U.S. patent number 3,922,413 [Application Number 05/475,815] was granted by the patent office on 1975-11-25 for lightweight, high strength, reinforced concrete constructions.
Invention is credited to Richard G. Reineman.
United States Patent |
3,922,413 |
Reineman |
November 25, 1975 |
Lightweight, high strength, reinforced concrete constructions
Abstract
Lightweight, high strength, reinforced concrete constructions
formed of a plurality of substantially coextensive, parallel,
spaced apart membranes consisting of alternate, integrally bonded
layers of fiber-reinforced epoxy resin and epoxy resin-containing
concrete interconnected by continuous longitudinal and lateral
transverse webs of epoxy resin-containing concrete that form a
unitary structure having a plurality of enclosed cavities which are
each filled with a hollow-form core. The construction can be in the
form of a flat sheet or panel of any desired size, or it can have a
curvilinear configuration.
Inventors: |
Reineman; Richard G. (Newport
Beach, CA) |
Family
ID: |
23889276 |
Appl.
No.: |
05/475,815 |
Filed: |
June 3, 1974 |
Current U.S.
Class: |
428/119; 52/576;
264/DIG.57; 264/129; 264/250; 428/319.1; 428/413; 264/256;
428/319.3; 428/703; 52/405.1 |
Current CPC
Class: |
B32B
13/12 (20130101); B32B 3/26 (20130101); B32B
27/38 (20130101); E04C 2/36 (20130101); E04C
2/2885 (20130101); Y10T 428/31511 (20150401); C04B
2111/00663 (20130101); Y10T 428/24999 (20150401); Y10S
264/57 (20130101); B32B 2305/08 (20130101); B32B
2607/00 (20130101); B32B 2305/028 (20130101); Y10T
428/249991 (20150401); Y10T 428/24174 (20150115) |
Current International
Class: |
E04C
2/34 (20060101); E04C 2/288 (20060101); E04C
2/26 (20060101); E04C 2/36 (20060101); B32B
003/12 () |
Field of
Search: |
;161/43,68,69,162,184
;52/DIG.7,576,577,405 |
References Cited
[Referenced By]
U.S. Patent Documents
Primary Examiner: Ansher; Harold
Assistant Examiner: Epstein; Henry F.
Attorney, Agent or Firm: Sandford; Dean
Claims
Having now described my invention, I claim:
1. A relatively lightweight, high strength, cementitious
construction comprising a plurality of substantially coextensive,
parallel, spaced-apart membranes consisting of alternate,
integrally bonded layers of fiber-reinforced epoxy resin and epoxy
resin-containing concrete, said membranes being interconnected by
continuous longitudinal and lateral transverse webs of epoxy
resin-containing concrete so as to form a unitary structure having
a plurality of enclosed cavities which are filled with cellular
core material.
2. The article defined in claim 1 wherein said fiber-reinforced
epoxy resin is epoxy resin reinforced with metal, plastic, or glass
fibers.
3. The article defined in claim 1 wherein said epoxy
resin-containing concrete is a hardened admixture in the proportion
of 1 to 3 cubic feet of aggregate, 1/4 to 3 gallons of epoxy resin,
1 to 6 fluid ounces of water reducing additive, and about 4 to 6
gallons of water per 94 pound sack of cement.
4. The article defined in claim 1 wherein said epoxy resin is an
admixture of diglycidal ether of bisphenol A and a reactive
hardener.
5. The article defined in claim 1 wherein said epoxy resin is an
admixture of diglycidal ether of bisphenol A, ortho cresyl glycidal
ether and a reactive hardener.
6. The article defined in claim 1 wherein said cellular core
material is foamed polystyrene.
7. The article defined in claim 1 wherein said cellular core
material is a closed holow member.
8. The article defined in claim 1 wherein said construction is
comprised of two spaced apart membrances, each membrane including
an interior layer of fiber-reinforced epoxy resin and an exterior
layer of epoxy resin-containing concrete.
9. The article defined in claim 1 wherein said spaced apart
membranes are each comprised of first and second layers of epoxy
resin-containing concrete and an intermediate integrally bonded
layer of fiber-reinforced epoxy resin.
10. The article defined in claim 1 wherein said spaced apart
membranes are each comprised of at least three alternate layers of
epoxy resin-containing concrete interspaced by integrally bonded
layers of fiber-reinforced epoxy resin.
