US3874981A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Resin sheet having an appearance of carpet or velvet and process therefor
Assignee: Sekisui Kaseihin Kogyo KK
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Filing: 1972-07-14
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Granted: 1975-04-01
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Expires: 1992-07-14
Abstract
Abstract The present invention provides a process and a resulting product wherein the process relates to preparing a resin sheet having an appearance of carpet or velvet wherein a polyolefin or polyamide is admixed with a foaming agent and the resulting mixture is extruded into a sheet, characterized in that the sheet extruded from a die mounted on an extruder is immediately introduced into an enclosed channel or passageway without allowing the sheet to be exposed to the air, with the sheet then being maintained under such conditions that the front and reverse sides of the sheet are held at such a temperature lower than that of the intermediate layer thereof and such that the sheet is not allowed to expand excessively in the direction of its width but is allowed to expand substantially exclusively in the direction of its thickness, whereby a sheet is produced with a core or intermediate layer of which has been well foamed and the pore walls of which have been broken or fragmented, with the sheet being finally split into two sheets along the middle part of the direction of its thickness.
Inventors
- 👤 Motoshige Hayashi
- 👤 Mikio Kukumura
- 👤 Zengo Sano
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-31 16:03
CPC Classifications
B; B29; B29C; B29C44/00; B29C44/34; B29C44/56; B29C44/36; B29C44/46; B29C44/50; B29C44/507; B29C48/00; B29C48/03; B29C48/07; B29C48/08; B29C48/25; B29C48/30; B29C48/32; B29C48/001; B29C48/0018; B29C48/0019; B29C48/09; B29C48/10; B29C48/15; B29K; B29K2023/00; B29K2077/00; B29K2105/00; B29K2105/04; B29K2105/043; B29K2827/00; B29K2827/12; B29K2827/18; B29L; B29L2023/00; B29L2023/003; B29L2031/00; B29L2031/732; B29L2031/7322; Y; Y10; Y10S; Y10S264/00; Y10S264/14; Y10T; Y10T225/00; Y10T225/10; Y10T225/12; Y10T225/14; Y10T428/00; Y10T428/23907; Y10T428/23943; Y10T428/31504; Y10T428/31725; Y10T428/31739; Y10T428/31743; Y10T428/31746
Claims Analysis
Total Claims: 8
Claim 1
Independent Claim
228 words
A RESIN SHEET HAVING AN APPEARANCE OF CARPET OR VELVET WHICH IS PREPARED BY SPLITTING OFF AN EXTRUDED FOAMED SHEET OF A RESIN ALONG MIDDLE PORTIONS IN THE THICKNESS DIRECTION THEREOF TO FORM A SURFACE HAVING A GREAT NUMBER OF IRREGULAR PROJECTIONS STANDING UPRIGHT TO THE SURFACE, SAID RESIN BEING SELECTED FROM THE GROUP CONSISTING OF POLYOLEFIN AND POLYAMIDE, SAID EXTRUDED FOAMED SHEET PRIOR TO SPLITTING HAVING SUBSTANTIALLY UNFOAMED FRONT AND BACK SURFACE LAYERS AND A FOAMED INTERMEDIATE LAYER THEREBETWEEN, SAID INTERMEDIATE LAYER HAVING PORES WHICH ARE OF GRADUALLY INCREASING SIZE AS THE PERPENDICULAR DISTANCE FROM EITHER SURFACE APPROACHES THE CENTER OF SAID INTERMEDIATE LAYER, SAID PORES BEING INCREASINGLY ELONGATED IN SHAPE IN SAID PERENDICULAR DIRECTION AS THE DISTANCE FROM EITHER SURFACE APPROACHES THE CENTER OF SAID INTERMEDIATE LAYER, SAID PORES AT THE CENTER BEING RUPTED AND COMMUNICATED WITH EACH OTHER AND THE WALLS OF THE PORES BEING DISPERSED IN THE FORM OF THIN FILMS ORIENTED IN SAID PERPENDICULAR DIRECTION, THE EXTRUDED SHEET THUS HAVING A STRUCTURE SUCH THAT HALF PORTIONS, FRONT AND BACK, ARE PARTLY CONNECTED TO EACH OTHER BY BRIDGES OF SAID THIN FILMS, SO THAT THE SHEET HAS NO PERMEABILITY IN THE DIRECTION OF THE THICKNESS, BUT CONSIDERABLE PERMEABILITY IN A LATERAL DIRECTION SUCH AS TO PERMIT MORE THAN 15 G OF METHANOL TO PASS THROUGH THE SHEET PER SQUARE CENTIMETER THEREOF IN THE MINUTES.
