Composite structural member

Abstract

A composite structural panel is provided. The panel comprises a frame having a longitudinal frame axis; a plurality of beam elements mounted in the frame, each of the beam elements has a respective longitudinal beam axis generally parallel to the frame axis; a reinforcing fibre wrapping that extends around each of the beam elements, the wrapping has a fibre direction running generally obliquely to the beam axis; a plurality of wire strands that extend about the wrapping, the wire strands run generally parallel to the beam axis and the frame axis; an outer layer of reinforcing fibre mat that surround the frame, the wrapped beams and the wire strands, the mat has a majority of its fibres running generally parallel to the frame axis; and, a solidified epoxy resin that extends throughout and encasing the beam elements, beam wrapping, wire strands, outer layer and frame.

We claim:  
     
         1 . A structural panel comprising: 
 a frame having a longitudinal frame axis;    a plurality of beam elements mounted in said frame, each of said beam elements having a respective longitudinal beam axis generally parallel to said frame axis;    a reinforcing fibre wrapping extending around each of said beam elements, said wrapping having a fibre direction running generally obliquely to said beam axis;    a plurality of wire strands extending about said wrapping, said wire strands running generally parallel to said beam axis and said frame axis;    an outer layer of reinforcing fibre mat surrounding said frame, said wrapped beams and said wire strands, said mat having a majority of its fibres running generally parallel to said frame axis; and,    a solidified epoxy resin extending throughout and encasing said beam elements, beam wrapping, wire strands, outer layer and frame.    
     
     
         2 . The structural panel of  claim 1  wherein: 
 said frame is configured to receive at least opposite ends of said beams; and,  
 said reinforcing fibre mats of said beam wrapping and said outer layer are of a glassy fibre.  
 
     
     
         3 . The structural panel of  claim 2  wherein: 
 said reinforcing fibre mat of said beam wrapping is a woven mat having about the same quantity of fibres extending in each of two generally orthogonal directions; and,  
 said reinforcing fibre mat of said outer layer has about 90% of its fibres extending longitudinally generally parallel to said beam axis.  
 
     
     
         4 . The structural panel of  claim 3  wherein: 
 said beams are of wood; and,  
 said wire strands are of steel.  
 
     
     
         5 . The structural panel of  claim 4  wherein: 
 each of said beams is made up of a plurality of panels having adjacent faces laminated together and having a grain running along said beam axis; and,  
 said wires are of high tensile strength steel.  
 
     
     
         6 . The structural panel of  claim 5  wherein: 
 said structural panel is a bridge deck having an upper face coated with a road surfacing material; and,  
 said planks are aligned with said adjacent faces generally parallel to said upper face.  
 
     
     
         7 . The structural panel of  claim 6  wherein: 
 said upper face is canted with a longitudinally extending centre section higher than and sloping toward opposite side edges of said structural panel to promote drainage.  
 
     
     
         8 . The structural panel of  claim 7  wherein: 
 said structural panel is thicker at said opposite side edges than at said centre section thereby providing a curb at said outer edges with enhanced stiffness to allow said structural panel to be thinner at said centre section than would be required of a panel having the same load bearing capacity but of generally constant thickness.  
 
     
     
         9 . The structural panel of  claim 8  wherein: 
 said frame has longitudinally extending edge flanges generally parallel to said frame axis;  
 said frame has a plurality of spars extending there across between said edge flanges;  
 said spars have sockets formed therein toward said upper face for receiving said opposite ends of said beam elements.