U.S. patent application number 09/785692 was filed with the patent office on 2001-12-13 for composite structural components for outdoor use.
Invention is credited to Gagas, John M., Mullett, Donald H..
Application Number | 20010051249 09/785692 |
Document ID | / |
Family ID | 25400505 |
Filed Date | 2001-12-13 |
United States Patent
Application |
20010051249 |
Kind Code |
A1 |
Gagas, John M. ; et
al. |
December 13, 2001 |
Composite structural components for outdoor use
Abstract
A structure according to the invention comprises a series of
interconnected structural members. The structural members, such-as
panels, are made of a composition comprising as its first essential
ingredient a cured (cross-linked) resin having sufficient strength
when filled as described below to support weights up to about 700
pounds without significant buckling, but which has sufficient
resilience to flex and rebound from impacts such as low speed
collisions with small boats or dropping of heavy human-carried
objects without cracking or breaking. The cured resin matrix
contains a first filler consisting essentially of inorganic
particles effective to improve the impact resistance and flame
resistance of the structure, and an amount of a second filler
consisting essentially of fibers effective to enhance the rigidity
of the structure and reduce crack propagation therein. An optional
third filler consisting essentially of plastic microspheres may be
added in an amount effective to reduce the weight of the panel by
at least 10% without significantly affecting the other essential
properties of the cross-linked resin and first and second fillers,
namely flexural strength, flame resistance, impact resistance,
rigidity, resistance to crack propagation, and resistance to
outdoor environments, particularly marine environments. Piers and
docks made from panels of the composite of the invention provide
superior performance as compared to conventional materials used to
build such structures.
Inventors: |
Gagas, John M.; (Milwaukee,
WI) ; Mullett, Donald H.; (Hartland, WI) |
Correspondence
Address: |
Scott D. Anderson
FOLEY & LARDNER
Firstar Center
777 East Wisconsin Avenue
Milwaukee
WI
53202-5367
US
|
Family ID: |
25400505 |
Appl. No.: |
09/785692 |
Filed: |
February 16, 2001 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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09785692 |
Feb 16, 2001 |
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08892796 |
Jul 15, 1997 |
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6194051 |
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Current U.S.
Class: |
428/99 ; 428/192;
428/45; 428/480; 428/52 |
Current CPC
Class: |
Y02A 10/11 20180101;
Y10T 428/24008 20150115; Y10T 428/31786 20150401; Y10T 428/169
20150115; Y10T 428/161 20150115; Y02A 10/18 20180101; Y10T
428/24777 20150115; E02B 3/068 20130101; B29C 44/1266 20130101 |
Class at
Publication: |
428/99 ; 428/45;
428/52; 428/192; 428/480 |
International
Class: |
B32B 003/06 |
Claims
1. A structure, comprising: a series of structural members made of
a composition comprising a cured vinyl ester resin having
distributed therein an amount of a first filler consisting
essentially of inorganic particles effective to improve impact
resistance of the structure and an amount of a second filler
consisting essentially of plastic fibers effective to increase
rigidity and crack propagation resistance of the structural
members; and means for interconnecting the structural members.
2. The structure of claim 1, wherein the structure is a marine
structure.
3. The structure of claim 1, wherein the structure is a pier or
dock, and the structural members comprise a series of panels.
4. The structure of claim 3, wherein the interconnecting means
comprises mechanical fasteners.
5. The structure of claim 1, wherein the structural members
comprise a series of panels, and the structure further comprises a
rigid framework having surfaces configured for supporting the
panels.
6. The structure of claim 5, wherein the rigid framework includes a
pair of horizontal parallel brackets spaced to fit the panels
therebetween, and vertical posts rigidly secured to each of the
brackets for supporting the brackets in an elevated position.
7. The structure of claim 1, wherein the structural members are
made of a composition consisting essentially of the vinyl ester
resin, the first filler, the second filler, and plastic
microspheres as a third filler in an amount effective to reduce the
weight of the structural panel by at least about 10 wt. % relative
to a structural member of like composition and size but lacking the
microspheres, but which amount is insufficient to substantially
reduce the structural strength of the members.
8. The structure of claim 1, wherein the structural members are
cured products made from a composition consisting essentially of:
about 30 to 70 wt. % of a vinyl ester resin; about 46 wt. % to
about 70 wt. % of inorganic particles as the first filler
distributed in the resin, which particles are effective in increase
the impact resistance of the structural members; and about 0.33 wt.
