FORM 2
THE PATENTS ACT, 1970
[39 of 1970]
&
THE PATENTS RULES, 2003
COMPLETE SPECIFICATION
[See Section 10 and Rule 13]
TITLE: “A HYBRID COMPOSITE PANEL OF STRATIFIED CONSTRUCTION AND A METHOD FOR MANUFACTURING THERE OF”
Name and Address of the Applicant:
RELIANCE INDUSTRIES LIMITED, 3rd Floor, Maker Chamber-IV, 222, Nariman Point, Mumbai – 400 021, Maharashtra, India;
Nationality: INDIAN
The following specification particularly describes the nature of the invention and the manner in which it is to be performed.

TECHNICAL FIELD
Present disclosure relates in general to the field of materials and material science. Particularly, but not exclusively, the present disclosure relates to a hybrid composite panel. Further, embodiments of the disclosure disclose a method for manufacturing the hybrid composite panel.
BACKGROUND OF THE DISCLOSURE
Steel is generally used in manufacturing an array of mechanical parts, constructional components, and the like. However, properties of steel such as high density, low corrosion resistance, low thermal conductance or electrical conductance, and the like, may lead to obvious related problems like degraded life, noise generation and transmission during operation, dents and damages due to impact, increased heat transmission, electrical shock and operator safety hazard, thereby limiting industrial application of the steel in requirements like high strength to mass ratio, noise insulation, impact absorption, thermal and electrical resistance, and low maintenance over usable life.
Composite materials have become one of reliable alternatives for the steel. In general, the composites are manufactured by combining two or more layers having different properties for improving characteristics when combined to form panels of said composite (also referred to as “composite panel”). The composite panels may include fibre reinforced composites, particle reinforced composites, metal matrix composites, ceramic matrix composites, and the like. With advent of technology, there has been rise in demand of the composite panels for being employed in various industrial applications such as construction, interior designing, pavements, floorboards, and the like. Such requirement caters to designing and manufacturing lighter panels without compromising on strength. Such panels may also include properties such as thermal and electrical resistance, acidic/corrosion resistant, higher payload capacity, impact resistance, and the like.
Conventionally, the composite panels for applications such as flooring, building facades, pavements, walking platforms, trench covers and the like, are manufactured by using metal/concrete/wood based composite materials. However, such materials are structurally heavy and are prone to environmental /industrial corrosion. Further, wood based composite panels generally react with environment, whereby leading to decay, rot and warp when exposed

to moisture, chemicals and/or water. On the other hand, conventionally known composite panels involve complex method of manufacturing or may include expensive raw material, that increases cost associated with such panels. Moreover, some of the method employed for manufacturing of the conventional composite panels may not be suitable for mass production or may involve high manufacturing lead time, whereby adding to overall production capacity related problems.
The present disclosure is directed to overcome one or more limitations stated above or any other limitation associated with the prior arts.
SUMMARY OF THE DISCLOSURE
One or more shortcomings of the prior art are overcome by method as disclosed and additional advantages are provided through the method as described in the present disclosure.
Additional features and advantages are realized through the techniques of the present disclosure. Other embodiments and aspects of the disclosure are described in detail herein and are considered a part of the claimed disclosure.
In one non-limiting embodiment, a hybrid composite panel of stratified construction is disclosed. The hybrid composite panel comprises a first layer formed of a first composite material, and an intermediate layer formed of at least one of polymer, rubber or elastomer-based material. The intermediate layer is configured to accommodate the first layer on one side, wherein the intermediate layer includes a predefined structure including void spaces. The hybrid composite layer further comprises a second layer formed of a second composite material. The second layer is defined by a predetermined profile connected to the intermediate layer on other side, opposite to the one side. The intermediate layer is removably or adhesively fixed to the second layer, and at least one of the first layer and the second layer are formed independently by the process of at least one of pultrusion, sheet moulding compounds (SMC), infusion, blow moulding, hand layup, resin transfer moulding (RTM), injection moulding, compression moulding and extrusion, or direct composite layup on top of intermediate layer. In an embodiment, the first layer and the intermediate layer are at least one of adhesive bonded, heat fused, mechanically fastened together, or coextruded together.
In an embodiment, the predefined structure is at least one of solid, porous, foamed and honeycomb structure.

