US3867495A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Method for fabricating molded elements by bonding solid particles with a resin
Assignee: Rheinmetall Air Defence AG
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Filing: 1972-06-02
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Granted: 1975-02-18
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Expires: 1992-06-02
Abstract
Abstract A method of fabricating dimensionally stable and load-carrying artificial concrete-construction elements wherein (a) a loose mass of mineral grains is admixed with (b) a relatively low amount of weight of a fine grain granulate of plastic material which can expand into essentially voluminous dimensionallyelastic foamed grains within a given swelling temperature range while internally developing pressure and (c) a non-hardened thermosetting resin which begins to gell within the aforementioned swelling temperature range and completely hardens at higher temperature values, until there is formed a homogeneous distribution of these components. This mixture is filled into the hollow mold cavity of a mold. The mold is then closed in a pressure-tight fashion. The mold is initially heated up to the swelling temperature range and thereafter to the higher hardening temperature range of the resin.
Inventors
- 👤 Rudolf Heller
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-26 11:34
CPC Classifications
E; E04; E04C; E04C2/00; E04C2/02; E04C2/10; E04C2/16; C; C04; C04B; C04B26/00; C04B26/02; C04B26/10; C04B26/12; C04B26/122; Y; Y10; Y10S; Y10S264/00; Y10S264/02; Y10S264/07; Y10S264/17; Y10S264/57; Y10S264/63
Claims Analysis
Total Claims: 10
Claim 1
Independent Claim
144 words
A METHOD OF FABRICATING DIMENSIONALLY STABLE AND LOADCARRYING ARTIFICIAL CONCRETE-CONSTRUCTION ELEMENTS COMPRISING THE STEPS OF: ADMIXING WITH AT LEAST 85 PERCENT BY WEIGHT OF A LOOSE MASS OF MINERAL GRAINS FROM 2 TO 5 PERCENT BY WEIGHT OF A FINE GRAIN GRANULATE OF THERMOPLASTIC MATERIAL WHICH CAN EXPAND INTO ESSENTIALLY VOLUMINOUS FOAMED GRAINS WITHIN A GIVEN SWELLING TEMPERATURE RANGE WHILE INTERNALLY DEVELOPING PRESSURE AND FROM ABOUT 5 TO 10 PERCENT BY WEIGHT OF A NONHARDENING THERMOSETTING RESIN WHICH BEGINS TO GELL WITHIN THE AFOREMENTIONED SWELLING TEMPERATURE RANGE AND COMPLETELY HARDENS AT HIGHER TEMPERATURE VALUES, UNTIL FORMING A HOMOGENEOUS DISTRIBUTION OF THESE COMPONENTS, FILLING THIS MIXTURE INTO THE HOLLOW MOLD CAVITY OF A MOLD, THEN SEALING THE MOLD IN A PRESSURE-TIGHT FASHION AND INITIALLY EXTERNALLY HEATING THE MOLD UP TO THE SWELLING TEMPERATURE RANGE AND THEREAFTER TO THE HIGHER HARDENING TEMPERATURE RANGE OF THE RESIN.
Claim 2
Independent Claim
144 words
A METHOD OF FABRICATING DIMENSIONALLY STABLE AND LOADCARRYING ARTIFICIAL CONCRETE-CONSTRUCTION ELEMENTS COMPRISING THE STEPS OF: ADMIXING WITH AT LEAST 85 PERCENT BY WEIGHT OF A LOOSE MASS OF MINERAL GRAINS FROM 2 TO 5 PERCENT BY WEIGHT OF A FINE GRAIN GRANULATE OF THERMOPLASTIC MATERIAL WHICH CAN EXPAND INTO ESSENTIALLY VOLUMINOUS FOAMED GRAINS WITHIN A GIVEN SWELLING TEMPERATURE RANGE WHILE INTERNALLY DEVELOPING PRESSURE AND FROM ABOUT 5 TO 10 PERCENT BY WEIGHT OF A NONHARDENING THERMOSETTING RESIN WHICH BEGINS TO GELL WITHIN THE AFOREMENTIONED SWELLING TEMPERATURE RANGE AND COMPLETELY HARDENS AT HIGHER TEMPERATURE VALUES, UNTIL FORMING A HOMOGENEOUS DISTRIBUTION OF THESE COMPONENTS, FILLING THIS MIXTURE INTO THE HOLLOW MOLD CAVITY OF A MOLD, THEN SEALING THE MOLD IN A PRESSURE-TIGHT FASHION AND INITIALLY EXTERNALLY HEATING THE MOLD UP TO THE SWELLING TEMPERATURE RANGE AND THEREAFTER TO THE HIGHER HARDENING TEMPERATURE RANGE OF THE RESIN.
Claim 3
Dependent Claim
85 words
The method as defined in claim 1, including the step of filling the mixture into a mold which is still pervious to water vapor after closing such mold, said thermoplastic material being expandable polystyrene grit, said thermo-setting resin being a liquid resole phenol-formaldehyde resin which gells at the swelling temperature range of the polystyrene and thermally hardens at higher temperature values, the resin constituent of the liquid phenol-formaldehyde resin based upon the liquid quantity of such phenol-formaldehyde resin containing at most 20 percent volatile constituents.
Claim 4
Dependent Claim
65 words
The method as defined in claim 1, including the step of depositing into the mold different layers of mineral grain mixtures having different content of any one of the expandable granulate, resin, or different grain size spectrum, and in a single working operation while developing internal pressure in the mold thermally hardening the mixture so as to intimately bond together the mixture components into one-piece.
Claim 5
Dependent Claim
48 words
The method as defined in claim 1, including the step of filling into the mold a mixture which additionally contains fibers in a homogeneous and random dispersion therein, said fibers being present in an amount by weight which exceeds 2 percent of the total weight of the mixture.
Claim 6
Independent Claim
104 words
A method of fabricaTing dimensionally stable and load-carrying components, especially artificial concrete-construction elements, comprising the steps of admixing (a) at least 85 percent by weight of a loose mass of mineral grains, (b) from 2 to 5 percent by weight unexpanded thermoplastic material capable of expanding into voluminous foamed granules, and (c) from about 5 to 10 percent by weight of a non-hardened thermosetting resin which begins to gell within the swelling temperature of the expandable plastic and at increased temperatures completely hardens, then filling this mixture into a mold, closing the mold, heating the mold to the swelling temperature of the expandable plastic.
Claim 7
Independent Claim
104 words
A method of fabricaTing dimensionally stable and load-carrying components, especially artificial concrete-construction elements, comprising the steps of admixing (a) at least 85 percent by weight of a loose mass of mineral grains, (b) from 2 to 5 percent by weight unexpanded thermoplastic material capable of expanding into voluminous foamed granules, and (c) from about 5 to 10 percent by weight of a non-hardened thermosetting resin which begins to gell within the swelling temperature of the expandable plastic and at increased temperatures completely hardens, then filling this mixture into a mold, closing the mold, heating the mold to the swelling temperature of the expandable plastic.
Claim 8
Dependent Claim
17 words
The method as defined in claim 5, further including the step of adding fibers to the mixture.
Claim 9
Dependent Claim
13 words
The method as defined in claim 5, wherein said expandable plastic is polystyrene.
Claim 10
Dependent Claim
15 words
The method as defined in claim 5, wherein the resin is a resole phenol-formaldehyde resin.
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1978-02-17 | 1978-08-19 | 1979-02-18 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1982-02-17 | 1982-08-19 | 1983-02-18 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1986-02-17 | 1986-08-19 | 1987-02-18 | $7700.00 | Window Closed / Lapsed |