Abstract: In accordance with one embodiment of the present invention, the invention comprises a continuous structural composite preform wet out system and apparatus which takes as an input pre-formed structural composite structures with a structural foam core, passes these structures through a wetting system which may comprise sprayers, brushes, a die or dies, or other wetting means; applies a cure process such as ultraviolet light, heat, curing agent or other cure method, and produces a completed, cured structural composite structure such as a beam or panel for use in any structure as desired by the user. The improved structural composite wet out system of the invention provides run rate, ease of use, structure efficiency and handling advantages over the pultrusion systems of the prior art by achieving higher production rates, the ability to use light cure resins and the ability to produce composite structures of non-uniform cross-section.

Abstract: A composite structural panel for use in bridge structures, and method of manufacturing same, comprises a top panel and a bottom panel separated by and attached to at least one, but preferably a plurality, of structural composite preforms which may be fabricated by a continuous manufacturing process and may be saturated by resin using a continuous wetting process. The composite preforms may take any cross-sectional shape but are preferably trapezoidal. The top and bottom panels may be fabricated from a plurality of layers of woven fabric layers and non-woven fabric layers which are saturated with a resin that is subsequently cured using cure processes known in the art. The composite structural panel of the invention is usable as a flat structural member for use as bridge decking, ramps, trestles, and any application requiring a structural panel.

Abstract: A composite structure joining system and method comprises a structural panel, preferably but not necessarily fabricated from structural composite materials, that further comprises a nesting C-joint feature that facilitates assembly of a plurality of panels of the invention to form a planar structure such as a wall. An embodiment of the present invention comprises a plurality of the panels of the invention, joined together using the C joint of the invention, captured in a frame. The frame structural elements may comprise metals such as aluminum or steel, or may be hand laid or extruded fiberglass as described in more detail below. The invention further comprises methods of manufacturing a plurality of structural panels of the invention. The method of the invention may be used to fabricate intermodal shipping containers that have superior structural and thermal characteristics, are lightweight, resulting in lower transportation costs and lower container costs.

Abstract: A composite structural panel for use in bridge structures, and method of manufacturing same, comprises a top panel and a bottom panel separated by and attached to at least one, but preferably a plurality, of structural composite preforms which may be fabricated by a continuous manufacturing process and may be saturated by resin using a continuous wetting process. The composite preforms may take any cross-sectional shape but are preferably trapezoidal. The top and bottom panels may be fabricated from a plurality of layers of woven fabric layers and non-woven fabric layers which are saturated with a resin that is subsequently cured using cure processes known in the art. The composite structural panel of the invention is usable as a flat structural member for use as bridge decking, ramps, trestles, and any application requiring a structural panel.

Abstract: Co-cured urethane and vinyl ester, epoxy, or unsaturated polyester gel coats having improved toughness and flexibility compared with conventional polyester gel coats are disclosed. The gel coats, which have 10-50 wt. % urethane content, adhere well to structural layers and can be used in a traditional in-mold process. Co-cured elastomeric coatings comprising from 50 to 95 wt. % of a urethane component and an unsaturated polyester, epoxy, or vinyl ester are also disclosed. Unlike conventional urethane coatings, the elastomeric coatings adhere well to structural layers and can be used in a traditional in-mold process. Castings or structural layers comprising a reinforced thermoset of co-cured urethane and vinyl ester, epoxy, or unsaturated polyester components, including 10-95 wt. % of the urethane component, are also described. The invention includes in-mold processes for making laminates that utilize the gel coats, elastomeric coatings, and/or structural layers.

Abstract: A composite structure joining system and method comprises a structural panel, preferably but not necessarily fabricated from structural composite materials, that further comprises a nesting C-joint feature that facilitates assembly of a plurality of panels of the invention to form a planar structure such as a wall. An embodiment of the present invention comprises a plurality of the panels of the invention, joined together using the C joint of the invention, captured in a frame. The frame structural elements may comprise metals such as aluminum or steel, or may be hand laid or extruded fiberglass as described in more detail below. The invention further comprises methods of manufacturing a plurality of structural panels of the invention. The method of the invention may be used to fabricate intermodal shipping containers that have superior structural and thermal characteristics, are lightweight, resulting in lower transportation costs and lower container costs.

