US3895086A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Method and apparatus for forming laminated molded bodies
Assignee: Individual
•
Filing: 1972-08-28
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Granted: 1975-07-15
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Expires: 1992-08-28
Abstract
Abstract Laminated foamed product and method and apparatus in which a sheet is folded as a wrapper and filled with heat expandable plastic material and heated to expand the filler by passing heating fluid through perforations in the sheet.
Inventors
- 👤 Erling Berner
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-01 15:29
CPC Classifications
B; B32; B32B; B32B7/00; B32B7/04; B32B7/12; B29; B29C; B29C44/00; B29C44/20; B29C44/206; B29C44/32; B29C44/326; B32B27/00; B32B27/06; B32B27/08; B32B3/00; B32B3/26; B32B3/266; B29C53/00; B29C53/36; B29C53/38; B29C53/48; B32B2325/00
Claims Analysis
Total Claims: 33
Claim 1
Independent Claim
104 words
THE METHOD OF PRODUCING A LAMINATED FOAMED PLASTIC BODY HAVING AT LEAST ONE PROTECTIVE SHEET SECURED TO AT LEAST ONE SURFACE THEREOF, SAID SHEET BEING FORAMINOUS BY INCLUDIND NUMEROUS PERFORATIONS WITH LARGE ENOUGH SLOTS TO ALLOW EASY PASSAGE OF HEATING FLUID THROUGH THE SURFACES, COMPRISING MOLDING A HEAT EXPANDABLE GRANULAR MATERIAL IN SURFACE CONTACT WITH THE PREFORMED FORAMINOUS SHEET AND PASSING A HEATING FLUID AT LEAST IN PART THROUGH THE FORAMINOUS SHEET AND HEAT EXPANDABLE GRANULAR PLASTIC TO EXPAND AND FOAM SAID GRANULAR PLASTIC AND CAUSE THE GRANULES TO COHERE TO EACH OTHER AND TO AID SHEET MATERIAL, AND THEN COOLING THE MOLDED PRODUCT.
Claim 2
Independent Claim
104 words
THE METHOD OF PRODUCING A LAMINATED FOAMED PLASTIC BODY HAVING AT LEAST ONE PROTECTIVE SHEET SECURED TO AT LEAST ONE SURFACE THEREOF, SAID SHEET BEING FORAMINOUS BY INCLUDIND NUMEROUS PERFORATIONS WITH LARGE ENOUGH SLOTS TO ALLOW EASY PASSAGE OF HEATING FLUID THROUGH THE SURFACES, COMPRISING MOLDING A HEAT EXPANDABLE GRANULAR MATERIAL IN SURFACE CONTACT WITH THE PREFORMED FORAMINOUS SHEET AND PASSING A HEATING FLUID AT LEAST IN PART THROUGH THE FORAMINOUS SHEET AND HEAT EXPANDABLE GRANULAR PLASTIC TO EXPAND AND FOAM SAID GRANULAR PLASTIC AND CAUSE THE GRANULES TO COHERE TO EACH OTHER AND TO AID SHEET MATERIAL, AND THEN COOLING THE MOLDED PRODUCT.
Claim 3
Independent Claim
114 words
The method of continuously molding a laminated product comprising foamed heat expandable plastic granules containing a foaming agent as a laminate between sheets confining and supporting the foamed granules between them, comprising passing said granules between sheets together with a heating fluid to soften and expand said granules as a foam, cohering said granules to each other and to said confining sheets as a heat softened body, and molding and forming the heat softened body by pressing the laminate between confining surfaces to desired dimension, said laminating sheet reenforcing, strengthening and confining the expanded granules therebetween, and drawing the assembled laminate through said heating and dimension adjusting means continuously as the body is formed.