Claim 2
Dependent Claim
228 words
A RESIN SHEET HAVING AN APPEARANCE OF CARPET OR VELVET WHICH IS PREPARED BY SPLITTING OFF AN EXTRUDED FOAMED SHEET OF A RESIN ALONG MIDDLE PORTIONS IN THE THICKNESS DIRECTION THEREOF TO FORM A SURFACE HAVING A GREAT NUMBER OF IRREGULAR PROJECTIONS STANDING UPRIGHT TO THE SURFACE, SAID RESIN BEING SELECTED FROM THE GROUP CONSISTING OF POLYOLEFIN AND POLYAMIDE, SAID EXTRUDED FOAMED SHEET PRIOR TO SPLITTING HAVING SUBSTANTIALLY UNFOAMED FRONT AND BACK SURFACE LAYERS AND A FOAMED INTERMEDIATE LAYER THEREBETWEEN, SAID INTERMEDIATE LAYER HAVING PORES WHICH ARE OF GRADUALLY INCREASING SIZE AS THE PERPENDICULAR DISTANCE FROM EITHER SURFACE APPROACHES THE CENTER OF SAID INTERMEDIATE LAYER, SAID PORES BEING INCREASINGLY ELONGATED IN SHAPE IN SAID PERENDICULAR DIRECTION AS THE DISTANCE FROM EITHER SURFACE APPROACHES THE CENTER OF SAID INTERMEDIATE LAYER, SAID PORES AT THE CENTER BEING RUPTED AND COMMUNICATED WITH EACH OTHER AND THE WALLS OF THE PORES BEING DISPERSED IN THE FORM OF THIN FILMS ORIENTED IN SAID PERPENDICULAR DIRECTION, THE EXTRUDED SHEET THUS HAVING A STRUCTURE SUCH THAT HALF PORTIONS, FRONT AND BACK, ARE PARTLY CONNECTED TO EACH OTHER BY BRIDGES OF SAID THIN FILMS, SO THAT THE SHEET HAS NO PERMEABILITY IN THE DIRECTION OF THE THICKNESS, BUT CONSIDERABLE PERMEABILITY IN A LATERAL DIRECTION SUCH AS TO PERMIT MORE THAN 15 G OF METHANOL TO PASS THROUGH THE SHEET PER SQUARE CENTIMETER THEREOF IN THE MINUTES.
Claim 3
Dependent Claim
191 words
A process for preparing a resin sheet having an appearance of carpet or velvet which comprises extruding a mixture of a foaming agent and a resin selected from the group consisting of polyolefin and polyamide through an orifice of a die, introducing the thus extruded mixture directly into a cooled passage having a width substantially equal to that of the orifice and a thickness which is abruptly enlarged along the length of the passage to more than three times the thickness of the orifice, the abrupt enlargement of the orifice occurring in at least one portion of the passage extending from the portion adjacent to the die to the portion in the midpoint of the passage, and the thickness of the remaining portion after ultimate enlargement being substantially constant or reduced gradually towards the discharge end, cooling the foamable resin sheet from the surface thereof and expanding the sheet primarily in the thickness direction thereof within the passage, thereafter further expanding the sheet immediately after the sheet has passed through the passage, and splitting the resulting foamed sheet along the central part thereof in the thickness direction to form two sheets.
Claim 4
Dependent Claim
191 words
A process for preparing a resin sheet having an appearance of carpet or velvet which comprises extruding a mixture of a foaming agent and a resin selected from the group consisting of polyolefin and polyamide through an orifice of a die, introducing the thus extruded mixture directly into a cooled passage having a width substantially equal to that of the orifice and a thickness which is abruptly enlarged along the length of the passage to more than three times the thickness of the orifice, the abrupt enlargement of the orifice occurring in at least one portion of the passage extending from the portion adjacent to the die to the portion in the midpoint of the passage, and the thickness of the remaining portion after ultimate enlargement being substantially constant or reduced gradually towards the discharge end, cooling the foamable resin sheet from the surface thereof and expanding the sheet primarily in the thickness direction thereof within the passage, thereafter further expanding the sheet immediately after the sheet has passed through the passage, and splitting the resulting foamed sheet along the central part thereof in the thickness direction to form two sheets.
Claim 5
Dependent Claim
17 words
A process for preparing a resin sheet, according to claim 2, wherein the resin is a polyolefin.
Claim 6
Dependent Claim
17 words
A process for preparing a resin sheet, according to claim 2, wherein the resin is a polyamide.
Claim 7
Dependent Claim
51 words
A process for preparing a resin sheet, according to claim 2, wherein the mixture extruded through the orifice expands in the portion of the passage immediately following said extrusion and wherein this expansion of the mixture is the only expansion on an enlarged portion of the passage immediately following the orifice.
Claim 8
Dependent Claim
29 words
A process for preparing a resin sheet, according to claim 2, wherein the mixture is expanded in a second enlarged portion of the passage which immediately precedes the orifice.
References Cited (Backward Citations)
US3483602A
Cited
US3709752A
Cited
USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1978-03-31 | 1978-09-30 | 1979-04-01 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1982-03-31 | 1982-09-30 | 1983-04-01 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1986-03-31 | 1986-09-30 | 1987-04-01 | $7700.00 | Window Closed / Lapsed |