Composite structure with waste plastic core and method of making

Stock material or miscellaneous articles – Web or sheet containing structurally defined element or... – Composite having voids in a component

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52586, 52588, 52805, 248679, 248346, 264 69, 264257, 2642711, 428 70, 428188, 428192, 428193, 428339, 428703, B32B 516, B32B 524, B32B 1302, F16M 500

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active

052682269

ABSTRACT:
A low cost, lightweight, high strength, long lasting, crack resistant, monolithically formed composite structural material and the method of making the same in which the composite consists of a core constructed from lightweight, granulated scrap or waste plastic bonded together with a relatively inexpensive cementitious slurry binder. The core is covered on one or more of its surfaces with a high strength outer layer constructed of layers of non-woven fabric material impregnated with a cementitious slurry binder having a different formulation than the core cementitious slurry binder to effectively bond with the fibers in the layers of non-woven fabric material to form a three-dimensional reinforcement matrix for the outer layer cementitious slurry binder. The composite of the core and covering is co-formed and cured monolithically with the outer layer cementitious slurry binder being continuous throughout the fibers of the layers of non-woven fabric and the core cementitious slurry being continuous throughout the waste plastic core material with the lightweight scrap or waste plastic serving as an aggregate for the core.

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