US4194026A
Expired / Lapsed
US
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Method of manufacturing textured foam coatings and materials
Assignee: United Foam Corp
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Filing: 1977-03-18
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Granted: 1980-03-18
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Expires: 1997-03-18
Abstract
Abstract A method of making textured foam coatings and materials is disclosed. A mixture of a curable frothed elastomeric emulsion composition and 20 pounds or less of thermally expandable beads to each 100 pounds of elastomeric composition is applied to a foam substrate and heated. During heating the plastic beads expand to produce a textured pebble-like coated elastomeric article.
Inventors
- 👤 Clark W. Goodale
- 👤 Charles W. Morgan
- 👤 Albert L. Rhoton
- 👤 David F. McNeil
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-04 16:09
CPC Classifications
B; B32; B32B; B32B5/00; B32B5/18; B32B5/20; B32B27/00; B32B27/06; B32B27/065; B32B37/00; B32B37/06; C; C08; C08J; C08J9/00; C08J9/35; D; D06; D06N; D06N3/00; D06N3/0043; D06N3/005; D06Q; D06Q1/00; D06Q1/10; B32B38/00; B32B38/0012; B32B2038/0024; B32B2607/00; B32B2607/02
Claims Analysis
Total Claims: 37
Claim 1
Independent Claim
108 words
A method of producing a flexible material having a textured surface for use as an acoustical wall and ceiling covering comprising the steps of: (a) providing a mixture of a curable frothed elastomeric emulsion composition comprising 20 pounds or less of thermally expandable plastic beads to each 100 pounds of said elastomeric composition, said thermally expandable plastic beads having a diameter of at least approximately 0.5 millimeters; (b) uniformly distributing said mixture over one surface of a flexible urethane foam sheet; and (c) heating said mixture to expand the plastic beads and to dry and cure the frothed elastomeric emulsion composition to form a textured pebble-like elastomeric coating.
Claim 2
Independent Claim
108 words
A method of producing a flexible material having a textured surface for use as an acoustical wall and ceiling covering comprising the steps of: (a) providing a mixture of a curable frothed elastomeric emulsion composition comprising 20 pounds or less of thermally expandable plastic beads to each 100 pounds of said elastomeric composition, said thermally expandable plastic beads having a diameter of at least approximately 0.5 millimeters; (b) uniformly distributing said mixture over one surface of a flexible urethane foam sheet; and (c) heating said mixture to expand the plastic beads and to dry and cure the frothed elastomeric emulsion composition to form a textured pebble-like elastomeric coating.
Claim 3
Dependent Claim
42 words
The method of claim 1 wherein the urethane foam sheet has a thickness in the range of one-eighth of an inch to one inch and a density in the range of one pound per cubic foot to six pounds per cubic foot.
Claim 4
Dependent Claim
27 words
The method of claim 1 wherein said elastomeric emulsion composition is dried and cured in an oven at a temperature of about 200° F. to 325° F.
Claim 5
Dependent Claim
36 words
The method of claim 1 comprised of the further steps of providing a layer of curable elastomeric composition over the flexible material formed in steps (a) through (c), and heating said layer to cure the elastomer.
Claim 6
Dependent Claim
38 words
The method of claim 1 wherein said mixture is frothed to a density in the range of one hundred forty grams per liter to two hundred sixty grams per liter prior to its distribution on the urethane foam.
Claim 7
Dependent Claim
18 words
The method of claim 5 further comprised of the step of crushing the resulting material after said curing.
Claim 8
Dependent Claim
39 words
The method of claim 1 in which said elastomeric emulsion composition is based on an elastomer selected from the group consisting of acrylic polymers, styrene-butadiene copolymers; nitrile rubber; vinyl chloride-acrylic copolymers; vinylidene chloride-vinyl chloride copolymers; neoprene; and natural rubber.
Claim 9
Dependent Claim
26 words
The method of claim 7 in which the curable elastomeric emulsion composition is an emulsion having a solids content of about 40% to 55% by weight.
Claim 10
Dependent Claim
15 words
The method of claim 1 wherein the elastomeric emulsion composition is an acrylic emulsion composition.
Claim 11
Dependent Claim
101 words
The method of claim 9 wherein step (a) comprises the step of providing the mixture of a frothed acrylic emulsion composition and expandable plastic beads in the proportions in the range of three pounds to twenty pounds of the expandable plastic beads to each one hundred pounds of acrylic emulsion composition, and step (b) comprises the step of distributing said mixture over one surface of a urethane foam sheet having a thickness in the range of one-eighth of an inch to one inch and a density in the range of one pound per cubic foot to six pounds per cubic foot.
