US4717624A — Method of manufacturing a molded article having g…

Claim 1

Independent Claim 113 words

A method for manufacturing an article of superior dimensional stability comprising laminating: (a) at least one first layer of a molecularly oriented sheet formed by the melt-processing of a thermoplastic polymer which exhibits an anisotropic melt phase wherein said molecularly oriented sheet exhibits a negative linear thermal expansion coefficient in the direction of the polymer flow during its formation, and (b) at least one second layer which exhibits a positive linear thermal expansion coefficient, wherein said first and second layers are regulated in thickness so that in the resulting article the respective negative and positive linear thermal expansion coefficients of (a) and (b) are substantially balanced thereby imparting stability to the overall laminate.

Claim 2

Independent Claim 113 words

A method for manufacturing an article of superior dimensional stability comprising laminating: (a) at least one first layer of a molecularly oriented sheet formed by the melt-processing of a thermoplastic polymer which exhibits an anisotropic melt phase wherein said molecularly oriented sheet exhibits a negative linear thermal expansion coefficient in the direction of the polymer flow during its formation, and (b) at least one second layer which exhibits a positive linear thermal expansion coefficient, wherein said first and second layers are regulated in thickness so that in the resulting article the respective negative and positive linear thermal expansion coefficients of (a) and (b) are substantially balanced thereby imparting stability to the overall laminate.

Claim 3

Dependent Claim 44 words

A method for manufacturing an article of superior dimensional stability according to claim 1 wherein said at least one first layer (a) of a molecularly oriented sheet of a thermoplastic polymer which exhibits an anisotropic melt phase is formed by melt-extrusion followed by drawing.

Claim 4

Dependent Claim 39 words

A method for manufacturing an article of superior dimensional stability according to claim 1 wherein said at least one second layer (b) is formed from a substantially non-oriented layer of a thermoplastic polymer which exhibits an anisotropic melt phase.

Claim 5

Dependent Claim 39 words

A method for manufacturing an article of superior dimensional stability according to claim 1 wherein said at least one second layer (b) is formed from a substantially non-oriented layer of a thermoplastic polymer which exhibits an isotropic melt phase.

Claim 6

Dependent Claim 26 words

A method for manufacturing an article of superior dimensional stability according to claim 1 wherein said at least one second layer (b) is a metallic sheet.

Claim 7

Dependent Claim 28 words

A method for manufacturing an article of superior dimensional stability according to claim 1 wherein said at least one second layer (b) is formed of a thermosetting resin.

Claim 8

Dependent Claim 30 words

A method for manufacturing an article of superior dimensional stability according to claim 1 wherein said article consists of an odd number of total layers which is at least three.

Claim 9

Dependent Claim 31 words

A method for manufacturing an article of superior dimensional stability according to claim 1 wherein the resulting article exhibits a linear thermal expansion coefficient on the order of 1×10 -6 cm./cm.°C.

Claim 10

Dependent Claim 109 words

A laminated article of superior dimensional stability comprising adjoining bonded layers comprising: (a) at least one first layer of a molecularly oriented sheet formed by the melt-processing of a thermoplastic polymer which exhibits an anisotropic melt phase wherein said molecularly oriented sheet exhibits a negative linear thermal expansion coefficient in the direction of the polymer flow during its formation, and (b) at least one second layer which exhibits a positive linear thermal expansion coefficient, wherein said first and second layers are regulated in thickness so that the respective negative and positive linear thermal expansion coefficients of (a) and (b) are substantially balanced thereby imparting stability to the overall laminate.

Claim 11

Dependent Claim 109 words

A laminated article of superior dimensional stability comprising adjoining bonded layers comprising: (a) at least one first layer of a molecularly oriented sheet formed by the melt-processing of a thermoplastic polymer which exhibits an anisotropic melt phase wherein said molecularly oriented sheet exhibits a negative linear thermal expansion coefficient in the direction of the polymer flow during its formation, and (b) at least one second layer which exhibits a positive linear thermal expansion coefficient, wherein said first and second layers are regulated in thickness so that the respective negative and positive linear thermal expansion coefficients of (a) and (b) are substantially balanced thereby imparting stability to the overall laminate.

Claim 12

Dependent Claim 41 words

A laminated article of superior dimensional stability according to claim 9 wherein said at least one first layer (a) of a molecularly oriented sheet of a thermoplastic polymer which exhibits an anisotropic melt phase is formed by melt-extrusion followed by drawing.

Claim 13

Dependent Claim 36 words

A laminated article of superior dimensional stability according to claim 9 wherein said at least one second layer (b) is formed from a substantially non-oriented layer of a thermoplastic polymer which exhibits an anisotropic melt phase.

