Patent US3004189A successfully refreshed from Google Patents.
Patent US3911186A successfully refreshed from Google Patents.
US3911186A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Perforate composite and continuous-strip manufacturing methods and apparatus
Assignee: Individual
•
Filing: 1973-01-12
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Granted: 1975-10-07
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Expires: 1993-01-12
Abstract
Abstract Continuous processes and apparatus for manufacturing novel perforate composites from non-perforate solidified plastic sheet material and perforate substrate while controllably producing porosity in the composite. The plastic sheet material is conditioned and drawn into interstices of the substrate and ruptured by vacuum-induced gas flow. Mechanical interlocking results from such drawing and ruptured portions of the plastic being wrapped around subsurface portions of the substrate. End product uses are increased by use of adhesive. Porosity and avoidance of damage to film and substrate are controlled by control of process variables including line speed, conditioning temperatures, and vacuum applied.
Inventors
- 👤 Herbert H Trotman
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-03 12:16
CPC Classifications
B; B32; B32B; B32B27/00; B32B27/12; B32B27/30; B32B27/304; B32B27/32; B32B27/40; B32B3/00; B32B3/26; B32B3/266; B32B37/00; B32B37/12; B32B38/00; B32B38/18; B32B38/1858; B32B5/00; B32B5/02; B32B5/024; B32B5/026; B32B7/00; B32B7/04; B32B7/12; B32B2255/00; B32B2255/02; B32B2255/26; B32B2270/00; B32B2305/00; B32B2305/02; B32B2305/026; B32B2307/00; B32B2307/50; B32B2307/554; B32B2307/70; B32B2307/724; B32B2307/726; B32B2307/7265; B32B2309/00; B32B2309/02; B32B2309/08; B32B2309/10; B32B2309/105; B32B2309/14; B32B2310/00; B32B2310/08; B32B2310/0806; B32B2310/0825; B32B2310/0862; Y; Y10; Y10T; Y10T156/00; Y10T156/17; Y10T156/1702; Y10T156/1712; Y10T428/00; Y10T428/24; Y10T428/24273; Y10T428/24322; Y10T428/249921; Y10T428/249953
Claims Analysis
Total Claims: 40
Claim 1
Independent Claim
299 words
CONTINUOUS-LINE PROCESS FOR MANUDACTURING A PERFORATE COMPOSITE FROM NON-PERFORATE SOLIDFIDE PLASTIC SHEET MATERIAL AN PERFORATE SUBSTRATE WHILE CONTROLLABLY PRODUCING POROSITY IN THE COMPOSITE, COMPRISING THE STEPS OF PROVIDING AN ELONGATED PERFORATE CONTINUOUS-LENGTH WOVEN SUBSTRATE WITH DEFINED INTERSTICES, DIRECTING SUCH SUBSTRATE LONGITUDINALLY ALONG A CONTINUOUSPROCESSING LINE, PROVIDING AN ELONGATED CONTINUOUS-LENGTH PLASTIC SHEET MATERIAL IN SOLDIFIED NON-PERFORATE FILM FROM OF SUBSTANTIALLY UNIFORM THICKNESS, DIRECTING SUCH PLASTIC SHEET MATERIAL LONGITUDINALLY ALONG THE CONTINUOUS PROCESS LINE, CONTINUOUSLY FEEDING THE SUBSTRATE AND PLASTIC SHEET MATERIAL LONGITUDINALLY INTO ALIGNED CONTIGUOUS RELATIONSHIP WHILE EACH IS TRAVELING ALONG THE CONTINUOUS PROCESSING LINE AT SUBSTANTIALLY THE SAME LONGITUDINAL SPEED, APPLYING SUCH PLASTIC SHEET MATERIAL TO OVERLAY SUBSTANTIALLY ENTIRELY ONE SURFACE OF THE ELONGATED SUBSTRATE FORMING A NON-PERFORATE COMPOSITE IN SUCH AREA OF OVERLAY. HEATING THE PLASTIC SHEET MATERIAL AFTER CONTACT WITH THE SUBSTRATE WHILE APPLYING A VACUUM TO REMAINING SURDACE OF THE SUBSTRATE BY DIRECTING SUCH COMPOSITE