% to about 1 wt. % of plastic fibers as the second filler
distributed in the resin, which fibers are effective to increase
the rigidity and crack propagation resistance of the structural
members.
9. The structure of claim 8, wherein the composition from which the
structural members are made contains from about 0.3 wt. % to 1 wt.
% of plastic microspheres.
10. The structure of claim 9, wherein the vinyl ester resin
contains a vinyl ester having the formula: 2wherein n is from 1 to
3, a styrene monomer, and a peroxide catalyst.
11. The structure of claim 8, wherein the structural members are
made of a composition containing effective amounts of one or more
of a UV absorber, a flame retardant, and a colorant.
12. The structure of claim 8, wherein the inorganic particles are
selected from the group consisting of particles of limestone,
crystalline silica, calcium carbonate, and hydrated alumina.
13. The structure of claim 1, wherein the structural members are
made of a composition free of glass spheres, glass fragments and
glass fibers.
14. The structure of claim 1, wherein the structural members
comprise substantially flat panels having a support grid molded
therein.
15. A process for making a molded structure, comprising: forming a
mixture comprising a curable resin having distributed therein an
amount of a first filler consisting essentially of inorganic
particles effective to improve impact resistance of the structure
and an amount of a second filler consisting essentially of plastic
fibers effective to increase rigidity and crack propagation
resistance of the structural members, wherein the resin when cured
in the molded structure has sufficient strength when filled with
the first and second fillers to support weights up to about 700
pounds for a panel having dimensions 3' by 4' by 0.75", without
substantial buckling, but which has sufficient resilience to flex
and rebound from impacts; placing a support into a mold; adding an
effective amount of a curing catalyst to the mixture; introducing
the mixture into a mold so that the support becomes embedded
therein; curing the mixture in the mold; and removing the
thus-formed molded structure from the mold.
16. A curable plastic composition, consisting essentially of: about
30 to 70 wt. % of a curable vinyl ester resin; about 46 wt. % to 70
wt. % of inorganic particles distributed in the cured resin, which
particles are effective in increase the impact resistance of the
structural members; and about 0.33 wt. % to about 1 wt. % of
plastic fibers effective to increase the rigidity and crack
propagation resistance of the composition when the composition is
cured.
17. The composition of claim 16, wherein the composition contains
from 0.3 wt. % to 1 wt. % of plastic microspheres.
18. The composition of claim 17, wherein the vinyl ester resin
consists essentially of a vinyl ester of the formula: 3wherein n is
from 1 to 3, and a styrene monomer.
19. The composition of claim 18, wherein the composition contains
effective amounts of one or more of a UV absorber, a flame
retardant, and a colorant.
20. The composition of claim 16, wherein the inorganic particles
are selected from the group consisting of particles of limestone,
crystalline silica, calcium carbonate, and hydrated alumina.
21. The composition of claim 16, wherein the composition is free of
glass spheres, glass fragments and glass fibers.
22. A structure, comprising: a series of structural members made of
a composition comprising a cured resin having distributed therein
an amount of a first filler consisting essentially of inorganic
particles effective to improve impact resistance of the structure
and an amount of a second filler consisting essentially of plastic
fibers effective to increase rigidity and crack propagation
resistance of the structural members, wherein the cured resin has
sufficient strength when filled with the first and second fillers
to support weights up to about 700 pounds for a panel having
dimensions 3' by 4' by 0.75" without substantial buckling, but
which has sufficient resilience to flex and rebound from impacts;
and means for interconnecting the structural members.
Description
TECHNICAL FIELD
[0001] This invention relates to composite plastic compositions
having properties suitable for use in making components for outdoor
structures, particularly marine structures such as piers and
docks.
BACKGROUND OF THE INVENTION
[0002] A pier is a wharf that projects perpendicularly or obliquely
from a shore, serving as a berth for boats to load and unload
passengers and cargo or for extending out into the water for other
purposes such as fishing, swimming, and recreation. Piers are
normally constructed as a pile structure-supported platform using
materials selected from steel, coated metal, aluminum, timber,
pressure-treated lumber, polypropylene (from milk bottles),
fiberglass, and concrete. Piers may be open-deck or housed-over,
and are commonly constructed from panels, laths, or sheets
assembled and joined together in series on the supporting
structure.