11. The article defined in claim 1 including three spaced apart
membranes.
12. The article defined in claim 1 wherein at least a portion of
the outer exposed surface of said membranes is coated with epoxy
paint.
13. The article defined in claim 1 including an integrally bonded
coating of polyester or epoxy gel coat on the outer exposed surface
of said membranes.
14. A relatively lightweight, high strength, cementitious
construction comprising first and second substantially coextensive,
parallel, spaced apart membranes consisting of alternate,
integrally bonded layers of glass fiber-reinforced epoxy resin and
epoxy resin-containing concrete, said membranes being
interconnected by continuous longitudinal and lateral transverse
webs of epoxy resin-containing concrete so as to form a unitary
structure having a plurality of enclosed cavities filled with
foamed plastic, said epoxy resin-containing concrete comprising a
hardened admixture in the proportion of 1 to 3 cubic feet of
aggregate, 1/4 to 3 gallons of epoxy resin, 1 to 6 fluid ounces of
a water reducing additive, and sufficient water to harden the
cement per 94 pound sack of cement.
15. The article defined in claim 14 wherein said epoxy resin is an
admixture of diclycidal ether of bisphenol A and a reactive
hardener.
16. The article defined in claim 14 wherein said epoxy resin is an
admixture of diglycidal ether of bisphenol A, ortho cresyl glycidal
ether and a reactive hardener.
17. The article defined in claim 14 wherein said foamed plastic is
foamed polystyrene.
18. The article defined in claim 14 wherein said first and second
spaced apart membranes are each comprised of an interior layer of
galss-fiber reinforced epoxy resin and an exterior layer of epoxy
resin-containing concrete.
19. The article defined in claim 14 wherein said first and second
spaced apart membranes are each comprised of at least three
alternate layers of epoxy resin-containing concrete interspaced by
integrally bonded layers of glass fiber-reinforced epoxy resin.
20. a relatively lightweight, high strength, cementitious
construction comprising first and second substantially coextensive,
parallel, spaced apart membranes consisting of alternate,
integrally bonded layers of glass fiber-reinforced epoxy resin and
epoxy resin-containing concrete, said membranes being
interconnected by continuous longitudinal and lateral transverse
webs of epoxy resin-containing concrete so as to form a unitary
structure having a plurality of enclosed cavities filled with
foamed polystyrene, said epoxy resin-containing concrete comprising
a hardened admixture in the proportion of 1 to 3 cubic feet of
sand, 1/4 to 3 gallons of epoxy resin, 1 to 6 fluid ounces of a
water reducing additive, and sufficient water to harden the cement
per 94 pound sack of cement.
21. The article defined in claim 1 wherein said lateral transverse
webs are disposed at oblique angles with respect to the
longitudinal axis of said membranes.
Description
This invention relates to lightweight, high strength reinforced
concrete constructions, and more particularly to relatively
lightweight flat or curved, high strength, concrete members useful
in the construction of buildings, and for like purposes.
Many of the heretofore commonly employed materials used in the
construction of buildings, such as wood, steel, brick, masonry, and
the like, are becoming increasingly less available and more costly.
Also, the construction systems employing these materials do not
provide adequate fire, flood, tornado, and earthquake resistance;
nor do these materials adapt readily to the construction of
buildings of non-rectangular design, which often prohibits the use
of imaginative and otherwise practical and economic architectural
designs.
Because of its relatively low cost, durability, high compressive
strength, availability, and other desirable properties, reinforced
concrete has been widely used as a material of construction.
However, reinforced concrete has been largely limited to use in
constructions where weight and bulk are not limiting factors. U.S.
Pat. No. 3,753,849 issued to Raymond A. Duff on Aug. 21, 1973,
discloses improved cementitious constructions formed of alternate
integrally bonded layers of epoxy resin-containing concrete and
fiber-reinforced epoxy resin. These constructions exhibit high
tensile and flexural strengths and have excellent utility in the
form of thin sheets and panels and in a wide variety of molded and
formed articles. Although the patented constructions can have
substantial thickness and bulk, because of the high strength of
this material, the thicker constructions are not warranted in many
applications; the patented constructions being most often used in
relatively thin-wall articles having thicknesses of about 1/8-inch
to about 2-inches, and more often of about 1/8-inch to about
1-inch. However, many applications require a bulkier or thicker
construction, but do not require the extraordinary strength
provided by a solid body of alternate integrally bonded layers of
epoxy resin-containing concrete and fiber-reinforced epoxy
resin.
