U.S. patent application number 10/511163 was filed with the patent office on 2007-05-24 for composite structural material and method of making same.
Invention is credited to Michael H. Clement, Cheruvari Karthik Hari Dharan, Arthur J. Roth, Patrick H. Winters.
Application Number | 20070113759 10/511163 |
Document ID | / |
Family ID | 29214806 |
Filed Date | 2007-05-24 |
United States Patent
Application |
20070113759 |
Kind Code |
A1 |
Roth; Arthur J. ; et
al. |
May 24, 2007 |
Composite structural material and method of making same
Abstract
A composite structural material suitable, for example, as a
replacement for wooden boards, is disclosed. It comprises a
dimensionally stable core material ensheathed in a dimensionally
stable, laminar covering that is adherent to the core material. The
laminar covering is comprised of at least one layer of parallel
cords (19) bonded to at least one layer of a rigidified web
material (10) selected from the group consisting of paper and
cloth. Suitable core materials include polyurethane foam (38),
optionally filled with particles (32) of granulated rubber,
expanded perlite, expandable polymer beads, and/or glass
microspheres. The parallel cords (19) preferably are supplied in
the form of a strip of polyester cloth, as the warp cords thereof.
The web material (10) preferably is kraft paper that is rigidified
with an epoxy resin.
Inventors: |
Roth; Arthur J.; (Orinda,
CA) ; Winters; Patrick H.; (Moraga, CA) ;
Clement; Michael H.; (Antioch, CA) ; Dharan;
Cheruvari Karthik Hari; (Berkeley, CA) |
Correspondence
Address: |
FITZPATRICK CELLA HARPER & SCINTO
30 ROCKEFELLER PLAZA
NEW YORK
NY
10112
US
|
Family ID: |
29214806 |
Appl. No.: |
10/511163 |
Filed: |
April 21, 2003 |
PCT Filed: |
April 21, 2003 |
PCT NO: |
PCT/US03/12281 |
371 Date: |
August 4, 2005 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
10125573 |
Apr 19, 2002 |
6972144 |
|
|
10511163 |
Aug 4, 2005 |
|
|
|
Current U.S.
Class: |
108/161 ;
442/221 |
Current CPC
Class: |
B29C 44/1209 20130101;
B29C 2035/0855 20130101; Y10T 428/23 20150115; Y10T 428/233
20150115; Y10T 442/3967 20150401; Y10T 428/249986 20150401; Y10T
428/249987 20150401; Y10T 442/198 20150401; B29C 2035/0811
20130101; B29C 2035/0861 20130101; Y10T 428/249942 20150401; Y10T
442/3325 20150401; Y10T 428/239 20150115; B29C 44/326 20130101;
Y10T 442/3927 20150401; B32B 5/28 20130101; Y10T 428/24132
20150115; Y10T 428/31993 20150401; B29C 70/50 20130101; B32B 29/02
20130101; Y10T 428/24537 20150115; B32B 27/40 20130101; Y10T
428/249952 20150401; B32B 5/08 20130101 |
Class at
Publication: |
108/161 ;
442/221 |
International
Class: |
A47B 13/00 20060101
A47B013/00; B32B 5/24 20060101 B32B005/24; B32B 5/18 20060101
B32B005/18 |
Claims
1-67. (canceled)
68. A method of making an elongated, composite, structural
material, comprising the following steps: (a) supplying a
substantially continuous length of a porous web material selected
from the group consisting of paper and cloth; (b) laying
substantially continuous, parallel strands of reinforcing cords on
at least one side of the web material, with the cords running in
the lengthwise direction of the web material; (c) applying a
thermosetting-resin-precursor mixture to each of the cords and the
web material; (d) forming the web material into a sleeve-like
configuration having the desired cross-sectional shape of the
structural material, with the cord-carrying side of the web
material facing the interior of the configuration; (e) depositing
on the cord-carrying side of the web material a fluid
matrix-resin-precursor composition that is compatible with the
thermosetting-resin-precursor mixture applied to each of the web
material and the cords in step (c) and which, when reacted, yields
a rigid matrix resin; and (f) holding the sleeve-like configuration
together under conditions that are conducive to the setting of (i)
the matrix resin in the core space and (ii) the thermosetting resin
applied to each of the web material and the cords, and for a length
of time sufficient for all of the resins to set, whereby the cords
are bonded to the web material, a core space within the sleeve-like
configuration is substantially filled with the matrix resin, and
the matrix resin is bonded to the sleeve-like configuration.
69. The method of claim 68, wherein the matrix-resin-precursor
composition comprises the reactants and blowing agent necessary to
form a rigid foamed polyurethane as the matrix resin.
70. The method of claim 68, wherein the web material is paper.
71. The method of claim 68, wherein the
thermosetting-resin-precursor mixture comprises the reactants
necessary to form an epoxy resin.
72. The method of claim 68, wherein the cords comprise synthetic
fibers or filaments.
73. The method of claim 72, wherein the cords comprise glass fibers
or filaments.
74. The method of claim 72, wherein the cords comprise polyester
fibers or filaments.
75. The method of claim 68, wherein the cords are laterally
connected to each other in order to keep the cords in place during
at least steps (b) and (c).
76. The method of claim 75, wherein the cords are laterally
connected to each other by cross-cording.
77. The method of claim 68, wherein the matrix-resin-precursor
composition comprises pieces of at least one filler solid selected
from the group consisting of lignocellulosic materials, cellulosic
materials, vitreous materials, cementitious materials, carbonaceous
materials, plastics, and rubbers.
78. The method of claim 77, wherein the filler solid comprises tire
rubber fragments.
79. The method of claim 77, wherein the filler solid comprises a
vitreous material.
80. The method of claim 68, wherein the web material is kraft paper
that has a basis weight of about 65 to 100 lbs.
81. The method of claim 68, wherein the web material is kraft paper
that has a basis weight of about 90 lbs.
82. The method of claim 77, wherein the filler solid comprises tire
rubber fragments, in an amount such that the rubber occupies about
20 to 90 volume percent of the core space following the completion
of step (f).
83. The method of claim 77, wherein the filler solid comprises tire
rubber fragments, in an amount such that the rubber occupies about
45 to 75 volume percent of the core space following the completion
of step (f).
84. The method of claim 77, wherein the filler solid comprises tire
rubber fragments, in an amount such that the rubber occupies about
55 to 65 volume percent of the core space following the completion
of step (f).
85. The method of claim 79, wherein the filler solid comprises
expanded perlite.
86. The method of claim 79, wherein the filler solid comprises
expanded perlite, in an amount such that the perlite occupies about
10 to 80 volume percent of the core space following the completion
of step (f).
87. The method of claim 77, wherein the filler solid comprises tire
rubber fragments and expanded perlite.
88. The method of claim 68, further comprising a step of providing
the exterior of the sleeve-like configuration with at least one
coating selected from the group consisting of plant-growth
repellants, fire or flame retardants, reflective particles,
pigments, dyes, anti-corrosion chemicals, friction-increasing
coatings, and wood veneers.
89. A method of making an elongated, composite, structural
material, comprising the following steps: (a) forming a foldable
laminate of two strips of porous web material selected from the
group consisting of paper and cloth, with at least one strip of a
band of reinforcing cords sandwiched therebetween, with the cords
running in the lengthwise direction and with the strips of porous
web material and all materials lying between those strips being
impregnated with a thermosetting-resin-precursor mixture; (b)
folding the laminate into a trough shape and orienting it
horizontally, with one of the strips of porous web material on the
top and the other strip of porous web material on the bottom; (c)
depositing in the trough of the laminate, while still foldable, a
fluid matrix-resin-precursor composition that is compatible with
the thermosetting-resin-precursor mixture in the laminate and
which, when fully reacted, yields a thermoset matrix resin that is
at least semi-rigid; (d) folding closed and sealing shut the
laminate so that it surrounds and defines a core space containing
said matrix resin precursor composition; and (e) holding the closed
laminate and its contents in a mold under conditions conducive to
the setting of both the thermosetting resin in the laminate and the
matrix resin in the core space, for a time sufficient for both
resins to set, whereby (i) the laminate and the matrix resin are
both made at least semi-rigid, (ii) the matrix resin, together with
any filler solid it may contain, fills the core space, and (iii)
the laminate and matrix resin are bonded together.
90. The method of claim 89, wherein the matrix-resin-precursor
mixture comprises the reactants and blowing agent necessary to form
a foamed polyurethane that is at least semi-rigid.
91. The method of claim 90, wherein the two strips of web material
are paper.
92. The method of claim 91, wherein the two strips of web material
are kraft paper that has a basis weight of about 65 to 100 lbs.
93. The method of claim 91, wherein the two strips of web material
are kraft paper that has a basis weight of about 90 lbs.
94. The method of claim 91, wherein the bottom strip of paper is a
two-ply paper in which a layer of resin that is a barrier to the
bleeding through of an epoxy resin is sandwiched between the two
plies, and wherein the top strip of paper is devoid of such a
barrier layer.
95. The method of claim 91, wherein the thermosetting resin
precursor mixture comprises the reactants necessary to form an
epoxy resin.
96. The method of claim 95, wherein the cords sandwiched between
the strips of paper are comprised of continuous polyester filament
and/or fiberglass.
97. The method of claim 96, wherein, during step (e), the laminate
is held under sufficient tension in the lengthwise direction that
the outer paper layer of the structural material resulting from
that step is substantially unwrinkled.
98. The method of claim 89, wherein, during step (e), the cords
sandwiched between the strips of paper are comprised of continuous
polyester filament.
99. The method of claim 89, wherein the matrix-resin-precursor
composition comprises pieces of at least one filler solid selected
from the group consisting of tire rubber, glass microspheres,
expandable polymer beads, and expanded perlite.
100. The method of claim 89, wherein the matrix-resin-precursor
composition contains pieces of tire rubber containing no more than
about 3 percent of belt metal, based on the weight of the rubber,
and the amount of such rubber is such that it constitutes about 20
to 90 volume percent of the finished material's core.
101. The method of claim 100, wherein the amount of the rubber is
such that it constitutes about 45 to 75 volume percent of the
finished material's core.
102. The method of claim 100, wherein the amount of the rubber is
such that it constitutes about 55 to 65 volume percent of the
finished material's core.
103. The method of claim 89, wherein the matrix-resin-precursor
composition contains glass microspheres, the weight majority of
which have a particle size in the range of about 5 to 225 microns,
and the amount of such microspheres is such that they constitute
about 2 to 90 volume percent of the finished material's core.
104. The method of claim 89, wherein the matrix-resin-precursor
composition contains expanded perlite in an amount such that it
constitutes about 10 to 80 volume percent of the finished
material's core.
105. The method of claim 89, wherein the matrix-resin-precursor
composition contains expanded perlite and pieces of tire
rubber.
106. The method of claim 89, further comprising a step of providing
the exterior of the laminate with at least one coating selected
from the group consisting of plant-growth repellants, fire or flame
retardants, reflective particles, pigments, dyes, anti-corrosion
chemicals, friction-increasing coatings, and wood veneers.
107. The method of claim 89, wherein in step (a), two strips of the
band of reinforcing cords are sandwiched between the two strips of
porous web material.
108. The method of claim 89, wherein in step (a), the foldable
laminate is formed of three strips of porous web material selected
from the group consisting of paper and cloth, with at least one
strip of the band of reinforcing cords sandwiched between each
adjacent pair of strips of porous web material.
