US4731276A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Scrim reinforced, quilted cloth-like composite laminate and a method of making
Assignee: Fort James Corp
•
Filing: 1985-04-08
•
Granted: 1988-03-15
•
Expires: 2005-04-08
Abstract
Abstract A method of making a quilted cloth-like composite laminate is produced. The method includes the steps of inserting a scrim coated with a thermoplastic binder between two nonwoven layers each of the nonwoven layers being formed of three-dimensional cellulosic fibers bound with a latex adhesive; heating the scrim and the two nonwoven layers to a temperature sufficient to activate the thermoplastic binder while maintaining unequal tension on the scrim and the two nonwoven layers; and pressing the scrim and the two nonwoven layers together to form a quilted cloth-like composite laminate having the nonwoven layers of cellulosic fibers adhered to opposite sides of the scrim. The surface of each nonwoven layer is quilted and interrupted by the scrim.
Inventors
- 👤 James H. Manning
- 👤 Wayne P. Sorenson
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-01 09:14
CPC Classifications
B; B32; B32B; B32B3/00; B32B3/26; B32B3/30; B32B5/00; B32B5/02; B32B5/022; B32B5/22; B32B5/24; B32B5/26; D; D04; D04H; D04H1/00; D04H1/40; D04H1/42; D04H1/425; D04H1/54; D04H1/559; D04H1/58; D04H1/64; D04H3/00; D04H3/02; D04H3/04; D04H3/045; D04H5/00; D04H5/06; B32B2260/00; B32B2260/02; B32B2260/021; B32B2260/04; B32B2260/046; B32B2262/00; B32B2262/06; B32B2262/062; B32B2262/067; B32B2305/00; B32B2305/08; B32B2305/38; B32B2307/00; B32B2307/50; B32B2307/554; B32B2432/00; Y; Y10; Y10S; Y10S428/00; Y10S428/913; Y10T; Y10T428/00; Y10T428/24; Y10T428/24058; Y10T428/24074; Y10T428/24091; Y10T428/24099; Y10T428/25; Y10T428/253; Y10T442/00; Y10T442/10; Y10T442/184; Y10T442/197
Claims Analysis
Total Claims: 32
Claim 1
Independent Claim
120 words
A method of making a quilted cloth-like composite laminate comprising the steps of: (a) inserting a scrim coated with a thermoplastic binder between two nonwoven layers each of the nonwoven layers being formed of three-dimensional cellulosic fibers bound with a latex adhesive; (b) heating the scrim and the two nonwoven layers to a temperature sufficient to activate the thermoplastic binder while maintaining unequal tension on the scrim and the two nonwoven layers; and (c) pressing the scrim and the two nonwoven layers together to form a quilted cloth-like composite laminate having substantially all of each nonwoven layer of cellulosic fibers adhered to opposite sides of the scrim, the surface of each nonwoven layer being quilted and interrupted by the scrim.
Claim 2
Independent Claim
120 words
A method of making a quilted cloth-like composite laminate comprising the steps of: (a) inserting a scrim coated with a thermoplastic binder between two nonwoven layers each of the nonwoven layers being formed of three-dimensional cellulosic fibers bound with a latex adhesive; (b) heating the scrim and the two nonwoven layers to a temperature sufficient to activate the thermoplastic binder while maintaining unequal tension on the scrim and the two nonwoven layers; and (c) pressing the scrim and the two nonwoven layers together to form a quilted cloth-like composite laminate having substantially all of each nonwoven layer of cellulosic fibers adhered to opposite sides of the scrim, the surface of each nonwoven layer being quilted and interrupted by the scrim.
Claim 3
Dependent Claim
19 words
The method of claim 1, wherein greater tension is applied to the scrim than to the two nonwoven layers.
Claim 4
Dependent Claim
23 words
The method of claim 1, wherein the heating step is performed by passing the scrim and two nonwoven layers over a heated roll.
Claim 5
Dependent Claim
21 words
The method of claim 3, wherein the heated roll has a temperature within the range of 280° F. to 450° F.
Claim 6
Dependent Claim
26 words
The method of claim 1, wherein the pressing step is performed by feeding the scrim and the two nonwoven layers through a pair of calender rolls.
Claim 7
Dependent Claim
21 words
The method of claim 5, wherein the calender rolls have a temperature within the range of 280° F. to 450° F.
Claim 8
Dependent Claim
23 words
The method of claim 5, wherein the nip pressure of the calender rolls is within the range of 100 pli to 300 pli.
Claim 9
Dependent Claim
14 words
The method of claim 1, wherein the three-dimensional cellulosic fibers are wood pulp fibers.
Claim 10
Dependent Claim
27 words
The method of claim 8, wherein the wood pulp fibers are selected from the group consisting of cedar fibers, southern pine fibers, spruce fibers, and hemlock fibers.
Claim 11
Dependent Claim
12 words
The method of claim 8, wherein the wood pulp fibers are twisted.
Claim 12
Dependent Claim
27 words
The method of claim 1, wherein the weight of the three-dimensional cellulosic fibers forming each nonwoven layer is within the range of 20 pounds/ream to 50 pounds/ream.
