High strength, light weight structural composite and method of preparing same

Claim 1

A ground opening cover, which comprises: a substantially flat lower facing layer for supporting said cover on the ground while said cover spans an opening in the ground; an upper facing layer which is spaced from said lower facing layer and which extends substantially parallel thereto; core means disposed between said facing layers, said core means comprising a plurality of generally square or rectangular cellular blocks having flat upper and lower surfaces lying substantially parallel to said upper and lower facing layers and having substantially flat side walls disposed generally perpendicular to said upper and lower facing layers, said cellular blocks being disposed in a spaced planar array in a single layer such that the side walls of each adjacent pair of blocks define a channel-like spaces which extend between each adjacent pair of blocks generally perpendicularly from said lower facing layer to said upper facing layer, said blocks having a length and width substantially greater than the thickness thereof and being characterized by a high strength to weight ratio; said upper and lower facing layers comprising a fiber reinforced hardenable resin material selected from the group consisting of epoxies, phenolics, nylons, polyesters, polyurethanes and polysulfones; said hardenable resin material additionally being disposed in said channel-like spaces between said cellular blocks and on all of the surfaces of said blocks so as to essentially exclude any air from being trapped in said ground opening cover; said hardenable resin material in said channel-like spaces and on said surfaces of said blocks being integrally bonded to said hardenable resin material in said upper and lower facing layers so as to form said ground cover into a substantially air bubble-free monolithic composite having an ability to carry a static axle load of 32,000 lbs. and an impact load of 41,600 lbs. even when said cover is supported only on two sides while spanning a ground opening; said ground cover having at least one peripheral edge portion which is tapered such that thickness of said edge portion decreases when measured away from the center and toward the periphery of said cover, said peripheral edge portion defining a ramp-like incline adapted to facilitate vehicular traffic over said cover.