109. A method of making an elongated, composite, structural
material, comprising the following steps: (a) obtaining a first
elongated C channel of a porous web material selected from the
group consisting of paper and cloth that is impregnated with a
thermosetting resin precursor mixture and orienting the channel
with the C facing up; (b) impregnating a strip of cloth with a
thermosetting resin precursor mixture that is compatible with the
resin precursor mixture in the web material; (c) laying said strip
of cloth on the inside bottom of the first C channel, with the warp
running in the lengthwise direction of the channel, so as to extend
the length of the channel; (d) depositing on the top of said strip
of cloth a fluid matrix resin precursor composition that is
compatible with both the resin precursor mixture in the web
material and the resin precursor mixture in the cloth and which,
when reacted, yields a matrix resin that is at least semi-rigid;
(e) covering the first C channel with a second C channel of a
porous web material that is impregnated with a thermosetting resin
precursor mixture that is oriented with the C facing down, so that
the vertical sides of the two channels overlap and touch each other
and the two C channels define a core space between them; and (f)
holding the two C channels together under conditions that are
conducive to the setting of (i) the matrix resin in the core space,
(ii) the thermosetting resin in the porous web material, and (iii)
the thermosetting resin in the cloth, and for a length of time
sufficient for all three resins to set, whereby the two C channels
are bonded together where they overlap, the cloth strip is bonded
to the first C channel, the core space is filled with the matrix
resin, and the matrix resin is bonded to the cloth and the web
material.
110. An elongated, composite structural material comprised of a
dimensionally stable core material ensheathed in a laminar covering
that is bonded to the core material, wherein the laminar covering
is comprised of at least one band of substantially parallel
reinforcing cords bonded, by a resin, to at least one layer of a
dimensionally stable web material that is exterior to the cords,
the web material being selected from the group consisting of
rigidified paper and rigidified cloth, with the web material and
the cords being impregnated with the same resin that is used to
bond the cords to the web material, the amount of the resin being
sufficient to render the laminar covering dimensionally stable, and
the cords being oriented in the longitudinal direction of the
structural material and extending substantially the entire length
thereof.
111. A composite structural material comprised of a dimensionally
stable core material ensheathed in a laminar covering that is
bonded to the core material, wherein the laminar covering is
comprised of at least one band of substantially parallel
reinforcing cords that is wound spirally around the core material
and is bonded to at least one layer of a dimensionally stable web
material that is exterior to the cords, the web material being
selected from the group consisting of rigidified paper and
rigidified cloth.
112. An elongated, four-sided composite structural material having
a substantially uniform, rectangular cross section throughout its
length, the material comprising: a core comprised of rubber-tire
fragments embedded in a foamed polyether polyurethane resin, having
a free-rise density of about 4 to about 35 pounds per cubic foot,
the rubber-tire fragments constituting about 45 to 75 volume
percent of the core and having a longest dimension that is no more
than about 50 percent of the thickness of the composite structural
material; and a one-piece laminar covering that ensheaths the core
and is bonded to the core, the laminar covering including a
plurality of layers of substantially parallel fiberglass cords,
each cord layer being bonded, by an unfoamed epoxy resin, to at
least one of a plurality of layers of rigidified kraft paper having
a basis weight of about 65 to 100 pounds per thousand square feet,
wherein the cord layers and the paper layers are impregnated with
the same unfoamed epoxy resin that is used to bond the cord layers
to the paper layers, the amount of the unfoamed epoxy resin being
sufficient to render the laminar covering dimensionally stable, and
wherein the cords are oriented in the longitudinal direction of the
structural material and extend substantially the entire length
thereof, each cord layer comprises at least 10 cords per lateral
inch, and at least one paper layer is exterior to the cord
layers.
113. The composite structural material of claim 112, wherein the
laminar covering is comprised of a first layer of paper, a first
layer of reinforcing cords, a second layer of paper, a second layer
of reinforcing cords, and a third layer of paper, in that
order.
114. A shipping pallet comprised of deck boards and deck-support
boards, wherein at least one of the deck-support boards is the
composite structural material of claim 113.
115. An elongated, four-sided composite structural material having
a substantially uniform, rectangular cross section throughout its
length, the material comprising: a core comprised of pieces of
expanded perlite embedded in a foamed polyether polyurethane resin,
having a free-rise density of about 15 to 21 pounds per cubic foot,
the expanded perlite constituting about 10 to 80 volume percent of
the core and having a longest dimension that is no more than about
50 percent of the thickness of the composite structural material;
and a one-piece laminar covering that ensheaths the core and is
bonded to the core, the laminar covering including a plurality of
layers of substantially parallel fiberglass cords, each cord layer
being bonded, by an unfoamed epoxy resin, to at least one of a
plurality of layers of rigidified kraft paper having a basis weight
of about 65 to 100 pounds per thousand square feet, wherein the
cord layers and the paper layers are impregnated with the same
unfoamed epoxy resin that is used to bond the cord layers to the
paper layers, the amount of the unfoamed epoxy resin being
sufficient to render the laminar covering dimensionally stable, and
wherein the cords are oriented in the longitudinal direction of the
structural material, and extend substantially the entire length
thereof, each cord layer comprises at least 10 cords per lateral
inch, and at least one paper layer is exterior to the cord
layers.
116. The composite structural material of claim 115, wherein the
laminar covering is comprised of a first layer of paper, a first
layer of reinforcing cords, a second layer of reinforcing cords,
and a second layer of paper, in that order.
117. A shipping pallet comprised of deck boards and deck-support
boards, wherein at least one of the deck boards is the composite
structural material of claim 116.
118. The composite structural material of claim 116, wherein the
core further comprises pieces of rubber tire fragments in an amount
constituting about 10 to 15 volume percent of the core.
119. A shipping pallet comprised of deck boards and deck-support
boards, wherein at least one of the deck boards is the composite
structural material of claim 118.
Description
BACKGROUND OF THE INVENTION
[0001] There are many different structural materials made at least
in part from synthetic resins, that are intended to be used in
place of wood. An elusive goal in designing such materials is the
combination of reasonable cost with relatively high strength and
stiffness. Thus, for example, synthetic lumber made by hot melt
extrusion of mixtures of waste wood fiber and recycled
thermoplastic material such as polyethelene can be produced at a
low enough cost to make them feasible for use as decking boards.
Such synthetic lumber is generally considered unsuitable, however,
for uses that require it to withstand higher bending and
compression loads, require increased static strength and stiffness
requirements, and/or require greater shock and impact resistance.
Thus, it is generally unsuitable for use as primary structural
load-bearing elements, such as posts, joists, beams, and stringers
for shipping pallets. For those types of uses a material has to
have a higher flexural modulus of rupture, izod impact resistance,
ultimate compressive strength, Young's modulus, and/or accelerating
weight resistance than are found in the hot melt extrudates of
polymer and wood particles.
[0002] As a result of extensive experimentation, the present
inventors have discovered a type of design for a composite
structural material that can be manufactured economically, yet have
a relatively high flexural modulus of rupture, izod impact
resistance, ultimate compressive strength, Young's modulus, and
accelerating weight impact resistance. Also, if desired, relatively
light weight materials can be used, so that the composite can have
a specific gravity approaching that of some species of wood that
are used for lumber.
SUMMARY OF THE INVENTION
[0003] The composite structural material of the present invention
comprises a dimensionally stable core material ensheathed in a
dimensionally stable, laminar covering that is adherent to the core
material. The laminar covering is comprised of at least one band of
substantially parallel reinforcing cords bonded to at least one
layer of a dimensionally stable web material selected from the
group consisting of rigidified paper and rigidified cloth.
[0004] The core material can be any dimensionally stable solid.
Rigid as well as semi-rigid solids can be used. (By "rigid" is
meant herein at least substantially rigid.) As examples of rigid
solids, wood itself can be used as the core material, as can gypsum
and Portland cement compositions, e.g., cement that is mixed
(diluted) with cellulose fiber. In the semi-rigid category are
elastomers, e.g., natural or synthetic rubber. Preferably the core
has sufficient crush resistance that it will transfer a load
(stress) on one surface of the composite to the opposite surface
thereof. I.e., if the top surface is put under a compressive load
the bottom surface will be placed under tension, due to the core's
resistance to crushing.
[0005] Whether rigid or semi-rigid, the core material is preferably
comprised of a resin. For some applications the core material
preferably is comprised of pieces of a filler solid embedded in a
resinous matrix. (The term "resinous matrix," as used herein, is
intended to embrace both filled and unfilled resins.) Because the
laminar covering is dimensionally stable, it functions rather like
an exoskeleton in the composite structural material of the present
invention.
DETAILED DESCRIPTION OF THE INVENTION THE RESINOUS MATRIX
[0006] When the core material comprises a resinous matrix,
preferably it is a thermosetting resin. Examples of suitable
thermosetting resins include epoxy resins, urea-formaldehyde
resins, melamine-formaldehyde resins, phenol-formaldehyde resins,
polyester resins, and polyurethane resins (both
polyether-polyurethanes and polyester-polyurethanes).
[0007] When it is important that the structural material have as
low a specific gravity as is reasonably possible, it is preferred
that the resinous matrix be a foamed synthetic resin, most
preferably a rigid or semi-rigid polyurethane or phenolic foam.
Polyurethane resins are made by reacting polyols with
polyisocyanates. The reaction is exothermic. Cross-linking, or
branching, of the polyurethane molecules can be achieved by
including in the reaction mixture some polyol molecules and/or
isocyanate molecules that have at least three functional groups,
and by adjusting the ratio of reactants accordingly. With
sufficient cross-linking, rigid or semi-rigid thermoset polymers
are obtained. The degree of rigidity can be controlled, for
example, by the choice of polyol that is used, which is well-known
in the art.
[0008] To make rigid or semi-rigid polyurethane foam, a mixture is
made of a polyfunctional isocyanate, a polyol, a blowing agent, a
catalyst, and, usually, a cell-size regulator (e.g., a surfactant).
A urethane-forming reaction begins once the ingredients are
combined. An exotherm forms, and the blowing agent or agents cause
closed cells to form in the polymer as the mass expands and
solidifies. The exotherm typically reaches a peak temperature of at
least about 150.degree. F. The isocyanate and polyol reactants
include enough molecules with three or more functional groups that
the degree of cross-linking or branching is sufficient to produce
at least a semi-rigid foam.
[0009] Aromatic polyisocyanates often are used when making rigid or
semi-rigid foam. Some examples are toluene diisocyanate (TDI) and
polymeric isocyanate (PMDI), which is obtained by the condensation
of aniline with formaldehyde.
[0010] Polyols that can be used include polyether polyols and
polyester polyols. Propylene oxide adducts of polyfunctional
hydroxy compounds or amines are one type of polyether polyol that
can be used. Mixtures of polyester polyols and polyether polyols
sometimes are employed.
[0011] Halogenated hydrocarbons, such as hydrochlorofluorocarbons
and hydrofluorocarbons, can be used as blowing agents. Lower
alkanes such as butanes, pentanes, and cyclopentanes can be used as
well. Liquid carbon dioxide can be used. Water can also be used, as
it will react with isocyanate to generate carbon dioxide in situ.
Sometimes water or carbodiimide catalysts are used to generate
carbon dioxide as a co-blowing agent. Often the blowing agent or
agents are preblended with the polyol, together with the catalyst
and the cell-size regulator, which usually is a surfactant.
[0012] All of this is well known to persons of ordinary skill in
the art and is described, for example, in Kirk-Othmer Encyclopedia
of Chemical Technology, 4.sup.th Ed. (1997), vol. 24, pp. 695-715,
which is incorporated herein by reference.
[0013] The term "polyurethane system" can be used to refer to a
particular combination of isocyanate, polyol, catalyst, blowing
agent, and cell size regulator that is capable of reacting to form
a polyurethane foam. A characteristic that helps identify and
distinguish polyurethane systems is the density of the foam a
particular system will create when the components are mixed in an
open vessel (the "free rise density"). It is thought that
polyurethane systems capable of yielding a free rise density of
about 3 or 4 pcf to about 35 pcf are generally preferred for use in
the present invention, most preferably those capable of yielding a
free rise density of about 4 to about 20 or 25 pcf.
