Composite and methods of making and using the same
View Patent ↗Disclosed herein are composites as well as methods of making these composites. The composite may, for example, be used as light-weight, high-strength structural members and wall panels. In some embodiments, the composites can be prepared from a light-weight assembly using simple procedures. Also disclosed herein are assemblies for preparing the composites.
1. A method of making a composite, comprising:
providing a plurality of layers, each layer comprising:
a fabric sheet;
a resin fixed to the fabric sheet; and
a water-expandable polymer disposed along portions of each layer,
wherein each layer is fixed to an adjacent layer at regions disposed between the portions of each layer having the water-expandable polymer;
applying water to the plurality of layers; and
curing the resin to form the composite.
2. The method of claim 1 , further comprising drying the plurality of layers.
3. The method of claim 1 , further comprising applying an ionic solution to the plurality of layers.
4. The method of claim 1 , wherein a volume of the water-expandable polymer after applying the water is at least about 10 times greater than a volume of the water expandable polymer before applying the water.
5. The method of claim 1 , wherein the regions of each layer fixed to an adjacent layer comprise an adhesive layer disposed between the adjacent layers.
6. The method of claim 1 , wherein the regions of each layer fixed to an adjacent layer comprise one or more fasteners.
7. The method of claim 1 , wherein each layer has a thickness of at least about 0.5 mm.
8. The method of claim 1 , wherein the fabric sheet comprises fibers including a material selected from the group consisting of cellulose, acryls, a protein, glass, aramids, polyesters, resins, and combinations thereof.
9. The method of claim 1 , wherein each layer comprises at least about 20 of the portions of the water-expandable polymer.
10. The method of claim 1 , wherein each layer comprises a plurality of tubular structures.
11. The method of claim 10 , wherein the water-expandable polymer is disposed within the lumens of the tubular structures.
12. The method of claim 1 , wherein the regions of each layer fixed to an adjacent layer are located at repeating intervals.
13. The method of claim 12 , wherein the repeating interval is at least about 20 mm.
14. A composite comprising:
a plurality of layers, each layer comprising a cured resin fixed to a fabric sheet, wherein adjacent layers of the plurality of layers are fixed together at regions disposed between the adjacent layers; and
a plurality of lumens disposed between the adjacent layers, wherein the plurality of lumens contain a water-expandable resin.
15. The composite of claim 14 , wherein the regions of the adjacent layers fixed together comprise an adhesive layer disposed between the adjacent layers.
16. The composite of claim 14 , wherein the regions of the adjacent layers fixed together comprise one or more fasteners.
17. The composite of claim 14 , wherein each layer comprises a plurality of tubular structures.
18. The composite of claim 14 , wherein the regions of the adjacent layers fixed together are located at repeating intervals.
19. The composite of claim 14 , wherein each layer has a thickness of at least about 0.5 mm.
20. The composite of claim 14 , wherein the fabric sheet comprises fibers including a material selected from the group consisting of cellulose, acryls, a protein, glass, aramids, polyesters, resins, and combinations thereof.
21. The composite of claim 14 , wherein a number of lumens in the composite relative to a number of layers in the composite is at least about 20 to 1.
22. An assembly for forming a composite, the assembly comprising:
a plurality of layers, each layer comprising:
a resin fixed to a fabric sheet; and
a water-expandable resin disposed along portions of each layer,
wherein each layer is fixed to an adjacent layer at regions disposed between the portions of each layer having the water-expandable resin.
23. The assembly of claim 22 , wherein the assembly is disposed in a water-impermeable packaging.
24. The assembly of claim 22 , wherein each layer comprises a plurality of tubular structures.
25. The assembly of claim 22 , wherein the water-expandable resin is configured to expand at least 10 times by volume when water is applied.
26. The assembly of claim 22 , wherein the regions of each layer fixed to an adjacent layer comprise one or more fasteners.
27. The assembly of claim 22 , wherein the regions of each layer fixed to an adjacent layer are located at repeating intervals along each layer.
28. The assembly of claim 22 , wherein each layer comprises at least about 20 of the portions of water-expandable resin extending along each layer.