Abstract: A composite structure joining system and method comprises a structural panel, preferably but not necessarily fabricated from structural composite materials, that further comprises a nesting C-joint feature that facilitates assembly of a plurality of panels of the invention to form a planar structure such as a wall. An embodiment of the present invention comprises a plurality of the panels of the invention, joined together using the C joint of the invention, captured in a frame. The frame structural elements may comprise metals such as aluminum or steel, or may be hand laid or extruded fiberglass as described in more detail below. The invention further comprises methods of manufacturing a plurality of structural panels of the invention. The method of the invention may be used to fabricate intermodal shipping containers that have superior structural and thermal characteristics, are lightweight, resulting in lower transportation costs and lower container costs.

Abstract: A composite structural panel for use in bridge structures, and method of manufacturing same, comprises a top panel and a bottom panel separated by and attached to at least one, but preferably a plurality, of structural composite preforms which may be fabricated by a continuous manufacturing process and may be saturated by resin using a continuous wetting process. The composite preforms may take any cross-sectional shape but are preferably trapezoidal. The top and bottom panels may be fabricated from a plurality of layers of woven fabric layers and non-woven fabric layers which are saturated with a resin that is subsequently cured using cure processes known in the art. The composite structural panel of the invention is usable as a flat structural member for use as bridge decking, ramps, trestles, and any application requiring a structural panel.

Abstract: A composite structural panel for use in bridge structures, and method of manufacturing same, comprises a top panel and a bottom panel separated by and attached to at least one, but preferably a plurality, of structural composite preforms which may be fabricated by a continuous manufacturing process and may be saturated by resin using a continuous wetting process. The composite preforms may take any cross-sectional shape but are preferably trapezoidal. The top and bottom panels may be fabricated from a plurality of layers of woven fabric layers and non-woven fabric layers which are saturated with a resin that is subsequently cured using cure processes known in the art. The composite structural panel of the invention is usable as a flat structural member for use as bridge decking, ramps, trestles, and any application requiring a structural panel.

Abstract: A composite structure joining system and method comprises a structural panel, preferably but not necessarily fabricated from structural composite materials, that further comprises a nesting C-joint feature that facilitates assembly of a plurality of panels of the invention to form a planar structure such as a wall. An embodiment of the present invention comprises a plurality of the panels of the invention, joined together using the C joint of the invention, captured in a frame. The frame structural elements may comprise metals such as aluminum or steel, or may be hand laid or extruded fiberglass as described in more detail below. The invention further comprises methods of manufacturing a plurality of structural panels of the invention. The method of the invention may be used to fabricate intermodal shipping containers that have superior structural and thermal characteristics, are lightweight, resulting in lower transportation costs and lower container costs.

Abstract: A composite structure joining system and method comprises a structural panel, preferably but not necessarily fabricated from structural composite materials, that further comprises a nesting C-joint feature that facilitates assembly of a plurality of panels of the invention to form a planar structure such as a wall. An embodiment of the present invention comprises a plurality of the panels of the invention, joined together using the C joint of the invention, captured in a frame. The frame structural elements may comprise metals such as aluminum or steel, or may be hand laid or extruded fiberglass as described in more detail below. The invention further comprises methods of manufacturing a plurality of structural panels of the invention. The method of the invention may be used to fabricate intermodal shipping containers that have superior structural and thermal characteristics, are lightweight, resulting in lower transportation costs and lower container costs.

Abstract: A composite structural panel for use in bridge structures, and method of manufacturing same, comprises a top panel and a bottom panel separated by and attached to at least one, but preferably a plurality, of structural composite preforms which may be fabricated by a continuous manufacturing process and may be saturated by resin using a continuous wetting process. The composite preforms may take any cross-sectional shape but are preferably trapezoidal. The top and bottom panels may be fabricated from a plurality of layers of woven fabric layers and non-woven fabric layers which are saturated with a resin that is subsequently cured using cure processes known in the art. The composite structural panel of the invention is usable as a flat structural member for use as bridge decking, ramps, trestles, and any application requiring a structural panel.

Abstract: A composite structural panel for use in bridge structures, and method of manufacturing same, comprises a top panel and a bottom panel separated by and attached to at least one, but preferably a plurality, of structural composite preforms which may be fabricated by a continuous manufacturing process and may be saturated by resin using a continuous wetting process. The composite preforms may take any cross sectional shape but are preferably trapezoidal. The top and bottom panels may be fabricated from a plurality of layers of woven fabric layers and non-woven fabric layers which are saturated with a resin that is subsequently cured using cure processes known in the art. The composite structural panel of the invention is usable as a flat structural member for use as bridge decking, ramps, trestles, and any application requiring a structural panel.

