US4243464A — Laminating method

Claim 1

Independent Claim 190 words

A method for laminating a thin film onto a rough, porous surface of a sheet of wood, particle board, fiber board and the like of the type having resins therein, comprising the steps of: providing a pair of opposing members, each disposed so as to define a continuous pressure line therebetween; providing means for moving one of said members toward and away from the other member so as to permit variation of the space between said two members; feeding said sheet into said space in a first direction; feeding said film onto said surface and with said sheet in said first direction; applying pressure between said two members in an amount substantially above 50 lbs. per lineal inch along said pressure line and against said film-sheet combination, and less than 400 lbs. per lineal inch in order to effect the desired bonding of said film to said sheet without destroying said sheet; heating said film-sheet combination while between said members to render said resins amorphous; and wherein said amorphous resins are smoothed under pressure to calendar said rough, porous surface of said sheet to facilitate lamination of said film thereto.

Claim 2

Independent Claim 190 words

A method for laminating a thin film onto a rough, porous surface of a sheet of wood, particle board, fiber board and the like of the type having resins therein, comprising the steps of: providing a pair of opposing members, each disposed so as to define a continuous pressure line therebetween; providing means for moving one of said members toward and away from the other member so as to permit variation of the space between said two members; feeding said sheet into said space in a first direction; feeding said film onto said surface and with said sheet in said first direction; applying pressure between said two members in an amount substantially above 50 lbs. per lineal inch along said pressure line and against said film-sheet combination, and less than 400 lbs. per lineal inch in order to effect the desired bonding of said film to said sheet without destroying said sheet; heating said film-sheet combination while between said members to render said resins amorphous; and wherein said amorphous resins are smoothed under pressure to calendar said rough, porous surface of said sheet to facilitate lamination of said film thereto.

Claim 3

Dependent Claim 17 words

The method recited in claim 1 wherein said first direction is substantially transverse to said pressure line.

Claim 4

Dependent Claim 17 words

The method recited in claim 2 wherein each said member is formed of a substantially incompressible material.

Claim 5

Dependent Claim 19 words

The method recited in claim 3 wherein the hardness of said members is substantially equal to that of steel.

Claim 6

Dependent Claim 11 words

The method recited in claim 4 wherein said members comprise steel.

Claim 7

Dependent Claim 16 words

The method recited in claim 4 wherein said members comprise a pair of parallel, cylindrical rollers.

Claim 8

Dependent Claim 19 words

The method recited in claim 6 wherein said pressure line is parallel with the axis of said cylindrical rollers.

Claim 9

Dependent Claim 43 words

The method recited in claim 7 wherein said rollers are hollow, said heating step comprising circulating a heated fluid in said hollow rollers to heat the periphery thereof, to thereby heat said film-sheet combination along said pressure line during passage between said rollers.

Claim 10

Independent Claim 183 words

A method for laminating a thin film onto a rough, porous surface of a sheet of wood, particle board, fiber board and the like of the type having resins therein, comprising the steps of: providing a pair of opposing and substantially parallel cylindrical steel rollers defining a continuous pressure line between the outer cylindrical surfaces thereof; feeding said sheet between said rollers in a first direction substantially transverse to said pressure line; feeding said film onto said sheet surface and with said sheet in said first direction; applying relative pressure between said two rollers along said pressure line during passage of said film-sheet combination therebetween, said pressure being in an amount to sufficiently compress said sheet to effect complete bonding of said film to said sheet surface, but in an amount less than that which destroys said sheet; heating said film-sheet combination while between said rollers; and wherein said pressure and heat being sufficient to render said resins in said sheet amorphous, whereby said resins are smoothed to calendar said rough, porous surface of said sheet to facilitate lamination of said film thereto.

Claim 11

Independent Claim 183 words

A method for laminating a thin film onto a rough, porous surface of a sheet of wood, particle board, fiber board and the like of the type having resins therein, comprising the steps of: providing a pair of opposing and substantially parallel cylindrical steel rollers defining a continuous pressure line between the outer cylindrical surfaces thereof; feeding said sheet between said rollers in a first direction substantially transverse to said pressure line; feeding said film onto said sheet surface and with said sheet in said first direction; applying relative pressure between said two rollers along said pressure line during passage of said film-sheet combination therebetween, said pressure being in an amount to sufficiently compress said sheet to effect complete bonding of said film to said sheet surface, but in an amount less than that which destroys said sheet; heating said film-sheet combination while between said rollers; and wherein said pressure and heat being sufficient to render said resins in said sheet amorphous, whereby said resins are smoothed to calendar said rough, porous surface of said sheet to facilitate lamination of said film thereto.