[0014] Examples of some commercial isocyanate/polyol pairings that
can be employed in forming polyurethane systems for use in the
present invention are the following: TABLE-US-00001 Rated Free Rise
Isocyanate Component Polyol Component Density (pcf) Rubinate M
Rimline WL 87380 8-9 Rubinate M Rimline WL 87381 15-18 Baydur 645 B
Baydur 645 A 5 Baydur 730 B (U 731 B) Baydur 649 A 9
[0015] In the above table, the Rubinate and Rimline reactants are
available from Huntsman Chemicals, and the Baydur reactants are
available from Bayer Corporation.
[0016] Phenolic foams can be made, for example, from resole resins,
e.g., phenol-formaldehyde resins made from a molar excess of
formaldehyde. The preparation of such a foam is disclosed, for
example, in U.S. Pat. No. 5,653,923 to Spoo et al., which is
incorporated herein by reference.
The Filler Solid
[0017] The filler solid, when used, preferably comprises pieces of
one or more of the following: lignocellulosic material, cellulosic
material, vitreous material, cementitious material, carbonaceous
material, plastic, and rubber.
[0018] Cellulosic and Lignocellulosic Fillers
[0019] Suitable lignocellulosic materials include wood, e.g., wood
powder, wood flake, and waste wood fiber, as well as fiber from
woody plants. Suitable cellulosic materials include, for example,
plant material such as bamboo, palm fiber, bagasse, rice straw,
rice hulls, wheat straw chaff, hemp, sisal, corncobs, and seed
shells, e.g., walnut shells. If lignocellulosic or cellulosic
material is used, preferably it is fibrous.
[0020] Vitreous Fillers
[0021] Suitable vitreous materials include glass (including
volcanic glass), fly ash, and ceramic particles. Vitreous spheres
can be used, e.g., glass or ceramic microspheres, the weight
majority of which have a diameter of about 5 to 225 microns. To
lighten the weight, such microspheres can be hollow. Specific
examples include Z-Light.RTM. ceramic microspheres, which are
available from 3M Company and which have a bulk density of
approximately 0.7 g/cc and a crush strength of about 2,000 to 3,500
psi. These come in different versions. One version that it is
believed may be especially suitable is Z-Light W-1020 microspheres,
the weight majority of which have diameters in the range of about
10 to 120 microns and a crush strength of approximately 3,500
psi.
[0022] Among the various hollow glass microspheres that can be used
are Scotchlite.RTM. Glass Bubbles, also from 3M Company, e.g.,
Scotchlite 538, which has a bulk density of about 0.38 g/cc, a
crush strength of about 4,000 psi, and particle sizes that mostly
(as measured by weight, not the number of microspheres) fall in the
range of about 8 to 88 microns.
[0023] Where a filler having a relatively high specific gravity can
be used, as, for example, where a savings in the cost of raw
materials is a greater priority than keeping down the weight of the
composite, solid glass microspheres, which are relatively
inexpensive, can be used.
[0024] When used, glass microspheres might constitute, for example
about 2 to 90 percent of the volume of the finished material's
core.
[0025] Perlite is often preferred as a vitreous filler, especially
when expanded to form a lightweight aggregate. When used, expanded
perlite might constitute, for example, about 10 to 80 percent of
the volume of the finished material's core. Glass or ceramic
reinforcing fibers also can be used.
[0026] Cementitious Fillers
[0027] As suitable cementitious material may be mentioned, for
example, Portland cement, gypsum, blast furnace cement, silica
cement, and alumina cement.
[0028] Carbonaceous Fillers
[0029] As suitable carbonaceous material may be mentioned, for
example, carbon black and graphite, as well as carbon fibers.
[0030] Plastic Fillers
[0031] As regards plastic materials, both thermoset and
thermoplastic resins can be used. As suitable plastics may be
mentioned, for example, addition polymers (e.g., polymers of
ethylenically unsaturated monomers), polyesters, polyurethanes,
aramid resins, acetal resins, phenol-formaldehyde resins,
melamine-formaldehyde resins, and urea-formaldehyde resins.
Homopolymers and copolymers can be used. Suitable copolymers
include interpolymers, graft copolymers, and block copolymers.
[0032] As examples of suitable addition polymers may be mentioned
polyolefins, polystyrene, and vinyl polymers. Suitable polyolefins
include, for example, those prepared from olefin monomers having
two to ten carbon atoms, e.g., ethylene, propylene, butylene, and
dicyclopentadiene. Poly(vinyl chloride) and acrylonitrile polymers
can be used. Particles of waste plastic, e.g., post-consumer waste
plastic such as used plastic bags and containers, can be used.
Examples include bottles made of high density polyethylene and
polyethylene grocery store bags.
[0033] As suitable polyesters may be mentioned polymers formed by
condensation reaction of one or more polycarboxylic acids with one
or more polyhydric compounds, e.g., an alkylene glycol or a
polyether alcohol. Polyethylene terephthalate is an example of a
suitable polyester resin. Chopped up, used polyester containers are
a source of such filler particles.
[0034] Suitable plastics also include synthetic fibers--e.g.,
reclaimed fibers from discarded carpet, e.g., nylon, polyolefin, or
polyester carpet fibers.
[0035] Suitable polyurethanes include, for example, polyether
polyurethanes and polyester polyurethanes.
[0036] Among the various plastic fillers that can be used in the
core material are expandable polymer beads. By "beads" we here mean
particles of any geometry, e.g., spherical, cylindrical, or lumpy.
Expandable polymer beads are cellular pellets of expandable polymer
that often are used to form lightweight molded objects. Created in
a more or less granular form, and with an expanding agent in the
cells, typically the beads are pre-foamed, or "pre-expanded," by
heating to a temperature above their softening point, which often
will be in the range of about 165-185.degree. F., until they foam
to give a loose aggregate of the desired bulk density. The
pre-foamed particles, which retain their cellular structure, may
then be placed in a mold or other cavity and heated with live
steam, causing them to sinter and fuse together to form a
lightweight, cellular solid whose dimensions correspond to those of
the mold cavity. When fully expanded, the beads often will have a
diameter that is about 2 to 4 times that of the unexpanded, or
"raw," beads.
[0037] Depending upon the manner in which the rigid core material
is made, the beads can possibly be heated to such a high
temperature that they will sinter while enclosed in the resinous
matrix of the core material. If so, at least a substantial portion
of the beads will then lose their cellular structure, creating
gas-filled pockets, of various sizes, in the foam, which are lined
with the polymer of which the cellular structure was formed. It
appears that isolated spherical beads generate relatively spherical
pockets. These hard, polymeric globules can lower the density of
the core material without significantly lowering its crush
resistance. Indeed, it appears that they may even enhance the crush
resistance.
[0038] The source of the heat necessary to cause bead sintering can
be an exothermic reaction that generates the matrix resin in which
the beads are trapped. Thus, for example, the matrix resin can be
formed by blending the necessary reactants to generate an exotherm
having a peak temperature in the range of about 185-285.degree.
F.
[0039] Chief among expandable polymer beads are expandable
polystyrene (EPS) beads and expandable polyolefin (EPO) beads.
[0040] Methods of making expandable polystyrene beads are well
known. As disclosed in U.S. Pat. Nos. 3,991,020; 4,287,258;
4,369,227; 5,110,835; 5,115,066; and 5,985,943, for example, all of
which are incorporated herein by reference, EPS beads may be made
by polymerizing styrene in an aqueous suspension, in the presence
of one or more expanding agents that are fed at the beginning,
during, or at the end of polymerization. Alternatively, they may be
made by adding an expanding agent to an aqueous suspension of
finely subdivided particles of polystyrene.
[0041] The expanding agent, also called a "blowing agent," is a gas
or liquid that does not dissolve the styrene polymer and which
boils below the softening point of the polymer. Examples of
suitable blowing agents include lower alkanes and halogenated lower
alkanes, e.g., propane, butane, pentane, cyclopentane, hexane,
cyclohexane, dichlorodifluoromethane, and trifluorochloromethane.
Often the beads contain about 3 to 15%, based on the weight of the
polymer, of the blowing agent. Preferably, the blowing agent will
be present at a level of about 3 to 7%.
[0042] By "polystyrene" is here meant a styrene homopolymer or
copolymer containing 50 wt. % or more, preferably at least 80 wt.
%, of styrene. Examples of suitable comonomers are
.alpha.-methylstyrene, ring-halogenated styrenes, ring-alkylated
styrenes, acrylonitrile, esters of acrylic or methacrylic acid with
alcohols having from 1 to 8 carbon atoms, N-vinylcarbazole, and
maleic acid or anhydride. A minor amount of a copolymerized
chain-branching agent may be included in the polymer as well.
Suitable such agents are compounds containing at least two
.alpha.,.beta.-ethylenically unsaturated groups, such as divinyl
benzene, butadiene, and butanediol diacrylate. Branching agents are
generally used in an amount of about 0.005 to 0.05 mol %, based on
the styrene.
[0043] The polystyrene in the EPS beads usually has a weight
average molecular weight in the range of about 130,000 to about
300,000.
[0044] EPS beads come in different unexpanded particle sizes.
Generally, a bead's longest dimension (e.g., its diameter), on a
weight average basis, will be in the range of about 0.1 to 6 mm,
often about 0.4 to 3 mm. It is thought that unexpanded particle
sizes in the range of about 0.4 to 1.6 mm are preferred for the
beads used in the present invention.
[0045] Unexpanded polymer beads vary as to their expansion
capability, i.e., how large they can get when heated to expansion
temperature. In part, this is a function of how much blowing agent
they contain. The expansion capability of a polymer bead can be
reported in terms of the bulk density of the loose aggregate the
beads will form when they are fully expanded ("fully expanded
density"). By "fully expanded" is here meant the expansion that
results from the "two pass" expansion process described in Example
2 of U.S. Pat. No. 5,115,066. This entails the use of a Tri
Manufacturing Model 502 expander (or equivalent), operated at an
inlet steam temperature of about 211.degree. F. and an inlet steam
flow rate of approximately 74 pounds per hour. The first-pass
throughput rate is about 208 pounds per hour. A fluidized bed
drier, blowing ambient air, is used to cool the resulting prepuff.
After aging for 3 hours at ambient temperature and humidity, the
prepuff is run through the expander again, under the same
conditions, except operating at a throughput rate of about 217
pounds per hour.
[0046] It is thought that the use of EPS beads having a capability
of reaching a fully expanded density in the range of about 0.5 to
4.5 pounds per cubic foot (pcf), e.g., about 1 to 3 pcf, is
preferred in the present invention. Examples of some commercial EPS
beads that can be used in the present invention are Types 3371,
5371, and 7371 from Huntsman Chemical and Types BFL 322, BFL 422,
BF 322, BF 422, and P 240 from BASF Corporation.
[0047] As examples of expandable polyolefin beads may be mentioned
expandable polyethylene (EPE), expandable polypropylene (EPP),
expandable polybutylene (EPB), and copolymers of ethylene,
propylene, butylene, 1,3-butadiene, and other olefin monomers,
particularly alpha-olefin monomers having from 5 to 18 carbon
atoms, and/or cycloalkylene monomers such as cyclohexane,
cyclopentene, cyclohexadiene, and norbornene. Propylene/ethylene
copolymers and propylene/butylene copolymers may be preferred.
[0048] Methods of making expandable polyolefin beads are disclosed,
for example, in U.S. Pat. Nos. 6,020,388; 5,496,864; 5,468,781;
5,459,169; 5,071,883; 4,769,393; and 4,675,939, all of which are
incorporated herein by reference.
[0049] Expandable polymer beads may contain other additives to
impart specific properties either to the beads or to the expanded
products. These include, for example, flameproofing agents,
fireproofing agents, nucleating agents, decomposable organic dyes,
lubricants, fillers, and anti-agglomerating additives. As disclosed
in U.S. Pat. No. 6,271,272, incorporated herein by reference, the
beads may also include additives, e.g., certain petroleum waxes,
that quicken the rate of expansion when the beads are heated to
expansion temperature. Depending on the intended effect, the
additives may be homogeneously dispersed in the beads or present as
a surface coating.
