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A composite module having a rigid foam core encapsulated in a shell of reinforced cementitious material. The shell is reinforced with at least two types of material, the first being a fiber reinforcing material distributed in an interconnected random matrix substantially throughout the shell and the

A composite module having a rigid foam core encapsulated in a shell of reinforced cementitious material. The shell is reinforced with at least two types of material, the first being a fiber reinforcing material distributed in an interconnected random matrix substantially throughout the shell and the second being a scrim reinforcing material adjacent at least one surface of the shell and/or the rigid foam core.

대표청구항 ▼

Composite panel-like building module comprising a rigid foam core encapsulated in a fiber-reinforced shell of cementitious material having edge portions and major surface portions: (i) said major surface portions being reinforced with a first fibrous reinforcing material in discrete fiber form distr

Composite panel-like building module comprising a rigid foam core encapsulated in a fiber-reinforced shell of cementitious material having edge portions and major surface portions: (i) said major surface portions being reinforced with a first fibrous reinforcing material in discrete fiber form distributed in an interconnected random matrix in the major surface portions of the shell; (ii) said edge portions being reinforced with two further fibrous reinforcing materials, one being in discrete fiber form which is premixed with the cementitious material forming the edge portions and the other being in scrim form which extends from the edge portions into the major surface portions of the shell, said premixed fibers being shorter than the first fibrous reinforcing material in the major surface portion of the shell. Composite module such as a highway barrier comprising a rigid foam core encapsulated in a shell of reinforced cementitious material which is formed in situ around the core by (a) providing a mold having a bottom and side walls; (b) lining said mold with a scrim reinforcing materials (c) suspending a rigid foam core member wrapped in a scrim reinforcing material in said mold leaving a free space between the wrapped core member and the mold bottom and side walls (d) filling said free space with a premix of wet cementitious material and fibers; and (e) curing said cementitious material and removing the thus formed module from the mold. Process for making a composite panel-like building module having a rigid foam core encapsulated in a shell of reinforced cementitious material which comprises: (a) providing a mold having a bottom and side walls; (b) successively applying wet cementitious material and individual fibers in the mold, the fibers being applied by chopping rolls of continuous fibers and spraying the chopped fibers into the mold; (c) distributing the fibers into the wet cementitious material in a random interconnected matrix to form a bottom layer; (d) placing scrim reinforcing material on top of the bottom layer and which extends therefrom up over the top of the mold side walls; (e) placing a rigid foam core member on said bottom layer, said core member having a peripheral shape smaller than the mold interior leaving a free space between the core member and the mold side walls, said core member having a thickness less than the height of the mold side walls; (f) depositing wet cementitious material premixed with fibers in the free space between the core member and the mold side walls; (g) folding the scrim material extending over the top of the mold side walls in over the core member; (h) successively applying wet cementitious material and individual fibers in the mold, the fibers being applied by chopping rolls of continuous fibers and spraying the chopped fibers into the mold; (i) distributing the fibers into the wet cementitious material applied in (h) in a random interconnected matrix to form a top layer over the core and folded scrim material to encase the core in an integral fiber reinforced shell of cementitious material; and (j) curing the wet cementitious shell surrounding the core and removing the thus formed module from said mold. Process for forming a composite module such as a highway barrier having a rigid foam core encapsulated in a shell of reinforced cementitious material which comprises (a) providing a mold having a bottom and side walls; (b) lining said mold with a scrim reinforcing material; (c) suspending a rigid foam core member wrapped in a scrim reinforcing material in said mold leaving a free space between the wrapped core member and the mold bottom and side walls; (d) filling said free space with a premix of wet cementitious material and fibers; and (e) curing said cementitious material and removing the thus formed module from the mold.