While need exists throughout the building construction industry,
and elsewhere, for relatively bulky, lightweight, high strength,
concrete constructions, one particular need exists in the
manufacture of prefabricated buildings where the various components
of the building are individually fabricated and assembled into the
completed building at the installation site.
Accordingly, a principal object of this invention is to provide
relatively bulky, lightweight, high strength, concrete
constructions.
Another object of the invention is to provide lightweight concrete
articles of construction that exhibit relatively high
strengths.
Still another object of the invention is to provide lightweight,
high strength, concrete constructions useful in architectural
applications, and particularly in the construction of prefabricated
buildings.
A yet further object of the invention is to provide lightweight,
high strength, concrete panels, beams and architectural shapes.
These and other objects will be apparent from the following
disclosure and accompanying drawings, in which:
FIG. 1 is a partially cut-away isometric view showing a
construction in accordance with the present invention;
FIG. 2 is a partial cross-sectional view taken along the line 2--2
of FIG. 1;
FIG. 3 is a cross-sectional view along the longitudinal axis of a
construction showing another embodiment of the inventin utilizing
triangular-shaped hollow-form cores as fillers, and wherein the
transverse webs are situated at oblique angles;
FIG. 4 is a cross-sectional view along the longitudinal axis of a
construction showing still another embodiment of the invention
utilizing hexagonal-shaped hollow-form cores as fillers, and
wherein the transverse webs are arranged in a hexagonal
pattern;
FIG. 5 is a partial cross-sectional view along the longitudinal
axis of a construction illustrating an embodiment of the invention
employing a closed container to form the enclosed cavities;
FIG. 6 is a partial cross-sectional view along the longitudinal
axis of a construction in which the parallel membranes are formed
of alternate integrally bonded layers of epoxy resin-containing
concrete and an intermediate integrally bonded layer of fiber
reinforced epoxy resin;
FIG. 7 is a partial cross-sectional view along the longitudinal
axis of a construction illustrating still another embodiment of the
invention employing a plurality of layers of hollowform cores;
and
FIG. 8 is a partial cross-sectional view along the longitudinal
axis of another embodiment of the invention wherein the parallel
membranes are comprised of a plurality of alternate, integrally
bonded layers of epoxy resin-containing concrete and
fiber-reinforced epoxy resin.
Briefly, this invention involves a lightweight, high strength,
reinforced concrete construction formed of a plurality of
substantially coextensive, parallel, spaced-apart membrances
consisting of alternate, integrally bonded layers of
fiber-reinforced epoxy resin and epoxy resin-containing concrete
interconnected by transverse webs of epoxy resin-containing
concrete that form a unitary structure having a plurality of
enclosed cavities which are each filled with a holow-form core. The
construction can be in the form of a flat sheet or panel of any
desired size, or it can have a curvilinear configuration.
Referring specifically to FIG. 1, the numeral 10 designates a
lightweight, high strength, construction comprised of a pair of
substantially coextensive, parallel membranes 12 and 14 of
alternate integrally bonded layers of fiber-reinforced epoxy resin
and epoxy resin-containing concrete interconnected by longitudinal
transverse web 16 and lateral transverse webs 18 of epoxy
resin-containng concrete. The construction is bounded by
longitudinal transverse members 20 and end transverse members 22,
which form a unitary structure defining a plurality of enclosed
cavities filled with a hollow-form core material 24, the
hollow-form core material filling cavity 24a being deleted from the
drawing to illustrate the structural features of construction
10.
As more particularly illustrated in FIG. 2, parallel membranes 12
and 14 are formed of inner layers 26 and 28, respectively, of
fiber-reinforced epoxy resin and outer layers 30 and 32,
respectively, of epoxy resin-containing concrete.
FIG. 3 illustrates an embodiment of the invention in which the
hollow-form cores 34 are in the form of alternate upright and
inverted triangular blocks interspaced by longitudinal transverse
webs 36 and lateral transverse webs 38 disposed at oblique angles
with respect to the longitudinal axis of the member.
