US4810255A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Manufactured fuel article
Assignee: Kimberly Clark Corp
•
Filing: 1988-04-11
•
Granted: 1989-03-07
•
Expires: 2008-04-11
Abstract
Abstract Manufactured fuel articles having, as a first component, an inner core of a primary fuel element, and as a second component, a combustible covering layer on the primary fuel element. In some embodiments, the covering layer is preferably at least about a nominal 1.5 millimeters thick, with a preferred thickness being at least about 3 millimeters. In other embodiments, the fuel article may be described as a primary fuel element with a combustible covering layer, wherein the primary fuel element comprises a substantial portion of at least one of the ends, and the covering layer and the primary fuel element are in interfacial contact about a majority of the area of their facing surfaces. In still other embodiments, the fuel articles of the invention are described as a primary fuel element and a combustible covering layer in interfacial contact with the fuel element, and wherein the composition of the covering layer differs substantially from the composition of the primary fuel element and comprises a thermoplastic material and pulp fiber. The invention further comprises methods of producing manufactured fuel articles, including, as one method, extrusion coating of the covering layer onto a previously formed primary fuel element, and, as another method, coextruding the primary fuel element and the covering layer together.
Inventors
- 👤 James E. Fay, III
- 👤 Carl J. Gierke
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-25 02:45
CPC Classifications
C; C10; C10L; C10L5/00; C10L5/40; Y; Y02; Y02E; Y02E50/00; Y02E50/30
Claims Analysis
Total Claims: 40
Claim 1
Independent Claim
124 words
A manufactured fuel article, comprising: (a) an inner core of an elongated primary fuel element having an outer surface; and (b) a combustible covering layer, having a substantially uniform outer surface, on said primary fuel element, said covering layer being nominally at least above 1.5 millimeters thick, said covering layer having been applied to said primary fuel element in a melted state, whereby said covering layer flowed about any surface irregularities in said outer surface of said primary fuel element, such that the thickness of said covering layer varies according to the irregularities in said outer surface of said primary fuel element, said covering layer and said primary fuel element being in interfacial contact about a majority of the area of facing sufaces thereof.
Claim 2
Dependent Claim
124 words
A manufactured fuel article, comprising: (a) an inner core of an elongated primary fuel element having an outer surface; and (b) a combustible covering layer, having a substantially uniform outer surface, on said primary fuel element, said covering layer being nominally at least above 1.5 millimeters thick, said covering layer having been applied to said primary fuel element in a melted state, whereby said covering layer flowed about any surface irregularities in said outer surface of said primary fuel element, such that the thickness of said covering layer varies according to the irregularities in said outer surface of said primary fuel element, said covering layer and said primary fuel element being in interfacial contact about a majority of the area of facing sufaces thereof.
Claim 3
Dependent Claim
20 words
The manufactured fuel article as in claim 1 wherein said covering layer is, nomimally, at least about 3 millimeters thick.
Claim 4
Dependent Claim
57 words
The manufactured fuel article as in claim 1, said primary fuel element and said covering layer being in substantially complete interfacial contact about the entire area of the facing surfaces thereof, the composition of said outer covering layer comprising at least 20% wax, and sufficient polymer to provide a wax/polymer ratio of about 0.7/1 to about 3/1.
Claim 5
Dependent Claim
18 words
The manufactured fuel article as in claim 1, said covering layer being bonded to said primary fuel element.
Claim 6
Dependent Claim
16 words
The manufactured fuel article as in claim 1 wherein said covering layer is clean to touch.
Claim 7
Dependent Claim
18 words
The manufactured fuel article as in claim 1 wherein said covering layer comprises thermoplastic material and pulp fiber.
Claim 8
Dependent Claim
27 words
The manufactured fuel article as in claim 2, 3, or 4 wherein at least 55% of the volume of said fuel article comprises said primary fuel element.
Claim 9
Dependent Claim
130 words
A manufactured fuel article, comprising: (a) an inner core of a primary fuel element having sidewalls, ends, and an outer surface; and (b) a combustible covering layer, having a substantially uniform outer surface, said covering layer and said primary fuel element being in interfacial contact on said sidewalls of said primary fuel element, said primary fuel element comprising a substantial portion of the surface of at least one of said ends, said covering layer being bonded to said primary fuel element, and having been applied to said primary fuel element in a melted state, whereby said covering layer flowed about any surface irregularities in said primary fuel element, such that the thickness of said covering layer varies according to the irregularities in the outer surface of said primary fuel element.