Claim 14

Dependent Claim 36 words

A laminated article of superior dimensional stability according to claim 9 wherein said at least one second layer (b) is formed from a substantially non-oriented layer of a thermoplastic polymer which exhibits an isotropic melt phase.

Claim 15

Dependent Claim 25 words

A laminated article of superior dimensional stability according to claim 9 which exhibits a linear thermal expansion coefficient on the order of 1×10 -6 cm./cm.°C.

Claim 16

Dependent Claim 60 words

A laminated article of superior dimensional stability according to claim 9 wherein said at least one first layer (a) is formed from a melt-processable thermoplastic which is capable of forming an anisotropic melt phase which exhibits an inherent viscosity of at least about 2.0 dl./g. when dissolved in a concentration of 0.1 percent by weight in pentafluorophenol at 60° C.

Claim 17

Dependent Claim 60 words

A laminated article of superior dimensional stability according to claim 9 wherein said at least one first layer (a) is formed from a melt-processable thermoplastic which is capable of forming an anisotropic melt phase which exhibits an inherent viscosity of about 2.0 to 10.0 dl./g. when dissolved in a concentration of 0.1 percent by weight in pentafluorophenol at 60° C.

Claim 18

Dependent Claim 48 words

A laminated article of superior dimensional stability according to claim 9 wherein said at least one first layer (a) is formed from a melt-processable thermoplastic which is capable of forming an anisotropic melt phase which includes more than 10 mol of repeating units which contain a naphthalene moiety.

Claim 19

Dependent Claim 42 words

A laminated article of superior dimensional stability according to claim 16 wherein said naphthalene moiety of said melt-processable thermoplastic which is capable of forming an anisotropic melt phase is selected from the group consisting of 6-oxy-2-naphthoyl moiety, 2,6-dioxynaphthalene moiety, and 2,6-dicarboxynaphthalene moiety.

Claim 20

Dependent Claim 126 words

A laminated article of superior dimensional stability according to claim 9 wherein said at least one first layer (a) is formed from a melt-processable polyester which is capable of forming an anisotropic melt phase consisting essentially of the recurring moieties I and II which may include substitution of at least some of the hydrogen atoms present upon an aromatic ring wherein: ##STR18## with said optional substitution if present being selected from the group consisting of an alkyl group of 1 to 4 carbon atoms, an alkoxy group of 1 to 4 carbon atoms, halogen, phenyl, substituted phenyl, and mixtures of the foregoing, and wherein said polyester comprises approximately 10 to 90 mol percent of moiety I, and approximately 10 to 90 mol percent of moiety II.

Claim 21

Dependent Claim 37 words

A laminated article of superior dimensional stability according to claim 18 wherein moiety I is present in a concentration of about 30 mol percent and moiety II is present in a concentration of about 70 mol percent.

Claim 22

Dependent Claim 116 words

A laminated article of superior dimensional stability according to claim 9 wherein said at least one first layer (a) is formed from a melt-processable polyester which is capable of forming an anisotropic melt phase consisting essentially of recurring moieties I, II, and III which may include substitution of at least some of the hydrogen atoms present upon an aromatic ring wherein: ##STR19## with said optional substitution if present being selected from the group consisting of an alkyl group of 1 to 4 carbon atoms, an alkoxy group of 1 to 4 carbon atoms, halogen, phenyl, substituted phenyl, and mixtures of the foregoing, and wherein said polyester comprises about 30 to 70 mol percent of moiety I.

Claim 23

Dependent Claim 55 words

A laminated article of superior dimensional stability accordng to claim 20 wherein moiety I is present in a concentration of about 40 to 60 mol percent, moiety II is present in a concentration of about 20 to 30 mol percent, and moiety III is present in a concentration of about 20 to 30 mol percent.

Claim 24

Dependent Claim 110 words

A laminated article of superior dimensional stability according to claim 9 wherein said at least one first layer (a) is formed from a melt-processable polyester which is capable of forming an anisotropic melt phase consisting essentially of the recurring moieties I, II, III and IV wherein: ##STR20## where R is methyl, chloro, bromo, and mixtures thereof, and is substituted for a hydrogen atom present upon the aromatic ring, and wherein the polyester comprises about 20 to 60 mol percent of moiety I, about 5 to 18 mol percent of moiety II, about 5 to 35 mol percent of moiety III, and about 20 to 40 mol percent of moiety IV.

Claim 25

Dependent Claim 69 words

A laminated article of superior dimensional stability according to claim 22 wherein moiety I is present in a concentration of about 35 to 45 mol percent, moiety II is present in a concentration of about 10 to 15 mol percent, moiety III is present in a concentration of about 15 to 25 mol percent, and moiety IV is present in a concentration of about 25 to 35 mol percent.