Claim 4
Independent Claim
114 words
The method of continuously molding a laminated product comprising foamed heat expandable plastic granules containing a foaming agent as a laminate between sheets confining and supporting the foamed granules between them, comprising passing said granules between sheets together with a heating fluid to soften and expand said granules as a foam, cohering said granules to each other and to said confining sheets as a heat softened body, and molding and forming the heat softened body by pressing the laminate between confining surfaces to desired dimension, said laminating sheet reenforcing, strengthening and confining the expanded granules therebetween, and drawing the assembled laminate through said heating and dimension adjusting means continuously as the body is formed.
Claim 5
Dependent Claim
99 words
The method of forming a laminated foamed plastic body as defined in claim 1 comprising continuously folding a foraminous sheet having numerous perforations with large enough slots to allow easy passage of heating fluid through the surfaces to form upper and lower laminar sheet surfaces, passing heat expandable plastic granules as a filler into said folded sheet as an outer wrapper, and heating the assembly to soften and expand the foamaBle granules to fill the space between said folded sheets, cohering the expanded granules to each other and to the confining surfaces of said sheet as a laminated body.
Claim 6
Dependent Claim
27 words
The method as defined in claim 1 wherein the inner sheet surface is first coated with an adhesive suitable to bond the foamed plastic to said sheet.
Claim 7
Dependent Claim
27 words
The method as defined in claim 2 wherein the inner sheet surface is first coated with an adhesive suitable to bond the foamed plastic to said sheet.
Claim 8
Dependent Claim
43 words
The method as defined in claim 3 wherein the assembled sheet and expandable plastic filler therein is mechanically drawn through a forming and heating zone wherein the granules expand and cohere into an integral shaped body wrapped in said sheet as a laminate.
Claim 9
Dependent Claim
45 words
The method as defined in claim 3 wherein said sheet is perforated and is continuously folded into a wrapper, encasing said foamable granules, and the foamable granules and sheet are heated at least in part by heating fluid introduced through said perforations in said sheet.
Claim 10
Dependent Claim
74 words
The method as defined in claim 3 wherein said sheet is continuously folded into a wrapper encasing said foamable granules, and the foamable granules and sheet are heated at least in part by heating fluid introduced together with said granules within the confining wrapper to heat the particles therein sufficient to cause them to expand and to cohere to each other and to the encasing wrapper as a foamed body having a wrapper thereabout.
Claim 11
Dependent Claim
74 words
The method as defined in claim 3 wherein said sheet is perforated and is continuously folded into a wrapper encasing said foamable granules, and the foamable granules and sheet are heated in part by heating fluid introduced with said granules as they are emplaced within the wrapper and in part by heating fluid introduced laterally through the perforations in said sheet as the wrapped body is formed and foamed into a coherent molded product.
Claim 12
Dependent Claim
26 words
The method as defined in claim 6 wherein the heat softened laminate is cooled and the heat softened product is continuously drawn through said cooling means.
Claim 13
Dependent Claim
64 words
The method as defined in claim 1 wherein the sheet and foamed plastic in contact therewith are passed continuously through a longitudinal molding channel in which a heating fluid is introduced passing through said foraminous sheet and into contact with the foamable granular material therein to heat and expand the same, causing said granules to cohere to each other and to said sheet material.
Claim 14
Dependent Claim
20 words
The method as defined in claim 11 wherein said molded product is continuously mechanically drawn through said longitudinal molding channel.
Claim 15
Dependent Claim
30 words
The method as defined in claim 11 wherein said longitudinal molding channel is a channel formed between upper and lower perforated belts continuously supporting and moving said molded product therebetween.
Claim 16
Dependent Claim
41 words
The method as defined in claim 11 wherein said longitudinal molding channel is a channel formed between upper and lower confining surfaces of which only the lower surface is a movable belt operative to move the molded product through the channel.
Claim 17
Dependent Claim
85 words
The method as defined in claim 3 wherein the sheet is foraminous and the sheet and foamable plastic in contact therewith are passed continuously through an arcuate molding channel having closely spaced arcuate surfaces, at least one of said channel surfaces having perforations therein, and passing a heating fluid through said channel perforations and through the perforations of said sheet material to soften, expand, cohere the expanded granules to each other and to said sheet and mold the laminate as it passes through said channel.
