Mastic composition and composite structural panels formed therefrom
AssigneesBell Fibre Products Corporation, Robert C. Geschwender
InventorRobert C. Geschwender
Life of this patent
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Abstract
A mastic composition formed of a substantially homogeneous imporous mixture of a predetermined volume of low-density expanded closed-cell synthetic resin beads and a slurry prepared from calcined gypsum and water wherein the interstitial volume of the expanded beads is not substantially less than the volume of slurry. The substantially homogeneous mixture is self-adhering as a thick layer on an inverted smooth surface and yet separable therefrom as an integral layer, the mastic composition setting to a hard, strong, dimensionally stable, heat- and sound-retardant material. Method of mixing mastic compositions, and composite structural panels utilizing mastic compositions as well as the methods and apparatus for forming such panels are also disclosed.
Claims23
A method of making composite structural panels comprising a core of expanded honeycomb material having cells extending from one face thereof to the other and layers of a mastic composition on opposite faces of the core keyed into the ends of the cells, said method comprising:
- feeding honeycomb material of predetermined thickness in compacted condition from a supply and expanding it to form the cells;
- feeding the expanded honeycomb material forward on a predetermined horizontal path with the cells vertical and with the upper face of the honeycomb material spaced below an upper guide and the lower face of the honeycomb material spaced above a lower guide and with these guides being spaced a distance greater than the thickness of the expanded honeycomb material for travel of the expanded honeycomb material therebetween;
- supplying a first web of mastic-backing material to travel rearward in a horizontal path above the upper guide and then forward below the upper guide and above the honeycomb material;
- applying hardenable mastic material in a layer substantially thicker than one-half the difference between the spacing of the upper and lower guides and the thickness of the honeycomb material to the upper face of the first web as it travels rearward over the upper guide;
- supplying a second web of mastic-backing material to travel forward in a horizontal path over the lower guide means;
- applying hardenable mastic material in a layer thicker than one-half the difference between the spacing of the upper and lower guides and the thickness of the honeycomb material to the face of the second web which faces upward as the second web travels forward over the lower guide;
- said guides being operable to press the mastic layers into the upper and lower ends of the cells of the honeycomb material to a depth less than the thickness of the mastic layers.
A method of making a composite structural panel comprising feeding an expanded honeycomb core having walls with openings therein between each cell and adjacent the opposite core faces, and concurrently pressing layers of hardenable mastic composition into the opposite core faces with the layers penetrating into each cell generally to the point of closing the openings and thereby trapping air in the cells to predetermine the depth of layer penetration.
Dependencies are inferred from the claim text.