| abstract |
A precast composite plastic reinforcement insert, method of making the reinforcement insert and method of reinforcing a structural member. The insert includes pellets which are formed of a mixture of a thermoplastic polymeric resin and a blowing agent. Polymeric resins disclosed include a one-part epoxy with a thermal curing system or a thermoplastic polyester resin. The pellets in one embodiment are retained within a matrix of expanded polystyrene and in combination form the insert. The insert is formed in a mold cavity which receives the pellets and unexpanded polystyrene which is expanded during the process by heating the same within the mold cavity. The insert is used to reinforce a structural member by placing it in the structural member prior to a thermal paint curing operation. The insert is transformed into a lightweight, high-strength reinforcement during the paint curing operation wherein the expanded polystyrene of one embodiment is vaporized, the pellets are expanded and then cured, forming bonds between adjacent pellets and the structural member. If the pellets are not retained in a styrofoam matrix, the insert may be coated with a polymeric adhesive prior to placing it in the structural member. |