Claim 12
Dependent Claim
14 words
The method of claim 10 wherein said expandable plastic beads are expandable polystyrene beads.
Claim 13
Dependent Claim
34 words
The method of claim 10 wherein said mixture is distributed in an amount in the range of twenty grams per square foot to seventy grams per square foot of said urethane foam sheet surface.
Claim 14
Independent Claim
184 words
A method of producing a flexible composite wall and ceiling covering and the like having a textured pebble-like elastomeric outer surface comprising the steps of: (a) providing a mixture of a curable frothable water-based acrylic emulsion composition and thermally expandable polystyrene plastic beads having a diameter of about 0.5 to 2 millimeters, the mixture having proportions in the range of three pounds to twenty pounds of the expandable plastic beads to each one hundred pounds of acrylic emulsion composition, frothed to a density in the range of one hundred forty grams per liter to two hundred sixty grams per liter; (b) uniformly distributing said frothed mixture in an amount in the range of twenty grams per square foot to seventy grams per square foot over one surface of a urethane foam sheeting having a thickness in the range of one eighth of an inch to one inch and a density in the range of one pound per cubic foot to six pounds per cubic foot; and (c) heating said mixture to expand the plastic beads and to dry and cure the acrylic emulsion composition.
Claim 15
Independent Claim
184 words
A method of producing a flexible composite wall and ceiling covering and the like having a textured pebble-like elastomeric outer surface comprising the steps of: (a) providing a mixture of a curable frothable water-based acrylic emulsion composition and thermally expandable polystyrene plastic beads having a diameter of about 0.5 to 2 millimeters, the mixture having proportions in the range of three pounds to twenty pounds of the expandable plastic beads to each one hundred pounds of acrylic emulsion composition, frothed to a density in the range of one hundred forty grams per liter to two hundred sixty grams per liter; (b) uniformly distributing said frothed mixture in an amount in the range of twenty grams per square foot to seventy grams per square foot over one surface of a urethane foam sheeting having a thickness in the range of one eighth of an inch to one inch and a density in the range of one pound per cubic foot to six pounds per cubic foot; and (c) heating said mixture to expand the plastic beads and to dry and cure the acrylic emulsion composition.
Claim 16
Dependent Claim
18 words
The method of claim 13 further comprised of the step of crushing the resulting material after said curing.
Claim 17
Dependent Claim
14 words
The method of claim 13 wherein the expandable plastic beads are expandable polystyrene beads.
Claim 18
Dependent Claim
17 words
The method of claim 15 in which said beads have a diameter of 0.75 to 1.2 millimeters.
Claim 19
Independent Claim
184 words
A method of producing a flexible composite material for wall and ceiling covering and the like comprising the steps of: (a) providing a mixture of a curable frothable elastomeric emulsion composition and thermally expandable plastic beads having a diameter of about 0.5 to 2 millimeters, the mixture having proportions in the range of three pounds to twenty pounds of the expandable plastic beads to each one hundred pounds of elastomeric emulsion composition, frothed to a density in the range of one hundred forty grams per liter to two hundred sixty grams per liter; (b) uniformly distributing said frothed mixture in an amount in the range of twenty grams per square foot to seventy grams per square foot over one surface of a urethane foam sheeting having a thickness in the range of one eighth of an inch to one inch and a density in the range of one pound per cubic foot to six pounds per cubic foot; and (c) heating said mixture to expand the plastic beads and to dry and cure the elastomeric emulsion composition to form a textured pebble-like elastomeric coating.
Claim 20
Independent Claim
184 words
A method of producing a flexible composite material for wall and ceiling covering and the like comprising the steps of: (a) providing a mixture of a curable frothable elastomeric emulsion composition and thermally expandable plastic beads having a diameter of about 0.5 to 2 millimeters, the mixture having proportions in the range of three pounds to twenty pounds of the expandable plastic beads to each one hundred pounds of elastomeric emulsion composition, frothed to a density in the range of one hundred forty grams per liter to two hundred sixty grams per liter; (b) uniformly distributing said frothed mixture in an amount in the range of twenty grams per square foot to seventy grams per square foot over one surface of a urethane foam sheeting having a thickness in the range of one eighth of an inch to one inch and a density in the range of one pound per cubic foot to six pounds per cubic foot; and (c) heating said mixture to expand the plastic beads and to dry and cure the elastomeric emulsion composition to form a textured pebble-like elastomeric coating.
