US4045268A
Expired / Lapsed
US
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Mastic composition and composite structural panels formed therefrom
Assignee: Bell Fibre Products Corp
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Filing: 1976-05-06
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Granted: 1977-08-30
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Expires: 1996-05-06
Abstract
Abstract A mastic composition formed of a substantially homogeneous imporous mixture of a predetermined volume of low-density expanded closed-cell synthetic resin beads and a slurry prepared from calcined gypsum and water wherein the interstitial volume of the expanded beads is not substantially less than the volume of slurry. The substantially homogeneous mixture is self-adhering as a thick layer on an inverted smooth surface and yet separable therefrom as an integral layer, the mastic composition setting to a hard, strong, dimensionally stable, heat- and sound-retardant material. Method of mixing mastic compositions, and composite structural panels utilizing mastic compositions as well as the methods and apparatus for forming such panels are also disclosed.
Inventors
- 👤 Robert C. Geschwender
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-26 11:20
CPC Classifications
B; B32; B32B; B32B13/00; B32B13/04; B32B13/08; B32B3/00; B32B3/10; B32B3/12; C; C04; C04B; C04B28/00; C04B28/14; E; E04; E04C; E04C2/00; E04C2/30; E04C2/34; E04C2/36; E04C2/365; B32B2266/00; B32B2266/02; B32B2266/0214; B32B2266/0221; B32B2266/0228; B32B2266/08; B32B2305/00; B32B2305/02; B32B2305/024; B32B2607/00; Y; Y10; Y10T; Y10T156/00; Y10T156/10; Y10T156/1002; Y10T156/1003; Y10T428/00; Y10T428/24; Y10T428/24149; Y10T428/24157; Y10T428/24273
Claims Analysis
Total Claims: 25
Claim 1
Independent Claim
307 words
A method of making composite structural panels comprising a core of expanded honeycomb material having cells extending from one face thereof to the other and layers of a mastic composition on opposite faces of the core keyed into the ends of the cells, said method comprising: feeding honeycomb material of predetermined thickness in compacted condition from a supply and expanding it to form the cells; feeding the expanded honeycomb material forward on a predetermined horizontal path with the cells vertical and with the upper face of the honeycomb material spaced below an upper guide and the lower face of the honeycomb material spaced above a lower guide and with these guides being spaced a distance greater than the thickness of the expanded honeycomb material for travel of the expanded honeycomb material therebetween; supplying a first web of mastic-backing material to travel rearward in a horizontal path above the upper guide and then forward below the upper guide and above the honeycomb material; applying hardenable mastic material in a layer substantially thicker than one-half the difference between the spacing of the upper and lower guides and the thickness of the honeycomb material to the upper face of the first web as it travels rearward over the upper guide; supplying a second web of mastic-backing material to travel forward in a horizontal path over the lower guide means; applying hardenable mastic material in a layer thicker than one-half the difference between the spacing of the upper and lower guides and the thickness of the honeycomb material to the face of the second web which faces upward as the second web travels forward over the lower guide; said guides being operable to press the mastic layers into the upper and lower ends of the cells of the honeycomb material to a depth less than the thickness of the mastic layers.
Claim 2
Independent Claim
307 words
A method of making composite structural panels comprising a core of expanded honeycomb material having cells extending from one face thereof to the other and layers of a mastic composition on opposite faces of the core keyed into the ends of the cells, said method comprising: feeding honeycomb material of predetermined thickness in compacted condition from a supply and expanding it to form the cells; feeding the expanded honeycomb material forward on a predetermined horizontal path with the cells vertical and with the upper face of the honeycomb material spaced below an upper guide and the lower face of the honeycomb material spaced above a lower guide and with these guides being spaced a distance greater than the thickness of the expanded honeycomb material for travel of the expanded honeycomb material therebetween; supplying a first web of mastic-backing material to travel rearward in a horizontal path above the upper guide and then forward below the upper guide and above the honeycomb material; applying hardenable mastic material in a layer substantially thicker than one-half the difference between the spacing of the upper and lower guides and the thickness of the honeycomb material to the upper face of the first web as it travels rearward over the upper guide; supplying a second web of mastic-backing material to travel forward in a horizontal path over the lower guide means; applying hardenable mastic material in a layer thicker than one-half the difference between the spacing of the upper and lower guides and the thickness of the honeycomb material to the face of the second web which faces upward as the second web travels forward over the lower guide; said guides being operable to press the mastic layers into the upper and lower ends of the cells of the honeycomb material to a depth less than the thickness of the mastic layers.
Claim 3
Dependent Claim
26 words
A method according to claim 1, comprising the intermediate step of applying reinforcing fibers to the exposed surfaces of the layers prior to the pressing step.
Claim 4
Dependent Claim
21 words
A method according to claim 2, wherein the fibers are applied by spraying them onto the exposed surfaces of the layer.
Claim 5
Dependent Claim
25 words
A method according to claim 3, comprising the additional step of working at least some of the fibers from the exposed surfaces into the layers.