LONGITUDIALLY OVER VACUUM MEANS WHILE TRAVELING ALONG THE CONTINUOUS PROCESSING LINE, CONTROLLING LONGITUDINAL SPEED OF TRAVEL OF SUCH COMPOSITE OVER SUCH VACUUM MEANS WHILE CONTROLLING SUCH HEATING TO PRODUCE THERMOPLASTICITY IN THE PLASTIC SHEET MATERIAL, CONTROLLING THE VACUUM APPLIED THROUGH SUCH VACUUM MEANS TO DRAW SUCH HEATED PLASTIC SHEET MATERIAL INTO INTERSTICES OF THE SUBSTRATE AND STRETCH THE HEATED PLASTIC SHEET MATERIAL WITHIN SUCH INTERSTICES TOWARD SUCH REMAINING SURFACES SO AS TO COAT PORTIONS OF SUCH INTERSTICES BETWEEN OPPOSED SURFACES OF THE SUBSTRATE, RUPTURING THE PLASTIC SHEET MATERIAL WITHIN SUCH INTERSTICES BY FLOW OF A GASEOUS MEDIUM UNDER CONTROL OF SUCH VACUUM MEANS TO PRODUCE POROSITY IN THE COMPOSITE DISTRIBUTED OVER SUCH AREA OF PLASTIC SHEET MATERIAL OVERLAY, WITH PORTIONS OF THE RUPTURED PLASTIC SHEET MATERIAL EXTENDING TO THE REMAINING SURFACE OF THE SUBSTRATE AND WRAPPING AROUND PORTIONS OF SUCH SUBSURFACE TO MECHANICALLY INTERLOCK THE PLASTIC SHEET MATERIAL AND THE SUBSTRATE.
Claim 2
Dependent Claim
299 words
CONTINUOUS-LINE PROCESS FOR MANUDACTURING A PERFORATE COMPOSITE FROM NON-PERFORATE SOLIDFIDE PLASTIC SHEET MATERIAL AN PERFORATE SUBSTRATE WHILE CONTROLLABLY PRODUCING POROSITY IN THE COMPOSITE, COMPRISING THE STEPS OF PROVIDING AN ELONGATED PERFORATE CONTINUOUS-LENGTH WOVEN SUBSTRATE WITH DEFINED INTERSTICES, DIRECTING SUCH SUBSTRATE LONGITUDINALLY ALONG A CONTINUOUSPROCESSING LINE, PROVIDING AN ELONGATED CONTINUOUS-LENGTH PLASTIC SHEET MATERIAL IN SOLDIFIED NON-PERFORATE FILM FROM OF SUBSTANTIALLY UNIFORM THICKNESS, DIRECTING SUCH PLASTIC SHEET MATERIAL LONGITUDINALLY ALONG THE CONTINUOUS PROCESS LINE, CONTINUOUSLY FEEDING THE SUBSTRATE AND PLASTIC SHEET MATERIAL LONGITUDINALLY INTO ALIGNED CONTIGUOUS RELATIONSHIP WHILE EACH IS TRAVELING ALONG THE CONTINUOUS PROCESSING LINE AT SUBSTANTIALLY THE SAME LONGITUDINAL SPEED, APPLYING SUCH PLASTIC SHEET MATERIAL TO OVERLAY SUBSTANTIALLY ENTIRELY ONE SURFACE OF THE ELONGATED SUBSTRATE FORMING A NON-PERFORATE COMPOSITE IN SUCH AREA OF OVERLAY. HEATING THE PLASTIC SHEET MATERIAL AFTER CONTACT WITH THE SUBSTRATE WHILE APPLYING A VACUUM TO REMAINING SURDACE OF THE SUBSTRATE BY DIRECTING SUCH COMPOSITE LONGITUDIALLY OVER VACUUM MEANS WHILE TRAVELING ALONG THE CONTINUOUS PROCESSING LINE, CONTROLLING LONGITUDINAL SPEED OF TRAVEL OF SUCH COMPOSITE OVER SUCH VACUUM MEANS WHILE CONTROLLING SUCH HEATING TO PRODUCE THERMOPLASTICITY IN THE PLASTIC SHEET MATERIAL, CONTROLLING THE VACUUM APPLIED THROUGH SUCH VACUUM MEANS TO DRAW SUCH HEATED PLASTIC SHEET MATERIAL INTO INTERSTICES OF THE SUBSTRATE AND STRETCH THE HEATED PLASTIC SHEET MATERIAL WITHIN SUCH INTERSTICES TOWARD SUCH REMAINING SURFACES SO AS TO COAT PORTIONS OF SUCH INTERSTICES BETWEEN OPPOSED SURFACES OF THE SUBSTRATE, RUPTURING THE PLASTIC SHEET MATERIAL WITHIN SUCH INTERSTICES BY FLOW OF A GASEOUS MEDIUM UNDER CONTROL OF SUCH VACUUM MEANS TO PRODUCE POROSITY IN THE COMPOSITE DISTRIBUTED OVER SUCH AREA OF PLASTIC SHEET MATERIAL OVERLAY, WITH PORTIONS OF THE RUPTURED PLASTIC SHEET MATERIAL EXTENDING TO THE REMAINING SURFACE OF THE SUBSTRATE AND WRAPPING AROUND PORTIONS OF SUCH SUBSURFACE TO MECHANICALLY INTERLOCK THE PLASTIC SHEET MATERIAL AND THE SUBSTRATE.
