Composite structural components for outdoor use

Abstract

A structure according to the invention comprises a series of interconnected structural members. The structural members, such-as panels, are made of a composition comprising as its first essential ingredient a cured (cross-linked) resin having sufficient strength when filled as described below to support weights up to about 700 pounds without significant buckling, but which has sufficient resilience to flex and rebound from impacts such as low speed collisions with small boats or dropping of heavy human-carried objects without cracking or breaking. The cured resin matrix contains a first filler consisting essentially of inorganic particles effective to improve the impact resistance and flame resistance of the structure, and an amount of a second filler consisting essentially of fibers effective to enhance the rigidity of the structure and reduce crack propagation therein. An optional third filler consisting essentially of plastic microspheres may be added in an amount effective to reduce the weight of the panel by at least 10% without significantly affecting the other essential properties of the cross-linked resin and first and second fillers, namely flexural strength, flame resistance, impact resistance, rigidity, resistance to crack propagation, and resistance to outdoor environments, particularly marine environments. Piers and docks made from panels of the composite of the invention provide superior performance as compared to conventional materials used to build such structures.

1 . A structure, comprising: 
 a series of structural members made of a composition comprising a cured vinyl ester resin having distributed therein an amount of a first filler consisting essentially of inorganic particles effective to improve impact resistance of the structure and an amount of a second filler consisting essentially of plastic fibers effective to increase rigidity and crack propagation resistance of the structural members; and    means for interconnecting the structural members.    
     
     
         2 . The structure of    claim 1   , wherein the structure is a marine structure.  
     
     
         3 . The structure of    claim 1   , wherein the structure is a pier or dock, and the structural members comprise a series of panels.  
     
     
         4 . The structure of    claim 3   , wherein the interconnecting means comprises mechanical fasteners.  
     
     
         5 . The structure of    claim 1   , wherein the structural members comprise a series of panels, and the structure further comprises a rigid framework having surfaces configured for supporting the panels.  
     
     
         6 . The structure of    claim 5   , wherein the rigid framework includes a pair of horizontal parallel brackets spaced to fit the panels therebetween, and vertical posts rigidly secured to each of the brackets for supporting the brackets in an elevated position.  
     
     
         7 . The structure of    claim 1   , wherein the structural members are made of a composition consisting essentially of the vinyl ester resin, the first filler, the second filler, and plastic microspheres as a third filler in an amount effective to reduce the weight of the structural panel by at least about 10 wt. % relative to a structural member of like composition and size but lacking the microspheres, but which amount is insufficient to substantially reduce the structural strength of the members.  
     
     
         8 . The structure of    claim 1   , wherein the structural members are cured products made from a composition consisting essentially of: 
 about 30 to 70 wt. % of a vinyl ester resin;    about 46 wt. % to about 70 wt. % of inorganic particles as the first filler distributed in the resin, which particles are effective in increase the impact resistance of the structural members; and    about 0.33 wt. % to about 1 wt. % of plastic fibers as the second filler distributed in the resin, which fibers are effective to increase the rigidity and crack propagation resistance of the structural members.    
     
     
         9 . The structure of    claim 8   , wherein the composition from which the structural members are made contains from about 0.3 wt. % to 1 wt. % of plastic microspheres.  
     
     
         10 . The structure of    claim 9   , wherein the vinyl ester resin contains a vinyl ester having the formula:  
       
         
           
           
               
               
           
         
       
       wherein n is from 1 to 3, a styrene monomer, and a peroxide catalyst.  
     
     
         11 . The structure of    claim 8   , wherein the structural members are made of a composition containing effective amounts of one or more of a UV absorber, a flame retardant, and a colorant.  
     
     
         12 . The structure of    claim 8   , wherein the inorganic particles are selected from the group consisting of particles of limestone, crystalline silica, calcium carbonate, and hydrated alumina.  
     
     
         13 . The structure of    claim 1   , wherein the structural members are made of a composition free of glass spheres, glass fragments and glass fibers.  
     
     
         14 . The structure of    claim 1   , wherein the structural members comprise substantially flat panels having a support grid molded therein.  
     
     
         15 . A process for making a molded structure, comprising: 
 forming a mixture comprising a curable resin having distributed therein an amount of a first filler consisting essentially of inorganic particles effective to improve impact resistance of the structure and an amount of a second filler consisting essentially of plastic fibers effective to increase rigidity and crack propagation resistance of the structural members, wherein the resin when cured in the molded structure has sufficient strength when filled with the first and second fillers to support weights up to about 700 pounds for a panel having dimensions 3′ by 4′ by 0.75″, without substantial buckling, but which has sufficient resilience to flex and rebound from impacts;    placing a support into a mold;    adding an effective amount of a curing catalyst to the mixture;    introducing the mixture into a mold so that the support becomes embedded therein;    curing the mixture in the mold; and    removing the thus-formed molded structure from the mold.    
     
     
         16 . A curable plastic composition, consisting essentially of: 
 about 30 to 70 wt. % of a curable vinyl ester resin;    about 46 wt. % to 70 wt. % of inorganic particles distributed in the cured resin, which particles are effective in increase the impact resistance of the structural members; and    about 0.33 wt. % to about 1 wt. % of plastic fibers effective to increase the rigidity and crack propagation resistance of the composition when the composition is cured.    
     
     
         17 . The composition of    claim 16   , wherein the composition contains from 0.3 wt. % to 1 wt. % of plastic microspheres.  
     
     
         18 . The composition of    claim 17   , wherein the vinyl ester resin consists essentially of a vinyl ester of the formula:  
       
         
           
           
               
               
           
         
       
       wherein n is from 1 to 3, and a styrene monomer.  
     
     
         19 . The composition of    claim 18   , wherein the composition contains effective amounts of one or more of a UV absorber, a flame retardant, and a colorant.  
     
     
         20 . The composition of    claim 16   , wherein the inorganic particles are selected from the group consisting of particles of limestone, crystalline silica, calcium carbonate, and hydrated alumina.  
     
     
         21 . The composition of    claim 16   , wherein the composition is free of glass spheres, glass fragments and glass fibers.  
     
     
         22 . A structure, comprising: 
 a series of structural members made of a composition comprising a cured resin having distributed therein an amount of a first filler consisting essentially of inorganic particles effective to improve impact resistance of the structure and an amount of a second filler consisting essentially of plastic fibers effective to increase rigidity and crack propagation resistance of the structural members, wherein the cured resin has sufficient strength when filled with the first and second fillers to support weights up to about 700 pounds for a panel having dimensions 3′ by 4′ by 0.75″ without substantial buckling, but which has sufficient resilience to flex and rebound from impacts; and    means for interconnecting the structural members.