US4478660A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Method of placing a decorative layer on a carrier panel
Assignee: Alkor GmbH Kunstoffverkauf
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Filing: 1980-02-27
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Granted: 1984-10-23
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Expires: 2000-02-27
Abstract
Abstract A method for forming a laminate which is composed of a decorative layer and a carrier panel comprising applying a crosslinking plastic foam onto a decorative carrier web, subjecting the thus coated web to heat treatment to dry and partially crosslink the foam and then marrying the unfoamed side of the web to a carrier panel with the application of heat and pressure so as to further crosslink the foam. Laminates in accordance with the invention are described. Such laminates possess stability against delamination as well as relative freedom from gaseous inclusions.
Inventors
- 👤 Josef Landler
- 👤 Max Mayr
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-27 22:36
CPC Classifications
B; B05; B05D; B05D3/00; B05D3/12; B32; B32B; B32B5/00; B32B5/22; B32B5/24; B32B5/245; B32B21/00; B32B21/10; B32B27/00; B32B38/00; B32B38/06; B32B38/16; B32B38/164; B32B5/18; B32B5/20; B44; B44C; B44C3/00; B44C3/08; B32B2038/0052; B32B2038/0076; B32B2262/00; B32B2262/02; B32B2262/0253; B32B2262/0276; Y; Y10; Y10T; Y10T156/00; Y10T156/10; Y10T156/1002; Y10T156/1039; Y10T156/1043; Y10T156/1044; Y10T428/00; Y10T428/249921; Y10T428/249953; Y10T428/249955; Y10T428/249958; Y10T428/249981; Y10T428/249982; Y10T428/249987; Y10T428/249991; Y10T428/249992; Y10T428/249993
Claims Analysis
Total Claims: 26
Claim 1
Independent Claim
136 words
A method for forming a three-dimensional laminate comprising: (a) applying a layer of a crosslinkable plastic foam onto a sheet of fibrous material, so that the foam permeates partially into the surface of the sheet of fibrous material and a layer of foam remains on the sheet; (b) drying the foam; (c) heating a carrier panel sheet containing a thermoplastic binder to plastify the binder; (d) marrying the heated carrier panel sheet to the non-foam coated side of the fibrous sheet; and (e) pressing the married layers from step (d) between two three-dimensionally shaped opposing pressing members to form the desired shaped laminate and to at least partially crosslink the foam as a result of the heat from the preheated carrier panel and embed fibers of said fibrous material into the binder of the carrier panel.
Claim 2
Independent Claim
136 words
A method for forming a three-dimensional laminate comprising: (a) applying a layer of a crosslinkable plastic foam onto a sheet of fibrous material, so that the foam permeates partially into the surface of the sheet of fibrous material and a layer of foam remains on the sheet; (b) drying the foam; (c) heating a carrier panel sheet containing a thermoplastic binder to plastify the binder; (d) marrying the heated carrier panel sheet to the non-foam coated side of the fibrous sheet; and (e) pressing the married layers from step (d) between two three-dimensionally shaped opposing pressing members to form the desired shaped laminate and to at least partially crosslink the foam as a result of the heat from the preheated carrier panel and embed fibers of said fibrous material into the binder of the carrier panel.
Claim 3
Dependent Claim
16 words
The method of claim 1 wherein said foam layer is partially crosslinked before said marrying step.
Claim 4
Dependent Claim
11 words
The method of claim 1 wherein an acrylate foam is used.
Claim 5
Dependent Claim
21 words
The method of claim 3 wherein said acrylate foam is prepared by foaming an aqueous dispersion of a thermally crosslinking polyacrylate.
Claim 6
Dependent Claim
19 words
The method of claim 4 wherein an ammoniacal crosslinking agent is added to the aqueous dispersion of said polyacrylate.
Claim 7
Dependent Claim
27 words
The method of claim 4 or 5 wherein thickeners, foaming agents, foam stabilizers, pigments, or fillers are added to the aqueous dispersion of the thermally crosslinking polyacrylate.
Claim 8
Dependent Claim
19 words
The method of claim 4 or 5 wherein an ethylene urea triazine resin is added to the aqueous dispersion.
Claim 9
Dependent Claim
21 words
The method of claim 1, 3, 4 or 5 wherein the foaming of the plastic foam is effected by mechanical treatment.
Claim 10
Dependent Claim
17 words
The method of claim 1, 3, 4, or 5 wherein the fibrous material is a bonded web.
Claim 11
Dependent Claim
19 words
The method of claim 1, 3, 4, or 5 wherein the fibrous material is a synthetic bonded fiber web.
Claim 12
Dependent Claim
18 words
The method of claim 1, 3, 4, or 5 wherein the fibrous material is a polyester spunbonded web.
Claim 13
Dependent Claim
19 words
The method of claim 1, 3, 4, or 5 wherein the fibrous material is a polypropylene bonded fiber web.
Claim 14
Dependent Claim
35 words
The method of claim 1, 3, 4, or 5 wherein the fibrous material is a bonded web in which at least a portion of the fibers extend perpendicularly relative to the plane of the web.
Claim 15
Dependent Claim
36 words
The method of claim 1, 3, 4, or 5 wherein the fibrous material is a needle bonded web in which at least a portion of the fibers extend perpendicularly relative to the plane of the web.
Claim 16
Dependent Claim
25 words
The method of claim 1, 3, 4, or 5 wherein the carrier panel is composed of a thermoplastic material as the binder and a filler.
Claim 17
Dependent Claim
26 words
The method of claim 1, 3, 4, or 5 wherein the carrier panel contains a polyolefin as the binder and a cellulose material as the filler.
Claim 18
Dependent Claim
18 words
The method of claim 1, 3, 4 or 5 wherein the carrier panel is a polyolefin/wood dust panel.
Claim 19
Dependent Claim
31 words
The method of claim 1, 3, 4, or 5 wherein the carrier panel is a polypropylene/wood dust panel containing about 50% by weight polypropylene and about 50% by weight wood dust.
Claim 20
Dependent Claim
33 words
The method of claim 1, 3, 4, or 5 wherein an adhesion mediator of a thermoplastic material is applied to the side of the panel which contacts the fibrous material in step (c).
Claim 21
Dependent Claim
19 words
The method of claim 1, 3, 4 or 5 wherein the foamed surface is embossed during the pressing step.
Claim 22
Dependent Claim
29 words
The method of claim 1, 3, 4, or 5 wherein the foamed surface is embossed after step (b) and before step (d) by means of a hot embossing roller.
Claim 23
Dependent Claim
18 words
The method of claim 1, 3, 4, or 5 wherein unheated pressing members are used in step (e).
Claim 24
Dependent Claim
20 words
The method of claim 1, 3, 4, or 5 wherein the surface of the foam is embossed during the pressing.
Claim 25
Dependent Claim
26 words
The method of claim 1, 3, 4, or 5 wherein at least the foamed side is embossed during the pressing operation using a hot embossing tool.
Claim 26
Dependent Claim
25 words
The method of claim 1, 2, 3, or 4 wherein a flock is applied to the foamed side of the composite prior to step (c).
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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) | 1987-10-23 | 1988-04-23 | 1988-10-23 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1991-10-23 | 1992-04-23 | 1992-10-23 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1995-10-23 | 1996-04-23 | 1996-10-23 | $7700.00 | Window Closed / Lapsed |