[0003] Piers and similarly located marine structures are exposed to
a wide assortment of hostile environmental conditions that lead to
structural failure. Problems with the materials presently used to
make piers include catastrophic failure, corrosion, excessive
weight, attack by animals (such as worms eating wood), decay,
leaching of toxins into the water, non-reparability, cost of
manufacture, warping, splitting, brittleness, destruction by the
action of waves, the ability of water to transport materials, water
damage, UV degradation, chemical attack, color stability, entrapped
air pockets, poor resilience (the inability of a material to take
an impact without damage), delamination, harm to people, animals
and plants in use, water absorption, loss of physical properties,
poor stability, limited shapes and designs, costs and methods of
assembly, flammability, and overall weather resistance. A material
is needed which is reasonably versatile and light in weight, yet
highly resistant to the marine (fresh or salt water) environment
and having sufficient strength and resilience to function as a
dock. The present invention addresses the problems associated with
known materials used in dock and pier construction by providing a
filled plastic composition having properties uniquely adapted for
use in a marine or other outdoor environment.
[0004] Filled and unfilled plastic products and methods for their
manufacture are well documented, but suffer from a number of
problems. Many such known products use a methyl methacrylate
polyester resin (acrylic and polyester-based resin) that is
brittle. Others use an unsaturated polyester resin which is
likewise brittle. Acrylic by itself is very brittle, and can be
found in products such as Corian (Du Pont). Combining methyl
methacrylate (MMA) with polyester improves UV stability and
chemical resistance as compared to unsaturated polyester, but at
the cost of making the end product much more brittle. Brittleness
in polyester products will depend on the amount of methyl
methacrylate (acrylic) used, with larger amounts of acrylic
increasing brittleness. A sharp impact or drop to these products
will result in a cracked or shattered part, and cracks will
propagate within these products. For this reason, such brittle
plastics are generally unsuitable for applications such as piers,
wherein the structure must absorb occasional impacts (e.g., boats
striking the side of the pier) without breaking.
[0005] Various inorganic compounds such as aluminum trihydrates
(ATH), glass fibers, and glass beads have been used as fillers in
products such as the polyesters discussed above. ATH imparts a good
flame resistance to polyester, but must be loaded in large amounts
to achieve flame resistance (50 to 60% minimum by weight is
typical). ATH fillers add weight from 0.6 g/cm.sup.3 to 1.35
g/cm.sup.3 (37.46 lbs/ft.sup.3 to 84.28 lbs/ft.sup.3 for
loose-to-packed density) with a specific gravity of 2.42.
[0006] Glass fibers impart good strength to a product but increase
brittleness and add weight. Glass fibers also have sharp ends which
can cause problems to objects that come in contact with them. In
the case of a pier in which glass fibers are used, the sharp ends
can puncture a foot or hand when a person is touching or walking on
the pier. Glass fibers also tend to break off and splinter into a
person or object. Overcoating the glass fibers is one of the steps
taken to reduce this problem, but adds to cost and labor. Further,
all products with such a coating over glass fibers will in time,
due to wear, have glass fibers protruding from the product and thus
suffer the problems discussed above.
[0007] Glass spheres or beads used as a filler provide no strength
addition, but provide weight reduction and increased impact
resistance. Spheres made of glass add brittleness to the product,
and repeated impacts will break the spheres, thereby reducing
impact strength with a loss of overall tensile strength. Since the
spheres are made of glass and have a rigid nature, violent
operations such as mixing the spheres at high speeds, vacuuming to
remove air, and spraying the mix at high pressures cause breakage,
and the benefits provided by the glass spheres are lost. Similarly,
products containing glass fibers or glass microspheres as a filler
are not very workable or machinable. Sawing, sanding, nailing, and
screw holding are difficult due to the brittle nature of glass.
Glass fillers also lack flexibility.
[0008] Materials such as recycled polypropylene and polyethylene
have many problems when used for the manufacture of piers, benches
and other products. These problems include low temperature
embrittlement, high temperature softening, flowing and moving,
thermal stability (with repeated cold and hot temperature cycling,
products will lose physical properties), UV stability (exposure to
sun light or UV light will degrade products, resulting in loss of
physical properties, and/or loss of color), low strength (unfilled
materials are soft, not rigid), and high scratchability due to the
soft nature of the material. Additives such as anti-microbial
agents added to the products to keep growths from forming on the
surface are costly and result in a loss of physical properties.
