US4418106A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Method of producing a flocked composite body
Assignee: Alkor GmbH Kunstoffverkauf
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Filing: 1983-04-12
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Granted: 1983-11-29
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Expires: 2003-04-12
Abstract
Abstract A method for producing a flocked web by applying a layer of a thermosetting plastic foam onto a carrier sheet which foam penetrates into the surface of the carrier, flocking the uncrosslinked layer and then thermally hardening the layer and wherein prior to complete crosslinking of the flocked layer, the partially crosslinked flocked layer is submitted to heat pressing. In a preferred embodiment, the heat pressing can include an embossing step. The process of the present invention is not only easy to carry out, it avoids the presence of air bubbles as well as other inconsistancies in the product. The product obtained with the present invention is also disclosed.
Inventors
- 👤 Josef Landler
- 👤 Max Mayr
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-02 10:23
CPC Classifications
B; B32; B32B; B32B27/00; B05; B05D; B05D1/00; B05D1/16; B05D3/00; B05D3/12; B44; B44C; B44C3/00; B44C3/08; Y; Y10; Y10T; Y10T156/00; Y10T156/10; Y10T156/1002; Y10T156/1007; Y10T156/1023; Y10T156/1039; Y10T156/1041; Y10T428/00; Y10T428/23907; Y10T428/23929; Y10T428/23936; Y10T428/23943; Y10T428/23979; Y10T428/24; Y10T428/24628; Y10T428/249921; Y10T428/249953; Y10T428/249955; Y10T428/249958; Y10T428/249982
Claims Analysis
Total Claims: 34
Claim 1
Independent Claim
252 words
A method for producing a flocked web comprising: (a) applying a layer of a spreadable thermosetting plastic material in the form of a foam onto a porous sheet carrier, the viscosity of said spreadable material and the porosity of the sheet carrier being such that the spreadable material penetrates only into the upper portion of the porous sheet carrier and does not penetrate completely through the carrier; (b) applying flocked fibers onto the thermosetting plastic material layer; (c) partially crosslinking the thermosetting plastic layer to fix the flocked fibers in the thermosetting plastic material layer; (d) pressing the composite composed of the carrier sheet, partially crosslinked plastic material layer and flock between embossing tools, particularly embossing rollers, said embossing tools being heated so as to continue the crosslinking of the plastic material layer, wherein at least one of the embossing tools adjacent the flocked layer has an embossing design therein so as to provide a corresponding embossed pattern on the flocked layer; (e) connecting the side of the porous sheet carrier to a backing which increases the stiffness of the carrier, said backing being a polyolefin/wood-dust panel, said connecting being effected in a press having opposite pressing tools, said back panel being introduced in the hot state together with the sheet carrier carrying said flocked layer of plastic material foam between said pressing tools such as to effect connection of said porous sheet carrier and said panel under pressure exerted by said pressing tools through the thermoplastified polyolefin of the back panel.
Claim 2
Independent Claim
252 words
A method for producing a flocked web comprising: (a) applying a layer of a spreadable thermosetting plastic material in the form of a foam onto a porous sheet carrier, the viscosity of said spreadable material and the porosity of the sheet carrier being such that the spreadable material penetrates only into the upper portion of the porous sheet carrier and does not penetrate completely through the carrier; (b) applying flocked fibers onto the thermosetting plastic material layer; (c) partially crosslinking the thermosetting plastic layer to fix the flocked fibers in the thermosetting plastic material layer; (d) pressing the composite composed of the carrier sheet, partially crosslinked plastic material layer and flock between embossing tools, particularly embossing rollers, said embossing tools being heated so as to continue the crosslinking of the plastic material layer, wherein at least one of the embossing tools adjacent the flocked layer has an embossing design therein so as to provide a corresponding embossed pattern on the flocked layer; (e) connecting the side of the porous sheet carrier to a backing which increases the stiffness of the carrier, said backing being a polyolefin/wood-dust panel, said connecting being effected in a press having opposite pressing tools, said back panel being introduced in the hot state together with the sheet carrier carrying said flocked layer of plastic material foam between said pressing tools such as to effect connection of said porous sheet carrier and said panel under pressure exerted by said pressing tools through the thermoplastified polyolefin of the back panel.
Claim 3
Dependent Claim
19 words
The method of claim 1 wherein the connection is effected while simultaneously deforming the backing panel in three dimensions.
Claim 4
Dependent Claim
21 words
The method of claim 2 wherein an additional embossing of the flocked layer is effected between said parts of said press.
Claim 5
Dependent Claim
10 words
A flocked web obtained by the method of claim 3.
Claim 6
Dependent Claim
11 words
The method of claim 1 wherein the flock is electrostatically applied.
Claim 7
Dependent Claim
20 words
The method of claim 1 wherein the flock layer is embossed to exhibit a woven, knitted, or leather appearing surface.
Claim 8
Dependent Claim
21 words
The method of claim 1 wherein a sheet carrier is used which can be deformed to surfaces of a higher order.
Claim 9
Dependent Claim
11 words
The method of claim 1 wherein a fibrous carrier is used.
Claim 10
Dependent Claim
19 words
The method of claim 8 wherein the sheet carrier is a polyester spun-bonded web or polypropylene bonded fiber web.
Claim 11
Dependent Claim
21 words
The method of claim 9 wherein at least a portion of the fibers extend perpendicularly to the plane of said web.
Claim 12
Dependent Claim
16 words
The method of claim 10 wherein a needle bonded web is used as the sheet carrier.
