Patent US3844030A successfully refreshed from Google Patents.
US3844030A
Expired / Lapsed
US
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Composite of metal and thermoset plastic, and method of making it
Assignee: ROSTONE ACQUISITION Corp
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Filing: 1972-09-25
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Granted: 1974-10-29
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Expires: 1992-09-25
Abstract
Abstract An integrally bonded composite structure of a substrate part or layer of metal or the like, an elastic interface layer, and a thermoset plastic wall or layer molded in place against it is formed by: (1) coating the substrate, as by spraying, with a thin coating of a thermosetting soluble elastomer, such as a chloroprene rubber (Neoprene), formulated to chemically bond to the substrate surface, and also containing a coupling agent which will react with the thermoset plastic layer during curing of the latter; (2) heating the coating to dry and stabilize the same on the substrate so as to withstand transfer flow of molding composition but without completely curing the coating composition; and (3) molding the plastic layer against the coated substrate under heat and pressure as in a heated molding die while the coating is in incompletely cured state, and thereby completing the curing of the coating as the molded plastic layer is cured and producing an integral chemical bond from the molded layer through the interface layer to the substrate. This gives an impervious seal between the substrate and the plastic and a bond with very high resistance to separation. The parts and the interface between them may be of either simple or complex shape.
Inventors
- 👤 R Wilkinson
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-27 21:06
CPC Classifications
H; H01; H01F; H01F41/00; B; B29; B29C; B29C70/00; B29C70/68; F; F04; F04D; F04D29/00; F04D29/18; F04D29/22; F04D29/2205; F04D29/2222; F04D29/2227; H01B; H01B17/00; H01B17/26; H01B17/30; H01B17/303; H01B17/306; H01B17/56; H01B17/62; H01F27/00; H01F27/02; H01F27/04; F05; F05D; F05D2300/00; F05D2300/40; F05D2300/43; F05D2300/431; F05D2300/44; F05D2300/60; F05D2300/603; F05D2300/611; Y; Y10; Y10T; Y10T29/00; Y10T29/49; Y10T29/49002
Claims Analysis
Total Claims: 18
Claim 1
Independent Claim
139 words
THE METHOD OF FORMING A COMPOSITE OF A SUBSTRATE AND AN OVERLAY OF FIBER-REINFORCED THERMOSET PLASTIC COMPOSITION CONFORMING AND BONDED THERETO, WHICH COMPRISES PREPARING A SUBSTRATE HAVING AN EXTENDED SURFACE, COATING SAID SURFACE WITH AN UNCURED ELASTOMER COMPOSITION IN THE PRESENCE OF A BONDING AGENT FOR BONDING THE ELASTOMER TO THE SUBSTRATE SURFACE, AND TREATING THE COATING TO STABILIZE THE SAME AS A STABLE COATING LAYER ON SAID SURFACE WITHOUT COMPLETELY CURING THE ELASTOMER COMPOSITIONS, MOLDING A FIBER-REINFORCED THERMOSETTING PLASTIC MOLDING COMPOSITION IN PLACE AGAINST THE INCOMPLETELY CURED ELASTOMER LAYER UNDER PRESSURE AND HEAT, IN THE PRESENCE OF A COUPLING AGENT FOR BONDING THE PLASTIC TO THE ELASTOMER, AND MAINTAINING THE PRESSURE AND HEAT FOR A TIME SUFFICIENT TO CURE BOTH THE PLASTIC COMPOSITION AND THE ELASTOMER LAYER, AND TO EFFECT CHEMICAL BONDING OF THE PLASTIC AND ELASTOMER LAYERS.