[0009] Processing of filled plastics has been carried out by many
methods that are well known. Some methods, such as hand lay-up and
injection molding, are used to make piers and other products. These
processing methods are expensive and can be labor intensive.
Injection molding uses matched metal molds which are expensive.
Hand lay-up of materials such as fiberglass is very costly due to
the labor needed to make the product, and post-curing the product
is needed to attain the desired physical properties. This
post-curing step is time and temperature dependent, for example, 2
hours at a temperature of 180.degree. F. or 8 hours at 120.degree.
F. is used to cure a marine structure such as a pier or boat
haul.
[0010] In the casting of polyester marbles and granites, some
castings require a gel coat. These gel-coated products are not
homogenous, and the gel coat once removed results in a loss of
physical properties such as chemical and stain resistance and
strength.
[0011] In the foregoing methods of processing, entrapped or
entrained air is a common problem. In hand lay-up processes, air
gaps can reduce the physical properties of the product greatly. In
injection molding, air can cause similar problems with physical
properties. The present invention provides a composition that
avoids the foregoing problems with known materials and processing
methods.
SUMMARY OF THE INVENTION
[0012] A structure according to the invention comprises a series of
structural members secured with suitable means that interconnect
the structural members. The structural members, such as panels, are
made of a composition comprising as its first essential ingredient
a cured (cross-linked) resin having sufficient strength when filled
as described below to support weights up to 700 pounds for a 3' by
4' panel having a thickness of 0.75" without substantial buckling
(compared to 350 pounds for a comparable fiberglass-filled panel),
but which has sufficient resilience to flex and rebound from
impacts such as low speed collisions with small boats or dropping
of heavy human-carried objects without cracking or breaking. The
cured resin matrix contains a first filler consisting essentially
of inorganic particles effective to improve the impact resistance
and flame resistance of the structure, and an amount of a
second-filler consisting essentially of fibers effective to enhance
the rigidity of the structure and reduce crack propagation therein.
An optional third filler consisting essentially of microspheres may
be added in an amount effective to reduce the weight of the panel
by at least about 10 wt. % without significantly affecting the
other essential properties of the structure.
[0013] According to a preferred aspect of the invention, the
structure comprises a series of structural members made of a
composition comprising a cured vinyl ester resin having two fillers
distributed therein. The first filler consists essentially of
inorganic particles effective to improve the impact resistance of
the structure, and the second filler consists essentially of
plastic fibers effective to increase the rigidity and crack
propagation resistance of the structural members. Suitable means,
such as a stainless or galvanized steel framework and fasteners,
are provided for interconnecting the structural members.
[0014] Vinyl ester resins have unexpectedly proven successful at
providing the foregoing characteristics when other commonly
available commercial plastics, such as polyethylenes,
polypropylenes and polyesters, proved unable to provide the desired
strength, resilience, environmental resistance and other important
properties. In a preferred form of outdoor structure of the
invention, the structural members are made of a composition
comprising a cured vinyl ester resin having distributed therein
effective amounts of the fillers described above. The structural
members or panels are preferably free of glass spheres, fragments
or fibers for the reasons discussed above.
[0015] According to a further aspect of the invention, a curable
plastic composition suitable for making marine structures comprises
a curable vinyl ester resin and the above described two or three
fillers. A preferred curable composition of the invention consists
essentially of:
[0016] about 30 to 70 wt. % of a curable vinyl ester resin, to
which about 0.75 to about 5 wt. % based on the total resin of a
catalyst effective to cure the vinyl ester resin is added at the
time of curing;
[0017] about 5 wt. % to about 70 wt. % of inorganic mineral
particles;
[0018] about 0.3 wt. % to about 50 wt. % of a second, fibrous
filler effective to increase the strength of the composition when
the composition is cured; and
[0019] optionally from about 0.3 wt. % to 1 wt. % of plastic
microspheres may be added in order to reduce the eight (density) of
the material.
[0020] This composition is a substantially homogeneous mixture that
can be applied to a mesh or grid to provide an embedded
support.
[0021] A process for making a molded structure according to the
invention includes an initial step of forming a mixture comprising
a curable resin having the first and second fillers distributed
therein. A support is placed into a mold, and an effective amount
of a curing catalyst is added to the resin mixture. The mixture is
introduced into the mold so that the support becomes embedded
therein. The mixture is then cured in the mold, and the cured
structure is then removed. The composition of the invention can be
cast into shapes as well as sprayed onto surfaces, as further
described in the detailed description which follows.
