US4387118A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Minimizing voids in foam coating
Assignee: Burlington Industries Inc
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Filing: 1981-10-29
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Granted: 1983-06-07
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Expires: 2001-10-29
Abstract
Abstract A method and apparatus for foam coating a web are provided that allow for easier cleaning, greater versatility of fabric styles without the introduction of voids in the foam backing, and elimination of voids in the foam backing at seams, or within the web length, due to wrinkling or creasing of the fabric. A doctor blade is provided on top of and slightly in front of a roller, and a foam pillow is formed at the top of the roller, with the fabric providing a bottom barrier for the pillow. The fabric is continuously fed passed a slat expander, which removes wrinkles from it, and then immediately into contact with the periphery of the roller, the roller holding the fabric taut. Needle points can be provided on the fabric peripheral surface to facilitate positive holding of the cloth in place.
Inventors
- 👤 John H. Shelton
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-04 01:55
CPC Classifications
D; D06; D06B; D06B19/00; D06B19/0088; D06B19/0094
Claims Analysis
Total Claims: 32
Claim 1
Independent Claim
124 words
A method of foam coating a web utilizing a roller rotatable about a substantially horizontal axis of rotation, and a doctor blade positioned slightly vertically above the top periphery of the roller and slightly in front of the roller, comprising the steps of: (a) continuously rotating the roller about its axis; (b) establishing and maintaining a foam pillow on top of the roller with the doctor blade providing the front barrier of the foam pillow and the web the bottom barrier thereof; and (c) continuously feeding the web to be coated into contact with the roller periphery so that it passes between the top of the roller and the doctor blade through the foam pillow, the blade establishing the thickness of the foam coat.
Claim 2
Independent Claim
124 words
A method of foam coating a web utilizing a roller rotatable about a substantially horizontal axis of rotation, and a doctor blade positioned slightly vertically above the top periphery of the roller and slightly in front of the roller, comprising the steps of: (a) continuously rotating the roller about its axis; (b) establishing and maintaining a foam pillow on top of the roller with the doctor blade providing the front barrier of the foam pillow and the web the bottom barrier thereof; and (c) continuously feeding the web to be coated into contact with the roller periphery so that it passes between the top of the roller and the doctor blade through the foam pillow, the blade establishing the thickness of the foam coat.
Claim 3
Dependent Claim
24 words
A method as recited in claim 1 comprising the further step of cleaning the exterior surface of the roller while it is continuously rotating.
Claim 4
Dependent Claim
44 words
A method as recited in claim 1 comprising the further steps of: (d) tensioning the web in the width dimension just prior to the area where it is brought into contact with the roller periphery; and (e) maintaining the web taut during coating thereof.
Claim 5
Dependent Claim
22 words
A method as recited in claim 3 wherein (d) is practiced by passing the web into operative engagement with a slat expander.
Claim 6
Dependent Claim
39 words
A method as recited in claim 4 wherein (e) is practiced by the substeps consisting of: passing the web into immediate contact with the roller from the slat expander; and frictionally engaging the web with the roller peripheral surface.
Claim 7
Dependent Claim
41 words
A method as recited in claim 5 wherein said frictionally engaging substep is facilitated by providing surface manifestations on the roller periphery that allow simple cleaning of the roller, tightly hold the web in place, and do not damage the web.
Claim 8
Dependent Claim
25 words
A method as recited in claim 3 wherein steps (d) and (e) are practiced by engaging central portions of the web between the edges thereof.
Claim 9
Dependent Claim
18 words
A method as recited in claim 1, 3, 5 or 7 wherein the web is a fabric web.