[0050] If expandable polymer beads are used as filler solids in
making the core material for the present invention, they can be
mixed with the matrix resin precursor mixture in either the
unexpanded, partially expanded, or substantially fully expanded
state. Preferably, however, by the time the matrix resin has set,
the polymer beads will have undergone at least a partial expansion,
as well as a sintering, to yield the polymeric globules entrapped
in the matrix. This is described in greater detail in a copending
U.S. patent application, entitled "Improved Process of Making Rigid
Polyurethane Foam," filed Mar. 22, 2002, by Arthur J. Roth, one of
the present inventors. The specification of that application is
incorporated herein by reference.
[0051] Rubber Fillers
[0052] Pieces of natural or synthetic rubber can be used as a
filler solid also, e.g., rubber made of styrene-butadiene resin,
polybutadiene, or polyisoprene. A preferred source of rubber is
used and scrap tires, which can be pneumatic tires or non-pneumatic
tires.
[0053] Older tires are preferred because they generally have fewer
volatives and are less elastomeric. Truck tires are preferred over
passenger tires, because they have greater rigidity. Preferably any
metal in the tires from metal belts amounts to no more than about 3
weight percent of the rubber, most preferably one percent or less,
especially if the composite structure material is to be used to
construct shipping pallets. There are a number of reasons. The more
metal content, the greater the pallet weight, which increases
shipping costs. Also, the presence of pieces of metal can cause
additional wear and tear on the equipment used to make the
composite structural material, e.g., augers, extruders, and
injection heads. Also, if allowed to remain in or among the tire
fragments used as filler solids, metal cords, shards, or splinters
can project through the laminar covering when the composite is
under compression and damage the load on the pallet or present a
safety hazard to material-handling personnel.
[0054] Ground up used tire rubber is available commercially and
comes in different particle sizes. Perhaps preferred for the
present invention is No. 4 tire granule (minus 10 mesh), preferably
with the tire cord (referred to as "fluff") not removed. Both black
and white tire crumb can be used.
[0055] When used, granulated tire rubber might constitute, for
example, about 20 to 90 percent of the volume of the finished
material's core.
[0056] Scrap tire rubber is a relatively inexpensive filler, on a
volume basis. It is rather heavy, however, and if it is important
that the specific gravity of the composite structural material be
at or below a certain value, the amount of tire rubber that can be
used may be limited accordingly. Thus, for example, if the
composite structural material is to be used as synthetic boards to
fabricate shipping pallets, specific gravity (i.e., finished pallet
weight) is a concern. It is preferred that the core material of
such boards have a specific gravity of about 0.65 g/cc or less,
e.g., a finished density of about 40 pcf or less. Generally that
means using a core material that contains 45 weight percent or less
of rubber.
[0057] If, on the other hand, the structural material is to be used
for an application that is less demanding in terms of specific
gravity, e.g., as for range fencing, stationary decking, or highway
guard rail posts or blocks, such composites can have specific
gravities as high as, say 0.95, or even 1.10, g/cc, e.g., a
finished density of up to as high as 60 or 70 pcf. This often
permits the use of rubber concentrations of up to 70 or 85 percent,
based on the weight of the core material.
[0058] The filler particles can be in any shape, e.g., fibrous,
flake; or granular (including spherical, e.g., silicate spherules
and hollow polymeric spherules, including polymeric
microspheres).
[0059] As regards the size of the pieces of filler used in the core
material, preferably their longest dimension will be no more than
about 50% of the thickness of the composite structural material.
Thus, for example, if the composite structural material is a board
having a thickness of one inch, substantially all of the pieces of
filler solid preferably will have a longest dimension that is no
more than about 1/2 inch.
[0060] Preferably the nature of the matrix resin, the nature and
amount of the filler particles (if any), and the degree of foaming
(if any) of the matrix resin will all be chosen so that the core
material has a crush resistance of about 300 pounds per square inch
(psi) or more, e.g., in the range of about 300 to 2500 psi. (This
refers to the amount of pressure required to reduce the core
material's thickness by ten percent.) If the matrix resin is
foamed, such crush resistance can be measured, for example, by ASTM
D 1621-94, entitled "Compressive Properties of Rigid Cellular
Plastics."
[0061] The crush resistance of a rigid solid is generally directly
related to its density, and so is also related to the ability of
the material to hold a nail. (The denser the rigid solid, the more
able it generally is to hold a nail.) The present invention is
particularly useful for providing wooden-board-substitutes for
shipping pallets. For the deck boards of shipping pallets, which do
not have to hold nails, and for which the lowest feasible specific
gravity is often desired (to lighten the load), a crush resistance
as low as about 300 psi (with its concommitant low density) can
generally be used, although a crush resistance of at least about
1100 psi is preferred. For stringers in shipping pallets, which
generally do have to hold nails, generally the crush resistance
should be at least about 1800 psi, and most preferably at least
about 2200 psi.
[0062] For many applications it will be preferred that the
composition and amounts of the matrix resin and filler particles
(if any) be such that the structural material has a coefficient of
linear thermal expansion that is in the range of about 2.5 to
3.5.times.10.sup.-5/.degree. F.
The Web Material
[0063] The web material in the laminar covering is rigidified paper
or cloth. Because it is less expensive than cloth, paper is
preferred. When paper is used, preferably it will have a thickness
in the range of about 0.015 to 0.020 inch. Most preferred is a
thickness of about 0.017 inch. The paper can be a web of various
fibers, e.g., one or more types selected from the group consisting
of cellulosic, glass, carbon, metal, and synthetic resin. Examples
of suitable synthetic resin fibers include polyamide fibers and
polyester fibers. Most preferably the fibers are oriented in the
paper, e.g., as in paper in which the fibers are oriented in the
machine or warp direction, also sometimes called the "milled
direction."
[0064] For reasons of economy it is believed to be preferable to
use a paper that is made at least primarily of cellulosic fibers,
e.g., from wood pulp. A preferred cellulosic paper is kraft
linerboard paper, for example having a basis weight (or "grade
code") of at least about 65 lbs. per msf (thousand square feet),
e.g., about 65 to 100 lbs. The preferred moisture content is about
7 to 9 wt. %, e.g., approximately 8%. The Mullen value preferably
is about 130 or 140 to about 145 psi. The paper's CD Ring Crush
value is preferably about 120 or 130 to about 140 lbs.
[0065] One suitable paper is 100% recycled standard linerboard
paper having a basis weight of about 69 lbs. Such is manufactured,
for example, by Gaylord Container Corporation. Another suitable
paper is 25% recycled kraft linerboard having a basis weight of
about 90 lbs. Such can be obtained, for example, from Longview
Fibre Company, of Longview, Wash., under Specification No. 5204.
Virgin paper also can be used, of course, but it tends to have
lower capillarity than recycled paper, which, for that reason, is
generally preferred.
[0066] Generally it is preferred that the paper contain at least
about 40 wt. % of recycled material.
[0067] As will be explained later herein in more detail, it is
preferred that a resin be used to bond the cords to the web
material and to impregnate and stiffen the web material. In such an
embodiment it can be useful if the outermost ply of web material
(e.g., paper) includes a barrier layer to prevent the resin from
bleeding through the web material. The barrier layer may be
comprised, for example, of a resin, e.g., poly(vinyl alcohol),
which can be an effective barrier to the migration of an epoxy
resin through the thickness of the web material. By use of this
feature, if the outermost ply of web material has a core-facing
layer that is resin-permeable and a layer external to that that
bars resin migration, the resin, while stiffening the web material,
will not bleed to the outer surface of the composite, where it
could possibly foul the contact surfaces of a molding apparatus
that is used to hold the assembly of core, web material, and
cording in the desired shape while the resin sets.
[0068] If desired, after the composite is removed from the mold,
the resin-free outer layer of the bifurcated paper can be coated
(e.g., sprayed) with a finishing composition, to impart desired
physical and/or chemical properties to the outer surface of the
composite. An example of such a multi-layered paper is
Specification No. 6228 from Longview Fibre Company.
[0069] Another option is to concentrate a fireproofing agent in the
outer layer of a barrier-layer-containing paper, where the agent
will be most effective. This is best done if the paper comprises
two external porous layers (one of each side) and a barrier layer
sandwiched between the two.
The Parallel Cords
[0070] If the composite is elongated, it will often be preferred
that the cording used in the laminar covering be aligned in the
long direction. Alternatively, the cording can run perpendicularly
or diagonally to the composite's long direction. For example, if
the elongated composite has a round cross section, the cording can
be wound spirally around the core, preferably surrounding the core
with a uniform layer of cording. When a spiral-wound composite is
intended to be used as, for instance, a post to support a highway
guard rail, a suitable covering may consist of two plies of paper
with one ply of polyester cording, in the form of a scrim,
sandwiched between the two plies of paper.
[0071] Preferably the cording used in the laminar covering has a
tensile strength in the range of about 5 to 18 pounds per cord,
most preferably about 16 pounds. The cording preferably has a
breaking tenacity of about 0.67 to 1.10 gf/TEX, most preferably
about 0.85 gf/TEX.
[0072] The cording can be made of continuous filament or staple
fibers. Monofilament cording can be used, but cording made of a
plurality of continuous filaments (so-called "multifilament"
cording) is preferred. Preferred multifilament cording is that
which is made of about 40 to 70 filaments. If multifilament cording
is used, the filaments can be twisted or untwisted. If twisted, it
is preferred that the cord have not more than 3.25 twists per
inch.
[0073] As for breaking elongation, preferably the cording's is in
the range of about 10 to 50%, e.g., about 20 or 25% to about 45 or
50%. Most preferred for monofilament cording is a breaking
elongation of about 30 to 40%, e.g., about 35%. Most preferred for
multifilament cording is a breaking elongation of about 15 to 20%,
e.g., about 17%.
[0074] The cording can be made in whole or in part of either
natural or synthetic fibers or filaments, including
fibers/filaments of synthetic resin, glass, carbon, or metal.
Synthetic resin fibers/filaments are often preferred, e.g.,
polyester, polyamide (such as nylon and poly-paraphenylene
terephthalamide), or polyolefin fibers or filaments. Glass
fibers/filaments generally provide greater stiffness in the
composite structural material. For certain uses, e.g., fence
boards, a better ability to bend might be preferred; in that
situation polyester fiber/filaments generally work better than
fiberglass.
[0075] If the cording is made of shrinkable fibers/filament,
preferably it is heat stabilized prior to being used to construct
the composite structural material of the present invention.
[0076] When made of a monofilament, the cording preferably has a
diameter of about 8 to 15 mil (i.e., about 0.008 to 0.015 inch),
most preferably about 10 to 12 mil.) When made of multifilament,
the cording preferably has a denier of about 600 to 1,000, most
preferably about 900.
[0077] As for the density of the parallel cords in the band--i.e.,
the number of cords per inch of width of the band--the preferred
level varies in inverse relationship to the diameter or denier of
the cording. The thicker the cording, the lower the preferred
density. Generally, however, the density will preferably be at
least about 10 or 12 cords per inch of band width ("lateral inch"),
and usually not more than about 35 cords per lateral inch.
[0078] The parallel reinforcing cords can be unconnected one to the
other, or they can be laterally connected, e.g., by cross-cording.
The latter arrangement has the advantage that it can help keep the
longitudinal cords in place during the formation of the laminar
covering. An advantageous way of providing the cords in this
fashion is to use a strip of cloth in which the longitudinal cords
constitute the warp, i.e., the "yarn," "fiber," or "thread" that is
in the cloth's "machine direction." By "cloth" is here meant either
a woven cloth or a cross-laid scrim. The latter is a nonwoven
netting formed by laying parallel rows of continuous yarn or thread
in the warp direction and then laying parallel rows of cross yarns
or threads on top of that layer, at a 90 degree angle thereto, and
bonding the two layers together at the cord intersections, e.g.,
either by thermal bonding or by use of a glue. When cross-laid
scrim is used, the warp side can either face outwardly from the
composite or inwardly. Preferably, however, it will face outwardly
and will be next to a layer of web material.