BRIEF DESCRIPTION OF THE DRAWING
[0022] The invention will be described with reference to the
accompanying drawings, wherein like numerals represent like
elements, and:
[0023] FIG. 1 is a perspective view of a pier structure according
to the invention; and
[0024] FIG. 2 is a cross-sectional view taken along the line 2-2 in
FIG. 1.
DETAIL DESCRIPTION OF PREFERRED EMBODIMENTS
[0025] The invention provides a composition and process for the
production of flexible homogeneous solid surface structures that
can absorb and dissipate shock and impact loads without fracturing
or crack propagation, and with the ability to recover their
original shape. Preferred products of the invention are made from a
mixture of a base vinyl ester resin containing a vinyl ester and a
corresponding amount of a monomer such as styrene. The monomer
preferably comprises from about 50 to 70 wt. % of the resin mixture
depending on the properties desired, whereas the vinyl ester is
preferably present in an amount in the range of from 30 to 50 wt. %
of the resin mixture.
[0026] Vinyl esters are commonly esters of A-B-A-B epoxy resins
terminating in vinyl groups, particularly acrylates thereof. A
preferred vinyl ester for use in the invention is a dimethacrylate
ester of a bisphenol A epoxy having the formula: 1
[0027] wherein n is from 1 to 3. Preferred resins include
McWhorters Verimac vinyl ester 103-0636 or 184-0584 and Reichhold's
Dion ver vinyl ester 31-347-00 or 31-348-00, 9100-00.
[0028] When a vinyl ester according to the invention is clear cast
in the presence of the styrene monomer, the resulting plastic has a
tensile strength of 12,300 psi, tensile modulus of 5.5
psi/10.sup.5, tensile elongation of 6-8%, flexural strength of
21,700 psi, flexural modulus of 5.9 psi/10.sup.5, heat distortion
temperature of 200.degree. F., and Barcol hardness of 35-45.
Preferred resins according to the invention have properties at
least about equal to the foregoing, or not more than about 12
percent under each of the properties specified. Esters of other
commercially available epoxies similar in structure to the
bisphenol A-based structure shown above should provide properties
suitable for use in the present invention. Vinyl ester resins are
sold as a blend containing the vinyl ester together with effective
amounts of a crosslinking monomer, such as styrene, a wetting agent
for fibers and filler, and an air release agent. Such additives are
useful for purposes of the present invention.
[0029] The amount of resin mixture, including added catalyst as
described below, is preferably from 30 to 70 percent of the total
batch mixture weight, most preferably 30 to 50 percent of the total
batch mixture 35 weight. Below 30% resin, the product will be too
brittle, whereas above 70% resin, the cured mixture will be too
flexible to hold shape with a load on it even using fibers to hold
the matrix together.
[0030] A catalyst is added at the time of molding to cure the vinyl
ester resin. The amount of catalyst is in the range of about 0.75
to 5 wt. % of the total resin content. An organic peroxide catalyst
such as methyl ethyl ketone peroxide is preferred. Adding more
catalyst provides a faster gel time. A co-catalyst such as
2,4-pentanedione peroxide can be used to provide a slower cure at a
lower temperature. A higher temperature during the cure cycle time
eliminates post curing and results in a near-total cure with
complete crosslinking. The longer the chain formed by crosslinking,
the stronger the resulting part will be. Useful peroxide catalysts
include Norox MEKP-925, Norac, Inc. Hipoint 90, and Reichhold's
Superox 46-750 (methyl ethyl ketone peroxide). Co-catalysts for
retarding the cure time as noted above include Superox 46-709 and
Superox 46-731.
[0031] The composition of the invention contains fillers effective
to improve the strength, reduce the weight and reduce the overall
cost of the material. A first filler made of inorganic particles of
non-glass minerals such as limestone, crystalline silica, calcium
carbonate fillers, and hydrated alumina functions to increase the
strength of the resulting product. Preferred sizes (diameter or
largest dimension) for such particles range from 8 to 75 microns.
The amount of the first, inorganic filler ranges from about 5 to 70
wt. %, preferably from about 46 to 70 wt. %. Below 46 wt. % and
especially below 5 wt. %, the product's ability to take an impact
(sharp blow) and dissipate the energy are reduced, possibly
resulting in cracking. Above 70 wt. %, the amounts of the other
ingredients become insufficient and the product suffers the
problems noted, for example, brittleness if the amount of resin is
too low. It is most preferred to make the inorganic filler content
at least about 50 wt. % (defining a subrange of about 50-70 wt. %)
in order to reduce the amount of resin required, which is the most
costly component of the mixture.
