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.

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.

A low density coring material is described. In one embodiment, the low density coring material consists essentially of: about 40 to about 80 wt % resin; 0 to about 50 wt % monomer; 0 to about 5 wt % dispersion aid; 0 to about 5 wt % accelerator; about 3 to about 7 wt % microspheres; and about 1 to about 5 wt % catalyst; wherein a density of the cured coring material is less than about 5.0 lbs/gal. Composites made using the low density coring material and methods of making composites are also described.

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.

Light weight composites with high flexural strength comprise epoxy foam sandwiched between two layers of facing material have high strength and low weight and can be used to replace steel structures. The facing layer may be fibrous material especially glass or carbon fibres, the facing material is preferably embedded into the epoxy matrix. Alternatively they may be matching box structures or concentric metal tubes. The sandwich structures may be prepared by laying up the fibre; coating and/or impregnating the layer with epoxy resin, laying a layer of heat activatable foamable epoxy material, providing a further layer of the fibrous material optionally coated and/or impregnated with epoxy resin on the foamable material and heating to foam and cure the epoxy materials. Alternatively they may be formed by extrusion of the foamable material between the surface layers.

Damping skin for protecting composite parts includes a composite material having at least two superposed layers, namely a first layer formed from the juxtaposition of hollow spheres, which is intended to be applied and fixed, either directly or indirectly, to the surface of the part to be protected and a second layer covering the first and formed from a wall made of a material having plastic deformation properties.

Light weight composites with high flexural strength comprise epoxy foam sandwiched between two layers of facing material have high strength and low weight and can be used to replace steel structures. The facing layer may be fibrous material especially glass or carbon fibers, the facing material is preferably embedded into the epoxy matrix. Alternatively they may be matching box structures or concentric metal tubes. The sandwich structures may be prepared by laying up the fiber; coating and/or impregnating the layer with epoxy resin, laying a layer of heat activatable foamable epoxy material, providing a further layer of the fibrous material optionally coated and/or impregnated with epoxy resin on the foamable material and heating to foam and cure the epoxy materials. Alternatively they may be formed by extrusion of the foamable material between the surface layers.

The present invention relates to a composite material comprising nanoporous particles and at least one binder constructed from at least one isocyanate and at least one polymer P selected from the group consisting of polyvinylamine, poly(meth)acrylic acid, poly(meth)acrylic ester, polyvinyl alcohol, polyvinylthiol and mixtures thereof, wherein said at least one binder is used in an amount of 0.1 to 20 wt %, based on the amount of nanoporous particles, a composition for producing a composite material of this type, a process for producing a composite material of this type, shaped articles comprising said composite material and the use of said composite material for thermal and/or acoustical insulation.

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.

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.