Claim 3
Dependent Claim
23 words
The process of claim 1 in which such plastic sheet material is heated to its heat pliable stage after contact with the substrate.
Claim 4
Dependent Claim
43 words
The process of claim 2 in which the plastic sheet material is applied uniformly to the surface of the substrate by applying a vacuum to the remaining surface of the substrate as the plastic sheet material is raised to its heat pliable stage.
Claim 5
Dependent Claim
43 words
The process of claim 1 in which the plastic sheet material is selected from the group consisting of polyurethane, polyethylene, polypropylene, polyvinyl chloride, blends of polyvinyl chloride and copolymers made from acrylonitrile, butadiene, and styrene, blends of polyvinyl chloride and rubber, and polystyrene.
Claim 6
Dependent Claim
40 words
The process of claim 1 in which the plastic sheet material comprises polyurethane film of a thickness extending to five mils which is heated to a temperature in the range of about 250*F to about 350*F while applying such vacuum.
Claim 7
Dependent Claim
25 words
The process of claim 1 in which the plastic sheet material has a thickness in the range of approximately one mil to approximately ten mils.
Claim 8
Dependent Claim
25 words
The process of claim 1 in which heating of the plastic sheet material includes the step of applying radiant energy to the plastic sheet material.
Claim 9
Dependent Claim
28 words
The process of claim 1 in which heating of the plastic sheet material includes the step of applying infra-red heat to an opaque film of plastic sheet material.
Claim 10
Dependent Claim
28 words
The process of claim 1 in which heating of the plastic sheet material includes applying micro-wave energy of selected frequency for preferential heating of the plastic sheet material.
Claim 11
Dependent Claim
31 words
The process of claim 1 in which an adhesive material is utilized between the plastic sheet material and the substrate to augment bonding between the plastic sheet material and the substrate.
Claim 12
Dependent Claim
20 words
The process of claim 10 including the step of curing such adhesive subsequent to production of porosity in such composite.
Claim 13
Dependent Claim
51 words
The process of claim 1 including the steps of distributing an adhesive uniformly between the plastic sheet material and the substrate before placing the substrate and plastic sheet material in contacting relationship, and moving such adhesive into interstices of the substrate by the drawing of the heated plastic into such interstices.
Claim 14
Dependent Claim
21 words
The process of claim 1 in which the substrate comprises woven paper fibers coated with a sizing such as polyvinyl acetate.
Claim 15
Dependent Claim
42 words
The process of claim 1 in which the vacuum is applied uniformly across the full width of the continuous-length substrate and plastic sheet material exposing substantially all interstices of the substrate which are covered by the plastic sheet material to the vacuum.
Claim 16
Dependent Claim
13 words
The process of claim 1 in which the gaseous medium comprises ambient atmosphere.
Claim 17
Dependent Claim
35 words
The process of claim 1 further including the steps of measuring the porisity produced in the composite while traveling along the continuous processing line, and controllinG porosity of the composite responsively to such porosity measurement.
Claim 18
Dependent Claim
28 words
The process of claim 16 in which controlling porosity is carried out by selectively controlling heating of the plastic sheet material, speed of the line, and vacuum applied.