In an embodiment, the predetermined profile of the second layer is pultruded or cast in a grid structure.
In an embodiment, wt.% of the first layer ranges from 8 wt.% to 20 wt.%, wt.% of the intermediate layer ranges from 0.4 wt.% to 72 wt.%, and wt.% of the second layer ranges from 8 wt.% to 92 wt.%.
In an embodiment, composition of the adhesive ranges from 0.34 wt.% to 2 wt.%.
In an embodiment, the adhesive is selected from a group consisting of epoxy, polyurethane, structural acrylic, cyanoacrylates.
In an embodiment, thickness of the adhesive ranges from 0.1 mm – 1 mm.
In an embodiment, the first composite material is selected from a group consisting of unsaturated polyester, vinyl ester, epoxy, phenolic, polyurethane and thermoplastics including Polypropylene (PP), Polyethylene (PE), Polyvinyl Chloride (PVC), Polyethylene Terephthalate, Nylon and Polyetheretherketone (PEEK).
In an embodiment, the polymer-based material is selected from a group consisting of polyvinyl chloride (PVC)/PVC natural composite, polyurethane, polypropylene extrusion, expanded polypropylene, polystyrene and elastomer-based materials.
In an embodiment, the second composite material is selected from a group consisting of unsaturated polyester, vinyl ester, epoxy, phenolic, polyurethane and thermoplastics including Polypropylene (PP), Polyethylene (PE), Polyvinyl Chloride (PVC), Polyethylene Terephthalate, Nylon and Polyetheretherketone (PEEK).
In an embodiment, the first composite material is substantially similar or totally different to the second composite material.
In an embodiment, thickness of the first layer ranges from 0.5 mm to 25 mm.
In an embodiment, thickness of the intermediate layer ranges from 0.5 mm to 200 mm.
In an embodiment, the second layer is defined with a clearance width between each grid, and height in longitudinal direction of the grid structure.

In an embodiment, the clearance width in the grid structure of the second layer ranges from 20 mm to 200 mm in both directions, and height of the second layer ranges from 12 mm to 100 mm.
In another non-limiting embodiment of the present disclosure, there is provided a method for manufacturing hybrid composite panel of stratified construction is disclosed. The method comprises forming, a first layer of first composite material, an intermediate layer of polymer, rubber or elastomer-based material and a second layer of second composite material. Then, joining the first layer with the intermediate layer followed by fastening the second layer with the intermediate layer. In an embodiment, at least one of the first layer and the second layer are formed by pultrusion or extrusion process.
In an embodiment, the first layer and the intermediate layer are at least one of adhesive bonded, heat fused, or mechanically fastened together or co-extruded together.
In an embodiment, the adhesive is selected from a group consisting of epoxy, polyurethane, structural acrylic, cyanoacrylates.
In an embodiment, thickness of the adhesive ranges from 0.1 mm – 1 mm.
In an embodiment, the first composite material is selected from a group consisting of unsaturated polyester, vinyl ester, epoxy, phenolic, polyurethane, and thermoplastics including Polypropylene (PP), Polyethylene (PE), Polyvinyl Chloride (PVC), Polyethylene Terephthalate, Nylon and Polyetheretherketone (PEEK).
In an embodiment, the polymer-based material is selected from a group consisting of polyvinyl chloride (PVC)/PVC natural composite, polyurethane, polypropylene extrusion, expanded polypropylene, polystyrene and elastomer-based materials.
In an embodiment, the second composite material is selected from a group consisting of unsaturated polyester, vinyl ester, epoxy, phenolic, polyurethane, and thermoplastics including Polypropylene (PP), Polyethylene (PE), Polyvinyl Chloride (PVC), Polyethylene Terephthalate, Nylon and Polyetheretherketone (PEEK).
In an embodiment, thickness of the first layer ranges from 0.5 mm to 25 mm.

In an embodiment, thickness of the intermediate layer ranges from 0.5 mm to 200 mm.
In an embodiment, the second layer is defined with a clearance width between each grid, and height in longitudinal direction of the grid structure.
In an embodiment, the clearance width in the grid structure of the second layer ranges from 20 mm to 200 mm in both direction and height of the second layer ranges from 12 mm to 100 mm.
It is to be understood that the aspects and embodiments of the disclosure described above may be used in any combination with each other. Several of the aspects and embodiments may be combined together to form a further embodiment of the disclosure.
The foregoing summary is illustrative only and is not intended to be in any way limiting. In addition to the illustrative aspects, embodiments, and features described above, further aspects, embodiments, and features will become apparent by reference to the drawings and the following detailed description.
BRIEF DESCRIPTION OF THE ACCOMPANYING FIGURES
The novel features and characteristics of the disclosure are set forth in the appended description. The disclosure itself, however, as well as a preferred mode of use, further objectives and advantages thereof, will best be understood by reference to the following detailed description of an illustrative embodiment when read in conjunction with the accompanying figures. One or more embodiments are now described, by way of example only, with reference to the accompanying figures wherein like reference numerals represent like elements and in which:
Figure 1a illustrates a top perspective view of a hybrid composite panel, according to an exemplary embodiment of the present disclosure.
Figure 1b illustrates a bottom perspective view of the hybrid composite panel, according to an exemplary embodiment of the present disclosure.
Figure 1c illustrates a side view of the hybrid composite panel, according to an exemplary embodiment of the present disclosure.