Claim 10
Dependent Claim
130 words
A manufactured fuel article, comprising: (a) an inner core of a primary fuel element having sidewalls, ends, and an outer surface; and (b) a combustible covering layer, having a substantially uniform outer surface, said covering layer and said primary fuel element being in interfacial contact on said sidewalls of said primary fuel element, said primary fuel element comprising a substantial portion of the surface of at least one of said ends, said covering layer being bonded to said primary fuel element, and having been applied to said primary fuel element in a melted state, whereby said covering layer flowed about any surface irregularities in said primary fuel element, such that the thickness of said covering layer varies according to the irregularities in the outer surface of said primary fuel element.
Claim 11
Dependent Claim
31 words
The manufactured fuel article as in claim 8, said primary fuel element and said covering layer being in substantially complete interfacial contact about the entire area of the facing surfaces thereof.
Claim 12
Dependent Claim
22 words
The manufactured fuel article as in claim 8 or 9 wherein said covering layer is nominally at least about 1.5 millimeters thick.
Claim 13
Dependent Claim
20 words
The manufactured fuel article as in claim 9 wherein said covering layer is nominally at least about 3 millimeters thick.
Claim 14
Dependent Claim
21 words
The manufactured fuel article as in claim 8 wherein the composition of said covering layer comprises thermoplastic material and pulp fiber.
Claim 15
Dependent Claim
21 words
The manufactured fuel article as in claim 10 wherein the composition of said covering layer comprises thermoplastic material and pulp fiber.
Claim 16
Dependent Claim
21 words
The manufactured fuel article as in claim 11 wherein the composition of said covering layer comprises thermoplastic material and pulp fiber.
Claim 17
Dependent Claim
24 words
The manufactured fuel article as in claim 8 wherein at least 55% of the volume of said fuel article comprises said primary fuel element.
Claim 18
Dependent Claim
24 words
The manufactured fuel article as in claim 11 wherein at least 55% of the volume of said fuel article comprises said primary fuel element.
Claim 19
Dependent Claim
116 words
A manufactured fuel article, comprising: (a) an inner core of a primary fuel element; and (b) a combustible covering layer, the composition of said covering layer differing substantially from the composition of said primary fuel element and comprising (i) about 50% to about 90% by weight of a thermoplastic composition comprising wax and a polymer, the ratio of wax/polymer being between about 0.7/1 and 3/1, and (ii) about 50% to about 10% by weight pulp fiber, said wax comprising about 20% to about 50% by weight of the overall composition of said covering layer, said covering layer and said primary fuel element being in interfacial contact about a majority of the area of facing surfaces thereof.
Claim 20
Dependent Claim
116 words
A manufactured fuel article, comprising: (a) an inner core of a primary fuel element; and (b) a combustible covering layer, the composition of said covering layer differing substantially from the composition of said primary fuel element and comprising (i) about 50% to about 90% by weight of a thermoplastic composition comprising wax and a polymer, the ratio of wax/polymer being between about 0.7/1 and 3/1, and (ii) about 50% to about 10% by weight pulp fiber, said wax comprising about 20% to about 50% by weight of the overall composition of said covering layer, said covering layer and said primary fuel element being in interfacial contact about a majority of the area of facing surfaces thereof.
Claim 21
Dependent Claim
31 words
The manufactured fuel article as in claim 17, said primary fuel element and said covering layer being in substantially complete interfacial contact about the entire area of the facing surfaces thereof.
Claim 22
Dependent Claim
18 words
The manufactured fuel article as in claim 17, said covering layer being bonded to said primary fuel element.
Claim 23
Dependent Claim
16 words
The manufactured fuel article as in claim 17 wherein said covering layer is clean to touch.
Claim 24
Dependent Claim
20 words
The manufactured fuel article as in claim 17 wherein said covering layer is nominally at least about 1.5 millimeters thick.
Claim 25
Dependent Claim
20 words
The manufactured fuel article as in claim 21 wherein said covering layer is nominally at least about 3 millimeters thick.
Claim 26
Dependent Claim
24 words
The manufactured fuel article as in claim 17 wherein at least 55% of the volume of said fuel article comprises said primary fuel element.
Claim 27
Dependent Claim
24 words
The manufactured fuel article as in claim 23 wherein at least 55% of the volume of said fuel article comprises said primary fuel element.
Claim 28
Dependent Claim
37 words
The manufactured fuel article as in claim 17, 18, or 19, said primary fuel element having sidewalls and ends, said primary fuel element comprising a substantial portion of the surface of at least one of said ends.
Claim 29
Dependent Claim
18 words
The manufactured fuel article as in claim 1 said fuel article having been made by a coextrusion process.
Claim 30
Dependent Claim
18 words
The manufactured fuel article as in claim 5, said fuel article having been made by a coextrusion process.
Claim 31
Dependent Claim
31 words
The manufactured fuel article as in claim 8 wherein the composition of said covering layer comprises thermoplastic material and pulp fiber, said fuel article having been made by a coextrusion process.
