Composition and method to form a composite core material
AssigneeComposite Technologies International, LLC
InventorStephen Gleason, Sr.
Life of this patent
Estimating the term…
Abstract
A composite core material and methods for making same are disclosed herein. The composite core material comprises mineral filler discontinuous portions disposed in a continuous encapsulating resin. Further, the method for forming a composite core material comprises the steps of forming a mixture comprising mineral filler, an encapsulating prepolymer, and a polymerization catalyst; disposing the mixture onto a moving belt; and polymerizing said encapsulating prepolymer to form a composite core material comprising mineral filler discontinuous portions disposed in a continuous encapsulating resin.
Claims10
A method to form and utilize a composite core material, comprising:
- mixing a mineral filler, a first encapsulating prepolymer, and a first polymerization catalyst to form a mixture;
- curing said mixture such that the first encapsulating prepolymer is polymerized to form a sheet of a composite core material comprising mineral filler discontinuous portions disposed in a continuous encapsulating resin;
- scoring said sheet of said composite core material into a plurality of reinforcing blocks;
- drying a first layer comprised of a gel coat and a second polymerization catalyst;
- applying a second layer to the first layer, wherein the second layer is comprised of a laminate composition, the laminate composition comprising calcium sulfate, a second encapsulating prepolymer, a third polymerization catalyst, and a plurality of fiberglass pieces;
- applying the plurality of reinforcing blocks to the second layer;
- applying a third layer to the plurality of reinforcing blocks, wherein the third layer comprises the laminate composition;
- and
- curing the third layer to form a composite material.
A method of utilizing a composite core material, comprising the steps of:
- mixing a mineral filler, a first encapsulating prepolymer, and a first polymerization catalyst to form a mixture;
- positioning a mesh assembly onto a moving belt;
- evenly spreading the mixture onto the mesh assembly when the mesh assembly is on the moving belt;
- curing the mixture on the mesh assembly such that the first encapsulating prepolymer is polymerized to form a sheet of a composite core material comprising mineral filler discontinuous portions disposed in a continuous encapsulating resin;
- scoring the sheet of the composite core material into a plurality of reinforcing blocks;
- applying a first layer to a mold, wherein the first layer is comprised of gel coat with a second polymerization catalyst;
- drying but not curing the first layer on the mold;
- applying a second layer to the first layer after the first layer has dried, wherein the second layer is comprised of a laminate composition, the laminate composition comprising calcium sulfate, a second encapsulating prepolymer, a third polymerization catalyst, and a plurality of fiberglass pieces;
- applying the plurality of reinforcing blocks to the second layer;
- applying a third layer to the plurality of reinforcing blocks, wherein the third layer comprises the laminate composition;
- and
- curing the third layer to form a composite material enclosing the mold.
Dependencies are inferred from the claim text.