Figure 1d illustrates an exploded view of the hybrid composite panel, according to an exemplary embodiment of the present disclosure.
Figure 2 is a flowchart illustrating a method for manufacturing a hybrid composite panel, according to an exemplary embodiment of the present disclosure.
Figure 3 illustrates an exploded view of the hybrid composite panel mounted on a base structure, according to an exemplary embodiment of the present disclosure.
Figures 4a and 4b illustrate embodiments of application of the hybrid composite panel, according to an exemplary embodiment of the present disclosure.
Figure 5 illustrates analysis of load distribution on the hybrid composite panel for different types of loads, according to an exemplary embodiment of the present disclosure.
Figure 6 illustrates analysis of wind speed test on the hybrid composite panel, according to an exemplary embodiment of the present disclosure.
Figure 7 illustrates analysis of roller drop impact test on the hybris composite panel according to an exemplary embodiment of the present disclosure.
The figures depict embodiments of the disclosure for purposes of illustration only. One skilled in the art will readily recognize from the following description that alternative embodiments of the methods illustrated herein may be employed without departing from the principles of the disclosure described herein.
DETAILED DESCRIPTION
The foregoing has broadly outlined the features and technical advantages of the present disclosure in order that the detailed description of the disclosure that follows may be better understood. Additional features and advantages of the disclosure will be described hereinafter which form the subject of the description of the disclosure. It should also be realized by those skilled in the art that such equivalent product and method do not depart from the scope of the disclosure. The novel features which are believed to be characteristic of the disclosure, as to a product and method of manufacturing thereof, together with further objects and advantages will be better understood from the following description when considered in connection with the accompanying figures. It is to be expressly understood, however, that each of the figures is

provided for the purpose of illustration and description only and is not intended as a definition of the limits of the present disclosure.
In the present document, the word "exemplary" is used herein to mean "serving as an example, instance, or illustration." Any embodiment or implementation of the present subject matter described herein as "exemplary" is not necessarily to be construed as preferred or advantageous over other embodiments.
While the disclosure is susceptible to various modifications and alternative forms, specific embodiment thereof has been shown by way of example in the drawings and will be described in detail below. It should be understood, however that it is not intended to limit the disclosure to the particular forms disclosed, but on the contrary, the disclosure is to cover all modifications, equivalents, and alternative falling within the spirit and the scope of the disclosure.
The terms “comprises”, “comprising”, or any other variations thereof, are intended to cover a non-exclusive inclusion, such that a product and a method that comprises a list of acts does not include only those acts but may include other acts not expressly listed or inherent to such product and method. In other words, one or more acts in a method proceeded by “comprises… a” does not, without more constraints, preclude the existence of other acts or additional acts in the method.
Embodiments of the present disclosure discloses a hybrid composite panel. Conventionally, the composite panels for applications such as flooring, building facades, walking platforms, trench covers and the like, are manufactured by using metal/concrete/wood based composite materials. However, such materials are structurally heavy and are prone to environmental/industrial corrosion. Further, wood based composite panels generally react with environment, whereby leading to decay, rot and warp when exposed to moisture, chemicals and/or water. Accordingly, the present disclosure discloses the hybrid composite panel and a method for manufacturing the hybrid composite panel which involves the steps of forming the first layer, intermediate layer and second layer followed by joining the first layer with the intermediate layer and fastening the second layer with the intermediate layer. The hybrid composite panel exhibits high impact resistance, load bearing capacity and corrosion resistance.

Henceforth, the present disclosure is explained with the help of figures 1 - 6 for describing a hybrid composite panel and a method for manufacturing a hybrid composite panel. However, such exemplary embodiments should not be construed as limitations of the present disclosure, since the hybrid composite panel may be used on other types of composites where such need arises. A person skilled in the art can envisage various such embodiments without deviating from scope of the present disclosure.
Figures 1a – 1d are exemplary embodiments of the present disclosure illustrating top view, bottom view, side view, and exploded view, respectively, of a hybrid composite panel (200) of stratified construction. The term stratified construction refers to arrangement or formation of composite materials in horizontal layers. The hybrid composite panel (200) of the present disclosure comprises a first layer (201) of uniform or variable cross section, formed of a first composite material. The first composite material may be selected from a group consisting of unsaturated polyester, vinyl ester, epoxy, phenolic, thermoplastics and the like. In an embodiment, the first layer (201) formed of the first composite material may be a sheet-based structure and thickness of the first layer ranges from 0.5 mm to 25 mm. The first layer (201) may be formed by the process of at least one of pultrusion, sheet moulding compounds (SMC), infusion, blow moulding, hand layup, resin transfer moulding (RTM), injection moulding, compression moulding or extrusion in constant or variable cross section. In the exemplary embodiment, the first layer is formed independently by at least one of pultrusion or extrusion process (as sheet form) or direct composite layup on top of intermediate layer (co extruded in process or hand laid as a post process) in order to obtain a constant cross-section and a production rate for being employable to manufacture at an industrial scale. Further, production of the first layer by way of the pultrusion process may reduce manufacturing lead time, whereby reducing overall production costs associated with the hybrid composite panel.
The hybrid composite panel (200) further includes an intermediate layer (202), formed of a polymer, rubber or elastomer-based material. The polymer-based material may be selected from a group consisting of polyvinyl chloride (PVC)/PVC natural composite, polyurethane, polypropylene extrusion, expanded polypropylene, polystyrene, and the like. The intermediate layer (202) may be configured to accommodate the first layer (201) on one side. In an embodiment, the intermediate layer (202) includes a predefined structure may be of a square or rectangular configuration defining void spaces, where the predefined structure may be solid, porous, foamed or honeycomb structure. In the exemplary embodiment, the predefined