Claim 32
Dependent Claim
18 words
The manufactured fuel article as in claim 23, said fuel article having been made by a coextrusion process.
Claim 33
Dependent Claim
25 words
The manufactured fuel article as in claim 12, said fuel article having been made by extrusion coating said covering layer onto said primary fuel element.
Claim 34
Independent Claim
129 words
A method of poducing a manufactured fuel article, comprising: (a) forming a primary core fuel element having a longitudinal axis; (b) heating a thermoplastic composition above its melting point, thereby producing a flowable melt; (c) extruding said flowable melt through a die and depositing a coating of said flowable melt as a covering layer on said core fuel element along the direction of said longitudinal axis, whereby said flowable melt flows about any surface irregularities in the outer surface of said core fuel element, such that the thickness of said covering layer varies according to the surface irregularities, while maintaining a substantially uniform outer surface on said covering layer and thus on said fuel article; and (d) solidifying said flowable melt on the surface of said core fuel element.
Claim 35
Independent Claim
129 words
A method of poducing a manufactured fuel article, comprising: (a) forming a primary core fuel element having a longitudinal axis; (b) heating a thermoplastic composition above its melting point, thereby producing a flowable melt; (c) extruding said flowable melt through a die and depositing a coating of said flowable melt as a covering layer on said core fuel element along the direction of said longitudinal axis, whereby said flowable melt flows about any surface irregularities in the outer surface of said core fuel element, such that the thickness of said covering layer varies according to the surface irregularities, while maintaining a substantially uniform outer surface on said covering layer and thus on said fuel article; and (d) solidifying said flowable melt on the surface of said core fuel element.
Claim 36
Dependent Claim
23 words
The method of producing a manufactured fuel article as in claim 31 wherein said core fuel element is formed by an extrusion process.
Claim 37
Dependent Claim
50 words
The method of producing a manufactured fuel article as in claim 31 or 32 wherein said flowable melt of said covering layer comprises up to 50% by weight unmelted pulp fiber and wherein said flowable melt is extruded as a composition comprising both melted thermoplastic material and unmelted pulp fiber.
Claim 38
Independent Claim
169 words
A method of producing a manufactured fuel article, comprising: (a) extruding a continuous first primary core fuel element composition through an extruder and into a coextrusion die; (b) heating a thermoplastic composition above its melting point, thereby producing a flowable melt, and forcing said flowable melt through an extruder and into said coextrusion die; (c) concentrically combining said first core element composition with said flowable melt in said coextrusion die and coextruding said core fuel element composition and said flowable melt as an extrudate, said extrudate comprising said core primary fuel element and a covering layer, said covering layer being derived from said flowable melt, and substantially covering the outside surface of said core fuel element; (d) cooling said flowable melt below its melting temperature, to thereby form a solid outer covering on said extrudate, and thus to form a fuel article of said extrudate, said fuel article comprising said core fuel element covered by said solid outer covering layer; and (e) transversely separating said extrudate into individual pieces.
Claim 39
Independent Claim
169 words
A method of producing a manufactured fuel article, comprising: (a) extruding a continuous first primary core fuel element composition through an extruder and into a coextrusion die; (b) heating a thermoplastic composition above its melting point, thereby producing a flowable melt, and forcing said flowable melt through an extruder and into said coextrusion die; (c) concentrically combining said first core element composition with said flowable melt in said coextrusion die and coextruding said core fuel element composition and said flowable melt as an extrudate, said extrudate comprising said core primary fuel element and a covering layer, said covering layer being derived from said flowable melt, and substantially covering the outside surface of said core fuel element; (d) cooling said flowable melt below its melting temperature, to thereby form a solid outer covering on said extrudate, and thus to form a fuel article of said extrudate, said fuel article comprising said core fuel element covered by said solid outer covering layer; and (e) transversely separating said extrudate into individual pieces.
Claim 40
Dependent Claim
40 words
The method of producing a manufactured fuel article as in claim 34 and including coextruding said covering layer and said core element such that, in said coextrudate, said covering layer covers substantially the entire extruded surface of said fuel element.
References Cited (Backward Citations)
US1194613A
Cited
GB527705A
Cited
US2475768A
Cited
US2475767A
Cited
US3227530A
Cited
US3637355A
Cited
US3706540A
Cited
US3947255A
Cited
US3973922A
Cited
US4043765A
Cited
US4120666A
Cited
US4104034A
Cited
US4243394A
Cited
CA1113246A
Cited
US4539011A
Cited
USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1992-03-06 | 1992-09-05 | 1993-03-07 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1996-03-06 | 1996-09-05 | 1997-03-07 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2000-03-06 | 2000-09-05 | 2001-03-07 | $7700.00 | Window Closed / Lapsed |