Claim 19
Dependent Claim
284 words
Continuous-line apparatus for manufacturing a perforate composite from non-porous solidified plastic sheet material and porous substrate material comprising continuous line means defining a travel path for continuous-length materials from entry means through an intermediate processing means to exit means, means for feeding an elongated continuous-length woven substrate with defined interstices into the continuous line means and directing such substrate longitudinally along the continuous line means, means for feeding an elongated continuous-length plastic sheet material in solidified non-perforate film form of substantially uniform thickness into the continuous line means and directing such plastic sheet material longitudinally along the continuous line means, means for continuously feeding the substrate and plastic sheet material longitudinally into aligned continuous relationship while each is traveling along the continuous processing line means at substantially the same longitudinal speed, means for applying such plastic sheet material to overlay substantially entirely one surface of the elongated substrate forming a non-porous composite in such area of overlay, vacuum means for applying a vacuum to the remaining surface of such substrate while supporting such composite during its travel along the continuous line means, heating means for conditioning the plastic sheet material and heating the plastic sheet material to its thermoplastic range while applying vacuum to the remaining surface of the substrate, means for controlling heating of the plastic sheet material, means for controlling longitudinal speed of travel of such composite over such vacuum means, means for controlling the vacuum means to draw such heated plastic sheet material into interstices of the substrate and controlling gas flow induced by the vacuum means to rupture the plastic sheet material within such interstices to produce porosity in the composite distributed over such area of plastic sheet material overlay.
Claim 20
Dependent Claim
284 words
Continuous-line apparatus for manufacturing a perforate composite from non-porous solidified plastic sheet material and porous substrate material comprising continuous line means defining a travel path for continuous-length materials from entry means through an intermediate processing means to exit means, means for feeding an elongated continuous-length woven substrate with defined interstices into the continuous line means and directing such substrate longitudinally along the continuous line means, means for feeding an elongated continuous-length plastic sheet material in solidified non-perforate film form of substantially uniform thickness into the continuous line means and directing such plastic sheet material longitudinally along the continuous line means, means for continuously feeding the substrate and plastic sheet material longitudinally into aligned continuous relationship while each is traveling along the continuous processing line means at substantially the same longitudinal speed, means for applying such plastic sheet material to overlay substantially entirely one surface of the elongated substrate forming a non-porous composite in such area of overlay, vacuum means for applying a vacuum to the remaining surface of such substrate while supporting such composite during its travel along the continuous line means, heating means for conditioning the plastic sheet material and heating the plastic sheet material to its thermoplastic range while applying vacuum to the remaining surface of the substrate, means for controlling heating of the plastic sheet material, means for controlling longitudinal speed of travel of such composite over such vacuum means, means for controlling the vacuum means to draw such heated plastic sheet material into interstices of the substrate and controlling gas flow induced by the vacuum means to rupture the plastic sheet material within such interstices to produce porosity in the composite distributed over such area of plastic sheet material overlay.
Claim 21
Dependent Claim
58 words
The apparatus of claim 18 in which the vacuum means presents an extended surface area confronting and supporting such remaining surface of the substrate while vacuum is applied through aperture means in such extended surface area; such aperture means exposing substantially all interstices of the substrate across its full width to vacuum during passage over the vacuum means.
Claim 22
Dependent Claim
15 words
The apparatus of claim 18 in which the heating means comprises radiant energy heating means.
Claim 23
Dependent Claim
27 words
The apparatus of claim 18 in which the heating means comprises micro-wave energy means including means for selecting frequency for preferential heating of the plastic sheet material.
Claim 24
Dependent Claim
31 words
The apparatus of claim 18 including means for distributing an adhesive uniformly between the plastic sheet material and the substrate before placing the substrate and plastic sheet material in contacting relationship.
Claim 25
Dependent Claim
25 words
The apparatus of claim 22 including means for curing such adhesive located along the continuous line means subsequent to production of porosity in the composite.
Claim 26
Dependent Claim
41 words
The apparatus of claim 18 including means for measuring porosity of the composite after vacuum drawing while the composite is traveling along the continuous line means, and means for controlling porosity of the composite responsively to the means for measuring porosity.
Claim 27
Dependent Claim
38 words
The apparatus of claim 24 in which the means for controlling porosity includes means for selectively controlling heating of the plastic sheet material, speed of the line, and the vacuum applied responsively to the means for measuring porosity.
Claim 28
Dependent Claim
115 words
As a new article of manufacture a continuous-length, web-like composite material of controlLed porosity comprising a perforate continuous woven substrate having portions defining opposite surfaces and intersections of such portions defining interstices extending between opposite surfaces of the substrate, and a solidified plastic film coating which is continuous along portions of the substrate defining one surface of such substrate, with the solidified plastic film coating portions of the substrate defining selected interstices between opposed surfaces of the substrate and extending onto the remaining surface of such substrate through such selected interstices and being wrapped around portions of such substrate on the remaining surface mechanically interlocking the substrate and solidified plastic film into an integral composite.
