Modular fiber reinforced polymer composite structural panel system

Abstract

A modular fiber reinforced polymer (FRP) composite structural panel component for structural support systems having a plurality of cells adjacently connected forming a top side, a bottom side, a first edge side and a second edge side. Each cell is defined by at least four sides, wherein at least two adjacent sides intersect at an obtuse angle resulting in the first edge side and the second edge side providing a means for joining two panel components and having an extensive bonding surface. A structural panel component is comprised of a plurality of layers of multi-axial fiber reinforcement, e.g., multi-axial fabrics, mats, woven cloth and unidirectional rovings, and a resin matrix, and the layers are continuous throughout the shape of the cells and a structural panel component. The structural panel component is manufactured using the Vacuum Assisted Resin Transfer Molding or pultrusion process. Two structural panel components are joined by placing the components along side each other and using an adhesive along the extensive bonding surface. A mechanical fastener also may be used to hold two structural panel components together. An overlay may be placed over the top of one or more structural panel components joined together thereby providing a uniform surface. In addition, one or more exterior FRP composite laminates, grids, plates or fabrics may be bonded continuously to said top side. In certain embodiments, one or more cells of a structural panel component may be filled with a filler, e.g., thermal insulation, noise reduction insulation, or a strength enhancement.