Abstract: A composite structural panel for use in bridge structures, and method of manufacturing same, comprises a top panel and a bottom panel separated by and attached to at least one, but preferably a plurality, of structural composite preforms which may be fabricated by a continuous manufacturing process and may be saturated by resin using a continuous wetting process. The composite preforms may take any cross sectional shape but are preferably trapezoidal. The top and bottom panels may be fabricated from a plurality of layers of woven fabric layers and non-woven fabric layers which are saturated with a resin that is subsequently cured using cure processes known in the art. The composite structural panel of the invention is usable as a flat structural member for use as bridge decking, ramps, trestles, and any application requiring a structural panel.

Abstract: Co-cured urethane and vinyl ester, epoxy, or unsaturated polyester gel coats having improved toughness and flexibility compared with conventional polyester gel coats are disclosed. The gel coats, which have 10-50 wt. % urethane content, adhere well to structural layers and can be used in a traditional in-mold process. Co-cured elastomeric coatings comprising from 50 to 95 wt. % of a urethane component and an unsaturated polyester, epoxy, or vinyl ester are also disclosed. Unlike conventional urethane coatings, the elastomeric coatings adhere well to structural layers and can be used in a traditional in-mold process. Castings or structural layers comprising a reinforced thermoset of co-cured urethane and vinyl ester, epoxy, or unsaturated polyester components, including 10-95 wt. % of the urethane component, are also described. The invention includes in-mold processes for making laminates that utilize the gel coats, elastomeric coatings, and/or structural layers.

Abstract: A structural panel and method of fabricating and manufacturing same comprises a top panel and a bottom panel separated by and attached to at least one, but preferably a plurality, of structural composite preforms which may be fabricated by a continuous manufacturing process and may be saturated by resin using a continuous wetting process. The composite preforms may take any cross sectional shape but are preferably trapezoidal. The top and bottom panels may be fabricated from a plurality of layers of woven fabric layers and non-woven fabric layers which are saturated with a resin that is subsequently cured using cure processes known in the art. The composite structural panel of the invention is usable as a flat structural member for use as bridge decking, ramps, trestles, and any application requiring a structural panel.

Abstract: In accordance with one embodiment of the present invention, the invention comprises a continuous structural composite preform wet out system and apparatus which takes as an input pre-formed structural composite structures with a structural foam core, passes these structures through a wetting system which may comprise sprayers, brushes, a die or dies, or other wetting means; applies a cure process such as ultraviolet light, heat, curing agent or other cure method, and produces a completed, cured structural composite structure such as a beam or panel for use in any structure as desired by the user. The improved structural composite wet out system of the invention provides run rate, ease of use, structure efficiency and handling advantages over the pultrusion systems of the prior art by achieving higher production rates, the ability to use light cure resins and the ability to produce composite structures of non-uniform cross-section.

Abstract: A composite structural panel for use in bridge structures, and method of manufacturing same, comprises a top panel and a bottom panel separated by and attached to at least one, but preferably a plurality, of structural composite preforms which may be fabricated by a continuous manufacturing process and may be saturated by resin using a continuous wetting process. The composite preforms may take any cross sectional shape but are preferably trapezoidal. The top and bottom panels may be fabricated from a plurality of layers of woven fabric layers and non-woven fabric layers which are saturated with a resin that is subsequently cured using cure processes known in the art. The composite structural panel of the invention is usable as a flat structural member for use as bridge decking, ramps, trestles, and any application requiring a structural panel.

Abstract: In accordance with one embodiment of the present invention, the invention comprises a continuous structural composite preform wet out system and method which takes as an input pre-formed structural composite structures with a structural foam core, passes these structures through a wetting system which may comprise sprayers, brushes, a die or dies, or other wetting means; applies a cure process such as ultraviolet light, heat, curing agent or other cure method, and produces a completed, cured structural composite structure such as a beam or panel for use in any structure as desired by the user. The improved structural composite wet out system of the invention provides run rate, ease of use, structure efficiency and handling advantages over the pultrusion systems of the prior art by achieving higher production rates, the ability to use light cure resins and the ability to produce composite structures of non-uniform cross-section.

Abstract: A structural panel and method of fabricating and manufacturing same comprises a top panel and a bottom panel separated by and attached to at least one, but preferably a plurality, of structural composite preforms which may be fabricated by a continuous manufacturing process and may be saturated by resin using a continuous wetting process. The composite preforms may take any cross sectional shape but are preferably trapezoidal. The top and bottom panels may be fabricated from a plurality of layers of woven fabric layers and non-woven fabric layers which are saturated with a resin that is subsequently cured using cure processes known in the art. The composite structural panel of the invention is usable as a flat structural member for use as bridge decking, ramps, trestles, and any application requiring a structural panel.