US4454187A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Composite laminate material and process for making the same
Assignee: Allen Industries Inc
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Filing: 1983-06-22
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Granted: 1984-06-12
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Expires: 2003-06-22
Abstract
Abstract A composite laminate material and a process for making the same are provided, the process comprising the steps of providing an unbonded fibrous batt of desired thickness having a thermosetting binder material dispersed therethrough, applying a layer of desired thickness of a curable latex to at least one side of the fibrous batt, drying the layer to a predetermined moisture level to provide a dried composite material, and heating and compression molding the dried composite material to simultaneously mold the composite, cure the layer and cure the binder material by embossing a pattern into the exposed side of the layer before the layer and the binder material are cured to cause the layer to be contoured with the pattern substantially throughout the thickness thereof and thereby cause the pattern to be substantially impressed into one side of the batt so that the resulting embossed and cured layer has a substantially uniform thickness and the one side of the cured batt substantially conforms to the embossed contour of the layer. This application is a continuation patent application of copending parent application, Ser. No. 167,294, filed Jul. 10, 1980, now abandoned.
Inventors
- 👤 Thomas A. Flowers
- 👤 Samuel D. Vinch
- 👤 Chandru T. Shahani
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-29 21:18
CPC Classifications
D; D06; D06N; D06N7/00; D06N7/0063; D06N7/0071; D06N7/0076; D06N7/0073; D06N2201/00; D06N2201/02; D06N2201/0218; D06N2201/0236; D06N2201/0263; D06N2201/04; D06N2201/042; D06N2201/045; D06N2201/06; D06N2201/08; D06N2201/082; D06N2205/00; D06N2205/04; D06N2205/045; D06N2205/20; D06N2209/00; D06N2209/16; D06N2209/1628; D06N2211/00; D06N2211/12; D06N2211/26; D06N2211/263; Y; Y10; Y10T; Y10T156/00; Y10T156/10; Y10T156/1002; Y10T156/1007; Y10T156/1023; Y10T156/1039; Y10T156/1041; Y10T428/00; Y10T428/24; Y10T428/24479; Y10T428/24496; Y10T428/24504; Y10T428/24595; Y10T428/24603; Y10T428/24612; Y10T428/249921; Y10T428/249953; Y10T428/249981
Claims Analysis
Total Claims: 15
Claim 1
Independent Claim
168 words
A process for making a composite laminate material which comprises the steps of (a) providing an unbonded fibrous batt of desired thickness having a thermosetting binder material dispersed therethrough; (b) applying a layer of desired thickness of a cureable latex to at least one side of said fibrous batt; (c) drying said layer to a predetermined moisture level to provide a dried composite material; and (d) heating and compression molding said dried composite material to simultaneously mold said composite, cure said layer and cure said binder material by embossing a pattern into the exposed side of said layer before said layer and said binder material are cured to cause said layer to be contoured with said pattern substantially throughout the thickness thereof and thereby cause said pattern to be substantially impressed into said one side of said batt so that the resulting embossed and cured layer has a substantially uniform thickness and said one side of said cured batt substantially conforms to the embossed contour of said layer.
Claim 2
Dependent Claim
168 words
A process for making a composite laminate material which comprises the steps of (a) providing an unbonded fibrous batt of desired thickness having a thermosetting binder material dispersed therethrough; (b) applying a layer of desired thickness of a cureable latex to at least one side of said fibrous batt; (c) drying said layer to a predetermined moisture level to provide a dried composite material; and (d) heating and compression molding said dried composite material to simultaneously mold said composite, cure said layer and cure said binder material by embossing a pattern into the exposed side of said layer before said layer and said binder material are cured to cause said layer to be contoured with said pattern substantially throughout the thickness thereof and thereby cause said pattern to be substantially impressed into said one side of said batt so that the resulting embossed and cured layer has a substantially uniform thickness and said one side of said cured batt substantially conforms to the embossed contour of said layer.
Claim 3
Dependent Claim
24 words
The process of claim 1 wherein said latex is a foam and is applied to said batt by knife-coating said foam onto said batt.
Claim 4
Dependent Claim
24 words
The process of claim 1 wherein said latex is a foam and is applied to said batt by extruding said foam onto said batt.
Claim 5
Dependent Claim
39 words
The process of claim 1 wherein said latex is a foam and is applied to said batt by knife-coating said foam onto a carrier material and thereafter uniting said carrier material, having said foam layer thereon, with said batt.
Claim 6
Dependent Claim
25 words
The process of claim 1 wherein said latex is a foam that is dried to a moisture level of not greater than about 10 percent.
Claim 7
Dependent Claim
25 words
The process of claim 1 wherein said latex is a foam that is dried to a moisture level of not greater than about 3 percent.
Claim 8
Dependent Claim
39 words
The process of claim 1 wherein said latex is a foam that is dried at a drying temperature in the approximate range of 250° to 350° F. for a time in the approximate range of 5 to 20 minutes.
Claim 9
Dependent Claim
24 words
The process of claim 7 wherein said foam is heated during said foam drying step for a time sufficient to partially crosslink said foam.
Claim 10
Dependent Claim
13 words
The process of claim 1 wherein said cureable latex is an acrylic latex.
Claim 11
Dependent Claim
13 words
The process of claim 1 wherein said cureable latex is a nitrile latex.
Claim 12
Dependent Claim
8 words
The product of the process of claim 1.
Claim 13
Dependent Claim
40 words
The process of claim 1 wherein said step of heating and compression molding comprises the steps of disposing said composite material between a first platen and a second platen, and bringing said platens together to mold said composite material therebetween.
Claim 14
Dependent Claim
75 words
The process of claim 12 wherein said step of disposing said composite material comprises the step of disposing the exposed side of said batt onto a surface of said second platen, said step of bringing said platens together causing a decorative surface of said first platen to be embossed into said exposed side of said layer whereby the exposed side of the resulting cured batt has the contour of said surface of said second platen.
Claim 15
Dependent Claim
27 words
The process of claim 13 wherein said surface of said second platen is substantially flat whereby said cured batt has the exposed side thereof formed substantially flat.
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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) | 1987-06-12 | 1987-12-12 | 1988-06-12 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1991-06-12 | 1991-12-12 | 1992-06-12 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1995-06-12 | 1995-12-12 | 1996-06-12 | $7700.00 | Window Closed / Lapsed |