Composite hybrid resin panels, molded parts and filler enhanced polymers therefor

Abstract

A composite panel made of hybrid structural resins containing fillers and reinforcing members for use in, but not limited to, the construction and automotive industries. The panel provides superior weatherability and excellent mechanical properties while achieving various aesthetic appearances. The panel employs a multi-layer composite construction. The panel is made of a weatherable outer layer of hybrid resin, with a pigmented or graphic second layer that may or may not contain reinforcing fillers suspended in hybrid resin. The pigments in this second layer give the panel the outward appearance desired, such as wood, granite, stone, metal, or other appropriate cladding. The second layer is followed by at least one structural layer of hybrid resin that may or may not contain fillers and/or reinforcing agents. The panel may or may not have an insulating core of foam, fiberglass, or similar insulating material in order to achieve added R value.

What is claimed:  
     
         1 . A self-supporting structural panel comprised of at least one layer of high-density thermosetting hybrid resin, which is sufficiently thick and strong to be self-supporting, said one layer having an outer surface adapted to be visible, said layer containing a UV blocker to protect the layer and subsequent layers from the sun's UV radiation, adding to the weatherability of the panel.  
     
     
         2 . A panel according to  claim 1 , including at least one additional high-density thermosetting hybrid resin layer adhered to the at least one layer, the at least one additional layer containing at least one additive of: a pigment and/or a graphic additive and/or a filler or reinforcing additive.  
     
     
         3 . A panel according to  claim 2 , including a reinforcing additive in the at least one further layer, the reinforcing additive comprising at least one of: fibers, microspheres, ceramic particles, flyash, glass matt and/or reinforcing member.  
     
     
         4 . A panel according to  claim 2 , including a graphic additive in the at least one further layer, the graphic additive comprising flakes with color for simulating stone.  
     
     
         5 . A panel according the  claim 4 , wherein the flakes or granules are made of acrylic.  
     
     
         6 . A panel according to  claim 1 , including a structural element on the inner surface of the at least one layer and at least one additional layer of high-density thermosetting hybrid resin over the structural element for encasing the structural element and attaching the structural element and the at least one further layer to the at least one layer.  
     
     
         7 . A panel according to  claim 6  wherein the structural element comprises a grid element.  
     
     
         8 . A panel according to  claim 6  when the element comprises a corrugated sheet.  
     
     
         9 . A panel according to  claim 6  when the structural element comprises a sheet of fabric.  
     
     
         10 . A panel according to  claim 9  wherein a sheet of fabric is a non-woven fibrous fabric having a pattern thereon.  
     
     
         11 . A panel according to  claim 1 , including an outer layer element embedded in the outer surface of the at least one layer, the outer layer element being selected from the group consisting of two-dimensional indicia, a two-dimensional pattern and a three-dimensional surface texture material.  
     
     
         12 . A panel according to  claim 1 , including a further layer of high density, thermosetting hybrid resin connected to the inner surface of the at least one layer, the further layer containing at least one of pigment, a graphic component and a reinforcing component, and a third layer applied to the further layer, the third layer containing light-blocking pigment.  
     
     
         13 . A panel according to  claim 12  when the light-blocking pigment comprises silver or black particles or pigments.  
     
     
         14 . A panel according to  claim 1 , can include at least one recess in the outer surface of the at least one layer for producing indicia in the panel.  
     
     
         15 . A panel according to  claim 1 , including at least one projection on the outer surface of the least one layer for producing indicia on the panel.  
     
     
         16 . A panel according to  claim 14 , including pigmented hybrid resin in the recess for producing a contrasting color in the, recess from a remainder of at least one layer.  
     
     
         17 . A panel according to  claim 1  wherein the at least one layer is clear.  
     
     
         18 . A panel according to  claim 17 , including at least one additional layer attached to the inner surface of the at least one layer, the additional layer being made of high density thermosetting hybrid resin and may contain at least one of a pigment, a graphic component, and a reinforcing component, the additional layer being visible through the one layer.  
     
     
         19 . An apparatus for forming a self-supporting structural panel comprising: a base; a ridge on the base defining an open pan mold; and a means for spraying, pouring or injecting a two-component, high-density thermosetting hybrid resin onto the pan mold to form at least one layer of high density, thermosetting hybrid resin which is sufficiently thick to be self-supporting.  
     
     
         20 . A method of making a self-supporting structural panel comprising: spraying two components of a high density, thermosetting hybrid resin system into an open pan mold having the shape of the panel to be formed, to build up at least one layer of hybrid resin which is sufficiently thick and strong to be self-supporting; and, including in the system a UV blocker for blocking UV radiation from entering into the at least one layer.