US4034137A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Composite sheet structure and method for manufacturing same
Assignee: WR Grace and Co
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Filing: 1976-12-06
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Granted: 1977-07-05
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Expires: 1996-12-06
Abstract
Abstract The subject matter of the invention is a composite sheet structure having at least two layers of initially liquid-permeable material at least one of which layers is an initially resilient material with open and connected cells, and a thermosetting resinous material which impregnates the layers and which has been cured while the layers are maintained under compression, there being fibrils having a length not in excess of about 1/16 inch in the resinous material, the fibrils preferably being more numerous adjacent the interface of the two layers than in the portions thereof spaced from the interface. Further in accordance with the invention, such a composite sheet is preferably manufactured by applying a mixture of the resinous material, in liquid form, and the fibrils between the two layers and then compressing the two layers and heating them to the curing temperature of the resinous material whereby the liquid resinous material is driven through the two layers and then cured and whereby the concentration of the fibrils in the final cured composite sheet is greater at the interface of the two layers than in the portions spaced from the interface.
Inventors
- 👤 Peter H. Hofer
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-26 22:06
CPC Classifications
B; B32; B32B; B32B5/00; B32B5/14; B32B5/145; B32B5/18; B32B5/22; B32B5/24; B32B5/245; B32B5/32; B32B7/00; B32B7/04; B32B2260/00; B32B2260/02; B32B2260/021; B32B2260/04; B32B2260/046; B32B2262/00; B32B2262/10; B32B2262/101; B32B2266/00; B32B2266/02; B32B2266/0214; B32B2266/0278; B32B2266/06; B32B2305/00; B32B2305/30; B32B2307/00; B32B2307/70; B32B2307/726; B32B2315/00; B32B2315/08; B32B2315/085; Y; Y10; Y10T; Y10T428/00; Y10T428/249921; Y10T428/249953; Y10T428/249971; Y10T428/249972; Y10T428/249994; Y10T428/249999
Claims Analysis
Total Claims: 28
Claim 1
Independent Claim
93 words
A composite structure comprising two layers of initially liquid permeable material having opposed inner surfaces and having outer surfaces oriented in opposite directions, at least one of said layers being an initially resilient resin foam with open and connected cells, and a thermosetting resinous material which impregnates said layers and which has been cured while maintaining said layers under compression whereby the resinous material is disposed in said layers and therebetween as a continuous and rigid phase, said thermosetting resinous material containing fibrils having a length not in excess of about 1/16 inch.
Claim 2
Dependent Claim
93 words
A composite structure comprising two layers of initially liquid permeable material having opposed inner surfaces and having outer surfaces oriented in opposite directions, at least one of said layers being an initially resilient resin foam with open and connected cells, and a thermosetting resinous material which impregnates said layers and which has been cured while maintaining said layers under compression whereby the resinous material is disposed in said layers and therebetween as a continuous and rigid phase, said thermosetting resinous material containing fibrils having a length not in excess of about 1/16 inch.
Claim 3
Dependent Claim
32 words
A composite as set forth in claim 1 wherein said fibrils are more numerous adjacent the inner surfaces of said layers than in portions of said layers spaced from said inner surfaces.
Claim 4
Dependent Claim
21 words
A composite as set forth in claim 1 wherein said fibrils have a length of about 1/64 inch to 1/16 inch.
Claim 5
Dependent Claim
35 words
A composite as set forth in claim 1 wherein said fibrils are present in an amount of from about 3 to 15 parts by weight for each 100 parts by weight of said resinous material.
Claim 6
Dependent Claim
28 words
A composite as set forth in claim 1 wherein said thermosetting resinous material also contains hollow glass beads having a diameter less than the length of said fibrils.
Claim 7
Dependent Claim
36 words
A composite as set forth in claim 5 wherein said glass beads are present in an amount of from about 3 to 15 parts by weight for each 100 parts by weight of said resinous material.
Claim 8
Dependent Claim
57 words
A composite as set forth in claim 5 wherein said fibrils and said beads are more numerous adjacent said inner surface of said layers than in portions of said layers spaced from said inner surfaces, the gradation in concentration from the inner surfaces to said portions spaced therefrom being greater for said fibrils than for said beads.