Claim 10
Independent Claim
134 words
A method of producing from a feed fabric having a plurality of longitudinal seams, a foam-coated fabric free of voids due to wrinkles or creases around the seams, or within the web length, utilizing a roller rotatable about a substantially horizontally axis, comprising the steps of: (a) continuously rotating the roller about its axis; (b) establishing and maintaining a foam pillow on top of the roller periphery with the fabric web providing the bottom barrier for the foam pillow; (c) tensioning the fabric in the width dimension immediately prior to passing it into contact with the roller; (d) maintaining the fabric taut by frictional engagement between it and the roller periphery; and (e) continuously passing the fabric into operative contact with and past the foam pillow to provide a substantially void-free coated fabric web.
Claim 11
Independent Claim
134 words
A method of producing from a feed fabric having a plurality of longitudinal seams, a foam-coated fabric free of voids due to wrinkles or creases around the seams, or within the web length, utilizing a roller rotatable about a substantially horizontally axis, comprising the steps of: (a) continuously rotating the roller about its axis; (b) establishing and maintaining a foam pillow on top of the roller periphery with the fabric web providing the bottom barrier for the foam pillow; (c) tensioning the fabric in the width dimension immediately prior to passing it into contact with the roller; (d) maintaining the fabric taut by frictional engagement between it and the roller periphery; and (e) continuously passing the fabric into operative contact with and past the foam pillow to provide a substantially void-free coated fabric web.
Claim 12
Dependent Claim
31 words
A method as recited in claim 9 wherein step (c) is practiced by passing the fabric over a slat expander immediately prior to passing it into contact with the roller periphery.
Claim 13
Dependent Claim
41 words
A method as recited in claim 9 or 10 wherein step (d) is facilitated by providing surface manifestations on the roller peripheral surface that effect tight holding of the web in place on the roller periphery while not damaging the web.
Claim 14
Dependent Claim
28 words
A method as recited in claim 1 or 9 wherein the web comprises a fabric web having surface effects on the face thereof, opposite the surface being foam-coated.
Claim 15
Independent Claim
131 words
A method of producing from a feed fabric web having a plurality of longitudinal seams a foam-coated fabric web free of voids due to wrinkles or creases around the seams, or within the web length, and utilizing a doctor blade for controlling foam coating, comprising the steps of: establishing a foam pillow with the doctor blade as the front barrier thereof; continuously passing fabric web underneath the foam pillow in the doctor blade, with the web providing the bottom barrier of the foam pillow, to effect coating; tensioning the fabric in the width dimension prior to its passage into operative engagement with the doctor blade and holding the fabric tensioned as it passes past the foam pillow; and changing over from one width fabric to another without changing the doctor blade.
Claim 16
Independent Claim
131 words
A method of producing from a feed fabric web having a plurality of longitudinal seams a foam-coated fabric web free of voids due to wrinkles or creases around the seams, or within the web length, and utilizing a doctor blade for controlling foam coating, comprising the steps of: establishing a foam pillow with the doctor blade as the front barrier thereof; continuously passing fabric web underneath the foam pillow in the doctor blade, with the web providing the bottom barrier of the foam pillow, to effect coating; tensioning the fabric in the width dimension prior to its passage into operative engagement with the doctor blade and holding the fabric tensioned as it passes past the foam pillow; and changing over from one width fabric to another without changing the doctor blade.
Claim 17
Dependent Claim
113 words
Apparatus for foam coating a web comprising: a roller rotatable about a substantially horizontal axis; means for defining a foam pillow of a predetermined volume on a web to be backed, including means for confining the front and sides of the pillow with the web supporting the bottom of the pillow, said means positioned vertically above the top periphery of the roller, with the web in engagement with the roller; means for passing the web past the foam pillow; means for allowing only a portion of the foam in the pillow to pass with the web as it moves past the pillow; and means for continuously replenishing the foam material in the pillow.
Claim 18
Dependent Claim
113 words
Apparatus for foam coating a web comprising: a roller rotatable about a substantially horizontal axis; means for defining a foam pillow of a predetermined volume on a web to be backed, including means for confining the front and sides of the pillow with the web supporting the bottom of the pillow, said means positioned vertically above the top periphery of the roller, with the web in engagement with the roller; means for passing the web past the foam pillow; means for allowing only a portion of the foam in the pillow to pass with the web as it moves past the pillow; and means for continuously replenishing the foam material in the pillow.
