Abstract: A composition, utility material, and method of making a utility material is disclosed. A composition having an improved setting time may include a plurality of microparticles mixed with a sodium silicate binder and an isocyanate setting agent, where the microparticle composition has a setting time of less than or equal to one hour. A utility material may be a wallboard that includes the composition.

Abstract: The present disclosure is drawn to a lattice support structures and methods of making such structures, including tooling and articles used therein.

Abstract: Geometrically versatile composite lattice support structure having a seamless three-dimensional configuration are disclosed and described. The lattice support structure is created by forming two or more cross supports, such as helical, longitudinal, circumferential and/or lateral cross supports, which intersect to form a plurality of multi-layered nodes. The lattice support structure may be designed without any protrusions extending outward from the overall geometry, thus enabling efficient tooling, and thus enabling ease of mass production. The lattice support structure may comprise a completely circumferentially closed geometry, such as a cylinder, ellipse, airfoil, etc. The method for fabricating the lattice support structure comprises laying up a fiber material, in the presence of resin, within rigid channels of a rigid mold, thus creating a green, uncured three-dimensional geometry of unconsolidated cross supports and multi-layered nodes where these intersect.

Abstract: A building material configured to enhance sound attenuation and reduction in dB across a walled partition, the building material comprising a facing membrane, a core matrix disposed about the facing membrane, the core matrix comprising a plurality of microparticles and a binder solution configured to support the microparticles, the building material comprising at least a substantially exposed face, wherein a side of the core matrix is at least partially exposed to increase sound attenuation by reducing reflections from sound waves impinging on the building material as compared to a control building material lacking an exposed face. Two building materials may be used in conjunction with one another about a building structure, such as a stud wall, to create and define a sound trap that functions to reduce sound transmission across the partition formed by the stud wall and building materials.

Abstract: A method and system for fabricating a geometrically versatile composite lattice support structure having a seamless three-dimensional configuration. The lattice support structure is created by forming two or more cross supports, such as helical, longitudinal, circumferential and/or lateral cross supports, which intersect to form a plurality of multi-layered nodes. The lattice support structure may be designed without any protrusions extending outward from the overall geometry, thus enabling efficient tooling, and thus enabling ease of mass production. The lattice support structure may comprise a completely circumferentially closed geometry, such as a cylinder, ellipse, airfoil, etc. The method for fabricating the lattice support structure comprises laying up a fiber material, in the presence of resin, within rigid channels of a rigid mold, thus creating a green, uncured three-dimensional geometry of unconsolidated cross supports and multi-layered nodes where these intersect.

Abstract: A shear panel building material that includes a first facing membrane, a core matrix disposed on a face of the first facing membrane, and a semi-rigid or rigid material attached to the core matrix. The core matrix can include microspheres having a size of about 200 microns to about 800 microns, sodium silicate, and ethylene vinyl acetate. In one aspect, the shear panel is substantially free from glue and cement.

Abstract: A utility material can include microparticles, an organic binder and an inorganic binder. The microparticles can be present in an amount from about 25 wt % to about 60 wt %, based on wet formulation. The inorganic binder can optionally include sodium silicate. The organic binder can optionally include a vinyl acetate. The utility material can be formed into a variety of different products or building materials, such as wallboard, shear panels. In addition, the building material may be particularly used to attenuate sound.

Abstract: A method and system for fabricating a geometrically versatile composite lattice support structure having a seamless three-dimensional configuration. The lattice support structure is created by forming two or more cross supports, such as helical, longitudinal, circumferential and/or lateral cross supports, which intersect to form a plurality of multi-layered nodes. The lattice support structure may be designed without any protrusions extending outward from the overall geometry, thus enabling efficient tooling, and thus enabling ease of mass production. The lattice support structure may comprise a completely circumferentially closed geometry, such as a cylinder, ellipse, airfoil, etc. The method for fabricating the lattice support structure comprises laying up a fiber material, in the presence of resin, within rigid channels of a rigid mold, thus creating a green, uncured three-dimensional geometry of unconsolidated cross supports and multi-layered nodes where these intersect.

Abstract: A method of forming a wallboard material can include forming a mixture including microparticles, sodium silicate and vinyl acetate. The mixture can be disposed between a metallic facing membrane and a second facing membrane. The mixture can then be heat cured in a single step sufficient to form a wallboard material having the metallic facing membrane and the second facing membrane attached to a core matrix. The heat curing time is complete in less than about 1.5 hours without causing damage to the wallboard material.

Abstract: A shear panel building material that includes a first facing membrane, a core matrix disposed on a face of the first facing membrane, and a semi-rigid or rigid material attached to the core matrix. The core matrix can include microspheres having a size of about 200 microns to about 800 microns, sodium silicate, and ethylene vinyl acetate. In one aspect, the shear panel is substantially free from glue and cement.

