Composition and Method to Form a Composite Core Material
A composition and method to form a composite core material for use as a panel, molded product, sheet, or reinforcing material. The composition generally includes a microsphere discontinuous portion disposed in a continuous encapsulating portion, such as an encapsulating resin. Final products made with the composition may also comprise a mesh assembly on one or both sides of a sheet or panel, and may comprise a scored panel or sheet such that a plurality of reinforcing blocks or sections are formed which allow the cured product to conform to, and reinforce, irregular shapes and surfaces.
1 . A composite core material, comprising microsphere discontinuous portions disposed in a continuous encapsulating resin mixture;
wherein the microsphere discontinuous portion comprises plastic microspheres, glass microspheres, ceramic microspheres, polyvinyl chloride (PVC) microspheres, acrylic microspheres, and any combinations thereof.
2 . The composite core material of claim 1 , wherein the microsphere discontinuous portion comprises hollow or solid microspheres.
3 . The composite core material of claim 1 , further comprising a blowing agent.
4 . The composite core material of claim 1 , wherein the blowing agent is a chemical or mechanical blowing agent.
5 . The composite core material of claim 1 , wherein the encapsulating resin mixture comprises resin selected from the group consisting of polyester resin, vinyl ester resin, fire retardant resin and any combinations thereof.
6 . The composite core material of claim 1 , wherein the encapsulating resin mixture comprises a polyester resin.
7 . The composite core material of claim 1 , wherein the encapsulating resin mixture comprises a vinyl ester resin.
8 . The composite core material of claim 1 , wherein the encapsulating resin mixture comprises a fire retardant resin.
9 . The composite core material of claim 1 , wherein the encapsulating resin mixture has a weight percentage of about 90-99%; and
wherein the microspheres comprise hollow or solid microspheres having a weight percentage of about 1-10%.
10 . A method of making a composite core material product, comprising:
forming a mixture comprising microspheres, an encapsulating prepolymer, and a polymerization catalyst;
shaping the mixture into a particular form; and
polymerizing the encapsulating prepolymer to form a composite material comprising hollow or solid microsphere discontinuous portions disposed in a continuous encapsulating resin mixture.
11 . The method of claim 10 , wherein the hollow or solid microspheres are selected from the group consisting of plastic microspheres, glass microspheres, ceramic microspheres, polyvinyl chloride (PVC) microspheres, acrylic microspheres, and any combinations thereof.
12 . The method of claim 10 , wherein the encapsulating prepolymer is selected from the group consisting of a polyester prepolymer, a vinyl ester prepolymer, a fire retardant prepolymer, and any combinations thereof.
13 . The method of claim 10 , wherein the encapsulating prepolymer has a weight percentage of about 90-99%; and
wherein the microspheres comprise hollow or solid microspheres having a weight percentage of about 1-10%.
14 . The method of claim 13 , wherein:
shaping the mixture into a particular form step further comprises disposing said mixture onto a mesh assembly positioned on a moving belt to form a sheet comprising said mixture and the mesh assembly; and
wherein polymerizing the encapsulating prepolymer further comprises curing the encapsulating prepolymer to form a sheet of composite material having a mesh assembly proximate a first side of the sheet.
15 . The method of claim 14 , further comprising scoring the sheet of the composite material into a plurality of reinforcing blocks on a side of the sheet spaced apart from the first side of the sheet.
16 . The method of claim 10 , wherein:
shaping the mixture into a particular form further comprises disposing said mixture onto a mesh assembly positioned on a moving belt to form a sheet comprising said mixture and the mesh assembly; and
wherein polymerizing the encapsulating prepolymer further comprises curing the encapsulating prepolymer to form a sheet of composite material having a mesh assembly proximate a first side of the sheet.
17 . The method of claim 16 , further comprising scoring the sheet of the composite material into a plurality of reinforcing blocks on a side of the sheet spaced apart from the first side of the sheet.
18 . The method of claim 10 , wherein:
shaping the mixture into a particular form further comprises disposing the mixture into a mold with a mesh assembly located inside the mold; and
wherein polymerizing the encapsulating prepolymer further comprises curing the encapsulating prepolymer to form a composite material product according to the shape of the mold, the composite material product having a mesh assembly proximate a first surface of the product.
19 . The method of claim 18 , further comprising scoring the composite material product into a plurality of reinforcing blocks on a side of the product spaced apart from the mesh assembly.
20 . The method of claim 18 , further comprising positioning a second mesh assembly in the mold on a side of the mold spaced apart from the first mesh assembly.