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, the method comprising:
providing a plurality of layers, each layer comprising:
a fabric sheet,
a resin fixed to the fabric sheet, and
a water-expandable resin disposed along portions of each layer; and
curing the resin to form the composite.
2. The method of claim 1 , wherein curing the resin comprises applying at least one of heat, radiation, and water to the resin.
3. The method of claim 1 , further comprising applying at least one of water and an ionic solution to the plurality of layers.
4. The method of claim 1 , further comprising drying the plurality of layers.
5. The method of claim 3 , wherein a volume of the water-expandable resin after applying the at least one of the water and the ionic solution is at least about 10 times greater than a volume of the water expandable resin before applying the at least one of the water and the ionic solution.
6. The method of claim 1 , further comprising adhesive between the adjacent layers.
7. The method of claim 1 , further comprising stacking the plurality of layers such that the fabric sheets of the plurality of layers are generally parallel.
8. The method of claim 1 , wherein the resin comprises a polymer having a hydroxyl group and a polymer having an isocyanate group.
9. The method of claim 1 , wherein the water-expandable resin comprises a 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 resin is disposed within lumens of the tubular structures.
12. A composite 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 the resin comprises a cured resin.
13. The composite of claim 12 , wherein the cured resin is due to application of at least one of heat, radiation, and water to the resin.
14. The composite of claim 12 , wherein adjacent layers fixed together comprise an adhesive layer between the adjacent layers.
15. The composite of claim 12 , wherein the fabric sheet comprises woven fabric.
16. The composite of claim 13 , wherein the fabric sheet comprises non-woven fabric.
17. The composite of claim 12 , 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.
18. The composite of claim 12 , further comprising one or more fasteners.
19. The composite of claim 12 , wherein the resin comprises a polymer having a hydroxyl group and a polymer having an isocyanate group.
20. The composite of claim 12 , wherein the water-expandable resin comprises a water-expandable polymer.