Composite materials
A filled composite material, preferably having fire retardant or non-combustible properties, comprising a preformed syntactic composite material (1) of particulate structure defining interstitial spaces between the particles thereof, and a filler material (2) which may be aqueous or resin based, drawn into the interstitial spaces by applying to the composite material a partial vacuum.
1 . The filled composite material comprising a preformed syntactic composite material of particulate structure defining interstitial spaces between the particles thereof, and at least partially impregnated in the interstitial spaces by a reinforcing filler.
2 . The filled composite material according to claim 1 , wherein the preformed composite material is composed of particles of a lightweight mineral material.
3 . The filled composite material according to claim 1 , wherein the preformed composite material is composed of sintered foamed glass pellets.
4 . The filled composite material according to claim 1 , wherein the preformed composite material is composed of foamed clay pellets.
5 . The filled composite material according to claim 1 , wherein the reinforcing filler is non-combustible.
6 . The filled composite material according to claim 1 , wherein the reinforcing filler is derived from gypsum.
7 . The filled composite material according to claim 1 , wherein the reinforcing filler is an alkaline silicate with a hardener.
8 . The filled composite material according to claim 1 , wherein the reinforcing filler is an organic substance.
9 . The filled composite material according to claim 1 , wherein the reinforcing filler is a thermosetting resin.
10 . A method of producing a filled composite material comprising the steps of providing a preformed syntactic composite material of particulate structure defining interstitial spaces between the particles thereof, and causing a fluidic filler material to be drawn at least partially into the interstitial spaces by applying to the preformed composite at least a partial vacuum.
11 . The method according to claim 10 , wherein the fluidic filler is a curable material, and including the step of causing the filler material to cure within the interstitial spaces.
12 . The method according to claim 10 , including the step of curing the filler material at above ambient temperature.
13 . The method according to claim 10 , wherein the fluidic filler material is introduced into a mould followed by the preformed composite material and a bleed membrane, and the mould is disposed within a vacuum bag from which air is extracted by a pump to apply said partial vacuum.
14 . The method according to claim 10 , including the step of introducing a preformed reinforcing material and causing same to become integrated with the preformed composite by the filler material.