Claim 18
Dependent Claim
47 words
The method as defined in claim 15 wherein the assembled sheet and expandable plastic filler therein is mechanically drawn through a forming and heating zone in said arcuate channel wherein the granules expand and cohere into an integral shaped body wrapped in said sheet as a laminate.
Claim 19
Dependent Claim
37 words
The method as defined in claim 15 wherein only one of said arcuate surfaces is movable, the opposite surface being stationary, said movable surface engaging said laminated product in said molding channel and moving the same therethrough.
Claim 20
Dependent Claim
87 words
The method as defined in claim 3 wherein the said sheet is perforated and the assembled sheet and foamable granules encased therein are passed through a longitudinal molding channel having perforations through at least one surface thereof, and passing a heating fluid through said perforations and through the perforations of said confining sheet into contact with said heat expandable granules to soften, expand and cohere the same to each other and to said confining sheet material, and then cooling said laminated product in said longitudinal molding channel.
Claim 21
Dependent Claim
17 words
The method as defined in claim 18 wherein the molded product is drawn through said molding channel.
Claim 22
Dependent Claim
27 words
The method as defined in claim 18 wherein the longitudinal molding channel is defined by perforated movable surfaces and the heating medium is introduced through said perforations.
Claim 23
Dependent Claim
37 words
The method as defined in claim 18 wherein the molding channel is defined by at least one movable surface, and at least one stationary surface, the molded product being moved through said channel by said movable surface.
Claim 24
Dependent Claim
82 words
The method as defined in claim 7 wherein the molding channel is arcuate, defined by closely spaced arcuate surfaces, at least one of said arcuate surfaces having perforations therein, and passing a heating fluid through said perforations and through the perforations of said confining sheet in contact with said heat expandable granules to soften, expand and cohere the same to each other and to said sheet material, molding and then cooling the heat softened product as it passes through said arcuate channel.
Claim 25
Dependent Claim
49 words
The method as defined in claim 1 wherein the perforated sheet has larger perforations on one surface than the perforations on an opposite surface, and the heating fluid is passed into said heat expandable particles from one surface and passes out of the assembly through the opposite perforated surface.
Claim 26
Dependent Claim
23 words
The method as defined in claim 1 wherein the laminating sheet is selected from the group consisting of plastic, paper, metal and asbestos.
Claim 27
Dependent Claim
13 words
The method as defined in claim 1 wherein the laminating sheet is polystyrene.
Claim 28
Dependent Claim
15 words
The method as defined in claim 1 wherein the foamable plastic granules are foamable polystyrene.
Claim 29
Dependent Claim
14 words
The method as defined in claim 1 wherein the plastic sheet is foamed polystyrene.
Claim 30
Dependent Claim
21 words
The method as defined in claim 2 wherein the product is molded in longitudinal movement through heating and dimensions adjusting means.
Claim 31
Dependent Claim
24 words
The method as defined in claim 2 wherein the product is molded in an arcuate molding movement through the heating and dimension adjusting means.
Claim 32
Dependent Claim
27 words
The method as defined in claim 3 wherein the product as it is molded is passed through stationary side guides which shape the sides of the product.
Claim 33
Dependent Claim
46 words
The method as defined in claim 30 wherein the product is a continuously formed board and the side guides shape the sides of the board into a tongue on one side and a groove on the opposite side, cooperatively dimensioned to interfit as tongue-in-groove foamed board.
References Cited (Backward Citations)
USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1978-07-14 | 1979-01-13 | 1979-07-15 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1982-07-14 | 1983-01-13 | 1983-07-15 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1986-07-14 | 1987-01-13 | 1987-07-15 | $7700.00 | Window Closed / Lapsed |