[0032] A second, fiber-based filler is used to further improve the
strength of the product. Fiber fillers can range from about 0.3 to
50%, preferably about 0.33 to 1%, of the total batch weight of the
mixture. However, the higher the filler fiber loading, the thicker
the mixture becomes. A large amount of fibers holds the mixture
together forming a ball, and pouring becomes difficult. Plastic
fibers such as polypropylene fibers are preferred, e.g., 15 denier
polypropylene fibers having a 0.90-0.91 specific gravity. Such
fibers preferably range from about 8 to 30 denier fineness and 0.5
to 1 inch in length. Recycled carpet fibers or virgin fibers are
suitable. Polypropylene fibers are inert, durable, water insoluble,
remain dimensionally stable with changes in humidity, and have high
chemical, weather and abrasion resistance. Additionally,
polypropylene is highly soil and stain resistant, resistant to
bacterial attack, and does not support growth of mildew or
fungi.
[0033] As a third filler, polymer microspheres or micro-balloons
are highly preferred. The higher the percentage of polymer
microspheres in the mixture, the lighter the weight of the product
will be (i.e., density will be reduced.) The microspheres may be
solid or preferably hollow. The microspheres are used in an amount
effective to reduce the weight of the panel by at least about 10%,
preferably from 20 to 30%, relative to a panel or other structural
member of like composition and size but lacking the microspheres,
but which amount is insufficient to substantially reduce the
structural strength of the members. Such amount of microspheres
that can be added generally ranges from about 0.3 to 1 wt. %, most
preferably 0.33 to 0.55 wt. %. At levels above 1 wt. %, the
material becomes lighter but will indent or form a hole from an
impact with a sharp point such as a woman's pointed high heel shoe.
Below 0.33%, the amount of the weight reduction obtained by adding
the plastic spheres becomes insignificant. Suitable commercially
available fillers of this type include Pierce and Stevens Polymer
PVC Microspheres Dualite M6017AE-03, R. J. Marshall Company's
Polyrex 1,000, or 3M Spraylite 201.
[0034] As illustrated in the examples below, several additional
ingredients can be used in small amounts to further enhance the
properties of the mixture. Colorants such as pigment pastes or dry
color pigments can be added to change the color or look of the
finished product. Such colorants include titanium dioxide
(TiO.sub.2) (white), carbon black (black), iron oxide
(Fe.sub.2O.sub.3) and manganese oxide (MnO.sub.2). These and other
colorants can be added to make a solid color, a wood-like
appearance, or a simulated granite or stone which can also be made
by adding polyester chips with different colors to the mixture.
Organic and inorganic pigments may be dispersed directly into the
resin mix.
[0035] Ultraviolet UV(A and B) light absorbers, such as
Ciba-Geigy's Tinuvin P, 328, or UV 9, can be added as color
stabilizers that protect the product from sunlight. A flame
retardant such as hydrated alumina may be added as needed.
Available brands include Franklin Industrial Minerals' ATHDH-200
and R. J. Marshall's B-25X Alumina. The flame retardant can be a
component of the first inorganic filler. Cured polyester polymer
solids (e.g., McKee's button dust) can be added to lighten the
weight of the mix and to replace more expensive materials.
Effective amounts of these additives are each generally in the
range from about 0.5 to 25 wt. % of the total batch mixture.
[0036] Recycled glass fibers can be added if additional strength is
needed. Sources for such materials are Phoenix Fiberglass and PPG.
However, use of glass fibers will have adverse side effects as
discussed above, and is not preferred. Glass microspheres (3M
products) can also be added, but likewise suffer the problems noted
above.
[0037] The processing and dispensing for production of the
composition of the invention can be by hand mixing, vacuum mixing,
casting, spraying, pumping systems, vortex mixing, and low- and
high-shear mixing systems. The composition can be spread, poured,
gravity flowed, pumped into closed and open molds, or vacuumed into
a mold, and will take the shape of what ever it is being poured
into. The preferred method of mixing is vacuum mixing.
[0038] The mixture is preferably poured into an open mold with a
metal expanded mesh 20 (see FIG. 2) or similar support grid
supported in the middle of the mold. The mixture surrounds the mesh
and bonds to the mesh material. An aluminum mesh is preferred
because of its light weight, chemical resistance, and its
elongation properties. Other expanded mesh metals can also be used.