structure is a thermal composite with natural fibre. Such composite structure may promote panel stiffness while adding minimum weight and resisting shear forces when the hybrid composite panel (200) is loaded. Also, such composite structure increases impact load absorption of the hybrid composite panel (200). The first layer (201) and the one side of the intermediate layer (202) may be bonded by an adhesive material. Thickness of the adhesive between the first layer (201) and the one side of the intermediate layer (202) may range from 0.1 mm – 1 mm and composition of the adhesive ranges from 0.34 wt.% to 2 wt.%. The adhesive may be selected from a group consisting of epoxy, polyurethane, structural acrylic, cyanoacrylates. In an embodiment, thickness of the intermediate layer ranges from 0.5 mm to 200 mm. Further, thickness of the adhesive between the first layer (201) and the intermediate layer (202) may also be dependent on parameters of environment in which the hybrid composite panel (200) may be employed.
The hybrid composite panel (200) further comprises a second layer (203), formed of a second composite material. The second layer (203) construction may be similar to the first layer (201) as in sandwich construction or may be totally different like grid structure. The second composite material may be selected from a group consisting of unsaturated polyester, vinyl ester, epoxy, phenolic, thermoplastics and the like. The second layer (203) may be connected to the intermediate layer (202) on other side, opposite to the one side. The other side of the intermediate layer (202) may be removably fixed to the second layer (203) and may be fastened by fasteners to disassemble easily for inspection and repair purposes. The fasteners may include M clips, threaded bolts, and the like. In an embodiment, the second layer may be defined by a predetermined profile and the predetermined profile may be pultruded, moulded or casted in the form of a grid structure (205). The grid structure (205) may be at least one of composite frame, lattice, grating, leno weave grid-based structure. The grid structure (205) of the second layer (203) may be defined with a clearance width between each grid, and height in longitudinal direction of the grid structure (205). In an embodiment, the clearance width in the grid structure (205) of the second layer (203) ranges from 20 mm to 200 mm and height of the second layer (203) ranges from 12 mm to 100 mm. The second layer (203) may be formed by the process of at least one of pultrusion, sheet moulding compounds (SMC), infusion, blow moulding, hand layup, resin transfer moulding (RTM), injection moulding, compression moulding and extrusion.

In the illustrative embodiment, the first layer (201) and the second layer (203) of the hybrid composite panel (200) may be formed independently by at least one of pultrusion or extrusion process (as sheet form) or direct composite layup on top of intermediate layer (co extruded in process or hand laid as a post process). Further, the first composite material may be substantially similar or totally different to the second composite material. The first composite layer (201) and the second composite layer (203) of the hybrid composite panel (200) exhibits high strength, and the intermediate layer (200) absorbs the impact energy and distributes the load in longitudinal direction of the intermediate layer (202).
In an embodiment, wt.% of the first layer (201) ranges from 8 wt.% to 20 wt.%, wt.% of the intermediate layer (202) ranges from 0.4 wt.% to 72 wt.%, and wt.% of the second layer (203) ranges from 8 wt.% to 92 wt.%.
In another alternative embodiment of the present disclosure, the first layer (201) may be joined with the intermediate layer (202) by a resin layup of the intermediate layer (202) which may minimize thickness of adhesive for joining the first layer (201) with the intermediate layer (202) to produce the hybrid composite panel cost-effectively.
Figure 2 is an exemplary embodiment of the present disclosure illustrating a flowchart depicting a method for manufacturing hybrid composite panel (200) of stratified construction. In the present disclosure, properties such as load bearing capacity, impact resistance and corrosion resistance of the hybrid composite panel may be improved. The method is now described with reference to the flowchart blocks and is as below. The order in which the method is described is not intended to be construed as a limitation, and any number of the described method blocks can be combined in any order to implement the method. Additionally, individual blocks may be deleted from the methods without departing from the scope of the subject matter described herein. The method is particularly applicable to hybrid composite panel (200), and it may also be extended to other types of composites as well.
At block 101, the method comprises step of forming a first layer (201), an intermediate layer (202) and a second layer (203). The first layer (201) may be formed of a first composite material, the intermediate layer (202) may be formed of at least one of polymer, rubber or elastomer-based material and the second layer (203) may be formed of a second composite material. In an embodiment, the first composite material may be selected from a group consisting of unsaturated polyester, vinyl ester, epoxy, phenolic, polyurethane, thermoplastics