Claim 19
Dependent Claim
47 words
Apparatus as recited in claim 14 wherein said means for confining the front of the pillow and said means for allowing only a portion of the foam to pass with the web comprises a doctor blade positioned above the roller and slightly in front of the roller.
Claim 20
Dependent Claim
18 words
Apparatus as recited in claim 14 further comprising means for automatically cleaning the roller periphery during rotation thereof.
Claim 21
Dependent Claim
38 words
Apparatus as recited in claim 16 wherein said cleaning means comprises a stationarily mounted brush positioned so that the bristles thereof engage the roller periphery at a portion of the roller periphery not in engagement with the web.
Claim 22
Dependent Claim
29 words
Apparatus as recited in claim 14, 15, or 17 further comprising surface manifestations formed on the roller periphery for facilitating frictional holding of the web by the roller periphery.
Claim 23
Dependent Claim
46 words
Apparatus as recited in claim 14 or 15 further comprising means for tensioning web in the width dimension just prior to the area where it is brought into contact with the roller periphery, and means for maintaining the web taut during passage past the foam pillow.
Claim 24
Dependent Claim
50 words
Apparatus as recited in claim 19 wherein said tensioning means comprises a slat expander mounted for rotation about an axis parallel to the axis of rotation of said roller with the periphery thereof adjacent the roller periphery; and wherein said web width-dimension-tension-maintaining means comprises the peripheral surface of said roller.
Claim 25
Dependent Claim
37 words
Apparatus as recited in claim 14 further comprising a slat expander rotatable about an axis parallel to the axis of the roller, and positioned behind the roller with the periphery thereof slightly spaced above the roller periphery.
Claim 26
Dependent Claim
21 words
Apparatus as recited in claim 21 wherein said slat expander has a diameter significantly smaller than the diameter of said roller.
Claim 27
Dependent Claim
30 words
Apparatus as recited in claim 21 or 22 wherein said slat expander is mounted so that the axis of rotation thereof is below the axis of rotation of said roller.
Claim 28
Dependent Claim
25 words
Apparatus as recited in claim 21 wherein said roller has a plurality of needle points for engaging the web extending radially from the periphery thereof.
Claim 29
Dependent Claim
106 words
Apparatus for coating a web comprising: a relatively large diameter roller mounted for rotation about a horizontal axis; a doctor blade mounted vertically above the roller and slightly in front of the roller and providing a front surface defining a reservoir of coating material, the doctor blade spaced from the roller to allow passage of the web between the roller and the doctor blade with the coating material on top of the web; and a relatively small diameter slat expander mounted for rotation about an axis parallel to the roller axis, and positioned behind the roller with the periphery thereof slightly spaced from the roller periphery.
Claim 30
Dependent Claim
106 words
Apparatus for coating a web comprising: a relatively large diameter roller mounted for rotation about a horizontal axis; a doctor blade mounted vertically above the roller and slightly in front of the roller and providing a front surface defining a reservoir of coating material, the doctor blade spaced from the roller to allow passage of the web between the roller and the doctor blade with the coating material on top of the web; and a relatively small diameter slat expander mounted for rotation about an axis parallel to the roller axis, and positioned behind the roller with the periphery thereof slightly spaced from the roller periphery.
Claim 31
Dependent Claim
20 words
Apparatus as recited in claim 25 further comprising a plurality of needle points extending radially outwardly from the roller periphery.
Claim 32
Dependent Claim
19 words
Apparatus as recited in claim 25 wherein the roller periphery and the slat expander are made of stainless steel.
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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) | 1986-06-06 | 1986-12-06 | 1987-06-07 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1990-06-06 | 1990-12-06 | 1991-06-07 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1994-06-06 | 1994-12-06 | 1995-06-07 | $7700.00 | Window Closed / Lapsed |