Patent US4844955A successfully refreshed from Google Patents.
US4844955A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Multilayer polymeric composite and method for its manufacture
Assignee: JPMorgan Chase Bank NA
•
Filing: 1987-12-18
•
Granted: 1989-07-04
•
Expires: 2007-12-18
Abstract
Abstract A multilayer polymeric composite structure of high impact strength and delamination resistance possesses a polymeric cosmetic layer chemically bonded to a cross-linked, isocyanate-modified thermosetting polyester or polyether substrate layer. In one embodiment of the structure, a relatively thin, predominantly acrylic resin layer is chemically bonded through urethane linkages to a relatively thick, reinforced, polyester foam substrate layer. A reinforced reaction injection molding (RPIM) procedure for manufacturing the polymeric composite is also disclosed.
Inventors
- 👤 Peter U. Graefe
- 👤 Karl T. Kuszaj
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-25 10:24
CPC Classifications
C; C08; C08J; C08J5/00; C08J5/12; A; A47; A47K; A47K3/00; B; B32; B32B; B32B27/00; B32B27/06; B32B27/08; Y; Y10; Y10T; Y10T428/00; Y10T428/249921; Y10T428/249953; Y10T428/249987; Y10T428/249991; Y10T428/31504; Y10T428/31536; Y10T428/31551; Y10T428/31573; Y10T428/31786; Y10T428/31794; Y10T428/31797; Y10T428/31855; Y10T428/31859; Y10T428/31877
Claims Analysis
Total Claims: 18
Claim 1
Independent Claim
116 words
A cured polymeric composite of high impact strength and delamination resistance which comprises: (a) a polymeric cosmetic layer which, prior to the curing of a substrate layer in mutual contact therewith, possesses a chemically reactive first functionality on at least the surface thereof to be bonded to the substrate layer; and, (b) said substrate layer includes a cross-linked isocyanate-modified thermosetting unsaturated mixture of polyester and polyether resin which said substrate layer, prior to curing, possesses a chemically reactive second functionality such that upon curing while in mutual contact with a surface of the cosmetic layer, the substrate layer becomes bonded to the cosmetic layer through chemical linkages formed by reaction of said first and second functionalities.
Claim 2
Dependent Claim
116 words
A cured polymeric composite of high impact strength and delamination resistance which comprises: (a) a polymeric cosmetic layer which, prior to the curing of a substrate layer in mutual contact therewith, possesses a chemically reactive first functionality on at least the surface thereof to be bonded to the substrate layer; and, (b) said substrate layer includes a cross-linked isocyanate-modified thermosetting unsaturated mixture of polyester and polyether resin which said substrate layer, prior to curing, possesses a chemically reactive second functionality such that upon curing while in mutual contact with a surface of the cosmetic layer, the substrate layer becomes bonded to the cosmetic layer through chemical linkages formed by reaction of said first and second functionalities.
Claim 3
Dependent Claim
29 words
The polymeric composite of claim 1 wherein the polymeric cosmetic layer comprises at least one polymer which possesses the chemically reactive first functionality as part of its molecular structure.
Claim 4
Dependent Claim
39 words
The polymeric composite of claim 1 wherein the polymeric cosmetic layer comprises a first polymer which lacks chemically reactive first functionality but at least at its surface is blended with a second polymer which possesses chemically reactive first functionality.
Claim 5
Dependent Claim
26 words
The polymeric composite of claim 1 wherein the first functionality is an acrylic resin and the second functionality is a free hydroxyl group-containing thermosetting phenolic resin.
Claim 6
Dependent Claim
13 words
The polymeric composite of claim 1 wherein the substrate layer is a foam.
Claim 7
Dependent Claim
14 words
The polymeric composite of claim 1 wherein the substrate layer is a dense foam.
Claim 8
Dependent Claim
13 words
The polymeric composite of claim 1 wherein the substrate layer contains a reinforcement.