Claim 21
Dependent Claim
36 words
The method of claim 17 comprised of the further steps of providing a layer of curable elastomeric composition over the composite material formed in steps (a) through (c), and heating said layer to cure the elastomer.
Claim 22
Dependent Claim
16 words
The method of claim 17 in which said elastomeric coating is formed from an acrylic composition.
Claim 23
Dependent Claim
16 words
The method of claim 17 in which said elastomeric coating is formed from a styrene-butadiene composition.
Claim 24
Dependent Claim
17 words
The method of claim 17 in which said elastomeric coating is formed from a nitrile rubber composition.
Claim 25
Dependent Claim
17 words
The method of claim 17 in which said elastomeric coating is formed from a vinyl chloride-acrylic composition.
Claim 26
Dependent Claim
18 words
The method of claim 17 in which said elastomeric coating is formed from a vinylidene chloride-vinyl chloride composition.
Claim 27
Dependent Claim
16 words
The method of claim 17 in which said elastomeric coating is formed from a neoprene composition.
Claim 28
Dependent Claim
17 words
The method of claim 17 in which said elastomeric coating is formed from a natural rubber composition.
Claim 29
Independent Claim
300 words
A method for producing a flexible composite material for wall and ceiling covering and the like comprising the steps of: (a) providing a mixture of: (i) a curable frothable elastomeric emulsion composition based on an elastomer selected from the group consisting of acrylic polymers, styrene-butadiene copolymers; nitrile rubber; vinyl chloride-acrylic copolymers; vinylidene chloride-vinyl chloride copolymers; neoprene; and natural rubber, and (ii) thermally expandable polystyrene beads having a diameter in the range of approximately 0.5 millimeters to 2 millimeters; the mixture being in the proportions in the range of three pounds to twenty pounds of the expandable plastic beads to each one hundred pounds of elastomeric emulsion composition, frothed to a density in the range of one hundred forty grams per liter to two hundred sixty grams per liter; (b) uniformly distributing the frothed mixture in an amount in the range of twenty grams per square foot to seventy grams per square foot over one surface of a urethane foam sheeting having a thickness in the range of one eighth of an inch to one inch and a density in the range of one pound per cubic foot to six pounds per cubic foot; (c) heating the mixture to a temperature in the range of 200° F. to 325° F. to expand the plastic beads and to dry and cure the elastomeric emulsion composition to form a textured pebble-like elastomeric coating; (d) providing a layer of uncured elastomeric composition, based on an elastomer selected from the group consisting of acrylic polymers, styrene-butadiene copolymers; nitrile rubber; vinyl chloride-acrylic copolymers; vinylidene chloride-vinyl chloride copolymers; neoprene; and natural rubber, on the material formed by steps (a) through (c); and (e) heating the layer provided in step (d) to a temperature in the range of 200° F. to 325° F. to cure the elastomeric composition.
Claim 30
Independent Claim
300 words
A method for producing a flexible composite material for wall and ceiling covering and the like comprising the steps of: (a) providing a mixture of: (i) a curable frothable elastomeric emulsion composition based on an elastomer selected from the group consisting of acrylic polymers, styrene-butadiene copolymers; nitrile rubber; vinyl chloride-acrylic copolymers; vinylidene chloride-vinyl chloride copolymers; neoprene; and natural rubber, and (ii) thermally expandable polystyrene beads having a diameter in the range of approximately 0.5 millimeters to 2 millimeters; the mixture being in the proportions in the range of three pounds to twenty pounds of the expandable plastic beads to each one hundred pounds of elastomeric emulsion composition, frothed to a density in the range of one hundred forty grams per liter to two hundred sixty grams per liter; (b) uniformly distributing the frothed mixture in an amount in the range of twenty grams per square foot to seventy grams per square foot over one surface of a urethane foam sheeting having a thickness in the range of one eighth of an inch to one inch and a density in the range of one pound per cubic foot to six pounds per cubic foot; (c) heating the mixture to a temperature in the range of 200° F. to 325° F. to expand the plastic beads and to dry and cure the elastomeric emulsion composition to form a textured pebble-like elastomeric coating; (d) providing a layer of uncured elastomeric composition, based on an elastomer selected from the group consisting of acrylic polymers, styrene-butadiene copolymers; nitrile rubber; vinyl chloride-acrylic copolymers; vinylidene chloride-vinyl chloride copolymers; neoprene; and natural rubber, on the material formed by steps (a) through (c); and (e) heating the layer provided in step (d) to a temperature in the range of 200° F. to 325° F. to cure the elastomeric composition.
