Composite panel
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.
Claims15
A method to form and utilize a composite core material, comprising:
- forming a sheet of a composite core material including curing the composite core material, wherein the composite core material is comprised of a mineral filler, an encapsulating resin, and a first polymerization catalyst, wherein the mineral filler comprises at least one of a calcium sulfate, a calcium carbonate, an aluminum trihydrate, a talc, a gypsum, a magnesium hydroxide, or a dolomite;
- forming a plurality of reinforcing blocks by scoring the sheet of the composite core material;
- applying a gel coat to a mold, wherein the gel coat includes a second polymerization catalyst;
- applying a layer of a laminate composition to the gel coat, wherein the laminate composition is comprised of a calcium sulfate, a second encapsulating resin, a third polymerization catalyst, and a plurality of fiberglass pieces;
- applying the plurality of reinforcing blocks to the layer of the laminate composition;
- applying another layer of the laminate composition to the plurality of reinforcing blocks;
- and
- curing the another layer of the laminate composition to form a composite material.
A method of utilizing a composite core material, comprising the steps of:
- positioning a mesh assembly onto a moving belt;
- evenly spreading a mixture onto the mesh assembly when the mesh assembly is on the moving belt, wherein the mixture comprises a mineral filler, a polymerization catalyst, and an encapsulating resin, wherein the mineral filler comprises at least one of a calcium sulfate, a calcium carbonate, an aluminum trihydrate, a talc, a gypsum, a magnesium hydroxide, or a dolomite;
- curing the mixture on the mesh assembly to form a sheet of a composite core material comprising portions of the mineral filler disposed in the encapsulating resin;
- scoring the sheet of the composite core material into a plurality of reinforcing blocks;
- applying a gel coat to a mold, wherein the gel coat comprises a second polymerization catalyst;
- drying but not curing the gel coat on the mold;
- applying a first layer of a laminate composition to the gel coat after the gel coat has dried, wherein the laminate composition is comprised of calcium sulfate, the encapsulating resin, the polymerization catalyst, and a plurality of fiberglass pieces;
- applying the plurality of reinforcing blocks to the first layer of the laminate composition;
- applying a second layer of the laminate composition to the plurality of reinforcing blocks;
- and
- curing the second layer of the laminate composition to form a composite material enclosing the mold.
Dependencies are inferred from the claim text.