Composite material and method for the manufacture thereof

• US 6,153,282 A
• Filed: 03/24/1995
• Issued: 11/28/2000
• Est. Priority Date: 03/24/1995
• Status: Expired due to Fees

• Current Assignee: James E. Hillis, Reed S. Dickinson
• Original Assignee: James E. Hillis, Reed S. Dickinson
• Inventors: Dickinson, Reed S., Hillis, James E.
• Primary Examiner(s): KILIMAN, LESZEK B
• Application Number:
  US08/409,974
• Time in Patent Office: 2,076 Days
• Field of Search: 428/413, 428/141, 428/143, 428/147, 428/150, 428/404, 428/407, 428/417, 428/325, 428/446
• US Class Current: 428/141
• CPC Class Codes: B32B 13/00 Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material
• CPC Class Codes: B32B 13/12 of synthetic resin
• CPC Class Codes: B32B 2607/00 Walls, panels
• CPC Class Codes: B32B 27/38 comprising epoxy resins
• CPC Class Codes: B32B 3/30 characterised by a layer formed with recesses or projections, e.g. hollows, grooves, protuberances, ribs apertured layer B32B3/266; layer with cavities or internal voids B32B3/26
• CPC Class Codes: Y10T 428/24355 Continuous and nonuniform or irregular surface on layer or component [e.g., roofing, etc.]
• CPC Class Codes: Y10T 428/24372 Particulate matter
• CPC Class Codes: Y10T 428/24405 Polymer or resin [e.g., natural or synthetic rubber, etc.]
• CPC Class Codes: Y10T 428/2443 Sand, clay, or crushed rock or slate
• CPC Class Codes: Y10T 428/252 Glass or ceramic [i.e., fired or glazed clay, cement, etc.] [porcelain, quartz, etc.]
• CPC Class Codes: Y10T 428/2993 Silicic or refractory material containing [e.g., tungsten oxide, glass, cement, etc.]
• CPC Class Codes: Y10T 428/2998 including synthetic resin or polymer
• CPC Class Codes: Y10T 428/31511 Of epoxy ether
• CPC Class Codes: Y10T 428/31525 Next to glass or quartz

Abstract

Disclosed is a composite material and a method for the manufacture thereof. The disclosed material includes a layer of polymeric material in substantially continuous surface-to-surface contact with a layer of cementitious material. The composite material can be used as both a planar tactile warning and as a subunit in the construction of three dimensional structures. The external surface of the polymeric material can be configured, i.e., textured or smoothed, as needed for a given application.

Claims

1. A multilaminate composite material, said material consisting essentially of:

a first layer integrally bonded to a second layer, said first layer and said second layer being separate and distinct layers, said first layer being formed of a first selected material, said second layer being formed of a second selected material, said first material being different from said second material, said first layer being a substantially homogenous mixture of said first material, said second layer being a substantially homogenous mixture of said second material;

said first layer having a first external surface and a second external surface, said first layer being formed of a dimensionally stable polymeric material;

said second layer having a first external surface and a second external surface said first external surface of said second layer being directly bonded to said second external surface of said first layer such that said first external surface of said second layer is in substantially continuous surface-to-surface contact with said second external surface of said first layer, said second layer being a supportive backing material for said first layer, said second layer being formed of a cementitious material.

2. The composite material of claim 1 wherein said polymeric material forming said first layer is an epoxy resin.

3. The composite material of claim 1 wherein said cementitious material forming said second layer is a mixture of water, aggregate, cement, and a reinforcing material.

4. The composite material of claim 1 wherein said first layer has a series of raised bumps thereon, said bumps providing direction and warning to visually handicapped persons.

5. The composite material of claim 1 being configured as a paving block, said paving block being sized and shaped so as to be removably and replaceably positionable in areas of pedestrian traffic.

6. A composite construction material comprising a series of polygonal multilaminate segments connected to a common backing material, said polygonal multilaminate segments consisting essentially of:

a composite multilaminate material having a first material integrally and directly bonded to, and in substantially surface-to-surface contact with, a second material, said first material forming a first layer and said second material forming a second layer, said first layer and said second layer being separate and distinct layers, said first material being different from said second material, said first layer being a substantially homogenous mixture of said first material, said second layer being a substantially homogenous mixture of said second material;

said first material being a dimensionally stable polymeric material having a first external surface and a second external surface; and

said second material having a first external surface and a second external surface, said first external surface of said second material being directly bonded to said second external surface of said first material, said second external surface of said first material being in substantially continuous surface-to-surface contact with said first external surface of said second material, said second material being a cementitious material, said cementitious material forming a supportive backing for said first material, said second material connected to said common backing material.

7. The composite material of claim 6 wherein said material forming said first layer of said segments is an epoxy resin.

8. The composite material of claim 6 wherein said cementitious material forming said second layer of said segments is a mixture of water, sand, cement, and a reinforcing material.

9. The composite material of claim 6 wherein said first external surface of said first material of said segments has a series of substantially identical raised bumps extending therefrom, said bumps providing an indication of said areas of pedestrian traffic requiring caution.

10. The composite material of claim 9 wherein said segments are sized and shaped to be removably and replaceably connectable to a base surface located in said areas of pedestrian traffic.

11. The composite material of claim 10 wherein said segments are adjacently positioned in rows so as to form a parallel array, said array being configured to provide a demarcation of said area of pedestrian traffic requiring caution.

12. The composite material of claim 6 wherein said first external surface of said first material of said segments has a substantially smooth configuration.

13. The composite material of claim 12 wherein said segments are sized and shaped to be removably and replaceably connectable to a support means so as to form a wall structure.

14. The composite material of claim 10 wherein said segments are adjacently positioned in rows so as to form a parallel array of said segments, said array of said segments being configured so as to form a self-supporting wall structure, said wall structure having a first exposed surface and a second exposed surface, said first external surface of said first material forming at least one of either of said first and second exposed surfaces of said wall structure.