Claim 31
Dependent Claim
27 words
The method of claim 26 wherein the elastomeric composition of step (d) and the elastomeric foam emulsion of step (a) are based on the same elastomeric species.
Claim 32
Dependent Claim
24 words
The method of claim 26 wherein the thermally expandable polystyrene plastic beads have a diameter in the approximate range of 0.7 to 1.2 millimeters.
Claim 33
Independent Claim
94 words
A method of producing a flexible material having a textured surface comprising the steps of: (a) providing a mixture of a curable frothed elastomeric composition and thermally expandable plastic beads, the expandable beads having a diameter of approximately 0.5 millimeters to 2 millimeters; (b) uniformly distributing said mixture over one surface of a flexible foam sheet having a thickness of at least about one eighth of an inch; and (c) heating said mixture to expand the plastic beads and to dry and cure the elastomeric emulsion composition to form a textured pebble-like elastomeric coating.
Claim 34
Independent Claim
94 words
A method of producing a flexible material having a textured surface comprising the steps of: (a) providing a mixture of a curable frothed elastomeric composition and thermally expandable plastic beads, the expandable beads having a diameter of approximately 0.5 millimeters to 2 millimeters; (b) uniformly distributing said mixture over one surface of a flexible foam sheet having a thickness of at least about one eighth of an inch; and (c) heating said mixture to expand the plastic beads and to dry and cure the elastomeric emulsion composition to form a textured pebble-like elastomeric coating.
Claim 35
Dependent Claim
15 words
The method of claim 29 wherein said foam sheet is a flexible urethane foam sheet.
Claim 36
Independent Claim
240 words
A method of producing a flexible composite material for wall and ceiling covering and the like having a textured pebble-like elastomeric coating comprising the steps of: (a) providing a mixture of a curable frothable water-based acrylic emulsion composition and thermally expandable polystyrene plastic beads having a diameter of about 0.5 to 2 millimeters, the mixture having proportions in the range of three pounds to twenty pounds of the expandable plastic beads to each one hundred pounds of acrylic emulsion composition, frothed to a density in the range of one hundred forty grams per liter to two hundred sixty grams per liter; (b) uniformly distributing said frothed mixture in an amount in the range of twenty grams per square foot to seventy grams per square foot over one surface of a urethane foam sheeting having a thickness in the range of one eighth of an inch to one inch and a density in the range of one pound per cubic foot to six pounds per cubic foot; (c) heating said mixture to a temperature in the range of 200° F. to 325° F. to expand the plastic beads and to dry and cure the acrylic emulsion composition; (d) providing a layer of uncured acrylic emulsion composition over the layer formed in steps (a) through (c); and (e) heating the layer formed in step (d) to a temperature in the range of 200° F. to 325° F. to cure the elastomeric composition.
Claim 37
Independent Claim
240 words
A method of producing a flexible composite material for wall and ceiling covering and the like having a textured pebble-like elastomeric coating comprising the steps of: (a) providing a mixture of a curable frothable water-based acrylic emulsion composition and thermally expandable polystyrene plastic beads having a diameter of about 0.5 to 2 millimeters, the mixture having proportions in the range of three pounds to twenty pounds of the expandable plastic beads to each one hundred pounds of acrylic emulsion composition, frothed to a density in the range of one hundred forty grams per liter to two hundred sixty grams per liter; (b) uniformly distributing said frothed mixture in an amount in the range of twenty grams per square foot to seventy grams per square foot over one surface of a urethane foam sheeting having a thickness in the range of one eighth of an inch to one inch and a density in the range of one pound per cubic foot to six pounds per cubic foot; (c) heating said mixture to a temperature in the range of 200° F. to 325° F. to expand the plastic beads and to dry and cure the acrylic emulsion composition; (d) providing a layer of uncured acrylic emulsion composition over the layer formed in steps (a) through (c); and (e) heating the layer formed in step (d) to a temperature in the range of 200° F. to 325° F. to cure the elastomeric composition.
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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) | 1983-03-18 | 1983-09-17 | 1984-03-18 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1987-03-18 | 1987-09-17 | 1988-03-18 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1991-03-18 | 1991-09-17 | 1992-03-18 | $7700.00 | Window Closed / Lapsed |