Claim 26

Dependent Claim 207 words

A laminated article of superior dimensional stability according to claim 9 wherein said at least one first layer (a) is formed from a melt-processable polyester which is capable of forming an anisotropic melt phase consisting essentially of moieties I, II, III and IV which may include substitution of at least some of the hydrogen atoms present upon an aromatic ring wherein: ##STR21## III is a dioxyaryl moiety of the formula --O--AR--O-- where Ar is a divalent radical comprising at least one aromatic ring, and IV is a dicarboxyaryl moiety of the formula ##STR22## where Ar' is a divalent radical comprising at least one aromatic ring, with said optional substitution if present being selected from the group consisting of an alkyl group of 1 to 4 carbon atoms, an alkoxy group of 1 to 4 carbon atoms, halogen, phenyl, substituted phenyl, and mixtures of the foregoing, and wherein said polyester comprises about 20 to 40 mol percent of moiety I, in excess of 10 mol percent but less than about 50 mol percent of moiety II, in excess of 5 mol percent but less than about 30 mol percent of moiety III, and in excess of 5 mol percent but less than 30 mol percent of moiety IV.

Claim 27

Dependent Claim 69 words

A laminated article of superior dimensional stability according to claim 24 wherein moiety I is present in a concentration of about 20 to 30 mol percent, moiety II is present in a concentration of about 25 to 40 mol percent, moiety III is present in a concentration of about 15 to 25 mol percent, and moiety IV is present in a concentration of about 15 to 25 mol percent.

Claim 28

Dependent Claim 178 words

A laminated article of superior dimensional stability according to claim 9 wherein said at least one first layer (a) is formed from a melt-processable polyester which is capable of forming an anisotropic melt phase consisting essentially of recurring moieties I, II, and III which may include substitution of at least some of the hydrogen atoms present upon an aromatic ring wherein: ##STR23## II is a dioxyaryl moiety of the formula --O--Ar--O-- where Ar is a divalent radical comprising at least one aromatic ring, and III is a dicarboxyaryl moiety of the formula ##STR24## where Ar' is a divalent radical comprising at least one aromatic ring, with said optional substitution if present being selected from the group consisting of an alkyl group of 1 to 4 carbon atoms, an alkoxy group of 1 to 4 carbon atoms, halogen, phenyl, substituted phenyl, and mixtures of the foregoing, and wherein said polyester comprises about 10 to 90 mol percent of moiety I, about 5 to 45 mol percent of moiety II, and about 5 to 45 mol percent of moiety III.

Claim 29

Dependent Claim 55 words

A laminated article of superior dimensional stability according to claim 26 wherein moiety I is present in a concentration of about 20 to 80 mol percent, moiety II is present in a concentration of about 10 to 40 mol percent, and moiety III is present in a concentration of about 10 to 40 mol percent.

Claim 30

Dependent Claim 209 words

A laminated article of superior dimensional stability according to claim 9 wherein said at least one first layer (a) is formed from a melt-processable poly(ester-amide) which is capable of forming an anisotropic melt phase consisting essentially of recurring moieties I, II, and III, and optionally IV, wherein: ##STR25## II is ##STR26## where A is a divalent radical comprising at least one aromatic ring or a divalent transcyclohexane radical, III is --Y--Ar--Z-- where Ar is a divalent radical comprising at least one aromatic ring, Y is O, NH, or NR, and Z is NH or NR, where R is an alkyl group having 1 to 6 carbon atoms or an aryl group, and IV is --O--Ar'--O-- where Ar' is a divalent radical comprising at least one aromatic ring, with said optional substitution if present being selected from the group consisting of an alkyl group of 1 to 4 carbon atoms, an alkoxy group of 1 to 4 carbon atoms, halogen, phenyl, substituted phenyl, and mixtures of the foregoing, and wherein said poly(ester-amide) comprises about 10 to 90 mol percent of moiety I, about 5 to 45 mol percent of moiety II, about 5 to 45 mol percent of moiety III, and about 0 to 40 mol percent of moiety IV.

Claim 31

Dependent Claim 60 words

A laminated article of superior dimensional stability according to claim 28 wherein moiety I is present in a concentration of about 70 mol percent, moiety II is ##STR27## and is present in a concentration of about 15 mol percent, moiety III is ##STR28## and is present in a concentration of about 15 mol percent, and moiety IV is substantially absent.

Annuity Stage	Window Opens	Payment Deadline	Surcharge Period Until	Estimated Fee	Status
3.5 Years (Year 4)	1991-01-04	1991-07-06	1992-01-05	$2000.00	Window Closed / Lapsed
7.5 Years (Year 8)	1995-01-04	1995-07-06	1996-01-05	$3760.00	Window Closed / Lapsed
11.5 Years (Year 12)	1999-01-04	1999-07-06	2000-01-05	$7700.00	Window Closed / Lapsed

Method of manufacturing a molded article having good dimensional stability

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