The final shape of the molded material will be a substantially
homogenous mixture having the contours and shape of the mold in
which it is poured into.
[0039] FIGS. 1 and 2 show a pier 10 constructed using panels 11
made using the composition of the present invention. A support
framework 12 connects a series of adjacent panels 11 to form an
elevated pier. Framework 12 includes support poles or posts 13,
which may be made of stainless or galvanized steel. In the
embodiment shown, sides edges of panels 11 are secured to a pair of
inwardly facing, L-shaped parallel brackets 14 by screws 15
provided with washers 16. Screws 15 engage holes 17 in brackets 14.
Brackets 14 are rigidly secured to posts 13 by any suitable means,
such as by welding or mechanical interconnection. Vertical posts 13
may alternatively be made of the filled cross-linked resin
composition of the invention. Screws and washers 15, 16 may be
countersunk to provide the pier or dock with a flat upper surface.
Other conventional means of uniting the structural panels may also
be used, such as other forms of mechanical fasteners and
connectors, and cements or adhesives.
[0040] Pier 10 may be painted or provided with a protective
overcoating as desired, or may be left unpainted and provided with
a decorative appearance by means of decorative fillers as described
above. When damage occurs, repairs can be made readily by remixing
a small batch of the composite resin and applying it manually to
the damaged area. The newly-molded portion will bond readily with
the existing material. This ability of new material to bond to
existing cured material is an important advantage of the
invention.
[0041] Many of the advantages of structures built in accordance
with the invention are discussed above. In addition, the ability of
structures made according to the invention to resist catastrophic
failure over extended periods of use is clearly essential for
safety when the structure is a dock or pier that will be used by
the public. On the other hand, reducing the weight of the panels by
as much as 25% by means of the polymer microspheres decreases the
cost of the material and reduces the labor required to build an
outdoor structure. The UV stability and color stability of a panel
according to the invention are better than for a comparable
gel-coated fiberglass panel.
[0042] The following examples show a series of formulations for
preferred compositions of the invention.
EXAMPLE 1
[0043] A total mixture batch weight of 46.2 lbs included:
[0044] 18 lbs. total resins (39.24%)--103-0636 Verimac vinyl ester
resin
[0045] 27 lbs. of inorganic filler (58.4%)
[0046] 0.33 lbs (0.714%) of Dualite M6017AE-03 polymer
microspheres
[0047] 0.27 lbs UV (A and B) light absorbers (0.58%)--Ciba Geigy's
Tinuvin P, 328, or UV 9
[0048] 0.33 lbs polypropylene fibers (0.714 wt. % Amoco Fabrics and
Fibers Co., F1-CON polypropylene 15 denier, 0.75" long fibers)
[0049] 0.27 lbs (0.58%) catalyst--methyl ethyl ketone peroxide
(MEKP-925)
[0050] Percent amounts are by weight relative to the total batch
unless otherwise noted.
[0051] The amount of catalyst is most often related to the resin.
This method would relate it to 1.5 wt. % of the resin. Thus, 18
lbs. of resin times 1.5 percent equals 0.27 lbs of catalyst.
2,4-pentanedione peroxide (46-731) may be added to increase the gel
time, slowing the reaction time and lengthening the total cure time
cycle as needed.
[0052] Resin in an amount of 39.24 percent by batch weight of total
mixture was placed in a low shear mixing system, such as a Sea-Mar
or Gruber mixing system. The 103-0636 Verimac vinyl ester resin by
McWhorther Technologies Inc. used in this example has 20 percent
elongation, is flexible, has an intermediate viscosity, and
provides increased resiliency and improved adhesion to fillers. Its
viscosity is in the range of 150-450 cps, 150-200 being ideal, with
a peak cure temperature of only 340 to 400.degree. F. (peak
exotherm). This resin comprises 37.1 percent styrene and gives
excellent wet out and surface forming characteristics, has an
excellent cycle time for curing, and can be highly filled.
[0053] To this mixture 58.44 wt. % of total batch mixture of
mineral filler was added. The mineral filler in this example was
hydrated alumina ATHDH 200 from Franklin Industrial Minerals
Specialty, a mixture of limestone, crystalline silica, calcium
carbonate, and alumina trihydrate. The UV(A and B) light absorbers
were then added to the mixture, followed by the polyvinyl chloride
plastic (PVC) microspheres and the polypropylene fibers. A colorant
to make white products, e.g. TiO2 at about 3 percent the total
weight of resin, may also be added at this stage.
