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US4612224A Expired / Lapsed US ⏱️ 0.0 years remaining

Fiber web for compression molding structural substrates for panels

Assignee: Lear Corp EEDS and Interiors
•
Filing: 1985-12-02
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Granted: 1986-09-16
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Expires: 2005-12-02
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Abstract

Abstract A fibrous web useful for compression molding stiff, board-like structural substrates for panels is formed of a thoroughly intermixed blend of wood fibers and synthetic plastic fibers with a dry, powdery, resinous molding material uniformly disbursed throughout the blend. The mass of intermixed fibers and resinous molding material is covered with a thin, randomly oriented, fibrous scrim material and the fibers are locked to each other and to the scrim mechanically by means of needling them together. The web is formed by drying wood fibers, spreading them into a mat, covering the mat with the synthetic fibers and thereafter, dispersing the fibers through a dispersion chamber and re-collecting and re-spreading them into a web by means of a picker roller, gravity dropping a powdery resinous molding material upon the web, redistributing and intermixing the fibers and the molding material with a second picker roller, applying the scrim and needling the combined scrim and fiber web for mechanically interlocking them.

Inventors

  • 👤 Alfred L. Davis

Bibliographic Details

Application Number —
Jurisdiction US
Data Source google_patents
Last Synchronized 2026-11-07 12:06
CPC Classifications
B; B32; B32B; B32B5/00; B32B5/22; B32B5/24; B32B5/26; B27; B27N; B27N1/00; B27N3/00; B27N3/06; B27N3/08; B27N3/083; B32B38/00; B32B38/0004; B32B5/02; B32B5/06; B32B5/08; Y; Y10; Y10T; Y10T428/00; Y10T428/24; Y10T428/24058; Y10T428/24074; Y10T428/24091; Y10T428/29; Y10T428/2982; Y10T442/00; Y10T442/10; Y10T442/102; Y10T442/159

Claims Analysis

Total Claims: 6
Claim 1
Independent Claim 108 words
A fiber web for use in compression molding a panel structural substrate, comprising: a relatively wide and thick mat formed of randomly disposed, non-woven fibers which are thoroughly intermixed; an uncured molding plastic resin in powder form substantially uniformly disbursed and mixed within the fibers forming the mat; a thin, non-woven fiber scrim sheet covering at least one of the two opposite faces of the mat; and said fibers being mechanically interlocked together and to the scrim sheet by needling; wherein, the web may be cut to pre-determined size and shapes for compression molding, under heat and pressure, within closed cavity molds to form stiff substrates for panels.
Claim 2
Dependent Claim 108 words
A fiber web for use in compression molding a panel structural substrate, comprising: a relatively wide and thick mat formed of randomly disposed, non-woven fibers which are thoroughly intermixed; an uncured molding plastic resin in powder form substantially uniformly disbursed and mixed within the fibers forming the mat; a thin, non-woven fiber scrim sheet covering at least one of the two opposite faces of the mat; and said fibers being mechanically interlocked together and to the scrim sheet by needling; wherein, the web may be cut to pre-determined size and shapes for compression molding, under heat and pressure, within closed cavity molds to form stiff substrates for panels.
Claim 3
Dependent Claim 27 words
A construction as defined in claim 1, above, and including said fibers being formed of a thoroughly mixed blend of wood fibers and of synthetic plastic fibers.
Claim 4
Dependent Claim 23 words
A web as defined in claim 2, and wherein said wood fibers constitute a predominate portion, e.g., at least one-half of the blend.
Claim 5
Dependent Claim 55 words
A web as defined in claim 3, and wherein said wood fibers comprise between about 65-75%, by weight, of the blend, with said synthetic plastic fibers forming the remaining portion of the fiber blend and including said resin being formed of a phenolic resinous material making up between about 14%-18%, by weight, of the web.
Claim 6
Dependent Claim 41 words
A web as defined in claim 1, and wherein at least a substantial portion of said fibers are formed of a natural organic material of a substantially different classification than the remaining fibers which are also formed of an organic material.

References Cited (Backward Citations)

US2483405A Cited
US3629048A Cited
US3935046A Cited
US3924040A Cited
US4146564A Cited
US4418031A Cited
US4474846A Cited

USPTO Annuity & Maintenance Windows

Annuity Stage Window Opens Payment Deadline Surcharge Period Until Estimated Fee Status
3.5 Years (Year 4) 1989-09-15 1990-03-17 1990-09-16 $2000.00 Window Closed / Lapsed
7.5 Years (Year 8) 1993-09-15 1994-03-17 1994-09-16 $3760.00 Window Closed / Lapsed
11.5 Years (Year 12) 1997-09-15 1998-03-17 1998-09-16 $7700.00 Window Closed / Lapsed

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