Fiber reinforced thermoplastic composite panel

Abstract

A fiber reinforced thermoplastic composite panel is described. One use of the panel is to construct bridge decks although the panel may have several other uses. It comprises two flat plates formed of commingled glass fiber reinforced polypropylene secured in spaced parallel relationship to a core. The core is formed by either two corrugated sheets interconnected together along connecting ridge sections or else by a plurality of elongated FRP channel members disposed transversely between the flat plates. The corrugated sheets or channel members form hollow core spaces between the two flat plates and the core material and these hollow spaces are filled with a filler material to add stability to the panel. Both the flat plates and the core material are formed of commingled glass fiber reinforced polypropylene (FRP).

1 . A fiber reinforced thermoplastic composite panel comprising two corrugated sheets formed of commingled glass fiber reinforced polypropylene (FRP), each said corrugated sheet defining a plurality of opposed and offset, spaced-apart connecting ridge sections and integrally formed intermediate trough sections therebetween, said two corrugated sheets being interconnected in superimposition by connection means interconnecting at least some of said ridge sections disposed in abutting relationship and forming hollow core spaces by said trough sections formed therebetween, a flat plate constructed of FRP is connected to a respective one of opposed sides of said interconnected corrugated sheets and secured to at least some of said ridge sections disposed on said opposed sides, and a filler material disposed in said hollow core spaces defined by said trough sections between said two corrugated sheets and said two corrugated sheets and said flat plates. 
   
   
       2 . A fiber reinforced thermoplastic composite panel as claimed in  claim 1  wherein said connecting ridge sections have a flat top section. 
   
   
       3 . A fiber reinforced thermoplastic composite panel as claimed in  claim 2  wherein said flat top section of said ridges in abutting relationship are interconnected by fastener elements. 
   
   
       4 . A fiber reinforced thermoplastic composite panel as claimed in  claim 3  wherein a web of FRP material is interconnected between said connecting ridge sections lying intermediate said flat plates on said opposed sides, by fastening means. 
   
   
       5 . A fiber reinforced thermoplastic composite panel as claimed in  claim 3  wherein an epoxy adhesive is disposed between said flat top sections of said ridge sections disposed in abutting relationship. 
   
   
       6 . A fiber reinforced thermoplastic composite panel as claimed in  claim 3  wherein said panel is a bridge deck slab. 
   
   
       7 . A fiber reinforced thermoplastic composite panel as claimed in  claim 3  wherein said filler material is an expanding soft foam material. 
   
   
       8 . A fiber reinforced thermoplastic composite panel as claimed in  claim 6  wherein said corrugated sheets have a thickness of 4.0 mm, said flat plates have a thickness of 5.0 mm, said fastener elements are spaced-part a distance of 150 mm to interconnect all of said ridges in abutting relationship, and wherein said panel is capable of resisting a load of 515 kN between two points spaced apart a distance of 1800 mm representative of a pair of truck axles with said panel recovering all deformation upon the removal of said load. 
   
   
       9 . A fiber reinforced thermoplastic composite panel as claimed in  claim 1  wherein said panel is a multi-application lightweight structural panel. 
   
   
       10 . A fiber reinforced thermoplastic composite panel as claimed in  claim 9  wherein said panel is used in the construction of one of a mine shaft support structure or a military shelter. 
   
   
       11 . A fiber reinforced thermoplastic composite panel as claimed in  claim 10  wherein said filler material is one of a light concrete or sand. 
   
   
       12 . A fiber reinforced thermoplastic composite panel comprising a pair of flat plates constructed of commingled glass fiber reinforced polypropylene (FRP) interconnected in spaced parallel relationship by a plurality of elongated FRP channel members disposed transversely between said flat plates and spaced-apart in parallel relationship, each said channel members having a flat transverse wall and opposed connecting flanges extending at right angles along opposed longitudinal edges thereof, said flat plates being connected to said opposed connecting flanges by connection means, diagonal braces secured between said flat plates and each of said plurality of elongated FRP channels and spanning between adjacent ones of said channels; hollow spaces defined between said channel members, said flat plates and said diagonal braces; and a filler material in said hollow spaces. 
   
   
       13 . A fiber reinforced thermoplastic composite panel as claimed in  claim 12  wherein said opposed connecting flanges are integrally formed with said flat wall. 
   
   
       14 . A fiber reinforced thermoplastic composite panel as claimed in  claim 13  wherein said channel members are U-shaped channel members with said opposed connecting flanges projecting from said opposed longitudinal edges to a common side of said flat wall. 
   
   
       15 . A fiber reinforced thermoplastic composite panel as claimed in  claim 14  wherein said diagonal braces each extend from a free end edge of one of said connecting flanges at one end of a channel member diagonally to an opposed end edge at an opposite end of an adjacent channel member. 
   
   
       16 . A fiber reinforced thermoplastic composite panel as claimed in  claim 13  wherein said connecting means is constituted by high tensile bolts. 
   
   
       17 . A fiber reinforced thermoplastic composite panel as claimed in  claim 12  wherein said filler material is an expanding soft foam material. 
   
   
       18 . A fiber reinforced thermoplastic composite panel as claimed in  claim 12  wherein said diagonal braces are flat elongated brace plates constructed of FRP. 
   
   
       19 . A fiber reinforced thermoplastic composite panel as claimed in  claim 12  wherein said panel is a non-metallic bridge deck. 
   
   
       20 . A fiber reinforced thermoplastic composite panel as claimed in  claim 12  wherein said filler material is one of light concrete or sand.