FIG. 4 illustrates a further embodiment in which the hollow-form
cores 40 are in the form of hexagonal blocks interspaced by
hexagonally shaped transverse webs 42.
FIG. 5 illustrates an embodiment of the invention in which membrane
50 is formed of alternate layers of epoxy resin-containing concrete
52 and 54 interspaced with integrally bonded fiber-reinforced epoxy
resin layer 56, and membrane 60 is formed of alternate layers of
epoxy resin-containing concrete 62 and 64 interspaced with
integrally bonded fiber-reinforced epoxy resin layer 66. Membranes
50 and 60 are interconnected by transverse webs 68 of epoxy
resin-containing concrete. The cavities 70 are voids defined by
enclosed containers 72, such as metal, plastic, or paperboard cans;
or balloons; or inflated bladders of a resilient material.
In the embodiment illustrated in FIG. 6, membrane 80 is comprised
of alternate layers of epoxy resin-containing concrete 82 and 84,
interspaced by integrally bonded layer 86 of fiber-reinforced epoxy
resin, and membrane 90 is similarly comprised of layers 92 and 94
of epoxy resin-containing concrete interspaced by integrally bonded
layer 96 of fiber-reinforced epoxy resin. Membrane 90 is provided
with an outer layer 98 of epoxy resin or polyester resin gel coat,
as will be hereinafter more particularly described. The
substantially coextensive membranes 80 and 90 are interconnected by
transverse webs 100 of epoxy resin-containing concrete defining a
plurality of enclosed cavities filled with hollow-form cores
102.
The embodiment illustrated in FIG. 7 is particularly useful in
applications where higher strength members are reuired, such as in
beams, or the like. This embodiment consists of a plurality of
substantially coextensive, parallel membranes 110, 112 and 114
consisting of alternate, integrally bonded layers of epoxy
resin-containng concrete 116 and 118 interspaced by integrally
bonded layers 120 of fiber-reinforced epoxy resin. Membranes 110
and 112 are interconnected by transverse webs 122 and membranes 112
and 114 are interconnected by transverse webs 124 so as to define a
plurality of enclosed cavities filled by hollow-form cores 126.
In the embodiment illustrated in FIG. 8, parallel membranes 130 and
132 are formed of a plurality of layers 134, 138 and 142 of epoxy
resin-containing concrete interspaced by integrally bonded layers
136 and 140 of fiber-reinforced epoxy resin. The membranes 130 and
132 are inteconnected by transverse webs 144 so as to form a
plurality of enclosed cavities filled by hollow-form cores 146.
The hollow-form cores serve as forms during the casting of the
construction and further have insulating properties which reduce
the heat and sound conductivities of the construction. Any of a
wide variety of cellular materials can be employed as the core
material. By "cellular material" it is meant a low density solid
structural system such as a body comprised of a contiguous solid
material having a high proportion of air pockets or void spaces.
Among the useful cellular materials are corrugated and honeycomb
paperboard and natural and synthetic cellular materials including
balsa wood, natural sponge, synthetic sponge, foam rubber, foamed
nylon and foamed plastics such as foamed epoxies, foamed
polystyrene, foamed polyvinyl chloride, foamed polyethylene, foamed
cellulose acetate, foamed polyurethane, and the like. Foamed
polyurethane is a preferred core material.
Also, as illustrated in FIG. 5, the hollow-form cores can be closed
cans or containers constructed of metal, paperboard, or plastic, or
can be inflated balloons or bladders of a resilient material such
as rubber, or the like. The hollow-form cores can be employed in
any of a variety of regular and irregular shapes such as
cylindrical and polygonical blocks, and particularaly blocks having
triangular, rectangular, pentagonal, hexagonal, and like cross
sections.
The cementitious material used in the constructions of this
invention is a hardenable admixture of hydraulic cement, aggregate,
epoxy resin, water reducing additive, and sufficient water to
hydrate the cement. When first admixed, the material has a soft,
semisolid consistency and can be molded, cast, trowelled, or
applied by gun. On curing, the material hardens into a hard rigid
solid having high strength and durability.
The hydraulic cement can be any of the commercial hydraulic cements
such as ASTM Type I or normal Portland cement. ASTM Type II or
modified Portland cement, ASTM Type III or high-early-strength
Portland cement, ASTM Type IV or low-heat Portland cement, ASTM
Type V or sulphate resistance Portland cement, ASTM Type IP or
Portland-pozzolana cement, plastic cement, or gun plastic cement.