Claim 9
Dependent Claim
49 words
The polymeric composite of claim 1 wherein the polyester of the substrate layer is derived from a mixture of unsaturated liquid polyesters at least one of which possesses terminal ethylenic unsaturation and at least one functional group selected from the group consisting of hydroxyl, carboxylic acid and amine groups.
Claim 10
Dependent Claim
38 words
The polymeric composite of claim 1 wherein the polyester of the substrate layer is derived from a mixture of unsaturated liquid polyesters at least one of which is obtained by reacting methacrylic acid, maleic anhydride and propylene oxide.
Claim 11
Dependent Claim
71 words
The polymeric composite of claim 1 wherein the polymeric cosmetic layer comprises an acrylic resin, the surface of which in mutual contact with the substrate layer is a blend of the acrylic resin and a free hydroxyl group-containing thermosetting resin, the polyester of the substrate layer is a reinforced, dense, foamed polyester resin possessing, prior to curing, free isocyanate groups, the cosmetic layer being chemically bonded to the cured substrate layer.
Claim 12
Dependent Claim
10 words
The polymeric composite of claim 1 fabricated as a door.
Claim 13
Dependent Claim
14 words
The polymeric composite of claim 1 fabricated as a body panel for a vehicle.
Claim 14
Dependent Claim
33 words
The polymeric composite of claim 9 wherein said substrate layer includes a fumarate ester-monoalcohol formed by the isomerication of maleate ester obtained from said reaction of methacrylic acid, maleic anhydride and propylene oxide.
Claim 15
Independent Claim
155 words
A method for forming a cured polymeric composite of high impact strength and resistance to delamination which comprises: (a) providing a polymeric cosmetic layer which possesses a chemically reactive first functionality on at least the surface thereof to be bonded to a substrate layer; (b) contacting the surface of the cosmetic layer which possesses the first functionality with the precursor components of a substrate layer which includes a cross-linked, isocyanate-modified thermosetting unsaturated mixture of polyester and polyether resin, at least one component of which contains a chemically reactive second functionality capable, under conditions resulting in the cure of the substrate layer, of forming chemical linkages between the cosmetic layer and the substrate layer by reaction of said first and second functionalities; and, (c) subjecting the combined cosmetic layer and substrate layer to conditions effecting the cure of the substrate layer and the reaction of said first and second functionalities, thereby providing the cured polymeric composite.
Claim 16
Independent Claim
155 words
A method for forming a cured polymeric composite of high impact strength and resistance to delamination which comprises: (a) providing a polymeric cosmetic layer which possesses a chemically reactive first functionality on at least the surface thereof to be bonded to a substrate layer; (b) contacting the surface of the cosmetic layer which possesses the first functionality with the precursor components of a substrate layer which includes a cross-linked, isocyanate-modified thermosetting unsaturated mixture of polyester and polyether resin, at least one component of which contains a chemically reactive second functionality capable, under conditions resulting in the cure of the substrate layer, of forming chemical linkages between the cosmetic layer and the substrate layer by reaction of said first and second functionalities; and, (c) subjecting the combined cosmetic layer and substrate layer to conditions effecting the cure of the substrate layer and the reaction of said first and second functionalities, thereby providing the cured polymeric composite.
Claim 17
Dependent Claim
17 words
The method of claim 14 wherein step (b) is carried out employing a RIM or RRIM procedure.
Claim 18
Dependent Claim
43 words
The method of claim 14 wherein there is applied to the surface of the resin constituting the cosmetic layer a primer comprising a solution of thermosetting phenolic resin and an acrylic monomer resin having capability for dissolving the resin of the cosmetic layer.
References Cited (Backward Citations)
USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1992-07-03 | 1993-01-02 | 1993-07-04 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1996-07-03 | 1997-01-02 | 1997-07-04 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2000-07-03 | 2001-01-02 | 2001-07-04 | $7700.00 | Window Closed / Lapsed |