Claim 2
Independent Claim
139 words
THE METHOD OF FORMING A COMPOSITE OF A SUBSTRATE AND AN OVERLAY OF FIBER-REINFORCED THERMOSET PLASTIC COMPOSITION CONFORMING AND BONDED THERETO, WHICH COMPRISES PREPARING A SUBSTRATE HAVING AN EXTENDED SURFACE, COATING SAID SURFACE WITH AN UNCURED ELASTOMER COMPOSITION IN THE PRESENCE OF A BONDING AGENT FOR BONDING THE ELASTOMER TO THE SUBSTRATE SURFACE, AND TREATING THE COATING TO STABILIZE THE SAME AS A STABLE COATING LAYER ON SAID SURFACE WITHOUT COMPLETELY CURING THE ELASTOMER COMPOSITIONS, MOLDING A FIBER-REINFORCED THERMOSETTING PLASTIC MOLDING COMPOSITION IN PLACE AGAINST THE INCOMPLETELY CURED ELASTOMER LAYER UNDER PRESSURE AND HEAT, IN THE PRESENCE OF A COUPLING AGENT FOR BONDING THE PLASTIC TO THE ELASTOMER, AND MAINTAINING THE PRESSURE AND HEAT FOR A TIME SUFFICIENT TO CURE BOTH THE PLASTIC COMPOSITION AND THE ELASTOMER LAYER, AND TO EFFECT CHEMICAL BONDING OF THE PLASTIC AND ELASTOMER LAYERS.
Claim 3
Dependent Claim
17 words
The method of claim 1 in which the bonding agent is contained in the uncured elastomer composition.
Claim 4
Dependent Claim
17 words
The method of claim 1 in which the coupling agent is contained in the uncured elastomer composition.
Claim 5
Dependent Claim
17 words
The method of claim 3 in which the plastic molding composition is an ethylenically unsaturated resin composition.
Claim 6
Dependent Claim
16 words
The method of claim 4 in which the plastic molding composition is a polyester resin composition.
Claim 7
Dependent Claim
17 words
The method of claim 4 in which the plastic molding composition is a modified epoxy resin composition.
Claim 8
Dependent Claim
16 words
The method of claim 4 in which the plastic molding composition is an allyl resin composition.
Claim 9
Dependent Claim
17 words
The method of claim 4 in which the plastic molding composition is a vinyl ester resin composition.
Claim 10
Dependent Claim
38 words
The method of claim 3 in which the substrate is a metal liner having an extended surface to which the elastomer coating is applied and the plastic composition is molded to form a wall layer against said liner.
Claim 11
Dependent Claim
100 words
The method of claim 3 in which said substrate is a terminal conductor of elongated bar shape, said elastomer coating is continuous about the entire circumference of said bar shape over a substantial portion of its length, and said plastic composition is molded as a bushing about said bar shape with the ends of the bar exposed at opposite ends of the bushing to thereby form an electrical conductor through the bushing, so as to integrally bond the conductor to the surrounding bushing over a substantial portion of its length and hermetically seal it against leakage longitudinally of the bar.
Claim 12
Independent Claim
160 words
The method of forming a composite of a metal substrate and a polyester resin body conforming and bonded thereto, which comprises preparing a metal substrate having an extended surface, coating said surface with an uncured elastomer in the presence of a bonding agent for bonding the elastomer to said surface, said elastomer containing a coupling agent for bonding the same to the subsequently applied molding composition, and treating the coasting to stabilize the same as a stable layer of incompletely cured elastomer on said surface; mounting said coated substrate in molding dies with the coated surface thereof exposed to the molding cavity, molding a polyester resin molding composition against said incompletely cured elastomer layer in said dies under pressure and heat, and maintaining the heat for a time sufficient to cause curing of both the polyester resin composition and the elastomer and to cause said coupling agent to react therewith to effect chemical bonding of the resin and elastomer layers.
