US4040165A — Method of making syntatic modules

Claim 1

Independent Claim 244 words

The method of providing a pipe member with syntatic modules as floatation devices comprising the steps of: a. forming a hollow preform mold having surfaces defining a cavity of desired configuration and forming a casting mold having surfaces defining a cavity of similar cross section including an arcuately convex surface for forming one surface of said modules with an arcuately concave surface thereof; b. forming a woven roving of predetermined size to provide a skin; c. forming a layer of spacing material of predetermined size and containing a plurality of voids therein; d. attaching the roving to the spacer material to form a laminate thereof; e. forming the laminate to the inside walls of the preform mold; f. filling the preform mold with a plurality of hollow balls; g. pouring a thin layer of resin into the preform mold to connect the balls and form the composite; h. removing the composite from the preform mold and placing end sections of spacing material thereon before placing it into the casting mold; i. adding a syntatic foam resin into the casting mold interior so as to fill all spaces between the balls and all voids in the spacer material; j. curing said syntatic foam resin and removing said mold parts so as to produce a module; k. repeating steps b through j to produce additional like modules; and 1. assembling said module segments around said pipe with the concave surfaces of said modules adjacent said pipe.

Claim 2

Independent Claim 244 words

The method of providing a pipe member with syntatic modules as floatation devices comprising the steps of: a. forming a hollow preform mold having surfaces defining a cavity of desired configuration and forming a casting mold having surfaces defining a cavity of similar cross section including an arcuately convex surface for forming one surface of said modules with an arcuately concave surface thereof; b. forming a woven roving of predetermined size to provide a skin; c. forming a layer of spacing material of predetermined size and containing a plurality of voids therein; d. attaching the roving to the spacer material to form a laminate thereof; e. forming the laminate to the inside walls of the preform mold; f. filling the preform mold with a plurality of hollow balls; g. pouring a thin layer of resin into the preform mold to connect the balls and form the composite; h. removing the composite from the preform mold and placing end sections of spacing material thereon before placing it into the casting mold; i. adding a syntatic foam resin into the casting mold interior so as to fill all spaces between the balls and all voids in the spacer material; j. curing said syntatic foam resin and removing said mold parts so as to produce a module; k. repeating steps b through j to produce additional like modules; and 1. assembling said module segments around said pipe with the concave surfaces of said modules adjacent said pipe.

Claim 3

Independent Claim 187 words

The method of making syntatic modules comprising the steps of: a. forming a hollow preform mold having surfaces defining a cavity of desired configuration and forming a hollow casting mold having surfaces defining a cavity of the desired module configuration; b. forming a woven roving of predetermined size to form a skin; c. forming a layer of spacer material containing a plurality of voids and being of predetermined size; d. attaching the roving to the spacer material to form a laminate thereof; e. forming the laminate to the preform mold; f. filling the preform mold with a plurality of hollow balls; g. pouring a thin layer of resin into the preform mold to connect the balls and form a composite; h. removing the composite from the preform mold and attaching spacer material sections to the ends and placing into the casting mold; i. adding a syntatic foam resin into the casting mold interior so as to fill all spaces between the balls and all voids in the spacer material; and j. curing said syntatic foam resin and removing said mold parts so as to produce said modules.

Claim 4

Independent Claim 187 words

The method of making syntatic modules comprising the steps of: a. forming a hollow preform mold having surfaces defining a cavity of desired configuration and forming a hollow casting mold having surfaces defining a cavity of the desired module configuration; b. forming a woven roving of predetermined size to form a skin; c. forming a layer of spacer material containing a plurality of voids and being of predetermined size; d. attaching the roving to the spacer material to form a laminate thereof; e. forming the laminate to the preform mold; f. filling the preform mold with a plurality of hollow balls; g. pouring a thin layer of resin into the preform mold to connect the balls and form a composite; h. removing the composite from the preform mold and attaching spacer material sections to the ends and placing into the casting mold; i. adding a syntatic foam resin into the casting mold interior so as to fill all spaces between the balls and all voids in the spacer material; and j. curing said syntatic foam resin and removing said mold parts so as to produce said modules.

Claim 5

Dependent Claim 17 words

The invention in accordance with claim 2 wherein the woven roving is of a glass fiber material.

Claim 6

Dependent Claim 20 words

The invention in accordance with claim 2 wherein the spacer material is a synthetic fiber mat with a resin binder.

Claim 7

Dependent Claim 24 words

The invention in accordance with claim 2 wherein the roving is attached to the spacer material by sewing them together to form the composite.

Claim 8

Dependent Claim 20 words

The invention in accordance with claim 2 wherein the preform mold is one half the length of the casting mold.

Claim 9

Dependent Claim 23 words

The invention in accordance with claim 2 wherein the composite is formed to the inside walls of the preform mold by heat forming.

Claim 10

Dependent Claim 21 words

The invention in accordance with claim 2 including the step of applying surface treatment to the syntatic module for protective purposes.

Claim 11

Dependent Claim 26 words

The invention in accordance with claim 2 wherein the syntatic foam is pumped into the casting mold when the casting mold is a substantially upright position.

Claim 12

Dependent Claim 61 words

The invention in accordance with claim 2 wherein the casting mold has an open top end and an open bottom end and comprising the further steps of closing the bottom end with an end plate provided with a manifold, and closing the top end with an end plate vented to atmosphere with the syntatic foam resin being introduced through the manifold.

Claim 13

Dependent Claim 50 words

The invention in accordance with claim 2 wherein the manifold extends through a manifold orifice and said top end plate is provided with an air vent and comprising the further steps of removing said manifold and blocking said orifice and vent hole after adding said syntatic foam to said cavity.

Claim 14

Dependent Claim 18 words

The invention in accordance with claim 2 wherein the preform mold is vibrated while filling with said balls.

Annuity Stage	Window Opens	Payment Deadline	Surcharge Period Until	Estimated Fee	Status
3.5 Years (Year 4)	1980-08-08	1981-02-07	1981-08-09	$2000.00	Window Closed / Lapsed
7.5 Years (Year 8)	1984-08-08	1985-02-07	1985-08-09	$3760.00	Window Closed / Lapsed
11.5 Years (Year 12)	1988-08-08	1989-02-07	1989-08-09	$7700.00	Window Closed / Lapsed

Method of making syntatic modules

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