Lightweight structural composite for load bearing applications

Abstract

The present invention relates to a lightweight structural composite, which comprises an inner core of lightweight panel encapsulated by outer layers of polymer material. Specifically, the lightweight panel consists of multiple laminations of corrugated thin metal or fiber reinforced plastic sheets kept in position by polymeric foam and/or adhesive, and enclosed in a casing of the same material. The outer layer is made up of a blend of thermosetting and thermoplastic polymers. The method of forming the composite comprises of stacking the corrugated sheets, filling the interstitial spaces with the foam, constructing the casing, the surface treatment of the panel for good adhesion to the outer polymer layer and the high temperature/pressure encapsulation of the panel with the polymer blend containing curing agents. The composite has application as replacement to wood, concrete or particle board panels used in ship docking, panels for wall, door and windows, blast-proof panels, rail sleepers and shipping pallets.