US4178411A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Fibre expanded reinforced materials and their process of manufacture
Assignee: Imperial Chemical Industries Ltd
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Filing: 1977-07-11
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Granted: 1979-12-11
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Expires: 1997-07-11
Abstract
Abstract A very low density material is produced by extruding a composition comprising a settable fluid containing long resilient fibres through a narrow die under conditions which cause the extrudate to expand to form an open fibrous structure as it leaves the die, and then causing the fluid to set. This is applicable to both thermoplastic and thermosetting materials. Various coating layers may be applied to provide rigid light-weight panels and shaped articles for various uses including furniture and building applications.
Inventors
- 👤 Ernest A. Cole
- 👤 Frederic N. Cogswell
- 👤 Jonathan Huxtable
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-01 14:34
CPC Classifications
B; B29; B29C; B29C44/00; B29C44/34; B29C44/36; B29C44/46; B29C44/50; B32; B32B; B32B27/00; B32B27/06; B32B27/08; B32B27/32; B32B5/00; B32B5/16; B32B5/18; B32B7/00; B32B7/04; B32B7/12; C; C08; C08J; C08J9/00; C08J9/0085; B29C48/00; B29C48/03; B29C48/06; B29C48/12; B29C48/13; B29C48/25; B29C48/36; B29C48/475; B29K; B29K2105/00; B29K2105/06; B29K2105/12; B29L; B29L2031/00; B29L2031/771; Y; Y10; Y10S; Y10S264/00; Y10S264/05; Y10S264/13; Y10T; Y10T428/00; Y10T428/31504; Y10T428/31652; Y10T428/31667; Y10T428/31786; Y10T428/31797; Y10T428/31815
Claims Analysis
Total Claims: 17
Claim 1
Independent Claim
113 words
A method for producing a low density material comprising extruding a composition comprising a settable fluid containing resilient fibres through a die generally having a minimal land length so that relaxation of the fibres causes the extrudate to expand to form an open fibrous structure as it leaves the die, wherein the settable fluid used when resinous is selected from those having a melt viscosity of between 10 Ns/m 2 and 10,000 Ns/m 2 measured at a shear rate of 100 reciprocal seconds and the ratio of average length of the fibres to the diameter of the die is at least 2.5 to 1, and then causing or allowing the fluid to set.
Claim 2
Independent Claim
113 words
A method for producing a low density material comprising extruding a composition comprising a settable fluid containing resilient fibres through a die generally having a minimal land length so that relaxation of the fibres causes the extrudate to expand to form an open fibrous structure as it leaves the die, wherein the settable fluid used when resinous is selected from those having a melt viscosity of between 10 Ns/m 2 and 10,000 Ns/m 2 measured at a shear rate of 100 reciprocal seconds and the ratio of average length of the fibres to the diameter of the die is at least 2.5 to 1, and then causing or allowing the fluid to set.
Claim 3
Dependent Claim
21 words
A method according to claim 1 in which the die comprises a substantially circular hole and has substantially zero land length.
Claim 4
Dependent Claim
29 words
A method according to claim 1 in which a plurality of dies are used together, being arranged so that extrudates from adjacent dies merge together after leaving the dies.
Claim 5
Dependent Claim
31 words
A method according to claim 3 in which the settable fluid is extruded onto a moving former so as to build up the material on the former into a desired shape.
Claim 6
Dependent Claim
26 words
A method according to claim 1 in which the settable material comprises a polymeric material selected from the group consisting of thermoplastic and activatable thermosetting polymers.
Claim 7
Dependent Claim
61 words
A method for producing a low density material comprising extruding a composition according to the method of claim 1, forming a fibre expanded article of desired shape from the extrudate and adhering to at least part of the surface of the fibre expanded material a surface layer of a material having physical properties different from those of the fibre expanded article.
Claim 8
Dependent Claim
32 words
A method according to claim 6 in which said surface layer of material is applied in sheet form and adhered to at least part of the surface of the fibre expanded article.
Claim 9
Dependent Claim
17 words
A method according to claim 6 in which said surface layer of material comprises a particulate material.
Claim 10
Dependent Claim
42 words
A method according to claim 8 in which the particulate material is applied to the fibre expanded material in an adhesive or binder material which binds the particulate material together in the layer and bonds the layer to the fibre expanded material.
Claim 11
Dependent Claim
39 words
A method according to claim 8 in which the particulate material is a particulate thermoplastic material containing a blowing agent and is fused onto the surface of the fibre expanded material and is subsequently expanded into a foamed structure.
Claim 12
Dependent Claim
50 words
A method according to claim 6 in which said surface layer is of a settable material selected from the group consisting of cement, plaster and concrete slurries, bitumen and polyester gel coat and is applied to the surface of the fibre expanded material and is caused or allowed to set.
Claim 13
Dependent Claim
24 words
A low density structure comprising a fibre expanded material in the form of a shaped article produced according to the method of claim 1.
Claim 14
Dependent Claim
29 words
A composite low density structure comprising a fibre expanded material and bonded surface layer in the form of a shaped article produced according to the method of claim 6.
Claim 15
Dependent Claim
30 words
A composite low density structure comprising a fibre expanded material and a bonded surface sheet in the form of a shaped article produced according to the method of claim 7.
Claim 16
Dependent Claim
30 words
A composite low density structure comprising a fibre expanded material and a bonded surface sheet in the form of a shaped article produced according to the method of claim 8.
Claim 17
Dependent Claim
31 words
A low density structure according to claim 13 in which the material of the bonded layer is selected from the group consisting of cement, plaster, concrete, bitumen and polyester gel coat.
References Cited (Backward Citations)
US3846523A
Cited
USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1982-12-10 | 1983-06-11 | 1983-12-11 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1986-12-10 | 1987-06-11 | 1987-12-11 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1990-12-10 | 1991-06-11 | 1991-12-11 | $7700.00 | Window Closed / Lapsed |