Composite assembly with saturated bonding mass and process of reinforced attachment
AssigneeIntegritect Consulting, Inc.
InventorJames Michael Blahut
Life of this patent
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Abstract
A method of both permanently reinforcing and bonding, by means of a physical connection including a fabric or other arrangement of reinforcing fiber, saturated with a curing liquid resin, and building materials to create a composite assembly is disclosed. Once cured, the previously liquid resin, having surrounded the fiber and features of the surfaces of the elements being joined, combines them within a single, shared resin matrix. The resulting composite assembly incorporates a new method of providing reinforcement from within, and can be formed into any of various products or components in the light construction industry, such as window sashes, millwork, and the like.
Claims14
A building material composite assembly, comprising:
- an essentially planar first outer substrate that is at least partly porous;
- a first reinforced lamination layer;
- an essentially planar inner substrate that is at least partly porous;
- a second reinforced lamination layer;
- and
- an essentially planar second outer substrate that is at least partly porous,
- wherein the first reinforced lamination layer joins an at least partly porous surface of the first outer substrate to an at least partly porous first surface of the inner substrate,
- wherein the first reinforced lamination layer includes a pressed mat or fabric containing a plurality of reinforcing fibers and a thermoset resin, the thermoset resin forming a single continuous matrix encasing the plurality of reinforcing fibers and filling pores of the at least partly porous surface of the first outer substrate and filling pores of the at least partly porous first surface of the inner substrate to form a physical anchoring or bonding of the first outer substrate and the inner substrate, the single continuous matrix being formed by the thermoset resin being included in the first reinforced lamination layer as a liquid resin such that excess liquid resin of the first reinforced lamination layer is forced into and fills pores of the at least partly porous surface of the first outer substrate and of the at least partly porous first surface of the inner substrate before the thermoset resin is cured,
- wherein the second reinforced lamination layer joins an at least partly porous surface of the second outer substrate to an at least partly porous second surface of the inner substrate, and
- wherein the second reinforced lamination layer includes a plurality of reinforcing fibers and a thermoset resin, the thermoset resin forming a single continuous matrix encasing the plurality of reinforcing fibers and filling pores of the at least partly porous surface of the second outer substrate and filling pores of the at least partly porous second surface of the inner substrate to form a physical anchoring or bonding of the second outer substrate and the inner substrate, the single continuous matrix being formed by the thermoset resin being included in the second reinforced lamination layer as a liquid resin such that excess liquid resin of the second reinforced lamination layer is forced into and fills pores of the at least partly porous surface of the second outer substrate and of the at least partly porous second surface of the inner substrate before the thermoset resin is cured.
Dependencies are inferred from the claim text.