[0079] Generally it is preferred that any cloth that is used have a
warp direction tensile strength that is within the range of
approximately 90 to 200 pounds per lateral inch (pli), most
preferably approximately 155-185 pounds per lateral inch. By this
is meant the amount of longitudinal stress necessary to tear apart
a one-inch-wide band of the cloth, running in the warp
direction.
[0080] If the cloth comprises any shrinkable fibers/filament,
preferably those will be heat stabilized before the cloth is used
to construct the composite of the present invention.
[0081] It is preferred that the cross-cording (i.e., the woof or
weft of the cloth, also sometimes called the "pic" or the "fill")
be of a smaller diameter and/or of a lesser density (fewer cords
per inch of cloth) than the warp. Thus, for example, the diameter
or denier of the warp cords may be about 1.8 to 2.5 times that of
the woof cords, and the density of the warp cords (i.e., the number
of cords per lateral inch of the cloth) may be about 1.5 to 3 times
the density of the woof cords (i.e., the number of cords per
longitudinal inch of the cloth.)
[0082] When woven cloth made of 10-12 mil monofilament in the warp
direction is used, preferably the warp density will be at least
about 20 cords per lateral inch of the cloth, e.g., in the range of
about 20 to 35 cords per lateral inch of the cloth. The woof cords
of such a cloth preferably will have a diameter in the range of
about 4-8 mil, most preferably about 6-8 mil. The woof density for
such a cloth may be, for example, about 10 to 18 cords per
longitudinal inch of cloth.
[0083] Among the woven cloths that can be used very effectively to
supply the reinforcing cords are those composed of about 8-12 mil
polyester monofilament as the warp and about 6-8 mil polyester
monofilament as the woof Advantageously such polyester cloth has
approximately 20-30 cords/inch in the warp and approximately 10-15
cords/inch in the woof. Prototype fabric No. XF368080 from
Industrial Fabrics Corporation, of Minneapolis, Minn., is a woven
polyester cloth that meets these specifications. Its warp cording
has a diameter of approximately 10 mil, a tensile strength of
approximately 5.2 pounds per cord, and a breaking elongation of
approximately 46%. The density of the warp is approximately 27-29
cords per lateral inch. The woof cording has a diameter of about 8
mil. It is estimated that a one-inch-wide strip of this cloth has a
tensile strength in the warp direction of approximately 95-105
pounds and an elongation at break of approximately 46%.
[0084] Also suitable is the same woven polyester cloth as just
described, but having a warp cord density of only 24 cords per
lateral inch. It also can be obtained from Industrial Fabrics
Corporation. That fabric has a warp direction tensile strength of
approximately 91 pounds per lateral inch and an elongation at break
of approximately 46%.
[0085] An example of a suitable cross-laid scrim is Connect.TM.
scrim from Conwed Plastics, Inc., of Minneapolis, Minn. One
embodiment thereof has a warp composed of untwisted polyester
multifilament cord (60 filaments per cord) having a denier of about
1000. The warp has a cord density of 12 cords per lateral inch. The
warp cording has a tensile strength of about 17.5 pounds per strand
of the cord. A one-inch-wide, warp direction strip of the scrim has
a tensile strength of about 185 lbs., a breaking elongation of
about 24%, and a breaking tenacity of about 0.92 gf/TEX.
[0086] Preferably the laminar covering will comprise a band of
parallel cords (which, as indicated, can be a strip of cloth) that
covers at least one side of the structural material. For example,
at least about 25% of the cross-sectional circumference of the
material can be covered with one or more bands of parallel cords.
If the material is rectangular in cross section, it is most
preferred that at least two opposite sides be covered with bands of
the cords. Most preferably, all sides of the structural material
will be covered with bands of the cords. If the cross section is an
elongated rectangle and the material is to be used as deck boards
for shipping pallets, e.g., as a substitute for 1''.times.4'' or
1''.times.6'' lumber, it is preferred that at least the two wide
sides of the board be covered with bands of the cords.
[0087] For other uses, however, if only two sides are covered with
the bands of cords, it might be preferred that they be the narrower
sides. Thus, for example, in shipping pallets the stringers often
are wooden 2.times.4 s or 3.times.4 s set "on edge." If the
structural material of the present invention is to be used in place
of such wooden boards, then it is preferred that at least the two
narrow sides be covered with bands of the cords.
[0088] Most preferred for shipping pallets, however, is that all
four sides of both the deck boards and the stringers be reinforced
with bands of parallel cords. In this way not only is the pallet
able to withstand large loads, it also is more resistant to damage
along the vertical surfaces of the boards, e.g., due to being hit
by fork lift tines.
[0089] Where all sides of a board-shaped composite are to be
covered with bands of cords, the four bands need not always be
constructed the same. Thus, for example, one pair of opposite sides
might require bands of lower tensile strength than the other two
sides.
[0090] If the cording is being supplied by a scrim and it is
desired to use different cord bands (e.g., having different tensile
strengths) on different sides, one can use a multi-zone scrim that
is wide enough to wrap around the core of the board. If it is a
four-zone scrim, each zone will be the width of (and will register
with) one of the four sides of the board. Different warp cords
and/or different cord densities can be used in the four different
zones, while the cords and cord densities in the woof direction are
kept uniform.
[0091] As far as dimensions are concerned, the present invention is
very useful for the construction of board-shaped composites having
a thickness of about 1/2 inch to 8 inches and a width of about 2 to
48 inches and pole-shaped composites having a diameter in the range
of about 2 to 18 inches, although it certainly is not limited to
such materials.
[0092] For maximum strength, it is preferred that at least some of
the reinforcing cords in the laminar covering be bonded to the web
material in a pretensioned state. The amount of tension can be
expressed in terms of how much the cord is stretched. Thus, every
cord has an elongation-at-break value that is expressed as how
much, in percent, the cord's length can be increased by stretching,
before the cord breaks. The more it is stretched, the greater the
tension on the cord. In the present invention it is contemplated
that it generally will be preferred that the cord not be stretched
(i.e., elongated) beyond about 85% of its capacity. Thus, if its
elongation at break is 30%, say, then it is preferred that the cord
not be lengthened by tension to more than 125.5% of its starting
length.
[0093] As for the minimum amount of stretching, it is preferred
that the cord be stretched to at least about 10% of its capacity,
most preferably at least about 20%, 30%, or 40% of its capacity.
Often the most preferred range will be about 50 or 60% to about 80%
of its capacity. Generally it will be preferred, when cloth is used
as the source of the parallel cords, that it be pretensioned in the
warp direction to a value of at least about 10 pli, most preferably
at least about 50 pli, e.g., at least about 75 or 100 phi.
Dissimilar Embedments
[0094] The laminar covering can optionally contain an embedment of
a material that is dissimilar from the core and covering, and which
has a physical property that can be measured from a distance, e.g.,
a property such as inductance, reflectance, thickness, density, or
two-dimensional shape, which can serve as an identifying feature of
the composite, or the article in which the composite is included.
The material can be composed, for example, of a metal, a sulfate, a
chloride, or graphite. Examples of suitable metals include
aluminum, copper, gold, nickel, cadmium, zinc, bronze, chromium,
cobalt, potassium, chrome, lead, tin, and silver. A metallic layer
deposited on a substrate can be used, for example.
[0095] The embedment can be coterminus with the cording and/or web
material, or it can be a smaller section. The embedment's physical
property can be detectable by, for example, diffraction or
refraction techniques using external-source electromagnetic
radiation, e.g., x-rays or radio waves. The embedment can even
include a circuit pattern that emits a signal when contacted by an
electromagnetic field.
[0096] By use of this embedment feature, the composite (or an
object made therefrom, such as a shipping pallet) can be provided
with a type of tagging device, e.g., to indicate the nature of one
or more components of which the composite or object is made, or
where and/or when it was manufactured, or by whom it is owned.
Other Layers or Components
[0097] The laminar covering may optionally comprise one or more
plant-growth repellants. Thus, for example, the outermost coating
on a composite that is to be used as a highway guardrail post can
contain a chemical that repels climbing plants such as ivy.
[0098] Another chemical additive that can optionally be included in
the laminar covering is a fire or flame retardant. Similarly,
reflective particles can be embedded in the outermost coating,
e.g., reflective particles of the type used in highway safety
markers. Pigments and/or dyes can be included as well, for
decoration or identification purposes. Also, an anti-corrosion
chemical can be included, as, for example, when it is anticipated
that the composite might come into contact with a chemical that
could otherwise react with, and degrade, the laminar covering.
Thus, for example, a board-like composite that is to be used to
construct pallets for the shipping of drums containing a particular
corrosive chemical can contain in its outermost coating a component
that confers resistance to that chemical, in case of leakage.
[0099] For some purposes it may be important that the outermost
surface on one or more sides of a composite have a coefficient of
friction that is within certain defined limits. Thus, for example,
the top surface of deck boards on a shipping pallet should have a
high enough coefficient of friction that load shifting will not be
a problem during transit, but not so high a coefficient that it is
unacceptably difficult to slide freight on or off the pallet. To
help set the desired co-efficient of friction, the outermost
coating on the laminar covering can have friction-increasing
asperities projecting from the surface. Such asperities can be
provided by use of the same techniques as are used to make
pickup-truck bedliner surfaces slip resistant, e.g., by embedding a
grit material such as sand in the coating, by forming the polymeric
coating in such a way that it is non-smooth, or by stippling the
surface with droplets of a resin that leaves small bumps on the
surface.
[0100] For decoration or other purposes, the outermost layer of the
laminar covering can optionally be a wood veneer, e.g., having a
thickness of at least about 4 mil. If the thickness is about 20 mil
or more, such a veneer generally functions as a structural
membrane--i.e., it adds strength to the composite.
The Bonding/Stiffening Resin
[0101] The cords preferably are bonded to the web material by a
resin, most preferably a resin selected from the group consisting
of epoxy, polyurethane, acrylic, nitrile, butyl, allyl,
urea-melamine, vinyl ester, phenolic, silicone, and cyanoacrylate
resins. A thermosetting resin, e.g., a thermosetting vinyl ester
resin or a thermosetting epoxy resin, is most preferred. If the
core material comprises a matrix resin, then the bonding resin
preferably is compatible with the matrix resin, i.e., will adhere
thereto. In this regard, certain polyurethane and epoxy resins are
known to be compatible, as are certain phenolic and vinyl ester
resins.
[0102] To make the laminar covering dimensionally stable, it is
preferred that the web material be impregnated with a set resin,
most preferably a cured thermosetting resin. Again, compatibility
with any bonding resin and matrix resin that is used is desired.
Preferably the same binding resin that is used to bond the cords to
the web material is also used to impregnate and stiffen the web
material.
[0103] Epoxy resins are perhaps preferred for the stiffening resin
and the bonding resin. Both one-component epoxy resin systems that
require elevated temperatures to cure and two-component epoxy resin
systems that can cure at room temperature can be used. The
two-component systems have separate resin and hardener
components.
[0104] As for viscosity, the systems can be thin enough to be
sprayable or so viscous that they have to be applied with, for
example, a bath roller or a "pin" roller. An example of the
sprayable type is Product Code R 88-14B/H 88-14E from Copps
Industries, Inc., of Mequon, Wis., which is a two-component system
having a viscosity (immediately after mixing) of about 1,480 cP,
when mixed at a weight ratio of 4.2 parts resin to one part
hardener. Its gel time at 77.degree. F. is approximately 24
minutes, as measured by ASTM Test D2471. An example of a system
that also can be used, but which is too viscous to be sprayed
effectively, is Copps Industries R 88-14A/H-14D, which is a
two-component system having a viscosity of about 3,000 cP, when
mixed at a weight ratio of 3.1 parts resin to one part hardener,
and a gel time at 77.degree. F. of about 42 minutes.
