Composite structural elements and method of making same

摘要

A composite structural element and a method for making same are provided. The element includes a polymer foam core and at least one fibrous layer adhered to the polymer foam core by epoxy. Nano-particles are suspended in the epoxy prior to curing; preferably they are mixed with the hardener before it is mixed with the resin. The polymer foam core is preferably an exothermic foam such as polyurethane, and heat generated by the exothermic foam cures the epoxy, thereby causing the fibrous layer to adhere to the foam core. The nano-particles may be made from at least one of carbon, a ceramic, tungsten, a carbide, titanium, zircon, aluminum, silver, or boron. When carbon nano-particles are used, the strength of the composite is greatly increased, and the curing time of the heat-curable epoxy is significantly reduced. Ceramic nano-particles can be used to increase penetration resistance and provide increased ballistic protection.

主权项

1. A method of making a composite structural element comprising the steps of:
mixing nano-particles into nano-particles into a liquid epoxy, wherein said nano-particles comprise nano-fibers of approximately 60-200 nm in diameter, approximately 30-100 μm in length, and with a specific surface area (SSA) in the 30-50 m2/g range, that are suspended substantially evenly throughout said liquid epoxy, so that a weight ratio of said nano-particles to said epoxy is at least 1:200 and no more than 1:2; providing at least one fibrous layer and wetting the fibrous layer with the nano-particle impregnated liquid epoxy; and introducing a heat source to cure said epoxy.