Composite structure with foam plastic core and method of...

B - Operations – Transporting – 32 – B

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B32B 5/18 (2006.01) B28B 19/00 (2006.01) E04C 2/288 (2006.01)

Patent

CA 2113834

2113834 9301931 PCTABS00019 A composite structural material and the method of making a low cost, lightweight, ductile, long lasting, crack resistant, composite structural material which consists of a core (12) constructed from lightweight, expanded foam. The core is covered on one or more of its sides with a high strength outer layer (14) constructed of a layer of layers of non-woven web fibrous material impregnated with a cementitious slurry binder (22) with the fibers in the layers of non-woven web material forming a three-dimensional reinforcement matrix (18) for the cementitious slurry. The outer layer is formed and cured on one or more surfaces of the lightweight plastic core resulting in a crack resistant outer layer having greater ductility and thoughness than ordinary cement or concrete. The cement in the outer layer bonds directly to the lightweight plastic core thus requiring no additional bonding agent. Outer layers can be formed and cured around various shaped cores for various end uses.

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