Claim 12

Dependent Claim 35 words

The method recited in claim 9 further comprising the step of passing said film across a portion of the cylindrical surface of one of said rollers prior to feeding said film onto said sheet surface.

Claim 13

Dependent Claim 38 words

The method recited in claim 9 wherein said heating step comprises circulating a heated fluid into said rollers to heat the periphery thereof, to thereby heat said film-sheet combination along said pressure line during passage between said rollers.

Claim 14

Dependent Claim 30 words

The method recited in claim 9 wherein said heating step comprises heating the cylindrical surface of at least one of said rollers to a temperature substantially above 300 degrees Fahrenheit.

Claim 15

Dependent Claim 17 words

The method recited in claim 12 wherein said temperature is in a range between 375--425 degrees Fahrenheit.

Claim 16

Dependent Claim 23 words

The method recited in claim 12 further comprising said pressure is between 50 to 400 lbs. per lineal inch along said pressure line.

Claim 17

Independent Claim 196 words

A method for calendaring a rough, porous surface of a sheet material such as wood, particle board, fiber board and the like, and thereafter laminating a thin film onto said calendared surface; comprising the steps of: providing a pair of opposing and substantially parallel cylindrical steel rollers defining a continuous pressure line between the outer cylindrical surfaces thereof; feeding said sheet between said rollers in a first direction substantially transverse to said pressure line; applying pressure between said two rollers in an amount substantially above 50 lbs. per lineal inch along the pressure line and against the surface of said sheet, and less than 400 lbs. per lineal inch; heating the cylindrical surface of at least one of said rollers to a temperature substantially above 300 degrees Fahrenheit, in order to elevate the temperature of said rough, porous surface of said sheet material to thereby seal and smooth said surface such that said surface is substantially non-porous and calendared with respect to the rough, porous surface of said sheet prior to treatment; and thereafter applying said thin film to said calendared surface under heat and pressure to facilitate lamination of said film to said calendared surface.

Claim 18

Independent Claim 196 words

A method for calendaring a rough, porous surface of a sheet material such as wood, particle board, fiber board and the like, and thereafter laminating a thin film onto said calendared surface; comprising the steps of: providing a pair of opposing and substantially parallel cylindrical steel rollers defining a continuous pressure line between the outer cylindrical surfaces thereof; feeding said sheet between said rollers in a first direction substantially transverse to said pressure line; applying pressure between said two rollers in an amount substantially above 50 lbs. per lineal inch along the pressure line and against the surface of said sheet, and less than 400 lbs. per lineal inch; heating the cylindrical surface of at least one of said rollers to a temperature substantially above 300 degrees Fahrenheit, in order to elevate the temperature of said rough, porous surface of said sheet material to thereby seal and smooth said surface such that said surface is substantially non-porous and calendared with respect to the rough, porous surface of said sheet prior to treatment; and thereafter applying said thin film to said calendared surface under heat and pressure to facilitate lamination of said film to said calendared surface.

Claim 19

Independent Claim 189 words

A method for laminating a thin film onto a relatively rough, porous surface of a sheet of a compressible material of wood, particle board, fiberboard and the like of the type having resins therein. comprising the steps of: providing a pair of opposed, substantially parallel cylindrical steel rollers defining a continuous pressure line between the outer surfaces thereof; feeding said sheet between said rollers in a first direction which is substantially transverse to said pressure lines; feeding said film onto said sheet surface and with said sheet in first direction; applying relative pressure between said two rollers along said pressure line during passage of said film-sheet combination therebetween, said pressure being in an amount to compress said sheet to effect complete bonding of said film to said sheet surface, but in an amount less than that which would cause distruction of said sheet; heating said film-sheet combination while between said rollers; and wherein said pressure and heat being sufficient to render said resins amorphous, whereby said amorphous resins are smoothed under pressure to calendar said relatively rough porous surface of said sheet to facilitate lamination of said film hereto.

