US 12,221,522 B2
Composition and method to form a composite core material
Stephen Gleason, Sr., Burr Ridge, IL (US)
Assigned to Composite Technologies International, LLC, Anniston, AL (US)
Filed by Composite Technologies International, LLC, Anniston, AL (US)
Filed on Sep. 13, 2023, as Appl. No. 18/466,572.
Application 18/466,572 is a continuation of application No. 17/322,372, filed on May 17, 2021, granted, now 11,760,862.
Application 17/322,372 is a continuation of application No. 15/830,808, filed on Dec. 4, 2017, granted, now 11,008,438, issued on May 18, 2021.
Claims priority of provisional application 62/429,535, filed on Dec. 2, 2016.
Prior Publication US 2024/0002632 A1, Jan. 4, 2024
This patent is subject to a terminal disclaimer.
Int. Cl. C08K 3/30 (2006.01); B29C 37/00 (2006.01); B29C 41/00 (2006.01); B29C 41/20 (2006.01); B29C 41/22 (2006.01); B29C 41/30 (2006.01); B29C 41/32 (2006.01); B29C 70/02 (2006.01); B29C 70/30 (2006.01); B29C 70/54 (2006.01); B29C 70/60 (2006.01); B29C 70/68 (2006.01); B29C 70/70 (2006.01); B29C 70/86 (2006.01); B29C 70/88 (2006.01); B29K 31/00 (2006.01); B29K 67/00 (2006.01); B29K 105/06 (2006.01); B29K 105/16 (2006.01); B29K 105/20 (2006.01); B29K 231/00 (2006.01); B29K 267/00 (2006.01); B29K 303/00 (2006.01); B29K 303/04 (2006.01); B29K 309/00 (2006.01); B29K 509/00 (2006.01); B29K 631/00 (2006.01); B29K 667/00 (2006.01); C08J 5/04 (2006.01); C08J 5/18 (2006.01); C08J 5/24 (2006.01); C08K 3/013 (2018.01); C08L 35/02 (2006.01); G01N 1/36 (2006.01); G01N 3/10 (2006.01); G01N 33/44 (2006.01)
CPC C08K 3/30 (2013.01) [C08J 5/043 (2013.01); C08J 5/18 (2013.01); C08J 5/244 (2021.05); C08J 5/249 (2021.05); G01N 1/36 (2013.01); G01N 33/442 (2013.01); B29C 37/0025 (2013.01); B29C 41/00 (2013.01); B29C 41/003 (2013.01); B29C 41/20 (2013.01); B29C 41/22 (2013.01); B29C 41/30 (2013.01); B29C 41/32 (2013.01); B29C 70/02 (2013.01); B29C 70/30 (2013.01); B29C 70/305 (2013.01); B29C 70/545 (2013.01); B29C 70/60 (2013.01); B29C 70/68 (2013.01); B29C 70/682 (2013.01); B29C 70/70 (2013.01); B29C 70/86 (2013.01); B29C 70/865 (2013.01); B29C 70/88 (2013.01); B29K 2031/00 (2013.01); B29K 2067/00 (2013.01); B29K 2067/06 (2013.01); B29K 2105/06 (2013.01); B29K 2105/16 (2013.01); B29K 2105/20 (2013.01); B29K 2231/00 (2013.01); B29K 2267/00 (2013.01); B29K 2267/06 (2013.01); B29K 2303/00 (2013.01); B29K 2303/04 (2013.01); B29K 2309/00 (2013.01); B29K 2509/00 (2013.01); B29K 2631/00 (2013.01); B29K 2667/00 (2013.01); B29K 2667/06 (2013.01); C08J 2300/12 (2013.01); C08J 2335/02 (2013.01); C08J 2367/00 (2013.01); C08K 3/013 (2018.01); C08K 2003/3045 (2013.01); C08L 35/02 (2013.01); G01N 2001/364 (2013.01); G01N 3/10 (2013.01)] 12 Claims
OG exemplary drawing
 
1. A method to form a composite core material, comprising
polymerizing an encapsulating prepolymer of a first mixture to form a sheet of composite material comprising calcium sulfate or calcium sulfate hydrate discontinuous portions disposed in a continuous encapsulating resin, wherein the first mixture is comprised of (a) one or more of a calcium sulfate and a hydrate of the calcium sulfate; (b) the encapsulating prepolymer; and (c) a first polymerization catalyst;
cutting the sheet of composite material into a plurality of pieces of the composite material;
applying a gel coat having a second polymerization catalyst to a mold and drying the gel coat without completely curing the gel coat;
forming a second mixture to create a laminate, the second mixture comprising: (a) one or more of a calcium sulfate and a hydrate of the calcium sulfate; (b) an encapsulating prepolymer; (c) a third polymerization catalyst; and (d) a plurality of fiberglass pieces;
applying a first layer of the laminate to the dried gel coat;
without curing the first layer of the laminate applied to the dried gel coat, applying at least a portion of the plurality of pieces of the composite material to the first layer of the laminate;
applying a second layer of the laminate to the portion of the plurality of pieces of the composite material, which is atop the first layer of the laminate; and
curing the second layer of the laminate to enclose the mold.