Claim 6
Dependent Claim
26 words
A method according to claim 4, wherein working includes raking the exposed surfaces to effect penetration of at least some of the fibers into the layers.
Claim 7
Dependent Claim
23 words
A method according to claim 1, comprising the additional step of predeterminately limiting the penetration of the mastic layers into the honeycomb cells.
Claim 8
Dependent Claim
28 words
A method according to claim 6, wherein the additional step includes trapping air in each honeycomb cell thereby to limit penetration of the mastic layers into the cells.
Claim 9
Dependent Claim
38 words
A method according to claim 7, wherein in predeterminately limiting penetration of the mastic layers into the cells also includes controlling the thickness of the mastic layers between the opposed support surfaces and the faces of the core.
Claim 10
Dependent Claim
62 words
A method according to claim 1, comprising the preliminary step of forming the hardenable mastic composition comprising a homogeneous imporous mixture of low density closed cell expanded synthetic resin beads by combining a predetermined volume of said beads with a slurry prepared from calcined gypsum and water, the volume of slurry being not substantially less than the interstitial volume of the beads.
Claim 11
Dependent Claim
56 words
A method according to claim 9, wherein the preliminary step includes combining fiber glass with the beads for the subsequent combining with the slurry, and wherein the interstitial volume is that of a weight of expanded beads substantially equal to the total weight of the beads and the glass fibers which are combined with the slurry.
Claim 12
Dependent Claim
44 words
A method according to claim 1, comprising the additional step of embedding in the mastic layer open mesh reinforcing material which extends generally parallel between the support surfaces and the respective core faces as the mastic layers are pressed into the opposite core faces.
Claim 13
Dependent Claim
48 words
A method according to claim 1, comprising the intermediate step of inserting a strip of open mesh reinforcing material between adjacent strips of honeycomb material which are disposed substantially in side-by-side relation and which constitute the core, the reinforcing strip extending generally perpendicular to the opposite core faces.
Claim 14
Independent Claim
70 words
A method of making a composite structural panel comprising feeding an expanded honeycomb core having walls with openings therein between each cell and adjacent the opposite core faces, and concurrently pressing layers of hardenable mastic composition into the opposite core faces with the layers penetrating into each cell generally to the point of closing the openings and thereby trapping air in the cells to predetermine the depth of layer penetration.
Claim 15
Independent Claim
70 words
A method of making a composite structural panel comprising feeding an expanded honeycomb core having walls with openings therein between each cell and adjacent the opposite core faces, and concurrently pressing layers of hardenable mastic composition into the opposite core faces with the layers penetrating into each cell generally to the point of closing the openings and thereby trapping air in the cells to predetermine the depth of layer penetration.
Claim 16
Dependent Claim
49 words
A method according to claim 13, comprising a further step of applying the mastic layers onto a web of facing material prior to the pressing step, the trapped air in the cells also predetermining the layer thickness between the opposite core faces and the webs of facing material, respectively.
Claim 17
Dependent Claim
35 words
A method according to claim 14, comprising the additional step of inverting one of the webs of facing material and its mastic layer prior to the pressing thereof into one of the core opposite faces.
Claim 18
Dependent Claim
47 words
A method according to claim 13, comprising the further step of applying reinforcing fibers to the exposed surfaces of the mastic layers prior to pressing, at least some of the fibers extending between adjacent cells and through the openings thereby to provide a tie between adjacent cells.
Claim 19
Dependent Claim
18 words
A method according to claim 16, wherein fibers are applied by spraying them onto the exposed layer surfaces.
Claim 20
Dependent Claim
25 words
A method according to claim 16, comprising the additional step of working at least some of the fibers from the exposed surfaces into the layers.
Claim 21
Dependent Claim
28 words
A method according to claim 18, wherein the working includes raking the exposed surfaces to effect penetration of at least some of the fibers into the mastic layers.
Claim 22
Dependent Claim
50 words
A method according to claim 13, comprising the preliminary step of forming the hardenable mastic composition by mixing expanded low density closed cell synthetic resin beads with a slurry prepared from calcined gypsum and water, the volume of slurry being not substantially less than the interstitial volume of the beads.
Claim 23
Dependent Claim
41 words
A method according to claim 13, wherein two webs of open mesh reinforcing material are simultaneously fed with the core extending generally parallel adjacent to respective opposite faces thereof so as to be embedded in the mastic layers upon pressing thereof.
Claim 24
Dependent Claim
28 words
A method according to claim 13, wherein the feeding of the core includes simultaneously feeding ribbons of honeycomb material substantially in side-by-side relation which thereby constitutes the core.
Claim 25
Dependent Claim
26 words
A method according to claim 22, wherein a wire mesh strip is simultaneously fed between the side-by-side honeycomb material extending generally perpendicular to the core faces.
References Cited (Backward Citations)
USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1980-08-29 | 1981-02-28 | 1981-08-30 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1984-08-29 | 1985-02-28 | 1985-08-30 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1988-08-29 | 1989-02-28 | 1989-08-30 | $7700.00 | Window Closed / Lapsed |