Claim 13
Independent Claim
160 words
The method of forming a composite of a metal substrate and a polyester resin body conforming and bonded thereto, which comprises preparing a metal substrate having an extended surface, coating said surface with an uncured elastomer in the presence of a bonding agent for bonding the elastomer to said surface, said elastomer containing a coupling agent for bonding the same to the subsequently applied molding composition, and treating the coasting to stabilize the same as a stable layer of incompletely cured elastomer on said surface; mounting said coated substrate in molding dies with the coated surface thereof exposed to the molding cavity, molding a polyester resin molding composition against said incompletely cured elastomer layer in said dies under pressure and heat, and maintaining the heat for a time sufficient to cause curing of both the polyester resin composition and the elastomer and to cause said coupling agent to react therewith to effect chemical bonding of the resin and elastomer layers.
Claim 14
Dependent Claim
14 words
The method as in claim 11 in which the elastomer is a chloroprene rubber.
Claim 15
Dependent Claim
19 words
The method as in claim 11 in which the elastomer contains both said bonding agent and said coupling agent.
Claim 16
Dependent Claim
23 words
The method as in claim 13 in which the bonding agent is an amino-functional silane and said coupling agent is a methacrylate-functional silane.
Claim 17
Independent Claim
277 words
The method of forming a composite wall for an electrical transformer or the like, containing both a metal vapor barrier and molded-in terminal conductors, comprising forming a metal liner having the configuration of the wall and adapted to cover substantially its entire area, and forming openings in said liner to clear the desired terminal conductors, coating substantially the entire outer surface of the liner and the entire circumferential surface of terminal conductors over at least a portion of their length with an incompletEly cured elastomer composition containing both a bonding agent for bonding the elastomer to the metal of the liner and a coupling agent for coupling the elastomer to the subsequently applied molding composition, and stabilizing such coating, placing both the coated liner and terminal conductors in molding dies with their coated surfaces exposed in the mold cavity, and with the conductors positioned in the liner openings, and molding a fiber-reinforced thermosetting plastic composition in the mold cavity under heat and pressure against the uncured elastomer on said liner and conductors to form molded plastic layer against the liner over its entire outer surface and to form bushings integral therewith surrounding the terminal conductors and extending through said liner openings, and maintaining the heat and pressure for a time sufficient to cure the molded plastic and the uncured elastomer and bond the same together by the action of said coupling agent, thereby forming in a single molding step a composite wall complete with a metal vapor barrier liner and terminal conductors through the wall, with the wall exterior formed of plastic composition and with the liner and conductors integrally bonded and sealed to the plastic composition.
Claim 18
Independent Claim
277 words
The method of forming a composite wall for an electrical transformer or the like, containing both a metal vapor barrier and molded-in terminal conductors, comprising forming a metal liner having the configuration of the wall and adapted to cover substantially its entire area, and forming openings in said liner to clear the desired terminal conductors, coating substantially the entire outer surface of the liner and the entire circumferential surface of terminal conductors over at least a portion of their length with an incompletEly cured elastomer composition containing both a bonding agent for bonding the elastomer to the metal of the liner and a coupling agent for coupling the elastomer to the subsequently applied molding composition, and stabilizing such coating, placing both the coated liner and terminal conductors in molding dies with their coated surfaces exposed in the mold cavity, and with the conductors positioned in the liner openings, and molding a fiber-reinforced thermosetting plastic composition in the mold cavity under heat and pressure against the uncured elastomer on said liner and conductors to form molded plastic layer against the liner over its entire outer surface and to form bushings integral therewith surrounding the terminal conductors and extending through said liner openings, and maintaining the heat and pressure for a time sufficient to cure the molded plastic and the uncured elastomer and bond the same together by the action of said coupling agent, thereby forming in a single molding step a composite wall complete with a metal vapor barrier liner and terminal conductors through the wall, with the wall exterior formed of plastic composition and with the liner and conductors integrally bonded and sealed to the plastic composition.
References Cited (Backward Citations)
US3233198A
Cited
US3388212A
Cited
USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1977-10-28 | 1978-04-29 | 1978-10-29 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1981-10-28 | 1982-04-29 | 1982-10-29 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1985-10-28 | 1986-04-29 | 1986-10-29 | $7700.00 | Window Closed / Lapsed |