Claim 13
Dependent Claim
25 words
The method of claim 1, wherein the latex adhesive is selected from the group consisting of acrylate emulsions, butadiene-styrene emulsions, acetate-ethylene emulsions, and acrylonitrile-butadiene emulsions.
Claim 14
Dependent Claim
30 words
The method of claim 1, wherein the thermoplastic binder is selected from the group consisting of polyvinyl chloride plastisol, polyvinylidene chloride, polyvinyl acetate, ethylene acrylic acid, and ethylene vinyl acetate.
Claim 15
Dependent Claim
15 words
The method of claim 1, wherein the scrim is formed by a continuous filament material.
Claim 16
Dependent Claim
24 words
The method of claim 1, wherein the scrim is a material selected from the group consisting of nylon, rayon, polyester, polypropylene, glass, and aramids.
Claim 17
Dependent Claim
52 words
The method of claim 1, wherein the two nonwoven layers are made by the steps of: (a) forming two separate layers of three-dimensional cellulosic fibers; (b) applying a latex adhesive to each layer of three-dimensional cellulosic fibers; and (c) drying the latex adhesive to form two separate nonwoven layers of cellulosic fibers.
Claim 18
Dependent Claim
21 words
The method of claim 1, wherein the thermoplastic binder migrates from the scrim into the cellulosic fibers of the nonwoven layers.
Claim 19
Dependent Claim
73 words
A quilted cloth-like composite laminate comprising: (a) a scrim; (b) two nonwoven layers of three-dimensional cellulosic fibers positioned on opposite sides of the scrim, the surface of each nonwoven layer being quilted and interrupted by the scrim; (c) a latex adhesive binding together the celulosic fibers contained in each nonwoven layer; and (d) a thermoplastic binder coating opposite sides of the scrim and binding substantially all of each nonwoven layer to the scrim.
Claim 20
Dependent Claim
73 words
A quilted cloth-like composite laminate comprising: (a) a scrim; (b) two nonwoven layers of three-dimensional cellulosic fibers positioned on opposite sides of the scrim, the surface of each nonwoven layer being quilted and interrupted by the scrim; (c) a latex adhesive binding together the celulosic fibers contained in each nonwoven layer; and (d) a thermoplastic binder coating opposite sides of the scrim and binding substantially all of each nonwoven layer to the scrim.
Claim 21
Dependent Claim
24 words
The quilted cloth-like composite laminate of claim 18, wherein the thermoplastic binder migrates from the scrim into the cellulosic fibers of the nonwoven layers.
Claim 22
Dependent Claim
16 words
The cloth-like composite laminate of claim 18, wherein the three-dimensional cellulosic fibers are wood pulp fibers.
Claim 23
Dependent Claim
15 words
The quilted cloth-like composite laminate of claim 20, wherein the wood pulp fibers are twisted.
Claim 24
Dependent Claim
30 words
The quilted cloth-like composite laminate of claim 20, wherein the wood pulp fibers are selected from the group consisting of cedar fibers, southern pine fibers, spruce fibers, and hemlock fibers.
Claim 25
Dependent Claim
30 words
The quilted cloth-like composite laminate of claim 18, wherein the weight of the three-dimensional cellulosic fibers forming each nonwoven layer is within the range of 20 pounds/ream to 50 pounds/ream.
Claim 26
Dependent Claim
28 words
The quilted cloth-like composite laminate of claim 18, wherein the latex adhesive is selected from the group consisting of acrylate emulsions, butadiene-styrene emulsions, acetateethylene emulsions, and acrylonitrile-butadiene emulsions.
Claim 27
Dependent Claim
37 words
The quilted cloth-like composite laminate of claim 18, wherein the thermoplastic polymer binder is selected from the group consisting of polyvinyl chloride plastisol, polyvinylidene chloride, polyvinyl acetate, ethylene acrylic acid, ethylene vinyl acetate, and ethylene methyl acrylate.
Claim 28
Dependent Claim
18 words
The quilted cloth-like composite laminate of claim 18, wherein the scrim is made of a continuous filament material.
Claim 29
Dependent Claim
27 words
The quilted cloth-like laminate of claim lS, wherein the scrim is made from a material selected from the group consisting of nylon, rayon, polyester, polypropylene, and aramids.
Claim 30
Dependent Claim
30 words
The quilted cloth-like composite laminate of claim 18, wherein the weight of the scrim is within the range of 0.2 ounce per square yard to 2 ounces per square yard.
Claim 31
Dependent Claim
25 words
The quilted cloth-like composite laminate of claim 18, wherein the length of the cellulosic fiber is within the range of 0.5 millimeters to 5 millimeters.
Claim 32
Dependent Claim
25 words
The quilted cloth-like composite laminate of claim 18, wherein the thickness of the cellulosic fibers is within the range of 1 micron to 6 microns.
References Cited (Backward Citations)
US2902395A
Cited
US3025199A
Cited
US3546056A
Cited
US3775231A
Cited
US3700536A
Cited
US3629047A
Cited
US3629048A
Cited
US3622423A
Cited
US3726750A
Cited
US3708383A
Cited
US4001472A
Cited
USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1991-03-15 | 1991-09-14 | 1992-03-15 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1995-03-15 | 1995-09-14 | 1996-03-15 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1999-03-15 | 1999-09-14 | 2000-03-15 | $7700.00 | Window Closed / Lapsed |