Also, the cement can optionally contain additives to improve
various properties, such as workability, aggregate segregation, air
entrainment, and to accelerate or slow setting time. The aggregate
is sand, although fine pea gravel and crushed aggregate can be used
in part, particularly in thicker constructions, and lightweight or
low density aggregate can be employed where it is desired to
minimize weight.
Various commercial epoxy resin compositions can be employed in the
practice of this invention. These are typically undiluted low
viscosity liquids or more viscous resins diluted with a solvent,
and are conventionally employed in a two component system, i.e.,
the resin and the catalyst are separately packaged and admixed only
at the time of use. The epoxy resins preferred in the practice of
this invention are undiluted liquids that exhibit the following
properties after curing for 7 days:
Tensile strength 8,000 psi minimum Tensile elongation 10 percent
maximum Flexural strength 15,000 psi minimum Compressive yield
12,000 psi minimum Hardness above 60 shore D
A commercial epoxy resin exhibiting the foregoing properties and
which is particularly useful in the practice of this invention is a
relatively low viscosity, two component epoxy resin marketed by the
Adhesive Engineering Company under the trademark Concresive No.
1170, and identified as Part A and Part B. This material is admixed
in the ratio of about 2 parts of Part A to 3 parts of Part B to
about 3 parts of Part A to 2 parts of Part B, and is preferably
employed in the proportion of about equal parts of Part A and Part
B. Preferably, the two epoxy resin components are intimately
admixed prior to adding them to the wet cement mixture.
The fiber reinforcing material for the epoxy resin layer can be
metal, plastic, cloth, or fiber glass in the form of matting, woven
material, or short lengths of chopped fibers. Other fibers that can
be employed in addition to fiber glass are sisal, hemp, cotton,
nylon, rayon, polyethylene terephthalate (Dacron) acrylic fibers
(Orlon), and other synthetic and natural fibers. Included within
the woven materials are metal, plastic, cloth or glass screen or
mesh. A particularly preferred fiber reinforcing material that
imparts superior strength to the ultimate structure is woven fiber
glass roving. Fiber glass roving is a woven-type material in which
bundles of glass fibers are woven in a basket-like weave.
A suitable epoxy resin is the diglycidyl ether of bisphenol A which
can be formed by the condensation of epichlorohydrin and bisphenol
A, i.e., bis(4-hydroxy-phenyl)dimethyl methane. A preferred
bisphenol A diglycidyl ether is a liquid thermosetting resin having
a Brookfield viscosity of about 10,000 to 16,000 centipoise at a
temperature of 25.degree. C. and an epoxide equivalent weight of
about 185 to 200. A suitable bisphenol A diglycidyl ether of this
type is marketed by the Celanese Coatings Company under the
trademark Epi-Rez 510.
The bisphenol A diglycidyl ether can be admixed with a reactive
diluent to provide a modified resin system. A preferred epoxy resin
is an admixutre of bisphenol A diglycidyl ether and ortho-cresyl
glycidyl ether containing about 20 to 40 percent of the reactive
diluent. A particularly preferred resin combination is an admixture
of about 73 parts of bisphenol A diglycidyl ether and 27 parts of
ortho-cresyl glycidyl ether. A suitable orthocresyl glycidyl ether
reactive diluent having a Brookfield viscosity of 5 to 25
centipoises at 25.degree. C. and an epoxide equivalent weight of
180 to 200 is marketed by the Celanese Coatings Company under the
trademark Epi-Rez 5011. A commercially available admixture of 73
percent diglycidyl ether of bisphenol A and 27 percent ortho-cresyl
glycidyl ether suitable for use in the compositions of this
invention is marketed by the Celanese Coatings Company under the
trademark Epi-Rez 5077. This resin mixture has a Brookfield
viscosity of 500 to 700 centipoises at 25.degree. c. and an epoxide
equivalent weight of 185 to 200.
A wide variety of catalysts and reactive hardeners are known that
cure or harden epoxy resins. While a number of different agents can
be employed to cure the epoxy resins employed in the compositions
of this invention, the reactive amine-type hardeners are preferred.