[0105] System R 88-14B/H 88-14E is designed to bind laminated
structures and will bind well to cellulosic paper, fiberglass mesh,
polyurethane foam, and recycled rubber, among other materials. R
88-14A/H 88-14D also is designed to bond to a wide variety of
similar and dissimilar materials. Also suitable is a developmental
epoxy resin system from Copps that is designated R 900/H 900.
[0106] The laminar covering can be comprised of a single layer of
web material and a single layer of cording. Alternatively, a
plurality of layers of one or both can be used. Where a plurality
of parallel-cords layers are used, preferably a web layer will be
interleaved between every two parallel-cords layers. Preferably,
the covering will comprise at least one combination of a layer of
parallel cords bonded to a web layer that is exterior to the
parallel-cords layer. Thus, for example, excellent strength can be
obtained by a four-ply arrangement, starting from the core, of cord
layer/web layer/cord layer/web layer.
[0107] The properties of the composite will vary depending upon its
aspect ratios, i.e., the ratio in a particular cross-sectional
direction of the thickness of the composite's laminar covering (or
facia), T.sub.f, to the composite's total thickness, T. Thus, for
example, a composite in the shape of a 1''.times.4'' board that is
surrounded with a 1/8'' thick facia will have a thickness aspect of
0.25 (T.sub.f=2.times.1/8''=1/4''; T=1'') and a width aspect of
0.062 (T.sub.f=2.times.1/8''=1/4''; T=4''). Generally it is
preferred that, in at least one cross-sectional direction, the
composite have an aspect of at least 0.1.
[0108] Facia of different thicknesses can be used on different
sides of the composite, even on opposite sides. Thus, for example,
where the composite is a board that will be subjected to minimal
lateral loads but extensive vertical loads, one might save expense
by using thinner facia on the sides than on the top and bottom. In
a situation in which the board will be subjected to strenuous
vibrations, it may be desirable to use a thicker wall on the top
than on the bottom.
[0109] Greater surface smoothness generally can be obtained if the
outermost of all the parallel-cords and web layers is a web layer.
This can be advantageous in a case in which the structural material
has to be kept sanitary. If, for example, the structural material
is to be used as a board in a shipping pallet (e.g., as either a
stringer or a deck board), it might have to be sterilized when the
pallet is used in areas of food preparation or handling. This can
entail steam treatment and/or washing with disinfectants containing
bactericides, such as chlorine-containing reagents. The composite
structural material of the present invention, especially when
having a resin-stiffened web material at its outer surface, can be
easier to sanitize than boards of real wood, due to its having
fewer cracks, crevices, and pores in which microorganisms can
reside, and possibly escape the heat or contact with the
disinfectant.
Making the Composite Structural Material with a Segmented
Covering
[0110] The laminar covering can be in one piece or in longitudinal
sections. For ease of manufacture, it might be preferred that the
laminar covering be comprised of two mating C channels that run the
entire length of the structural material. The C channels would be
opposed, their openings facing each other. It is preferred that the
two channels overlap along their longitudinal edges and that they
be conjoined, for example with the same thermosetting resin as is
used to rigidify the web material. If the cross-sectional shape of
the structural material is a non-square rectangle, then it is
preferred that each of the C channels covers one of the wide sides
of the structural material--i.e., that the overlapping edges of the
two C channels be located on the narrow sides.
[0111] The C channel version of the composite structural material
of the present invention can be made, for example, by a method
comprising the following steps:
[0112] a) obtaining a first elongated C channel of a porous web
material that is impregnated with a thermosetting resin precursor
mixture and orienting the channel with the C facing up;
[0113] b) impregnating a strip of cloth with a thermosetting resin
precursor mixture that is compatible with the resin precursor
mixture in the web material;
[0114] c) laying said strip of cloth on the inside bottom of the
first C channel, with the warp running in the lengthwise direction
of the channel, so as to extend the length of the channel;
[0115] d) optionally placing one or more additional layers of said
web material and/or cloth on the C channel;
[0116] e) depositing on the top layer in said C channel a fluid
mixture of a matrix resin precursor composition and pieces of a
filler solid, the matrix resin precursor composition being
compatible with both the resin precursor mixture in the web
material and the resin precursor mixture in the cloth;
[0117] f) covering the first C channel with a second C channel of a
porous web material that is impregnated with a thermosetting resin
precursor mixture that is oriented with the C facing down, so that
the vertical sides of the two channels overlap and touch each other
and the two C channels define a core space between them; and
[0118] g) holding the two C channels together under conditions that
are conducive to the setting of (i) the matrix resin in the core
space, (ii) the thermosetting resin in the porous web material, and
(iii) the thermosetting resin in the cloth, and for a length of
time sufficient for all three resins to set, whereby the two C
channels become bonded together where they overlap, the cloth strip
becomes bonded to the first C channel, the core space becomes
filled with the mixture of matrix resin and pieces of filler solid,
and the matrix resin becomes bonded to the cloth and the web
material.
[0119] The foregoing steps do not have to be performed in the order
listed. For example, the strip of cloth can be laid on the porous
web material either before or after the latter is forced into a
C-channel shape. Also, the impregnation of the web material and the
cloth with thermosetting resin can occur before or after the
layering of the cloth on the web material.
[0120] To keep the density and cost of the structural material
relatively low, it is preferred to use a matrix resin that is
foamable, and to deposit the mixture of matrix resin precursor
composition and filler solid (if used) on the topmost layer in the
bottom C channel in a volume amount that is insufficient, without
foaming, to fill the cavity between the two C channels of web
material. In such a method, the two C channels are held together
under conditions that are conducive to the forming, foaming, and
setting of the matrix resin, whereby the mixture of resin and
filler solid (if used) expands to fill the cavity between the two C
channels. The foaming can be caused by the release, expansion, or
generation of one or more gases in the resin precursor mixture,
e.g., a gas selected from the group consisting of carbon dioxide,
nitrogen, hydrofluorocarbons (e.g., HFC 245SA and HFC 134A),
chlorofluorocarbons, and lower alkanes, e.g., pentanes. Resin
systems for generating foamed thermoset resins are well known in
the art, and include, for example, the aforementioned polyurethane
resin systems.
[0121] For maximum composite strength, when using the C channel
method of fabrication, the second (top) C channel that is used in
step e is underlaid with a second strip of cloth that also is
impregnated with a thermosetting resin precursor mixture that is
compatible with the resin precursor mixture in the web material.
That cloth also should extend the length of the second C channel,
and it too should become bonded to both the second C channel and
the matrix resin, during step f.
[0122] Preferably, in both C channels the layer that contacts the
matrix resin precursor composition is a layer of porous web
material, most preferably paper. E.g., in each C channel three
layers in all may be used: two layers of porous web material, with
a layer of cloth sandwiched between them. (In such a construction,
it is preferred that the innermost web material have no
resin-barrier layer.) Using web material, rather than cloth, as the
innermost layer appears to provide for more even pressure
distribution during the setting of the core's matrix resin and,
therefore, a more uniform composition of the ensheathed core
material.
[0123] The C channel method of fabrication can be run on a
substantially continuous basis by pulling each of the porous web
material strips and the woven cloth strip or strips off its own
supply roll. For each C channel, the porous web material can be
pulled through a wetting station where it is impregnated with the
thermosetting resin precursor mixture. Depending on the viscosity
of the thermosetting resin precursor mixture, wetting might be
accomplished by spraying, gravure printing a pattern of the mixture
on the web material, or passing the web material through a bath of
the mixture. Either before or after the wetting station, each run
of the web material can also be pulled through a forming station
where it is folded into the desired C channel cross section.
[0124] Meanwhile, each strip of cloth can be pulled through a
wetting station where it is impregnated with its thermosetting
precursor mixture. One of the impregnated strips of cloth is then
made to lie on the inside bottom of the first (upward facing) C
channel, following which the fluid mixture of the matrix resin
precursor composition and pieces of filler solid is deposited on
top of the cloth. The second impregnated strip of cloth is made to
lie against the underside of the second (downward facing) C
channel, which is poised above the first C channel.
[0125] After the station at which the fluid mixture is deposited
onto the upward facing first C channel, that channel can be covered
with the cloth-lined, downward-facing, second C channel. If the
dimensions of the two C channels are the same, the top one can be
slightly offset, in the lateral direction, so that one of its side
walls (i.e., its vertical walls) rides outside one of the side
walls of the bottom C channel, while the other side wall of the top
C channel rides inside the other side wall of the bottom C channel.
Alternatively, one of the C channels can be made slightly wider
than the other, so that it completely straddles (i.e., overarches)
the other C channel.
[0126] Once they are mated in this manner, the two runs of
resin-impregnated cloth and two runs of resin-impregnated web
material can be simultaneously pulled through a continuous molder
that is maintained at the proper temperature to cause the matrix
resin, the thermosetting resin in the porous web material, and the
thermosetting resin in the cloth all to form and set. It might be
preferred, however, before entering the continuous molder, that the
resin-precursor-mixture-impregnated web material and cloth be
heated. This can flash off some solvent in the mixture(s) and/or
accelerate the reactions that have to occur and, as a consequence,
shorten the time that the mated C channels have to remain in the
continuous molder.
[0127] The continuous molder can be, for example, at least one
tractor mold, which sometimes is referred to as a type of "endless
flexible belt mold." This is a type of mold in which cooperating
half-mold segments revolve on opposed ovoid conveyor tracks to grip
between them a section of an axially moving, continuous linear feed
material and hold it for a time, while the material and the
abutting half-mold segments continue to travel forward. The
half-mold segments are connected, back and front, to identical
segments, much like links in a tractor tread. Each pair cooperates
to form an external die that holds its section of the feed material
in the desired shape as the material solidifies. The half-mold
segments can be equipped with temperature-control means to cause
the synthetic resin in the feed material to become set by the time
the segments reach the end of their forward run. There the opposed
segments separate, releasing the section of the feed material, and
each segment circles back to the beginning to grip another section
of the feed material. Meanwhile, the intervening length of feed
material has been gripped and treated by other pairs of half-mold
segments. One example of a moving mold of this type is disclosed in
U.S. Pat. No. 5,700,495 to Kemerer, et al., which is incorporated
herein by reference. The forward run of the tractor mold preferably
is long enough that, by the time the two C channels emerge from the
mold, the impregnating resins and the matrix resin have all been
formed and are set. If necessary, however, the feed material can be
passed through a series of two or more tractor molds in order to
hold the material in the desired shape until the resins in it are
all set.
[0128] The mixture of matrix resin precursor composition and filler
solid can be preformed and pumped as one uniform mixture through an
applicator conduit, so as to land on the topmost layer in the
bottom C channel. Alternatively, the components of the mixture can
be kept separate in two or more segregated streams, and those
streams can be blended in a mixing nozzle, or even in the air space
between the exit openings of their respective applicator conduits
and the surface of the layer upon which the components land. In
this way, it can be arranged that none of the material streams is
independently settable; instead it requires that two or more
streams be blended before a settable mixture is obtained. Thus, the
method can be performed much like reaction injection molding
(called RIM molding) in which a necessary curing catalyst and/or
cross-linking agent is delivered to the fill hole of a mold cavity
in one stream, while a monomer or prepolymer that needs to be mixed
with the catalyst and/or cross-linking agent in order to provide a
settable mixture is delivered in a separate stream. To blend the
streams in the air space beyond each applicator conduit's exit
opening, they can be pumped through nozzles that are aimed to cause
the streams to collide in the air. Alternatively, the streams can
be blended in a mixing head.
[0129] One advantage in not forming a settable mixture until all of
the necessary ingredients enter or exit the applicator nozzle is
that if the process has to be shut down early, there will be no
volume of premixed resin in a supply vessel that will have to be
discarded due to its having too short a pot life.