including Polypropylene (PP), Polyethylene (PE), Polyvinyl Chloride (PVC), Polyethylene Terephthalate, Nylon and Polyetheretherketone (PEEK) and the like. Further, the polymer-based material may be selected from a group consisting of polyvinyl chloride (PVC)/PVC natural composite, polyurethane, polypropylene extrusion, expanded polypropylene, polystyrene and the like. The second composite material may be selected from a group consisting of unsaturated polyester, vinyl ester, epoxy, phenolic, polyurethane, thermoplastics including Polypropylene (PP), Polyethylene (PE), Polyvinyl Chloride (PVC), Polyethylene Terephthalate, Nylon and Polyetheretherketone (PEEK) and the like. In an embodiment, the first layer (201) and the second layer (203) may be formed by the process of at least one of pultrusion, sheet moulding compounds (SMC), infusion, blow moulding, hand layup, resin transfer moulding (RTM), injection moulding, compression moulding, and extrusion. In the illustrative embodiment, the first and the second layer of the hybrid composite panel may be formed by pultrusion process.
Now referring to block 102, the method comprises the step of joining the first layer (201) with the intermediate layer (202). The first layer (201) may be joined with the intermediate layer (202) by an adhesive and thickness of the adhesive ranges from 0.1 mm – 1 mm. In an embodiment, the adhesive is selected from a group consisting of epoxy, polyurethane, structural acrylic, cyanoacrylates and composition of the adhesive ranges from 0.34 wt.% to 2 wt.%. Further, the intermediate layer (202) may be configured to accommodate the first layer (201) on one side, and the intermediate layer (202) includes a predefined structure may be of a square or rectangular configuration defining void spaces, where the predefined structure may be a honeycomb structure.
At block 103, the method comprises the step of fastening the second layer (203) with the intermediate layer (202). The second layer (203) may be defined by a predetermined profile which may be connected to the other side of the intermediate layer (202). In an embodiment, the predetermined profile of the second layer may be pultruded or cast in the form of a grid structure (205). The grid structure (205) may be at least one of a composite frame, lattice, grating, leno weave grid-based structure. In an embodiment, the second layer (203) may be defined with a clearance width between each grid, and height in longitudinal direction of the grid structure (205).
In an embodiment, the first layer (201) formed of the first composite material is substantially similar to the second layer (203) formed of the second composite material but varies in

thickness of the layer. The thickness of the first layer (201) ranges from 0.5 mm to 25 mm whereas the thickness of the intermediate layer (202) ranges from 0.5 mm to 200 mm. Further, the clearance width in the grid structure (205) of the second layer ranges from 20 mm to 200 mm in both directions and height of the second layer (203) ranges from 12 mm to 100 mm.
In an embodiment, wt.% of the first layer (201) ranges from 8 wt.% to 20 wt.%, wt.% of the intermediate layer (202) ranges from 0.4 wt.% to 72 wt.%, and wt.% of the second layer (203) ranges from 8 wt.% to 92 wt.%.
The hybrid composite panel (200) produced by the method of present disclosure promotes design and development of working platform, mezz floor, walkway and building facades (interior or exterior). Further, the hybrid composite panel (200) exhibits properties such as high strength to weight ratio, impact/shock absorption, acid resistance, UV resistance, fire retardant, non-conductive, corrosion resistance and durability. The hybrid composite panel (200) may be applicable in personnel or equipment movement and for the goods storage such as working platform, walkways, flooring including but not limited to mezz floor and other applications include trench cover/drainage cover, roof, side wall, partition wall, ladder stairways, exteriors/interiors wall cladding (building facades).
In an embodiment, the hybrid composite panel (200) exhibits anti-slip property by coating of silica carbide/quartz with epoxy resin which may eliminate severe injuries and may provide health and safety value to the work environment. Further, the anti-slip performance of the hybrid composite panel (200) may be obtained by surface integrated features such as corrugations, texture, checkering, embossing and by using other anti-slip coating materials such as paints, polyurethane, polyvinyl chloride, rubber coating.
The hybrid composite panel (200) of the present disclosure may be applicable in personnel or equipment movement and for the goods storage such as working platform, walkways, flooring including but not limited to mezz floor and other applications include trench cover/drainage cover, roof, side wall, partition wall, ladder stairways, exteriors/interiors wall cladding (building facades). The hybrid composite panel (200) exhibits properties such as high strength to weight ratio, impact/shock absorption, acid resistance, UV resistance, fire retardant, non-conductive, corrosion resistance and durability.
Example:

Experiments have been carried out for the hybrid composite panel (200) produced by using the method of the present disclosure. Results have been compared on various fronts to show the contribution of intermediate layer in improvement of impact absorption.