[0054] The total mixture was mixed for 3 minutes not under vacuum
to wet the fibers and fillers, and then mixed with vacuum for 3
minutes. The catalyst, methyl ethyl ketone peroxide (MEKP-925), was
then added 2,4-pentanedione peroxide is added at this stage only if
the reaction time is otherwise too fast. The resulting mixture is
mixed for 3 minutes under vacuum to remove air and blend the
catalyst(s), and then poured into a mold.
[0055] The catalyst overcomes the inhibitors in the resin and
causes crosslinking of the resin to occur. One preferred inhibitor
is tertiary butyl catechol (TBC), but other conventional inhibitors
may be used. The reaction continues until the resin is completely
cured. Heat is given off during the process. The reaction produces
heat in the range of 180.degree. F. to 265.degree. F. peak
exotherm.
[0056] Tests showed that the material of this example to be more
than twice as strong as a fiberglass pier panel with wood inlay of
comparable size. The test results were 365 lbs. load failure for
the fiberglass-reinforced wood panel versus 762 lbs. load failure
for the composite material of this example.
EXAMPLE 2
[0057] The following mixture was processed in the same manner as
described in Example 1:
[0058] 19 lbs total resins (38.9%)--103-0636 Verimac vinyl ester
resin
[0059] 28 lbs. of inorganic filler--hydrated alumina ATHDH 200
(57.34%)
[0060] 0.345 lbs (0.706%) of Dualite M6017AE-03 polymer
microspheres
[0061] 0.27 lbs UV (A and B) light absorbers (0.58%)--Ciba Geigy's
Tinuvin P, 328, or UV 9
[0062] 0.34 lbs polypropylene fibers (same as Example 1)
[0063] 0.285 lbs catalyst--methyl ethyl ketone peroxide
(MEKP-925)
[0064] 0.57 lbs of TiO2 (colorant) (3%)
[0065] Virtually identical results to those obtained in Example 1
were obtained with the finished material, illustrating that small
amounts of inert additives such as the colorant can be added
without adversely affecting the properties of the composition.
EXAMPLE 3
[0066] The following mixture (total batch weight 47.145 lbs) was
processed in the same manner as described in Example 1:
[0067] 27 lbs total resins (57.27%)--103-0636 Verimac vinyl ester
resin
[0068] 18 lbs. of inorganic filler--hydrated alumina ATHDH 200
(38.18%)
[0069] 0.33 lbs (0.699%) of Dualite M6017AE-03 polymer
microspheres
[0070] 0.27 lbs UV (A and B) light absorbers (0.58%)--Ciba Geigy's
Tinuvin P, 328, or UV 9
[0071] 0.33 lbs polypropylene fibers (same as Example 1) (0.699 wt.
%)
[0072] 0.405 lbs catalyst--methyl ethyl ketone peroxide (MEKP-925)
(0.829%)
[0073] 0.81 lbs of TiO2 (colorant) (3%)
[0074] The tested results of this formula of high loaded resin
resulted in a very flexible material. The load testing on a sample
panel having a thickness of 0.75" showed a spring-board type
material with the ability to flex 6 inches in a 4 foot span without
failure. Loading was 380 lbs with 6 inches of deflection. With load
removed, the panel sample recovered completely, i.e., to the exact
point of starting distance.
[0075] This example shows that both the composition and dimensions
of a molded panel of the invention must be controlled in order to
obtain the desired structural properties. For example, a 6-inch
deflection would be unacceptable in a typical pier application
because it would be too unsteady to walk on. The amounts of the
fillers may accordingly be increased to ensure sufficient strength,
or the panel could be made thicker or of reinforced design as
needed to change the amount of weight it would be expected to
support. The resilience shown in this example is highly
advantageous for resisting impacts such as dropped objects,
collisions and the like.
[0076] It will be understood that the foregoing description is of
preferred exemplary embodiments of the invention, and that the
invention is not limited to the specific forms shown. In
particular, the composition of the invention could be used in a
variety of applications both indoor and outdoor, marine and
otherwise, such as sheds, boathouses, boat hauls, benches, walls,
indoor ceiling panels, and the like. These and other modifications
may be made in without departing from the scope of the invention as
expressed in the appended claims.
* * * * *