Abstract: A utility material can include microparticles, an organic binder and an inorganic binder. The microparticles can be present in an amount from about 25 wt % to about 60 wt %, based on wet formulation. The inorganic binder can optionally include sodium silicate. The organic binder can optionally include a vinyl acetate. The utility material can be formed into a variety of different products or building materials, such as wallboard, shear panels. In addition, the building material may be particularly used to attenuate sound.

Abstract: Vacuum bagging methods and systems are provided for lay-ups of pre-impregnated composite materials. Generally, the methods and systems of the present invention provide for applying a sealing layer of resin over a release layer, which is on a lay-up of pre-impregnated reinforcement composite materials.

Abstract: A composition, utility material, and method of making a utility material is disclosed. A composition having an improved setting time may include a plurality of microparticles mixed with a sodium silicate binder and an isocyanate setting agent, where the microparticle composition has a setting time of less than or equal to one hour. A utility material may be a wallboard that includes the composition.

Abstract: Mandrels of various configuration, and action, including collapsible mandrels, to be used in forming composite articles with preselected three dimensional shapes and construction are disclosed and described. In one aspect, such a mandrel may have a plurality of discrete segments coupled about a longitudinal axis and collectively forming an enclosure with a substantially continuous exterior working surface. The working surface can have a network of intersecting grooves formed therein, and such grooves can cooperatively establish a substantially continuous interconnected lattice corresponding to the three dimensional geometric configuration to be imparted to a composite article formed. The mandrel may optionally include a removable core assembly to aid in collapse of the mandrel.

Abstract: A method and system for fabricating a geometrically versatile composite lattice support structure having a seamless three-dimensional configuration. The lattice support structure is created by forming two or more cross supports, such as helical, longitudinal, circumferential and/or lateral cross supports, which intersect to form a plurality of multi-layered nodes. The lattice support structure may be designed without any protrusions extending outward from the overall geometry, thus enabling efficient tooling, and thus enabling ease of mass production. The lattice support structure may comprise a completely circumferentially closed geometry, such as a cylinder, ellipse, airfoil, etc. The method for fabricating the lattice support structure comprises laying up a fiber material, in the presence of resin, within rigid channels of a rigid mold, thus creating a green, uncured three-dimensional geometry of unconsolidated cross supports and multi-layered nodes where these intersect.

Abstract: A method and system for fabricating a geometrically versatile composite lattice support structure having a seamless three-dimensional configuration. The lattice support structure is created by forming two or more cross supports, such as helical, longitudinal, circumferential and/or lateral cross supports, which intersect to form a plurality of multi-layered nodes. The lattice support structure may be designed without any protrusions extending outward from the overall geometry, thus enabling efficient tooling, and thus enabling ease of mass production. The lattice support structure may comprise a completely circumferentially closed geometry, such as a cylinder, ellipse, airfoil, etc. The method for fabricating the lattice support structure comprises laying up a fiber material, in the presence of resin, within rigid channels of a rigid mold, thus creating a green, uncured three-dimensional geometry of unconsolidated cross supports and multi-layered nodes where these intersect.

Abstract: The present disclosure is drawn to a lattice support structure, comprising a plurality of fiber-based cross supports intersecting one another to form a multi-layered node. The multi-layered node can be consolidated within a rigid mold in the presence of resin, heat, and pressure. In another embodiment, a lattice support structure can comprise a first cross support comprising fiber material; a second cross support comprising a fiber material, said second cross support intersecting the first cross support; and multi-layered nodes located where the first cross support intersects the second cross support. The multi-layered nodes can comprise at least two layers of the first cross support separated by a least one layer of the second cross support. Also, one of the first cross support or the second cross support can be curved from node to node.

Abstract: A shear panel building material that includes a first facing membrane, a core matrix disposed on a face of the first facing membrane, and a semi-rigid or rigid material attached to the core matrix. The core matrix can include microspheres having a size of about 200 microns to about 800 microns, sodium silicate, and ethylene vinyl acetate. In one aspect, the shear panel is substantially free from glue and cement.

Abstract: A method of forming a wallboard material can include forming a mixture including microparticles, sodium silicate and vinyl acetate. The mixture can be disposed between a metallic facing membrane and a second facing membrane. The mixture can then be heat cured in a single step sufficient to form a wallboard material having the metallic facing membrane and the second facing membrane attached to a core matrix. The heat curing time is complete in less than about 1.5 hours without causing damage to the wallboard material.

Abstract: A building material configured to enhance sound attenuation and reduction in dB across a walled partition, the building material comprising a facing membrane, a core matrix disposed about the facing membrane, the core matrix comprising a plurality of microparticles and a binder solution configured to support the microparticles, the building material comprising at least a substantially exposed face, wherein a side of the core matrix is at least partially exposed to increase sound attenuation by reducing reflections from sound waves impinging on the building material as compared to a control building material lacking an exposed face. Two building materials may be used in conjunction with one another about a building structure, such as a stud wall, to create and define a sound trap that functions to reduce sound transmission across the partition formed by the stud wall and building materials.