Sl. N o Test Details Test Procedure Test Observations Remarks
1 Static UDL of 100kg/m
2 Load distribution on average area of 300 m2 – 300kg, load must be uniform, equally
distributed on the surface.
1. Hold for
10-15
min,
measure
the
deflection at the centre.
2. Hold for
24 hr –
measure
the
deflection at the centre and after load removal measure the
permanen t set. Specificatio n Deflectio n in mm No crack, delaminatio n or damage to the surface and assembly, deflection within the acceptable limit.

Initial deflection before loading < 10 mm 0

Hold for 10 – 15 mins
6.77

Hold for 24 hrs
8.4

After 24 hrs load removal 0.5

2 Welding machine load 100 kg load uniform
distribution at the area of 500 X 300 mm. 100 kg load uniform distributio n at the area of 500 X 300 mm < 10 mm 8.9 No crack, delaminatio n or damage to the surface and assembly, deflection within the acceptable limit.

3 Roller corner drop impact Hold the roller at an angle of 45° and allow to fall due to gravity (without force Drop No crack, delaminatio n or damage
application) from the height of at the centre of the conveyor plate in such a way that roller corner will hit the surface. height 1 m, 1.5 m – – to the surface and assembly
Table – 1
UDL – uniformly distributed load
The above table – 1 illustrates various test details that have been carried out on the hybrid composite panel (200) produced by the method of present disclosure. In the UDL test, 300 Kg load was uniformly distributed on the surface of the hybrid composite panel for a time period of 10 - 15 minutes and 24 hours and then load was removed after 24 hrs. After 10 – 15 minutes of time period, deflection of 6.77 mm was observed, and after 24 hours the deflection of 8.4 mm was observed. Further, removal of load after 24 hours results in the deflection of 0.5 mm. From the above test results, there was no crack observed on the surface of the hybrid composite panel and deflection was obtained within acceptable limit for some of the industrial applications. In an embodiment, such industrial application may be goods storage, working platform, walkways, flooring viz mezz floor and other applications includes trench cover/drainage cover, roof, side wall, partition wall, ladder stairways, exteriors/interiors wall cladding (building facades).
In the welding machine load test, 100 kg load was uniformly distributed on the surface of the hybrid composite panel (200) at the area of 500 X 300 mm. The test results indicate that the deflection of 8.9 mm was observed and there was no crack observed on the surface of the hybrid composite panel (200). Further, impact test was carried out using a roller held at an angle of 45° from the height of 1 m and allowed to fall due to gravity. After the test, results indicate that there was no crack observed on the surface of the hybrid composite panel (200).
Figure 3 illustrates an exploded view of the hybrid composite panel (200) mounted on a base structure (204). The second layer (203) of the hybrid composite panel (200) is fastened to the

base structure (204) by using a fastener i.e., bolts to withstand high loads during service and easy to disassemble for inspection and repair purposes.
Figures 4a and 4b illustrate the application of hybrid composite panel (200) in building facades in both exterior and interior walls which are resistant to corrosive environment. The hybrid composite panel (200) of the present disclosure provides aesthetic appearance to the building walls (interior/exterior) and protects the building walls from corrosive environments.
Figure 5 illustrates analysis of load on the hybrid composite panel (200) for different types of loads. The results of UDL test and point load test indicates that the hybrid composite panel (200) produced by the method of present disclosure was resistant to crack and deflection. In the UDL load test, under the stress of 10 MPa, displacement of 0.58 mm was observed. In the point load test, under the stress of 18 MPa, displacement of 1.24 mm was observed which are in the acceptable limits.
Figure 6 illustrates analysis of wind speed test on the hybrid composite panel (200). In the speed test, wind speed of 25 m/sec and 50 m/sec were applied on the hybrid composite panel (200) and there were no cracks or deflection observed on the hybrid composite panel (200). The results of the speed test indicate that the hybrid composite panel (200) produced by the method of present disclosure was resistant to crack and deflection under high wind speed.
Figure 7 illustrates analysis of roller drop impact test on the hybrid composite panel (200). The impact test was carried out on the hybrid composite panel (200) using a roller and there were no cracks observed on the surface of the hybrid composite panel (200). The results of the impact test indicate that the hybrid composite panel (200) produced by the method of present disclosure was resistant to impact forces which may result in crack formation and/or deflection under high impact. Due to such properties, it may be possible to employ the hybrid composite panel (200) in various applications including, but not limited to, floor tiles, wall tiles, and among others.
It should be understood that the experiments are carried out for a particular hybrid composite panel and the results brought out in the previous paragraphs are for the hybrid composite panel. However, this hybrid composite panel should not be construed as a limitation to the present disclosure as it could be extended to other types of composite panels as well.

