US3966526A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Process for making resilient laminar panel
Assignee: Indian Head Industries Inc
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Filing: 1974-12-09
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Granted: 1976-06-29
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Expires: 1994-12-09
Abstract
Abstract An improved decorative resilient laminar panel and the method of fabricating said panel which is characterized by its shape-retaining compound contour and selected embossments over predetermined areas thereof and which comprises a perforated thermoplastic resin foam disposed between a pair of perforated cover sheets which are coated with a moisture-resistant sealing material. The resilient laminar panel is particularly applicable for use as automobile interior trim panels in which the exposed face surfaces thereof are provided with decorative coatings or decorative plies to enhance the aesthetic and functional characteristics thereof.
Inventors
- 👤 Ralph G. Doerfling
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-29 09:54
CPC Classifications
G; G10; G10K; G10K11/00; G10K11/16; B; B29; B29C; B29C44/00; B29C44/34; B29C44/56; B60; B60R; B60R13/00; B60R13/02; B60R13/0212; B60R13/0225; B29L; B29L2031/00; B29L2031/30; B29L2031/3005; B29L2031/3011; B60R13/08; B60R13/0815; B60R13/0892; Y; Y10; Y10T; Y10T156/00; Y10T156/10; Y10T156/1002; Y10T156/1043; Y10T156/1044; Y10T156/1048; Y10T156/1052; Y10T156/1056; Y10T156/108; Y10T428/00; Y10T428/24; Y10T428/24273
Claims Analysis
Total Claims: 13
Claim 1
Independent Claim
227 words
A method for making a resilient laminar panel of a preselected shape-retaining contour which comprises the steps of forming a layer of substantially thermoplastic rigid foam having cover sheets bonded to the face surfaces thereof providing therewith an integral laminar foam-cored panel, piercing said foam-cored panel to impart a plurality of perforations extending therethrough from one face to the opposite face of said panel and performed in a manner to deform and laterally displace and locally densify said foam in a region surrounding each perforation without incurring any appreciable removal of material and without significantly reducing the thickness of said panel, said piercing step performed to distribute said perforations at spaced intervals over substantially the entire surface area of said panel, coating the exterior surfaces of said panel including the interior surfaces defining said perforations with a sealing material forming a substantially moisture-resistant barrier thereover, heating the sealed said panel to an elevated temperature for a period of time sufficient to effect a softening thereof, deforming the heat softened said panel to impart a preselected contour thereto, cooling the deformed said panel to a temperature at which a rigidification thereof occurs of a magnitude sufficient to retain at least a portion of the preselected contour therein, and applying and securing a pervious decorative ply to one said face surface of said panel forming a decorative laminar panel.
Claim 2
Independent Claim
227 words
A method for making a resilient laminar panel of a preselected shape-retaining contour which comprises the steps of forming a layer of substantially thermoplastic rigid foam having cover sheets bonded to the face surfaces thereof providing therewith an integral laminar foam-cored panel, piercing said foam-cored panel to impart a plurality of perforations extending therethrough from one face to the opposite face of said panel and performed in a manner to deform and laterally displace and locally densify said foam in a region surrounding each perforation without incurring any appreciable removal of material and without significantly reducing the thickness of said panel, said piercing step performed to distribute said perforations at spaced intervals over substantially the entire surface area of said panel, coating the exterior surfaces of said panel including the interior surfaces defining said perforations with a sealing material forming a substantially moisture-resistant barrier thereover, heating the sealed said panel to an elevated temperature for a period of time sufficient to effect a softening thereof, deforming the heat softened said panel to impart a preselected contour thereto, cooling the deformed said panel to a temperature at which a rigidification thereof occurs of a magnitude sufficient to retain at least a portion of the preselected contour therein, and applying and securing a pervious decorative ply to one said face surface of said panel forming a decorative laminar panel.
Claim 3
Dependent Claim
23 words
The method as defined in claim 1, including the further step of die-cutting said panel to a preselected configuration prior to deformation thereof.
Claim 4
Dependent Claim
26 words
The method as defined in claim 1, including the further step of trimming the periphery of said decorative laminar panel to a preselected shape and size.
Claim 5
Dependent Claim
39 words
The method as defined in claim 1, wherein said thermoplastic rigid foam comprises a polystyrene foam and the heating step is performed in a manner to heat said panel to a temperature ranging from about 150°F to about 300°F.
Claim 6
Dependent Claim
55 words
The method as defined in claim 1, wherein the piercing step is performed utilizing a pointed tapered piercing tool effecting a lateral displacement and local densification of said foam in a region surrounding each perforation and wherein one said cover sheet is turned inwardly in overlying encircling relationship over the inner surface of the perforations.
Claim 7
Dependent Claim
43 words
The method as defined in claim 1, wherein the piercing step is performed to produce a substantially uniform distribution of the perforations over the entire surface area of said panel at a frequency of about 10 to about 50 perforations per square inch.
Claim 8
Dependent Claim
35 words
The method as defined in claim 1, wherein the piercing step is performed to arrange the perforations in a triangular repetitive pattern and at a frequency of about 4 to about 6 per lineal inch.
Claim 9
Dependent Claim
27 words
The method as defined in claim 1, wherein the piercing step is performed to produce perforations of an average diameter of about 1/32 to about 3/32 inch.
Claim 10
Dependent Claim
61 words
The method as defined in claim 1, including the further step of heating the pierced said foam-cored panel after the piercing step and prior to the coating step to an elevated temperature for a period of time sufficient to effect an expansion of said panel to a thickness corresponding to at least about its original thickness prior to the piercing operation.
Claim 11
Dependent Claim
71 words
The method as defined in claim 1, including the further step of sizing the pierced said foam-cored panel after the piercing step and prior to the coating step by heating the thermoplastic rigid foam to an elevated temperature to effect a heat softening thereof in the stratum immediately adjacent to the cover sheets and thereafter compressing the heat softened said stratum in a manner to form substantially flat smooth face surfaces.
Claim 12
Dependent Claim
32 words
The method as defined in claim 9, wherein said post-expansion step is performed in a manner so as not to close the perforations imparted to said foam-cored panel during the piercing step.
Claim 13
Dependent Claim
33 words
The method as defined in claim 10, in which said sizing step is performed in a manner so as not to close the perforations imparted to said foam-cored panel during the piercing step.
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1979-06-29 | 1979-12-29 | 1980-06-29 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1983-06-29 | 1983-12-29 | 1984-06-29 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1987-06-29 | 1987-12-29 | 1988-06-29 | $7700.00 | Window Closed / Lapsed |