A particularly preferred hardener is an admixture of a reactive
amido-amine such as dicyandiamide and a high reactive modified
amine converter. A suitable hardening agent of this type is
marketed by the Celanese Coatings Company under the trademark
Epi-Cure 872. The preferred hardening agent is added to the epoxy
resin in the proportions of about 0.3 to 1 part of hardening agent
per part of resin, and preferably in the proportion of about 0.5
part of hardener per part of resin.
The water reducing additive employed in the composition of this
invention is a liquid admixture consisting principally of
hydroxylated polymers, calcium lignosulfonate, and an organic
accelerator. A suitable water reducing agent is marketed by Master
Builders under the trademark Pozzolith 300-N. the liquid water
reducing additive is employed in small amounts, such as in the
proportion of about 1 to 6 fluid ounces per 94 pound sack of
cement, and preferably in the proportion of about 2 to 4 fluid
ounces per sack of cement.
The cementitious material is prepared by admixing the ingredients
in the proportion of about 1/4 to 3, and preferably about 1/4 to
11/2 gallons of combined epoxy resin and hardener, about 1 to 3
cubic feet of aggregate, about 1 to 6 fluid ounces of liquid water
reducing additive, and about 4 to 6, and preferably about 41/2 to 5
gallons of water per 94 pound sack of cement. A preferred
composition comprises an admixture of about three-fourths gallon of
epoxy resin and hardener, about 2 cubic feet of aggregate, about 3
fluid ounces of liquid water reducing additive, and about 4 to 6
gallons of water per 94 pound sack of cement, the exact amount of
water depending upon the moisture content of the sand. The
aggregate content of this composition on a weight basis is about
100 to 300 pounds, and preferably about 200 pounds per 94 pound
sack of cement when using regular sand, and about 55 to 165 pounds
per sack when using lightweight aggregates. The amount of water
employed in the cementitious material is substantially less than
would be required to hydrate and cure conventional concrete.
Also, it has been found that the cementitious material cures or
hardens substantially faster than conventional concrete, curing
often being sufficiently complete in only a few hours at ambient
temperature to permit an article to be removed from a mold or
subjected to a moderate amount of handling, although several days
will be required for the material to reach substantially full
strength.
The cementitious material is preferably prepared by admixing the
water and the water reducing additive, then adding the cement and
mixing the mass to a uniform consistency. Next, the aggregate is
added and thoroughly mixed. The epoxy resin and the hardener is
premixed and, as a final step, thoroughly mixed into the
cementitious composition. It should be noted that no more water can
be added to the cementitious mixture after the resin has been
added. Any adjustment of moisture content must be done before
addition of the resin. Also, in an alternative mode of preparation,
the water reducing additive can be premixed with the epoxy resin
and hardener, and this admixture added to the wet cement.
The lightweight, high strength, reinforced concrete constructions
of this invention can be manufactured in a wide variety of shapes
and sizes depending upon the ultimate use of the construction.
These constructions can be in the form of flat panels or panels
having simple or compound curved surfaces or regular or irregular
shapes. The constructions can be readily manufactured in a variety
of complex architectural shapes useful in the construction of
buildings, and particularly in the manufacture of prefabricated
buildings. Also, the constructions can be in the form of elongated
members useful as posts or beams, and particularly as load-carrying
structural beams.
The exterior surfaces of the constructions of the invention can be
left unfinished, or all or a portion of the surfaces can be
provided with one or more coats of a suitable paint. A particularly
desirable finish is provided by coating the exterior surfaces with
epoxy paint. Also, the constructions can optionally be provided
with a resinous surface coating, such as exterior coating 98
illustrated in FIG. 6, integrally bonded to the surface of epoxy
resin-containing concrete layer 94 to provide a decorative and/or
serviceable outer surface. Various clear or pigmented resins such
as polyester and epoxy resins are suitable for use in this
application. Where these surface coatings are not utilized,
conventional concrete pigments can be incorporated into the outer
layers of epoxy resin-containing concrete to provide the desired
color.
The constructions of this invention are manufactured by casting, or
by a combination of casting and spray application, in a suitable
mold of any desired configuration and surface pattern. The mold is
preferably coated with a suitable concrete form release, mold
release, or separating compound to facilitate removal of the
completed construction from the mold.
