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 |
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.
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