Claim 29
Dependent Claim
115 words
As a new article of manufacture a continuous-length, web-like composite material of controlLed porosity comprising a perforate continuous woven substrate having portions defining opposite surfaces and intersections of such portions defining interstices extending between opposite surfaces of the substrate, and a solidified plastic film coating which is continuous along portions of the substrate defining one surface of such substrate, with the solidified plastic film coating portions of the substrate defining selected interstices between opposed surfaces of the substrate and extending onto the remaining surface of such substrate through such selected interstices and being wrapped around portions of such substrate on the remaining surface mechanically interlocking the substrate and solidified plastic film into an integral composite.
Claim 30
Dependent Claim
43 words
THE ARTICAL OF CLAM 26 IN WHICH THE SOLIDIFIED PLASTIC FILM IS SELECTED FROM THE GROUP CONSISTING OF POLYURETHANE, POLYETHYLENE, POLYPROPYLENE, POLYVINYL CHLORIDE, BLENDS OF POLYVINYL CHLORIDE AND COPOLYMERS MADE FROM ACRYLONITRILE, BUTADINENE, AND STRENE, BLENDS OF POLYVINYL CHORIDE AND RUBBER AND POLYSTYRENE.
Claim 31
Dependent Claim
43 words
THE ARTICAL OF CLAM 26 IN WHICH THE SOLIDIFIED PLASTIC FILM IS SELECTED FROM THE GROUP CONSISTING OF POLYURETHANE, POLYETHYLENE, POLYPROPYLENE, POLYVINYL CHLORIDE, BLENDS OF POLYVINYL CHLORIDE AND COPOLYMERS MADE FROM ACRYLONITRILE, BUTADINENE, AND STRENE, BLENDS OF POLYVINYL CHORIDE AND RUBBER AND POLYSTYRENE.
Claim 32
Dependent Claim
34 words
The article of claim 26 in which the solidified plastic film comprises polyurethane having a thickness in the range of one mil to about five mils along the continuously coated portions defining one surface.
Claim 33
Dependent Claim
13 words
The article of claim 26 in which the solidified plastic film is opaque.
Claim 34
Dependent Claim
13 words
The article of claim 26 in which the solidified plastic film is transparent.
Claim 35
Dependent Claim
26 words
The article of claim 26 in which such fiber portions are selected from the group consisting of plant fibers, protein fibers, mineral fibers, and synthetic fibers.
Claim 36
Dependent Claim
17 words
The article of claim 26 further including a bonding adhesive intermediate the substrate and solidified plastic film.
Claim 37
Dependent Claim
118 words
A flexible, perforate, composite which is moisture and abrasion resistant along at least one surface comprising a woven substrate with intersecting fibers defining interstices extending between opposite outer and inner surfaces of the textile substrate, a thin flexible coating of a thermoplastic applied in solidified form to the outer surface of such textile substrate to form a continuous, uniform-thickness, unitary film along the fibers on such surface of the textile substance, such thermoplastic coating being discontinuous at selected interstices distributed over the textile substrate and extending into such interstices to the inner surface of such substrate in wrap-around relation to fibers on such inner surface so as to interlock such substrate and thermoplastic coating into an integral composite.
Claim 38
Dependent Claim
118 words
A flexible, perforate, composite which is moisture and abrasion resistant along at least one surface comprising a woven substrate with intersecting fibers defining interstices extending between opposite outer and inner surfaces of the textile substrate, a thin flexible coating of a thermoplastic applied in solidified form to the outer surface of such textile substrate to form a continuous, uniform-thickness, unitary film along the fibers on such surface of the textile substance, such thermoplastic coating being discontinuous at selected interstices distributed over the textile substrate and extending into such interstices to the inner surface of such substrate in wrap-around relation to fibers on such inner surface so as to interlock such substrate and thermoplastic coating into an integral composite.
Claim 39
Dependent Claim
25 words
The composite of claim 33 in which the fibers are selected from the group consisting of plant fibers, mineral fibers, protein fibers, and synthetic fibers.
Claim 40
Dependent Claim
60 words
The composite fabric of claim 33 in which the thermoplastic coating is selected from solidified films consisting of polyurethane, polyethylene, polypropylene, polyvinyl chloride, blends of polyvinyl chloride and copolymers made from acrylonitrile, butadiene, and styrene, blends of polyvinyl chloride and rubber, and polystyrene, such films being of uniform thickness in the range of about 1 mil to about 10 mils.
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) | 1978-10-06 | 1979-04-07 | 1979-10-07 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1982-10-06 | 1983-04-07 | 1983-10-07 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1986-10-06 | 1987-04-07 | 1987-10-07 | $7700.00 | Window Closed / Lapsed |