[0130] Once the process is past its start-up phase, the strips of
cloth and web material can all be simultaneously and uniformly
pulled through the continuous molder by grasping the emerging rigid
composite and propelling it away from the molder, in the axial
direction, e.g., by use of a tractor mechanism. The composite can
then be cut into desired lengths at a cutting station, e.g., by use
of a flying cutter.
[0131] Once the process is past its start-up phase and the emerging
composite is being pulled away from the continuous molder and
thrust forward to the cutting station, tension can be placed on the
cloth strips entering the continuous molder, so that the cords that
make up the warp of the cloth (the lengthwise cords) are
pretensioned when they are bonded to the matrix resin and the web
material.
[0132] When using a foamable matrix resin, the specific gravity of
the structural material that exits the continuous molder is
controlled to some extent by the rate of deposit of the mixture of
matrix resin precursor composition and filler solid on the moving
web material. The greater the amount of mixture that is deposited
per each foot of the moving web material, the more compressed will
be the finished core material and, therefore, the greater will be
its specific gravity.
[0133] If a thermoplastic matrix resin is used, the mixture of
resin and filler solid has to be heated to a resin melting
temperature either prior to deposition on the web material or after
such deposition. Also, the last segment of the continuous molder
may be equipped with cooling means, so as to cause the matrix resin
to resolidify prior to the emergence of the composite material from
the exit end of the die.
[0134] Even if a thermosetting matrix resin is used, there may be
some advantage in cooling the last segment of the continuous molder
so as to lower the temperature of the composite material before it
exits the molder--namely, by cooling it in the continuous molder
the composite will undergo less deformation and its temperature
will more quickly drop into a range in which the composite can
safely be handled. Using tractor molds this requires a series of at
least two such molds, so that the last tractor mold can be operated
at a lower temperature than the mold in which the thermosetting
occurs.
[0135] If heat needs to be applied to the mixture of matrix resin
and filler solid while it is being carried through the continuous
molder, any suitable source thereof can be used, including, for
example, radio frequency, microwave, and induction heating.
Making the Composite Structural Material with a One-Piece
Covering
[0136] Alternatively, the composite structural material of the
present invention can be made by use of nonwoven strands of
reinforcing cord, and in such a way that the laminar covering is in
one piece, rather than in two longitudinal sections. Thus, for
example, a single strip of web material that is wide enough to
completely ensheath the core material, preferably with some
overlapping, can be used. Parallel strands of reinforcing cords,
each from its own supply spool, can be laid on a side of the web
material, the fluid mixture of matrix resin precursor composition
and pieces of filler solid can be deposited on the cord-carrying
side of the web material, and the web material can be forced into a
sleeve-like configuration having the desired cross-sectional shape
of the structural material, with the cord-carrying side facing the
interior of the configuration. Then the mixture-carrying web
material, while in the sleeve-like configuration, can be passed
through the continuous molder as described above. In this
embodiment the cords also can be pretensioned, once finished
composite material is being pulled away from the molder. The porous
web material can be sufficiently impregnated with stiffening resin
precursor mixture that the reinforcing cords will not need to be
independently wetted with bonding resin. Independent wetting of the
cords still remains an option, however.
[0137] Preferably the web material is forced into its sleeve-like
configuration prior to the mixture of matrix resin precursor
composition and filler solid particles being deposited on the web
material. The forcing of the web material into a sleeve-like
configuration can be facilitated by wrapping the material around,
and pulling it over, an elongated mandrel that corresponds in shape
to the external die segments of the continuous molder. In this
manner the mandrel imparts its shape to the web material and the
external die helps to hold that shape.
[0138] Since it is preferred to force the web material into its
sleeve-like configuration prior to depositing the resin/filler
solid mixture on the web material, it is advantageous to use a
mandrel that has an interior passage ending in an exit opening that
is poised above the moving strip of web material. In that way, the
mixture of resin and filler solid can be pumped through the
mandrel's interior passage and out the exit opening, so as to be
deposited on the web material. In this arrangement (as in the C
channel embodiment) the web material acts like a tubular conveyor
belt as it carries the mixture of matrix resin and filler solid
through the continuous molder.
[0139] This process can also be performed using one or more strips
of cloth, instead of individual strands of cord.
[0140] Yet another method of making an elongated version of the
composite structural material with a one-piece covering is by the
following steps:
[0141] a) forming a foldable laminate of two strips of porous web
material selected from the group consisting of paper and cloth,
with at least one strip of cloth sandwiched therebetween, with the
warp of the cloth running in the lengthwise direction and with the
strips of porous web material and all materials lying between those
strips being impregnated with a thermosetting resin precursor
mixture;
[0142] b) folding the laminate into a trough shape and orienting it
horizontally, with one of the strips of porous web material on the
top and the other strip of porous web material on the bottom;
[0143] c) depositing in the trough of the laminate, while still
foldable, a fluid matrix resin precursor composition that is
compatible with the resin precursor mixture in the laminate and
which, when fully reacted, yields a thermoset matrix resin that is
at least semi-rigid;
[0144] d) folding closed and sealing shut the laminate so that it
surrounds and defines a core space containing said matrix resin
precursor composition; and
[0145] e) holding the closed laminate and its contents in a mold
under conditions conducive to the setting of both the thermosetting
resin in the laminate and the matrix resin in the core space, for a
time sufficient for both resins to set, whereby (i) the laminate
and the matrix resin are both made at least semi-rigid, (ii) the
matrix resin, together with any filler solid it may contain, fills
the core space, and (iii) the laminate and matrix resin are bonded
together.
Shipping Pallets
[0146] As mentioned above, the present invention is ideally suited
for the manufacture of composite boards that can be used to
construct shipping pallets. Any type of shipping pallet that can be
constructed of wooden boards or blocks can be made using one or
more composite boards or blocks of the present invention. As is
well known in the art, such pallets typically have deck boards
(arranged horizontally) and stringers (also sometimes called
"runners" or "posts") arranged vertically under a top layer of deck
boards. Use of a bottom deck is optional. Stringer pallets
typically contain both edge and center stringers. Sometimes a
single center stringer is used; but other times two center
stringers will be used, e.g., either touching one another or
separated by about 6 to 20 inches to distribute the load
evenly.
[0147] Instead of stringers, some pallets comprise blocks and
connector boards, to which are nailed top and bottom deck
boards.
[0148] All of the boards may be of various widths, lengths, and
thicknesses. Typically, however, deck boards are 1.times.4 s or
1.times.6 s. Stringers are typically 2.times.4 s or 3.times.4 s. A
typical block pallet might contain 6 outer blocks, 3 center blocks,
3 connector boards, 4 top deck boards that are approximately
1.times.4.times.40 inches, 5 top deck boards that are approximately
1.times.6.times.40 inches, 3 bottom deck boards that are
approximately 1.times.6.times.37 inches, and 2 bottom deck boards
that are approximately 1.times.6.times.40 inches.
[0149] A stringer pallet can be configured as a two-way pallet,
wherein the stringers permit the entry of forktines from two
opposite directions only. Alternatively, the pallet can be
configured as a four-way pallet, wherein the stringers are notched,
or otherwise cut, to permit entry of forktines from all four
directions.
[0150] The deck and bottom boards in a stringer pallet can be flush
with the outer edge of the outer stringers, making for a "flush
pallet," or the deck and/or bottom boards can be extended past the
outer edge of the outer stringers, making for a "single-wing" or
"double-wing" pallet. Also, the bottom boards can be completely
omitted, making for a "single-deck" or "skid" pallet.
[0151] If desired, the deck and bottom boards can be configured
such that their number, size, and placement are the same, top and
bottom, making for a "reversible" pallet.
[0152] The deck board composites might, for example, have a core
that contains about 10 to 15 vol. % of granulated tire rubber and
about 40 to 50 vol. % expanded perlite.
[0153] The deck boards can also be made without any filler solids
in the core material, as they do not usually have to be dense
enough to tightly hold a nail. E.g., they might be made with a core
material consisting of polyurethane foam having a density of about
15 to 21 pounds per cubic foot (pcf), preferably about 17 to 19
pcf.
[0154] The deck-support boards preferably will contain at least
some amount of granulated tire rubber, e.g., about 45 to 75 vol. %,
most especially about 55 to 65 vol. %.
BRIEF DESCRIPTION OF THE DRAWINGS
[0155] FIG. 1 is a schematic representation of one method of making
a board-shaped composite material of the present invention.
[0156] FIG. 2 is an elevation view of a shipping pallet constructed
of boards of the present invention.
[0157] FIGS. 3 and 4 provide a schematic representation of another
method of making a board-shaped composite of the present
invention.
ILLUSTRATED PROCESS EXAMPLE 1
[0158] The invention perhaps will be better understood by
considering the following description of one way of manufacturing
the new composite structural material.
[0159] This example describes the construction of a composite board
having the cross-sectional dimensions of a 1.times.4, i.e., 3/4
inch by 31/2 inches, using the C-channel method. The process is
continuous and is illustrated schematically in FIG. 1. The
proportions in FIG. 1 are not to actual scale. For example, for
ease of illustration the thickness of papers 10 and 21 is
exaggerated. So is the diameter of the warp cords 19 and the woof
cords 20. And whereas the drawings depict approximately two dozen
warp cords across the width of a 1.times.4, in actual practice
there would preferably be at least 70. Also, FIGS. 1B through 1J
are on a larger scale than FIG. 1A, for ease of illustrating
certain details.
[0160] Referring to FIG. 1, a strip of recycled kraft paper 10 is
pulled off supply roll 11, passed around guide roller 50, tension
roller 51, and guide roller 52, and then passed over spray bar 12
where it is sprayed with a freshly prepared mixture of epoxy resin
and hardener components. The combination of guide rollers 50 and 52
and tension roller 51 helps provide a uniform delivery of paper 10,
i.e., without jerking. The cellulosic fibers (not shown) in paper
10 are oriented in the lengthwise direction of the strip.
Meanwhile, woven polyester cloth 14 is pulled off supply roll 15,
passed around guide roller 53, tension roller 54, guide roller 55,
and a second tension roller 17, and then passed over spray bar 16
where it is sprayed with the same epoxy resin mixture. The
resin-impregnated cloth 14 is pulled to laminating station 18,
where it is pressed against the wet underside of paper 10, to yield
the configuration shown in FIG. 1D. As shown in FIGS. 1C and 1D,
the warp of cloth 14 consists of cords 19. Cords 19 are held in
place by woof cording 20, which is smaller in diameter.
[0161] A second strip of recycled kraft paper 21, identical to
paper 10, is pulled from supply roll 22, passed around guide roller
56, tension roller 57, and guide roller 58, and then is impregnated
with the same epoxy resin composition, which is sprayed onto the
upperside of paper 21 from spray bar 23. Meanwhile, polyester cloth
25 is pulled off its supply roll 26, passed around guide roller 59,
tension roller 60, guide roller 61, and second tension roller 28,
and then is sprayed on its underside with the same epoxy resin
composition from spray bar 27. Cloth 25 is identical to cloth 14.
