Structural shell

1 . A method of manufacturing a structural shell, the structural shell comprising a basalt fibre-reinforced material, wherein the basalt fibre-reinforced material comprises a polymer material, the polymer material being capable of at least partially thermally cracking at a temperature of from 200 to 600° C., and wherein the polymer material comprises a polymethacrylate, the method comprising:

providing a mould;

introducing basalt fibres into the mould;

contacting the basalt fibres with a mixture comprising a resin, the resin comprising methacrylate monomers, and a hardening agent at a relative pressure of −0.65 bar or less to form a structural shell; and

recovering the structural shell from the mould;

wherein the method further comprises introducing a polymer core, a balsa core, or aluminium core into the mould prior to contacting the basalt fibres with the mixture.

2 . The structural shell of claim 1 , wherein the polymer material is a thermoplastic material.

3 . The method of claim 1 , wherein the polymer material comprises a poly(methyl methacrylate).

4 . The method of claim 1 , wherein the polymer material is capable of at least partially melting at a temperature of from 150 to 300° C. and/or wherein the polymer material is capable of at least partially melting at a lower temperature than it is capable of at least partially thermally cracking.

5 . The method of claim 1 , wherein the polymer material is capable of at least partially thermally cracking at a temperature of from 300 to 500° C., wherein the at least partially thermally cracked polymer material is a liquid at 20° C.

6 . The method of claim 1 , wherein the ratio by weight of basalt fibres to polymer material is from 80:20 to 40:60.

7 . The method of claim 1 , wherein basalt fibres are dispersed in the polymer material in a regular arrangement, wherein the basalt fibre-reinforced material comprises a plurality of layers of substantially parallel basalt fibres, wherein the average direction of the substantially parallel basalt fibres is different in adjacent layers.

8 . The method of claim 1 further comprising a gelcoat, wherein the gelcoat comprises unsaturated polyester resins and/or vinyl resins.

9 . The method of claim 1 , wherein the resin comprises from 50 to 85 wt. % methyl methacrylate monomers and/or from 10 to 50 wt. % acrylic polymers.

10 . The method of claim 1 , wherein the hardening agent comprises an organic peroxide, wherein the mixture comprises the hardening agent in an amount of from 0.5 to 30 phr.

11 . The method of claim 1 , wherein the method further comprises forming a gelcoat in the mould prior to the introduction of the basalt fibres into the mould.

12 . A method of manufacturing an object comprising a structural shell; the method comprising the method of manufacturing the structural shell of claim 1 , wherein the object is selected from the group consisting of a hull for a marine vessel, a structural grid for a marine vessel, a deck for a marine vessel, a marine vessel comprising at least one hull and/or at least one structural grid and/or at least one deck, a wind turbine blade, a ski or ski pole, a ballistic resistant panel, an automotive structure or body part, and a train, tramway or metro component.

13 . The method of claim 1 , further comprising a polymer core.

14 . The method of claim 13 , wherein the polymer core has a melting temperature of from 200 to 300° C.

15 . The method of claim 13 , wherein the polymer core comprises a polyester.

16 . The method of claim 15 , wherein the polyester comprises PET.