Claim 13
Dependent Claim
17 words
The method of claim 10 wherein a woven or knitted material is used as the sheet carrier.
Claim 14
Dependent Claim
18 words
The method of claim 1 wherein the foam is based on an aqueous dispersion of a plastic material.
Claim 15
Dependent Claim
19 words
The method of claim 13 wherein the foam is based on an aqueous dispersion of a thermally crosslinkable polyacrylate.
Claim 16
Dependent Claim
14 words
The method of claim 14 wherein the aqueous dispersion contains an ammoniacal crosslinking agent.
Claim 17
Dependent Claim
16 words
The method of claim 14 wherein the aqueous dispersion contains thickeners, thixotropic agents, pigments or fillers.
Claim 18
Dependent Claim
14 words
The method of claim 14 wherein the aqueous dispersion contains an ethylene urea/triazine resin.
Claim 19
Dependent Claim
20 words
The method of claim 1 wherein the foam is based on a plastic material and is dissolved in a solvent.
Claim 20
Dependent Claim
17 words
The method of claim 1 wherein the foam is based on a liquid mixture of interacting components.
Claim 21
Dependent Claim
20 words
The method of claim 1 wherein the plastic material is applied as foam which has been foamed through mechanical treatment.
Claim 22
Dependent Claim
11 words
The method of claim 20 wherein a foam stabilizer is added.
Claim 23
Dependent Claim
16 words
The method of claim 1 wherein the carrier is attached to the backing with an adhesive.
Claim 24
Dependent Claim
38 words
The method of claim 1 wherein the connection is effected while simultaneously deforming the backing web in three dimensions between reciprocating top and bottom parts of a press while simultaneously embossing said flocked or the partially crosslinked plastics.
Claim 25
Dependent Claim
23 words
The method of claim 1 wherein the panel is about 50 percent by weight polypropylene and about 50 percent by weight wood dust.
Claim 26
Dependent Claim
20 words
The method of claim 1 wherein the plastic material is injection molded on the back side of said sheet carrier.
Claim 27
Dependent Claim
22 words
The method of claim 16 wherein a foam backing is applied onto the side of said sheet carrier opposite the flocked side.
Claim 28
Dependent Claim
24 words
The method of claim 16 wherein a positionally stable adhesion mediator layer is applied to the side of the carrier opposite the flocked side.
Claim 29
Dependent Claim
16 words
The method of claim 27 wherein the adhesion mediator layer is covered with a foil layer.
Claim 30
Dependent Claim
18 words
The method of claim 27 wherein said adhesion mediator layer is applied in the form of a coating.
Claim 31
Dependent Claim
16 words
The method of claim 1 wherein the sheet carrier is connected to a soft foam backing.
Claim 32
Dependent Claim
10 words
A flocked web obtained by the method of claim 1.
Claim 33
Independent Claim
230 words
A method for producing a flocked web comprising: (a) applying a layer of a spreadable thermosetting plastic material in the form of a foam onto a porous sheet carrier, the side of said carrier opposite from the foam being connected with a backing which increases the stiffness of the carrier, said backing being a polyolefin/wood dust panel, the viscosity of said spreadable material and the porosity of the sheet carrier being such that the spreadable material penetrates only into the upper portion of the porous sheet carrier and does not penetrate completely through the carrier; (b) applying flocked fibers onto the thermosetting plastic material layer; (c) partially crosslinking the thermosetting plastic layer to fix the flocked fibers into the layer of the plastic material; (d) pressing the composite composed of the carrier sheet, partially crosslinked layer of plastic material and flock between pressing tools, said pressing tools being heated so as to continue the crosslinking of the plastic material, wherein at least one of the pressing tools adjacent the flocked layer has an embossed design therein so as to provide a corresponding embossed pattern on the flocked layer wherein the back panel is introduced in the hot state together with the sheet carrier carrying said flocked layer of plastic material foam between said pressing tools to effect connection of the sheet carrier by the thermoplastic binder of the backing panel.
Claim 34
Independent Claim
230 words
A method for producing a flocked web comprising: (a) applying a layer of a spreadable thermosetting plastic material in the form of a foam onto a porous sheet carrier, the side of said carrier opposite from the foam being connected with a backing which increases the stiffness of the carrier, said backing being a polyolefin/wood dust panel, the viscosity of said spreadable material and the porosity of the sheet carrier being such that the spreadable material penetrates only into the upper portion of the porous sheet carrier and does not penetrate completely through the carrier; (b) applying flocked fibers onto the thermosetting plastic material layer; (c) partially crosslinking the thermosetting plastic layer to fix the flocked fibers into the layer of the plastic material; (d) pressing the composite composed of the carrier sheet, partially crosslinked layer of plastic material and flock between pressing tools, said pressing tools being heated so as to continue the crosslinking of the plastic material, wherein at least one of the pressing tools adjacent the flocked layer has an embossed design therein so as to provide a corresponding embossed pattern on the flocked layer wherein the back panel is introduced in the hot state together with the sheet carrier carrying said flocked layer of plastic material foam between said pressing tools to effect connection of the sheet carrier by the thermoplastic binder of the backing panel.
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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) | 1986-11-28 | 1987-05-30 | 1987-11-29 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1990-11-28 | 1991-05-30 | 1991-11-29 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1994-11-28 | 1995-05-30 | 1995-11-29 | $7700.00 | Window Closed / Lapsed |