US4515848A
Expired / Lapsed
US
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Materials and methods for making resin-rigidified articles
Assignee: Gates Formed Fibre Products Inc
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Filing: 1983-09-23
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Granted: 1985-05-07
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Expires: 2003-09-23
Abstract
Abstract The subject invention relates to methods and materials for making porous resin rigidified shaped articles suitable for filters, surgical trays, and the like, which comprises the steps of impregnating a non-woven fabric with a predetermined amount of thermoplastic or thermosetting water-based epoxy resin; partially curing the resin-impregnated fabric; and, thereafter molding the partially cured fabric into a desired shape with sufficient heat to advance the curing of the resin.
Inventors
- 👤 Carl V. Leunig
- 👤 Robert F. Kovar
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-31 11:36
CPC Classifications
B; B29; B29C; B29C70/00; B29C70/04; B29C70/28; B29C70/40; B29C70/42; B29C70/46; B01; B01D; B01D39/00; B01D39/14; B01D39/16; B01D39/1607; B01D39/1623; B01D39/163; D; D04; D04H; D04H3/00; D04H3/005; D04H3/009; D04H3/011; D04H3/08; D04H3/12; B01D2239/00; B01D2239/10; B29K; B29K2063/00; B29K2105/00; B29K2105/06; B29K2105/08; B29K2105/0809; B29L; B29L2031/00; B29L2031/14; B29L2031/753; Y; Y10; Y10S; Y10S264/00; Y10S264/48; Y10T; Y10T428/00; Y10T428/24; Y10T428/24479; Y10T428/24612; Y10T442/00; Y10T442/20; Y10T442/2139; Y10T442/60; Y10T442/681
Claims Analysis
Total Claims: 21
Claim 1
Independent Claim
33 words
A resin rigidified porous and fluid permeable product, which comprises: a non-woven fabric comprised of synthetic organic filaments entangled together and partially impregnated with a partially cured thermosetting or thermoplastic water-based epoxy resin.
Claim 2
Dependent Claim
33 words
A resin rigidified porous and fluid permeable product, which comprises: a non-woven fabric comprised of synthetic organic filaments entangled together and partially impregnated with a partially cured thermosetting or thermoplastic water-based epoxy resin.
Claim 3
Dependent Claim
38 words
The resin regidified product recited in claim 1 wherein: the non-woven fabric is spun bonded polyester; and the thermosetting or thermoplastic water-based epoxy resin is selected from the group consisting of Novalac, Bis-Phenol A, and aliphatic epoxy resins.
Claim 4
Dependent Claim
28 words
The resin rigidified product recited in claim 1 wherein: the non-woven fabric is spun bonded polyester; and the thermosetting or thermoplastic water-based epoxy resin is Novalac epoxy resin.
Claim 5
Dependent Claim
50 words
A porous resin-rigidified shaped article permeable to gas, which comprises: a non-woven fabric comprised of synthetic organic filaments entangled together, partially impregnated with a cured thermoplastic or thermosetting water-based epoxy resin to impart the desired porosity and permeability to the article, and mold formed in a desired shape retaining configuration.
Claim 6
Dependent Claim
50 words
A porous resin-rigidified shaped article permeable to gas, which comprises: a non-woven fabric comprised of synthetic organic filaments entangled together, partially impregnated with a cured thermoplastic or thermosetting water-based epoxy resin to impart the desired porosity and permeability to the article, and mold formed in a desired shape retaining configuration.
Claim 7
Dependent Claim
39 words
The porous resin rigidified shaped article recited in claim 4, wherein: non-woven fabric is spun bonded polyester; and the thermosetting or thermoplastic water-based epoxy resin is selected from the group consisting of Novalac, Bis-Phenol A, and aliphatic epoxy resins.
Claim 8
Dependent Claim
30 words
The porous resin rigidified shaped article recited in claim 4, wherein: the non-woven fabric is spun bonded polyester; and the thermosetting or thermoplastic water-based epoxy resin is Novalac epoxy resin.
Claim 9
Dependent Claim
25 words
The porous resin-rigidified article or claim 4 in the form of a surgical tray which, in use is autoclavable allowing steam to permeate freely therethrough.
Claim 10
Dependent Claim
14 words
The porous resin-rigidified article of claim 4 in the form of a filter element.
Claim 11
Independent Claim
86 words
A method for making a porous resin-rigidified shaped article permeable to fluids, comprising: partially impregnating a non-woven fabric comprising synthetic organic entangled filaments with a thermosetting or thermoplastic water-based epoxy resin, the quantity of resin impregnant being selected to give porosity and fluid permeability to the finished shaped article; heating the impregnated fabric to partially cure the resin; molding the partially cured resin-impregnated fabric into a desired shaped article at sufficient temperature to advance the curing of the resin and impart shape retention to the article.
Claim 12
Independent Claim
86 words
A method for making a porous resin-rigidified shaped article permeable to fluids, comprising: partially impregnating a non-woven fabric comprising synthetic organic entangled filaments with a thermosetting or thermoplastic water-based epoxy resin, the quantity of resin impregnant being selected to give porosity and fluid permeability to the finished shaped article; heating the impregnated fabric to partially cure the resin; molding the partially cured resin-impregnated fabric into a desired shaped article at sufficient temperature to advance the curing of the resin and impart shape retention to the article.
Claim 13
Dependent Claim
37 words
The method recited in claim 9 wherein the partially cured resin-impregnated fabric is molded in a matched-die mold having male and female portions, at least a portion of such mold portions imparting curvature to the shaped article.
Claim 14
Dependent Claim
22 words
The method recited in claim 9 wherein the mold portions are so configured to impart a complex shape to the shaped article.
Claim 15
Dependent Claim
17 words
As an article of manufacture, a shaped article made in accordance with the method of claim 9.
Claim 16
Dependent Claim
25 words
The article of manufacture of claim 12, in the form of a surgical tray which, in use, is autoclavable allowing steam to permeate freely therethrough.
Claim 17
Dependent Claim
14 words
The article of manufacture of claim 12, in the form of a filter element.
Claim 18
Dependent Claim
43 words
The method for making a resin-rigidified shaped article recited in claim 9, further comprising the steps of: indexing a continuous length of the non-woven fabric through the entire process; and cooling, cutting and trimming the shaped article after completion of the molding step.
Claim 19
Dependent Claim
13 words
The method recited in claim 15, wherein: the non-woven fabric is spun-bonded polyester.
Claim 20
Dependent Claim
28 words
The method recited in claim 16 wherein: the thermosetting or thermoplastic water-based epoxy resin is selected from the group consisting of Novalac, Bis-Phenol A, and aliphatic epoxy resins.
Claim 21
Dependent Claim
18 words
The method recited in claim 16 wherein: the thermosetting or thermoplastic water-based epoxy resin is Novalac epoxy resin.
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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) | 1988-05-06 | 1988-11-05 | 1989-05-07 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1992-05-06 | 1992-11-05 | 1993-05-07 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1996-05-06 | 1996-11-05 | 1997-05-07 | $7700.00 | Window Closed / Lapsed |