In an embodiment of the present disclosure, the hybrid composite panel of the present disclosure may be used in any application including but not limiting to working platform, building facades, and the like. The hybrid composite panel may be used in any other industrial applications.
Equivalents:
With respect to the use of substantially any plural and/or singular terms herein, those having skill in the art can translate from the plural to the singular and/or from the singular to the plural as is appropriate to the context and/or application. The various singular/plural permutations may be expressly set forth herein for sake of clarity.
It will be understood by those within the art that, in general, terms used herein, and especially in the appended claims (e.g., bodies of the appended claims) are generally intended as "open" terms (e.g., the term "including" should be interpreted as "including but not limited to," the term "having" should be interpreted as "having at least," the term "includes" should be interpreted as "includes but is not limited to," etc.). It will be further understood by those within the art that if a specific number of an introduced claim recitation is intended, such an intent will be explicitly recited in the claim, and in the absence of such recitation no such intent is present. For example, as an aid to understanding, the following appended claims may contain usage of the introductory phrases "at least one" and "one or more" to introduce claim recitations. However, the use of such phrases should not be construed to imply that the introduction of a claim recitation by the indefinite articles "a" or "an" limits any particular claim containing such introduced claim recitation to inventions containing only one such recitation, even when the same claim includes the introductory phrases "one or more" or "at least one" and indefinite articles such as "a" or "an" (e.g., "a" and/or "an" should typically be interpreted to mean "at least one" or "one or more"); the same holds true for the use of definite articles used to introduce claim recitations. In addition, even if a specific number of an introduced claim recitation is explicitly recited, those skilled in the art will recognize that such recitation should typically be interpreted to mean at least the recited number (e.g., the bare recitation of "two recitations," without other modifiers, typically means at least two recitations, or two or more recitations). Furthermore, in those instances where a convention analogous to "at least one of A, B, and C, etc." is used, in general such a construction is intended in the sense one having skill in the art would understand the convention (e.g., "a system having at least one of A, B, and C" would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together,

and/or A, B, and C together, etc.). In those instances where a convention analogous to "at least one of A, B, or C, etc." is used, in general such a construction is intended in the sense one having skill in the art would understand the convention (e.g., "a system having at least one of A, B, or C" would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and/or A, B, and C together, etc.). It will be further understood by those within the art that virtually any disjunctive word and/or phrase presenting two or more alternative terms, whether in the description, claims, or drawings, should be understood to contemplate the possibilities of including one of the terms, either of the terms, or both terms. For example, the phrase "A or B" will be understood to include the possibilities of "A" or "B" or "A and B."
While various aspects and embodiments have been disclosed herein, other aspects and embodiments will be apparent to those skilled in the art. The various aspects and embodiments disclosed herein are for purposes of illustration and are not intended to be limiting, with the true scope and spirit being indicated by the following claims.
Referral Numerals

Referral Numerals Description
101-103 Flowchart blocks
101 Forming stage
102 Joining stage
103 Fastening stage
200 Hybrid composite panel
201 First layer
202 Intermediate layer
203 Second layer
204 Base structure
205 Grid structure

We claim:
1. A hybrid composite panel (200) of stratified construction, comprising:
a first layer (201) of uniform or variable cross section, formed of a first composite material;
an intermediate layer (202), formed of at least one of polymer, rubber or elastomer-based material, the intermediate layer (203) configured to accommodate the first layer (201) on one side, wherein the intermediate layer (202) includes a predefined structure including void spaces; and
a second layer (203), formed of a second composite material, the second layer (203) defined by a predetermined profile connected to the intermediate layer (202) on other side, opposite to the one side, wherein the intermediate layer (202) is removably fixed to the second layer (203), and
wherein at least one of the first layer (201) and the second layer (203) formed by at least one of pultrusion, sheet moulding compounds (SMC), infusion, blow moulding, hand layup, resin transfer moulding (RTM), injection moulding, compression moulding and extrusion.
2. The hybrid composite panel (200) as claimed in claim 1, wherein the first layer (201) and the intermediate layer (202) are adhesive bonded.
3. The hybrid composite panel (200) as claimed in claim 1, wherein the predefined structure is at least one of solid, porous, foamed and honeycomb structure.
4. The hybrid composite panel (200) as claimed in claim 1, wherein the predetermined profile of the second layer (203) is pultruded, moulded or cast in a grid structure (205).
5. The hybrid composite panel (200) as claimed in claim 1, wherein wt.% of the first layer (201) ranges from 8 wt.% to 20 wt.%, wt.% of the intermediate layer (202) ranges from 0.4 wt.% to 72 wt.%, and wt.% of the second layer (203) ranges from 8 wt.% to 92 wt.%.
6. The hybrid composite panel (200) as claimed in claim 2, wherein composition of the adhesive ranges from 0.34 wt.% to 2 wt.%.

