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US 9,308,670 B1Granted
Lightweight resin based polymer concrete articles and methods for making
OwnerRichard A. Cubetainventor
Life of this patent
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Abstract
A cast lightweight construction article and methods of making the same are disclosed herein. The cast lightweight construction article can include a thermosetting resin composition, a low moisture content aggregate, and a catalyst that enhances hardening. The cast lightweight construction article can have a density ranging from about 120 pounds per cubic feet to about 170 pounds per cubic feet. The method can include forming the articles by inserting columns of a low density expanded polystyrene, low density urethane foam, low density polymerized alpha olefins, or combinations into a form, and pouring mixed liquid and dry materials into the form to cure.
Claims7
A cast lightweight construction article made by a process comprising:
- a. positioning a plurality of columns of a core material that are substantially solid in a removable form, wherein each of the columns of core material are substantially parallel, each of the columns of core material having a cylindrical geometry, wherein the cylindrical geometry is substantially circular or substantially elliptical in cross section, wherein each column of core material comprises:
- an expanded polystyrene, a urethane foam, a polymerized alpha olefin, or combinations thereof;
- b. blending together liquid and dry materials for a time ranging from 2 minutes to 10 minutes, forming an aggregate-fortified thermosetting polymer concrete, wherein a total weight percent of the aggregate-fortified thermosetting polymer is 100 percent, and wherein the liquid and dry materials comprise:
- (i) from 7 percent by weight to 17 percent by weight of a liquid thermosetting resin composition, wherein the liquid thermosetting resin composition is a vinyl ester resin, a styrene-free vinyl ester resin, an unsaturated polyester resin, a styrene-free unsaturated polyester resin, or combinations thereof;
- (ii) from 60 percent by weight to 93 percent by weight of an aggregate having an average particle diameter ranging from 6 microns to 1.5 inches, and a bulk density ranging from 75 pounds per cubic foot to 160 pounds per cubic foot;
- and
- (iii) from 0.2 percent by weight to 3 percent by weight of a liquid catalyst for enhancing hardening, wherein the liquid catalyst is an aliphatic amine, an aromatic amine, a ketamine, a methyl ketamine, an anhydride, a peroxide, or a methyl ethyl ketone;
- c. pouring the aggregate-fortified thermosetting polymer in the removable form, and through and around the plurality of columns of the core material, encapsulating the plurality of columns of the core material;
- d. allowing the aggregate-fortified thermosetting polymer to cure, forming a substantially arched internal structure encompassing the core material;
- and
- e. removing the form, forming the cast lightweight construction article with the substantially arched internal structure.
8 more elements
A cast lightweight construction article made by a method comprising:
- a. disposing a first holding means to axially support a first column of a cylindrical geometry core material that is substantially solid, wherein the cylindrical geometry is substantially circular or substantially elliptical in cross section;
- b. disposing additional holding means to axially support additional columns of the cylindrical geometry core material that are substantially solid;
- c. positioning the first column of the cylindrical geometry core material with the first holding means and the additional columns of the cylindrical geometry core material with the additional holding means in a form, wherein the first column of the cylindrical geometry core material is positioned substantially in parallel with the additional columns of the cylindrical geometry core material, and wherein each column of the cylindrical geometry core material comprises:
- an expanded polystyrene, a urethane foam, a polymerized alpha olefin, or combinations thereof;
- d. blending together liquid and dry materials for a time ranging from 2 minutes to 10 minutes, forming an aggregate-fortified thermosetting polymer, wherein a total weight percent of the aggregate-fortified thermosetting polymer is 100 percent, wherein the liquid and dry materials comprise:
- (i) from 7 percent by weight to 17 percent by weight of a liquid thermosetting resin composition, wherein the liquid thermosetting resin composition is a vinyl ester resin, a styrene-free vinyl ester resin, an unsaturated polyester resin, a styrene-free unsaturated polyester resin, or combinations thereof;
- (ii) from 60 percent by weight to 93 percent by weight of an aggregate having an average particle diameter ranging from 6 microns to 1.5 inches, and a bulk density ranging from 75 pounds per cubic foot to 160 pounds per cubic foot;
- and
- (iii) from 0.2 percent by weight to 3 percent by weight of a liquid catalyst for enhancing hardening, wherein the liquid catalyst is an aliphatic amine, an aromatic amine, a ketamine, a methyl ketamine, an anhydride, a peroxide, or a methyl ethyl ketone;
- e. flowing the aggregate-fortified thermosetting polymer into the form, and through and around the columns of core material, encapsulating the columns of core material;
- f. allowing the aggregate-fortified thermosetting polymer to cure;
- and
- g. removing the form and the holding means, forming the cast lightweight construction article with a substantially arched internal structure;
- h. allowing the aggregate-fortified thermosetting polymer to cure;
- and
- i. removing the form and the holding means, forming the cast lightweight construction article with the substantially arched internal structure.
13 more elements
Dependencies are inferred from the claim text.