Claim 9
Dependent Claim
25 words
A composite as set forth in claim 1 wherein both of said layers are of an initially resilient resin foam with open and connected cells.
Claim 10
Dependent Claim
29 words
A composite as set forth in claim 8 wherein at least one of said outer surfaces is overlaid with a layer of fibrous material impregnated with said resinous material.
Claim 11
Dependent Claim
15 words
A composite as set forth in claim 9 wherein said fibrous material is glass cloth.
Claim 12
Dependent Claim
35 words
A composite as set forth in claim 1 wherein one of said layers is of said initially resilient resin foam with open and connected cells and the other of said layers is of fibrous material.
Claim 13
Dependent Claim
15 words
A composite as set forth in claim 11 wherein said fibrous material is glass cloth.
Claim 14
Dependent Claim
13 words
A composite as set forth in claim 1 wherein said fibrils are glass.
Claim 15
Independent Claim
86 words
A method for making a composite structure comprising the steps of forming an assembly which includes two sheets of liquid permeable material having between the opposed inner surfaces thereof a uniform mixture of liquid thermosetting resin and fibrils having a length not exceeding about 1/16 inch, at least one of said sheets being a resilient resin foam with open and connected cells; and then compressing and heating said assembly to cure said liquid thermosetting resin to permeate through said sheets and to cure said thermosetting resin.
Claim 16
Independent Claim
86 words
A method for making a composite structure comprising the steps of forming an assembly which includes two sheets of liquid permeable material having between the opposed inner surfaces thereof a uniform mixture of liquid thermosetting resin and fibrils having a length not exceeding about 1/16 inch, at least one of said sheets being a resilient resin foam with open and connected cells; and then compressing and heating said assembly to cure said liquid thermosetting resin to permeate through said sheets and to cure said thermosetting resin.
Claim 17
Dependent Claim
26 words
A method as set forth in claim 14 wherein the length of said fibrils is greater than the average diameter of the cells of said foam.
Claim 18
Dependent Claim
24 words
A method as set forth in claim 14 wherein said fibrils are glass and have a length of about 1/64 inch to 1/16 inch.
Claim 19
Dependent Claim
35 words
A method as set forth in claim 14 where said fibrils are present in an amount of from about 3 to 15 parts by weight from each 100 parts by weight of said resinous material.
Claim 20
Dependent Claim
28 words
A method as set forth in claim 14 wherein said thermosetting resinous material also contains hollow glass beads having a diameter less than the length of said fibrils.
Claim 21
Dependent Claim
26 words
A method as set forth in claim 18 wherein the diameter of said beads is less than the average diameter of the cells of said foam.
Claim 22
Dependent Claim
36 words
A method as set forth in claim 18 wherein said glass beads are present in an amount of from about 3 to 15 parts by weight for each 100 parts by weight of said resinous material.
Claim 23
Dependent Claim
25 words
A method as set forth in claim 14 wherein both of said layers are of an initially resilient resin foam with open and connected cells.
Claim 24
Dependent Claim
24 words
A method as set forth in claim 14 wherein at least one of said outer surfaces is overlaid with a layer of fibrous material.
Claim 25
Dependent Claim
15 words
A method as set forth in claim 22 wherein said fibrous material is glass cloth.
Claim 26
Dependent Claim
35 words
A method as set forth in claim 14 wherein one of said layers is of said initially resilient resin foam with open and connected cells and the other of said layers is of fibrous material.
Claim 27
Dependent Claim
15 words
A method as set forth in claim 24 wherein said fibrous material is glass cloth.
Claim 28
Dependent Claim
18 words
A method as set forth in claim 24 wherein said fibrous material is glass cloth of matted construction.
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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) | 1980-07-04 | 1981-01-03 | 1981-07-05 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1984-07-04 | 1985-01-03 | 1985-07-05 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1988-07-04 | 1989-01-03 | 1989-07-05 | $7700.00 | Window Closed / Lapsed |