To manufacture a construction in accordance with the embodiment
illustrated in FIGS. 1 and 2, the layer 32 of uncured epoxy
resin-containing cement is applied to the mold and overlayed with
layer 28 of epoxy resin-saturated fibers. Next, blocks of
hollow-form core materials 24 are placed on epoxy resin layer 28
and suitably spaced to provide the desired configuration of
transverse webs. Separate units of the core material can be placed
in the mold, or the core material can be placed in the mold in the
form of one or more large slabs, in which case the grooves for the
webs are formed by cutting out or routing the desired pattern of
grooves in the core material. After the hollow-form core material
is in place and properly positioned or cut, the grooves between
adjacent pieces of core material and around the periphery of the
core material is filled with uncured epoxy resin-containing cement.
Layer 26 of epoxy resin-saturated fibers is applied directly to the
surface of the core material and the wet epoxy resin-containing
cement in the web and peripheral grooves. The construction is
completed by applying the layer 30 of epoxy resin-containing
cement. This final layer of uncured cementitious material can be
finished in any conventional manner to provide the desired finish,
such as by trowelling, floating, rubber floating, brooming, and the
like, or it can be left unfinished. It is sometimes preferable to
apply a light coat of epoxy resin over this final layer to act as a
sealer and to inhibit crazing of the cementitious material. After
the wet cement mixture and epoxy resin have set sufficiently that
the structure has sufficient strength to be handled, the
construction can be removed from the mold. Also, where desired for
decorative purposes, a light finish coat of stucco or plaster, not
shown, can be applied to the exterior surfaces of the
construction.
The constructions illustrated in FIG. 5 are manufactured by
applying layer 62 of wet cement mixture to the mold, and next
applying the layer 66 of epoxy resin-saturated fibers and the layer
64 of wet cement mixture. The hollow-form cores, such as the sealed
cans 72, are positioned in the mold and the spaces between and
around the periphery of the cores filled with wet cement mixture
and the layer 54 of wet cement mixture applied over the cores. This
layer is overlayed with layer 56 of epoxy resin-saturated fibers
and the final layer 52 of wet cement mixture.
In the manufacture of the embodiment illustrated in FIG. 6, a first
relatively thin layer 98 of polyester or epoxy gel coat is applied
to the mold by spray or hand application. The gel coat reproduces
the mold surface exactly to form a mirror image of the mold on the
surface of the construction. In this manner, any form of surface
from a smooth, porcelain-like finish to a grained, textured pattern
can be obtained. Once the gel coat is applied, a thin layer of
epoxy resin-saturated fibers is applied and the construction
completed in the above-described manner.
The constructions illustrated in FIGS. 7 and 8 are manufactured by
the above-described general method with multiple layers of core
material being applied in the case of the embodiment illustrated in
FIG. 7, and a plurality of alternate layers of wet cement mixture
and epoxy rsin-saturated fibers being applied in forming each
membrane of the embodiment illustrated in FIG. 8.
The various layers of wet cement mixture and the wet cement mixture
forming the interconnecting transverse webs can be placed in the
mold by any convenient method, it being convenient in many
applications to pump the wet cement mixture into the grooves
between and arond the periphery of the hollow-form cores and,
alternatively, to either hand apply the material onto the larger
surfaces or to spray apply the wet cement with a conventional
plaster gun.
The epoxy resin utilized in fiber-reinforced epoxy resin layers can
be of the same composition as the epoxy resin used in preparing the
wet cement mixture. The fiber-reinforced epoxy resin layer can be
formed by presaturating the fibers with epoxy resin and applying
the epoxy resin-saturated fibers to the construction.
Alternatively, the fiber reinforcing material can be applied to the
appropriate surface, and the epoxy resin then applied by brushing,
rolling, or spraying. Where chopped fibers are employed, such as
chopped glass fibers, it is convenient to apply the fibers with a
chopper gun that simultaneously chops and blows the fibers and
sprays the epoxy resin onto the surface to be coated.
The construction of this invention are relatively lightweight, high
strength, rigid, precisely formed members exhibiting low heat and
sound conductivities and possessing excellent fire, weather, and
vermin resistances. Because of their high flexural strengths and
impact resistance, these constructions have high earthquake and
shock loading properties.
While various embodiments of the invention have been described, it
will be obvious to those skilled in the art that it is not so
limited, but is susceptible of various changes and modifications,
which are considered within the spirit and scope of the inventin as
defined by the attached claims.
* * * * *