Composition and Method to Form a Composite Core Material

Abstract

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.

What is claimed is: 
     
         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.