7. The hybrid composite panel (200) as claimed in claim 2, wherein the adhesive is selected from a group consisting of epoxy, polyurethane, structural acrylic, cyanoacrylates.
8. The hybrid composite panel (200) as claimed in claim 2, wherein thickness of the adhesive ranges from 0.1 mm – 1 mm.
9. The hybrid composite panel (200) as claimed in claim 1, wherein the first composite material is selected from a group consisting of unsaturated polyester, vinyl ester, epoxy, phenolic, polyurethane, and thermoplastics including Polypropylene (PP), Polyethylene (PE), Polyvinyl Chloride (PVC), Polyethylene Terephthalate, Nylon and Polyetheretherketone (PEEK).
10. The hybrid composite panel (200) as claimed in claim 1, wherein the polymer-based material is selected from a group consisting of polyvinyl chloride (PVC)/PVC natural composite, polyurethane, polypropylene extrusion, expanded polypropylene, polystyrene.
11. The hybrid composite panel (200) as claimed in claim 1, wherein the second composite material is selected from a group consisting of unsaturated polyester, vinyl ester, epoxy, phenolic, polyurethane and thermoplastics including Polypropylene (PP), Polyethylene (PE), Polyvinyl Chloride (PVC), Polyethylene Terephthalate, Nylon and Polyetheretherketone (PEEK.
12. The hybrid composite panel (200) as claimed in claim 1, wherein the first composite material is substantially similar or different to the second composite material.
13. The hybrid composite panel (200) as claimed in claim 1, wherein thickness of the first layer (201) ranges from 0.5 mm to 25 mm.
14. The hybrid composite panel (200) as claimed in claim 1, wherein thickness of the intermediate layer (202) ranges from 0.5 mm to 200 mm.

15. The hybrid composite panel (200) as claimed in claim 1, wherein the second layer (203) is defined with a clearance width between each grid, and height in longitudinal direction of the grid structure (205).
16. The hybrid composite panel (200) as claimed in claim 15, wherein the clearance width in the grid structure (205) of the second layer (203) ranges from 20 mm to 200 mm in both directions, and height of the second layer (203) ranges from 12 mm to 100 mm.
17. A method for manufacturing hybrid composite panel (200) of stratified construction, the method comprising:
forming, a first layer (201) of first composite material, an intermediate layer
(202) of at least one of polymer, rubber, elastomer-based material and a second layer
(203) of second composite material;
joining, the first layer (201) with the intermediate layer (202); and
fastening, the second layer (203) with the intermediate layer (202),
wherein at least one of the first layer (201) and the second layer (203) are formed by at least one of pultrusion or extrusion process.
18. The method as claimed in claim 17, wherein the first layer (201) and the intermediate layer (202) are at least one of adhesive bonded, heat fused, mechanically fastened together or co-extruded together.
19. The method as claimed in claim 18, wherein the adhesive is selected from a group consisting of epoxy, polyurethane, structural acrylic, cyanoacrylates.
20. The method as claimed in claim 18, wherein the thickness of the adhesive ranges from 0.1 mm – 1 mm.
21. The method as claimed in claim 17, wherein the first composite material is selected from a group consisting of unsaturated polyester, vinyl ester, epoxy, phenolic, polyurethane, and thermoplastics including Polypropylene (PP), Polyethylene (PE), Polyvinyl Chloride (PVC), Polyethylene Terephthalate, Nylon and Polyetheretherketone (PEEK).

22. The method as claimed in claim 17, wherein the polymer-based material is selected from a group consisting of polyvinyl chloride (PVC)/PVC natural composite, polyurethane, polypropylene extrusion, expanded polypropylene, polystyrene.
23. The method as claimed in claim 17, wherein the second composite material is selected from a group consisting of unsaturated polyester, vinyl ester, epoxy, phenolic, polyurethane and thermoplastics including Polypropylene (PP), Polyethylene (PE), Polyvinyl Chloride (PVC), Polyethylene Terephthalate, Nylon and Polyetheretherketone (PEEK).
24. The method as claimed in claim 17, wherein the thickness of the first layer (201) ranges from 0.5 mm to 25 mm.
25. The method as claimed in claim 17, wherein the thickness of the intermediate layer
(202) ranges from 0.5 mm to 200 mm.
26. The method as claimed in claim 17, wherein the grid structure (205) of the second layer
(203) is defined with a clearance width between each grid, and height in longitudinal
direction of the grid structure (205).
27. The method as claimed in claim 26, wherein the clearance width in the grid structure
(205) of the second layer (203) ranges from 20 mm to 200 mm in both directions, and
the height of the second layer (203) ranges from 12 mm to 100 mm.