 229910000831 Steel Inorganic materials 0.000 description 1
- 238000005260 corrosion Methods 0.000 description 1
- 230000007797 corrosion Effects 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 239000011368 organic material Substances 0.000 description 1
- 229910001220 stainless steel Inorganic materials 0.000 description 1
- 239000010935 stainless steel Substances 0.000 description 1
- 239000010959 steel Substances 0.000 description 1
- 239000002023 wood Substances 0.000 description 1
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C67/00—Shaping techniques not covered by groups B29C39/00 - B29C65/00, B29C70/00 or B29C73/00
- B29C67/24—Shaping techniques not covered by groups B29C39/00 - B29C65/00, B29C70/00 or B29C73/00 characterised by the choice of material
- B29C67/242—Moulding mineral aggregates bonded with resin, e.g. resin concrete
- B29C67/243—Moulding 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
Description
Claims
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)
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)
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 |
-
1997
- 1997-02-21 GB GBGB9703609.9A patent/GB9703609D0/en active Pending
-
1998
- 1998-02-23 AU AU63017/98A patent/AU6301798A/en not_active Abandoned
- 1998-02-23 WO PCT/GB1998/000565 patent/WO1998036897A1/en active Application Filing
Patent Citations (7)
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)
Title |
---|
DATABASE WPI Derwent World Patents Index; AN 93-070632, XP002066148 * |
Cited By (3)
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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