Claim 20

Independent Claim 189 words

A method for laminating a thin film onto a relatively rough, porous surface of a sheet of a compressible material of wood, particle board, fiberboard and the like of the type having resins therein. comprising the steps of: providing a pair of opposed, substantially parallel cylindrical steel rollers defining a continuous pressure line between the outer surfaces thereof; feeding said sheet between said rollers in a first direction which is substantially transverse to said pressure lines; feeding said film onto said sheet surface and with said sheet in first direction; applying relative pressure between said two rollers along said pressure line during passage of said film-sheet combination therebetween, said pressure being in an amount to compress said sheet to effect complete bonding of said film to said sheet surface, but in an amount less than that which would cause distruction of said sheet; heating said film-sheet combination while between said rollers; and wherein said pressure and heat being sufficient to render said resins amorphous, whereby said amorphous resins are smoothed under pressure to calendar said relatively rough porous surface of said sheet to facilitate lamination of said film hereto.

Claim 21

Independent Claim 142 words

A method for calendaring a rough, porous surface of a sheet material such as wood, particle board, fiber board, and the like of the type having resins therein, and thereafter laminating a thin film to said calendared surface, said method comprising the steps of: (a) providing a pair of opposing cylindrical rollers defining a pressure line between the outer cylindrical surfaces thereof; (b) heating said rough, porous surface of said sheet material to a temperature sufficient to render said resins amorphous; (c) feeding said sheet between said rollers in a first direction substantially transverse to said pressure line, and applying relative pressure between said rollers in an amount which is sufficient to smooth said amorphous resins; and thereafter (d) applying said thin film to said calendared surface under heat and pressure to facilitate lamination of said thin film to said calendared surface.

Claim 22

Independent Claim 142 words

A method for calendaring a rough, porous surface of a sheet material such as wood, particle board, fiber board, and the like of the type having resins therein, and thereafter laminating a thin film to said calendared surface, said method comprising the steps of: (a) providing a pair of opposing cylindrical rollers defining a pressure line between the outer cylindrical surfaces thereof; (b) heating said rough, porous surface of said sheet material to a temperature sufficient to render said resins amorphous; (c) feeding said sheet between said rollers in a first direction substantially transverse to said pressure line, and applying relative pressure between said rollers in an amount which is sufficient to smooth said amorphous resins; and thereafter (d) applying said thin film to said calendared surface under heat and pressure to facilitate lamination of said thin film to said calendared surface.

Claim 23

Dependent Claim 26 words

The method recited in claim 17 wherein said pressure-applying step comprises applying pressure against said rough, porous surface in excess of 50 pounds per lineal inch.

Claim 24

Dependent Claim 13 words

The method recited in claim 17 wherein said rollers comprise an incompressible material.

Claim 25

Dependent Claim 22 words

The method recited in claim 17 wherein said heating step comprises heating said rollers to a temperature in excess of 300° F.

Claim 26

Independent Claim 135 words

A method for laminating a thin film onto a rough, porous surface of a sheet of wood, particle board, fiberboard, and the like of a type having resins therein, said method comprising the steps of: (a) applying heat to said rough, porous surface of said sheet to render said resins amorphous; (b) applying pressure to said rough, porous surface of said sheet to smooth said amorphous resins and calendar said rough, porous surface; (c) feeding said calendared-surface sheet through opposing members in a first direction; (d) feeding said thin film onto said calendared surface of said sheet and through said opposing members in said first direction; (e) applying pressure between said members; and (f) applying heat to said film-sheet combination while under pressure between said members, whereby said film is laminated to said calendared surface.

Claim 27

Independent Claim 135 words

A method for laminating a thin film onto a rough, porous surface of a sheet of wood, particle board, fiberboard, and the like of a type having resins therein, said method comprising the steps of: (a) applying heat to said rough, porous surface of said sheet to render said resins amorphous; (b) applying pressure to said rough, porous surface of said sheet to smooth said amorphous resins and calendar said rough, porous surface; (c) feeding said calendared-surface sheet through opposing members in a first direction; (d) feeding said thin film onto said calendared surface of said sheet and through said opposing members in said first direction; (e) applying pressure between said members; and (f) applying heat to said film-sheet combination while under pressure between said members, whereby said film is laminated to said calendared surface.

Annuity Stage	Window Opens	Payment Deadline	Surcharge Period Until	Estimated Fee	Status
3.5 Years (Year 4)	1984-01-06	1984-07-07	1985-01-06	$2000.00	Window Closed / Lapsed
7.5 Years (Year 8)	1988-01-06	1988-07-07	1989-01-06	$3760.00	Window Closed / Lapsed
11.5 Years (Year 12)	1992-01-06	1992-07-07	1993-01-06	$7700.00	Window Closed / Lapsed

Laminating method

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