Resin-impregnated cloth 25 is pulled into laminating station 29
where it is pressed against the inside bottom of paper 21, yielding
the assembly illustrated in FIG. 1E. At folding station 24
(equipment not shown) the edges of paper 21 are bent upward,
creating an upward-facing C channel, as shown in FIG. 1F. The
combination of paper C channel 21 and polyester cloth strip 25 is
pulled past ejection nozzle 30 where a mixture of matrix resin
precursor components and filler solids is deposited on cloth strip
25. As shown in FIG. 1G, the mixture deposit 31 consists of filler
solids 32 suspended in a fluid mixture 33 of the components that
will react to form a rigid, thermoset, polymeric foam. The
combination of C channel, cloth, and core material precursor
mixture 31, as shown in FIG. 1G, is then pulled toward continuous
molder 37. Before that combination enters molder 37, however, the
laminated strips of paper 10 and cloth 14 are guided by roller 34
into position above bottom C channel 21, as shown in FIG. 1H. Then
top paper 10 is bent at folding station 13 (equipment not shown)
into a downward-facing C channel that overlaps upward facing C
channel 21, as shown in FIG. 1I. That assembly is then pulled
through continuous molder 37, which is maintained at an optimum
temperature for assisting the forming, foaming, and setting of the
resin precursor fluid 33, to yield cellular matrix resin 38, as
shown in FIG. 1J, which is a cross-sectional representation of the
finished board. The interior (not shown) of continuous molder 37
is, in effect, an external die that holds the assembly of paper,
cloth, and core material mixture in the desired cross-sectional
shape. Pressure that presses the paper and cloth against the
interior wall of continuous molder 37 is generated by the hot gas
that is causing the resin to foam.
[0162] The finished board 40 is continuously pulled out of
continuous molder 37 by tractor device 41. Once board 40 begins to
emerge from molder 37, tension is placed upon cloth 14 by
adjustment of tension roller 17, and tension is placed upon cloth
25 by adjustment of tension roller 28. Continuous molder 37 is long
enough that, before board 40 emerges from the molder, cords 19 in
both the top cloth 14 and the bottom cloth 25 are strongly enough
bonded to rigidified paper strips 10 and 21, as well as to the
foamed matrix resin 38, that, once the board is cut into sections,
the tension in cords 19 will not be sufficient to break those
bonds. Top C channel 10 is bonded to lower C channel 21 by the set
epoxy resin at their interfaces 42 and 43 where their side walls
overlap.
ILLUSTRATED PROCESS EXAMPLE 2
[0163] Another process for making a composite board of the present
invention is schematically illustrated in FIGS. 3 and 4. In FIG. 3,
two-ply paper 101, which has an internal barrier layer of
poly(vinyl alcohol), is fed from roll 102 over guide roller 103
through an epoxy resin applicator 104, using known technology and
equipment for manufacturing paper and plastic laminates. Polyester
scrim 106 is taken off roll 107 and also is passed through epoxy
resin applicator 104. At the same time, single-ply paper 108 is
taken off roll 109 and also is passed through epoxy resin
applicator 104. The liquid epoxy resin precursor composition 113
(hereinafter called "epoxy resin," for short) is delivered through
supply nozzle 110 to the space between papers 101 and 108.
[0164] As depicted coming off roll 102, the underside ply of paper
101 might advantageously be thinner than the upperside ply. This is
because the underside ply only needs to be thick enough to receive
a finish coating, not to absorb enough epoxy resin to be tightly
laminated to a cloth scrim.
[0165] After leaving epoxy resin applicator 104, papers 101 and 108
and scrim 106 pass downwardly between calendar rollers 105 and 106,
forming an unset laminate 111. The span of time between the
application of the resin and emergence of the laminate 111 from
rollers 105 and 106 is short enough that little or no epoxy resin
bleeds through paper 108 during that interval. However, as a
precaution, a gravure blade 112 rides against calendar 106 to
scrape off any epoxy resin that does get transferred to that
surface.
[0166] Scrim 106 is sufficiently porous that epoxy resin 113 is
easily pressed through the scrim by calendars 105 and 106. The
flexible laminate 111 passes over guide roller 114 and then weaves
its way over and under the array of festoon rollers 115. The space
between the upper and lower gangs of festoon rollers 115 is set by
computer so that the time required for the laminate 111 to complete
the trip through the array allows the epoxy resin to partially set,
but not rigidify. Rollers 115 can optionally be heated to speed up
the setting of the epoxy resin.
[0167] As shown in FIG. 4, flexible laminate 111 next passes
through adjustable web creaser 116, where it is scored with four
fold lines (not shown) that will form the four edges of the
finished board. The creased laminate 112 next passes through
forming station 117, in which it goes past forming rollers and/or
mandrels (not shown) to bend it into a J-like cross-sectional
configuration 118, using two of the crease lines imparted by web
creaser 116. Two remaining crease lines 119 and 120 are visible in
the high vertical side of the cross-sectional J.
[0168] Next the J-shape laminate 118 passes through core filling
station 121, in which a mixture of matrix resin precursor
components and filler solids (not shown) is deposited in the trough
section of laminate 118. The mixture consists of filler solids and
a fluid mixture of the components that will react to form thermoset
polyurethane foam. Known equipment such as a mezzanine-mounted
gravity feed filler (not shown) may be used to deposit the mixture
in the trough of the moving laminate. Ideally a splash guard will
be used to prevent any of the deposited mixture from bouncing out
of the laminate trough.
[0169] The mixture-carrying laminate 122 next is passed through
closing station 123, in which laminate 122 is folded along crease
lines 119 and 120, so that edge 124 lays against the near side of
the closed laminate 125. Closing station 123 includes a bead glue
laminator (not shown) that seals the composite closed at edge 124,
using a high-strength, heat-setting, fast-setting adhesive--for
example, an adhesive of the type used in the corrugated paperboard
industry, e.g., an epoxy or polyamide/polyurethane adhesive. For
example, a bead line of the sealing adhesive can be applied to the
outside of the upstanding vertical edge, and the downwardly
descending top edge can be pressed against the adhesive. In a few
seconds, the adhesive sets sufficiently that the mixture-carrying
sleeve 125 can enter tractor molding station 126, where sleeve 125
is held tightly in heated mold segments (not shown) while the
matrix resin foams and partially sets and the epoxy resin in the
laminate becomes at least somewhat rigid. Tractor mold 126
preferably is sufficiently strong to withstand an internal sleeve
pressure of up to about 10 psi from the foaming polyurethane
mixture. The resultant, partly rigid composite 127 then passes
through a less substantial continuous molder 128, for the purpose
of holding the composite in the desired rectangular shape while the
resins further set, thereby preventing any bulging due to internal
gas pressure. Continuous molder 128 might only need to withstand a
foaming pressure of about 6 or 7 psi. Therefore it might be a belt
type continuous molder, rather than the more expensive tractor
mold.
[0170] The resultant rigid composite 129 is pulled by tractor
mechanism 130 out of the second tractor mold 128 and is passed
forward to a cutting station (not shown). If desired, composite 129
can first be passed through a coating station where it is sprayed
with a finish coating (not shown).
[0171] Once the process of FIGS. 3 and 4 has passed the start-up
phase and is yielding a rigid composite 129 that is being pulled by
tractor mechanism 130, tension can be applied to scrim 106. Tension
can also be applied to paper 101 and/or paper 108. Preferably,
enough tension is applied to paper 101 to keep a smooth and even
outer surface all around the finished composite 129. Generally,
machine tension will be sufficient for this purpose.
[0172] As will be appreciated, the system shown in FIGS. 3 and 4
can be modified to allow for the use of more than 3 plys in the
laminate. The finished board's rigidity, flexibility, durability,
weight, burn characteristics, etc., can be affected by layering the
laminate with various materials and various configurations. The
following five laminates are specifically contemplated, with P
representing an interior layer of paper, P.sub.o representing the
outermost layer of paper, S representing a layer of scrim, and
P.sub.i representing the innermost layer of paper:
[0173] 1. P.sub.o-S-P.sub.i
[0174] 2. P.sub.o-S-S-P.sub.i
[0175] 3. P.sub.o-S-P-S-P.sub.i
[0176] 4. P.sub.o-P-S-S-P.sub.i
[0177] 5. P.sub.o-P-S-P-S-P.sub.i
ILLUSTRATED SHIPPING PALLET EXAMPLE
[0178] For illustration purposes, FIG. 2 is an elevation view of
just one type of shipping pallet that can be constructed of
composite boards of the present invention. It is comprised of an
upper deck 210 and a lower deck 211 that are both constructed of
1.times.4 s. The end stringers 212 and 213 are 3.times.4 s, set on
edge. The two center stringers 214 and 215 are both 2.times.4 s,
also set on edge. Now follows a description of how, for example,
the deck boards and stringers may be formed of composite structural
material of the present invention.
[0179] Each of the boards is made with one-piece laminated
coverings, as described in Example 2 and FIGS. 3 and 4. The
P.sub.o-S-S-P.sub.i arrangement of paper and scrim plies is used.
The scrim has a warp made of 1000 denier multifilament polyester
cords and a woof made of 250 denier multifilament polyester cords.
The warp density is 12 cords per lateral inch; the woof density is
6 cords per longitudinal inch. (Other cloth, e.g., a fiberglass
scrim, can be substituted for the polyester scrim.) The warp side
of the scrim is toward the outside in each board. The P.sub.o layer
in all the boards is 100% recycled two-ply kraft paper having a
basis weight of about 90 lbs., and the P.sub.i layer is 100%
recycled standard linerboard paper (single ply) having a basis
weight of about 90 lbs. The laminate is rigidified with a
two-component epoxy resin, such as Product Code R 88-14B/H 88-14E
from Copps Industries, Inc. In all of the boards, the warp cords
are pretensioned to about 80-85% of their capacity.
[0180] In the top deck boards 210, the core material is made of a
mixture of 25.55 parts by weight (pbw) of a polyurethane foam
system, 5.06 pbw of Huntsman Chemical 5371 EPS beads, and 69.39 pbw
of No. 4 tire granule (minus 10 mesh) which has been magnetically
separated, without removal of tire cord fluff. The polyurethane
system consists of Baydur 645B isocyanate and Baydur 645A polyol.
The EPS beads are substantially fully expanded prior to being mixed
with the other ingredients. This core material has a specific
gravity in the range of about 9.6 to 10.2 lbs/ft.
[0181] The bottom deck boards 211 all contain a core material made
of the same ingredients as the core material of boards 210, but in
this ratio: 21.26 pbw polyurethane foam system, 6.57 pbw EPS beads,
and 72.17 pbw granulated rubber. The cores of the bottom deck
boards 211 all have a specific gravity in the range of about 9.3 to
9.8 lbs/ft.sup.3, about 0.2 to 0.4 lbs/ft.sup.3 less than the
specific gravity of the core material in the top deck boards 210.
(Alternatively, although not shown, the bottom boards might have
the same core material as the top boards, but be about 17 to 33%
thinner than the top boards, since they do not have to carry as
much of a load. As a third option, the top and bottom deck boards
can, of course, be identical.)
[0182] The stringers 212-215 all contain a core material made of a
mixture of 28.58 pbw of a polyurethane foam system and 71.42 pbw of
a granulated rubber. The polyurethane foam system consists of
Baydur 645B isocyanate and Baydur 649A polyol. The same granulated
rubber is used as in the deck boards. Due to the increased
concentration of granulated rubber and the absence of any EPS
beads, the core material of the stringers 212-215 has a specific
gravity in the range of about 47.7 to 48.3 lbs/ft.
[0183] All the deck boards (top and bottom) are held to the
stringers 212-215 by Halstead gun nails No. HOR30131 and/or
Halstead bulk nails No. BOT 30131, both of which are high-grip,
combination rink shank/drive screw nails having the following
specifications: [0184] round, 0.295 to 0.305 inch diameter head
[0185] head thickness of 0.065-0.070 inch [0186] countersink angle
of 130.degree. [0187] 3 inches in length [0188] ring shank width of
0.130-0.132 inch [0189] made from 0.120 inch diameter drawn, low
carbon, steel wire [0190] diamond point with 42.degree. angle
[0191] minimum tensile strength (bend yield) of 100,000 psi [0192]
coated with thermoplastic resin (a dried latex adhesive)
[0193] Although specific embodiments of the present invention have
been described above in detail, it will be understood that this
description is merely for purposes of illustration. Various
modifications of and equivalent structures corresponding to the
disclosed aspects of the preferred embodiments described above may
be made by those skilled in the art without departing from the
spirit of the present invention, which is defined by the following
claims.
* * * * *