Lightweight, high strength, reinforced concrete constructions

• US 3,922,413 A
• Filed: 06/03/1974
• Issued: 11/25/1975
• Est. Priority Date: 06/03/1974
• Status: Expired due to Term

• Current Assignee: Richard G. Reineman
• Original Assignee: Richard G. Reineman
• Inventors: Reineman, Richard G.
• Primary Examiner(s): Ansher, Harold
• Assistant Examiner(s): Epstein, Henry F.
• Application Number:
  US05/475,815
• Time in Patent Office: 540 Days
• Field of Search: 161/43,68,69,162,184 52/DIG.7,576,577,405
• US Class Current: 428/119
• CPC Class Codes: B32B 13/12 of synthetic resin
• CPC Class Codes: B32B 2305/028 Hollow fillers; Syntactic material
• CPC Class Codes: B32B 2305/08 Reinforcements
• CPC Class Codes: B32B 2607/00 Walls, panels
• CPC Class Codes: B32B 27/38 comprising epoxy resins
• CPC Class Codes: B32B 3/26 characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids foam layer B32B5/18; layer of synthetic resin characterised by fillers that create voids or cavities B32B27/205; characterised by an apertured layer
• CPC Class Codes: C04B 2111/00663 as filling material for cavities or the like
• CPC Class Codes: E04C 2/2885 with the insulating material being completely surrounded by, or embedded in, a stone-like material, e.g. the insulating material being discontinuous
• CPC Class Codes: E04C 2/36 spaced apart by transversely-placed strip material, e.g. honeycomb panels honeycomb or other core members for layered products B32B
• CPC Class Codes: Y10S 264/57 Processes of forming layered products
• CPC Class Codes: Y10T 428/24174 including sheet or component perpendicular to plane of web or sheet
• CPC Class Codes: Y10T 428/24999 Inorganic
• CPC Class Codes: Y10T 428/249991 Synthetic resin or natural rubbers
• CPC Class Codes: Y10T 428/31511 Of epoxy ether

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.

Claims

1. A RELATIVELY LIGHTWEIGHT, HIGH STRENGTH, CEMENTITIIOUS CONSTRUCTION COMPRISING A PLURALITY OF SUBSTANTIALLY COEXTENSIVE, PARALLEL, SPACED-APART MEMBRANES CONSISTING OF ALTERNATE INTEGRALLY BONDED LAYERS OF FIBER:

RREINFORCED EPOXY RESIN AND EPOXY RESIN-CONTAINING CONCRETE, SAID MEMBRANES BEING INTERCONNECTED BY CONTINUOUS LONGITUDINAL AND LATERAL TRANSVERSE WEBS OF EPOXY RESIN-CONAINING 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.