Composition and method to form a composite core material
AssigneeComposite Technologies International, LLC
InventorStephen Gleason, Sr.
Life of this patent
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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.
Claims12
A method to form a composite core material, comprising
- polymerizing an encapsulating prepolymer of a first mixture to form a sheet of composite material comprising calcium sulfate or calcium sulfate hydrate discontinuous portions disposed in a continuous encapsulating resin, wherein the first mixture is comprised of (a) one or more of a calcium sulfate and a hydrate of the calcium sulfate;
- (b) the encapsulating prepolymer;
- and (c) a first polymerization catalyst;
- cutting the sheet of composite material into a plurality of pieces of the composite material;
- applying a gel coat having a second polymerization catalyst to a mold and drying the gel coat without completely curing the gel coat;
- forming a second mixture to create a laminate, the second mixture comprising:
- (a) one or more of a calcium sulfate and a hydrate of the calcium sulfate;
- (b) an encapsulating prepolymer;
- (c) a third polymerization catalyst;
- and (d) a plurality of fiberglass pieces;
- applying a first layer of the laminate to the dried gel coat;
- without curing the first layer of the laminate applied to the dried gel coat, applying at least a portion of the plurality of pieces of the composite material to the first layer of the laminate;
- applying a second layer of the laminate to the portion of the plurality of pieces of the composite material, which is atop the first layer of the laminate;
- and
- curing the second layer of the laminate to enclose the mold.
Dependencies are inferred from the claim text.