Patent EP0002998A1 successfully refreshed from Google Patents.
US4877671A
Expired / Lapsed
US
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Reducing shrinkage of phenolic foam composites
Assignee: BPCO Inc
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Filing: 1988-03-09
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Granted: 1989-10-31
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Expires: 2008-03-09
Abstract
Abstract A foam composite - especially useful as an insulating board - comprising first and second oppositely disposed corrugated skins having a core of foam material therebetween, and a reinforcement medium located at the interface between the foam core and each skin, the foam extending through interstices or pores in the medium and bonding to the medium and to the skins. The reinforced composite so formed has increased resistance to bending and other deformations and improved dimensional stability.
Inventors
- 👤 Malcolm J. Stagg
- 👤 Eric P. Stern
- 👤 Sunil Vidyarthi
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-03 11:28
CPC Classifications
B; B32; B32B; B32B5/00; B32B5/18; B32B3/00; B32B3/26; B32B3/28; B32B29/00; B32B29/002; B32B29/005; B32B29/007; B32B29/04; B32B5/22; B32B5/32; B32B2264/00; B32B2264/06; B32B2264/062; B32B2264/067; B32B2266/00; B32B2266/02; B32B2266/0214; B32B2266/0285; B32B2266/08; B32B2305/00; B32B2305/08; B32B2307/00; B32B2307/70; B32B2307/732; B32B2307/734; B32B2317/00; B32B2317/12; B32B2317/122; B32B2317/127; B32B2607/00; Y; Y10; Y10T; Y10T428/00; Y10T428/24; Y10T428/24273; Y10T428/24322; Y10T428/24331; Y10T428/24339; Y10T428/24479; Y10T428/24496; Y10T428/24504; Y10T428/24628; Y10T428/24661; Y10T428/24669; Y10T428/24694; Y10T428/24711; Y10T428/24727; Y10T428/249921; Y10T428/249953; Y10T428/24996; Y10T428/249982; Y10T428/249984
Claims Analysis
Total Claims: 43
Claim 1
Independent Claim
56 words
A foam composite comprising first and second oppositely disposed corrugates skins and a core of cured foam material between said skins, and a reinforcement medium located at the interface between said foam core and each said skin, said foam extending through interstices or pores in said medium and bonding to said medium and each said skin.
Claim 2
Dependent Claim
56 words
A foam composite comprising first and second oppositely disposed corrugates skins and a core of cured foam material between said skins, and a reinforcement medium located at the interface between said foam core and each said skin, said foam extending through interstices or pores in said medium and bonding to said medium and each said skin.
Claim 3
Dependent Claim
15 words
A foam composite as defined in claim 1, wherein said skins are corrugated kraft paper.
Claim 4
Dependent Claim
28 words
A foam composite as defined in claim 1, wherein said medium is a continuous porous mat or a particulate or fibrous material having interstices between the particles thereof.
Claim 5
Dependent Claim
13 words
A foam composite as defined in claim 3, wherein said medium is sawdust.
Claim 6
Dependent Claim
21 words
A foam composite as defined in claim 3, wherein said medium is selected from low density urethane foam and wadding paper.
Claim 7
Dependent Claim
34 words
A foam composite as defined in claim 1, wherein said medium is a continuous porous mat which is perforated at selected intervals to provide additional communication between said foam and each of said skins.
Claim 8
Dependent Claim
23 words
A foam composite as defined in claim 1, wherein said medium is a particulate material layer having a thickness of about 2 mm.
Claim 9
Dependent Claim
23 words
A foam composite as defined in claim 1, wherein said medium is a continuous porous mat having a thickness of about 1-2 mm.
Claim 10
Dependent Claim
78 words
A foam composite forming an insulating panel, said composite comprising first and second oppositely disposed skins of corrugated kraft paper having inwardly facing corrugations and a core of foam material therebetween, and first and second porous mats of reinforcement material located between said foam core and the respective corrugations of said skins, said foam extending through the pores of each said mat and bonding to said reinforcement material and to the corrugations of each said kraft paper skin.
Claim 11
Dependent Claim
78 words
A foam composite forming an insulating panel, said composite comprising first and second oppositely disposed skins of corrugated kraft paper having inwardly facing corrugations and a core of foam material therebetween, and first and second porous mats of reinforcement material located between said foam core and the respective corrugations of said skins, said foam extending through the pores of each said mat and bonding to said reinforcement material and to the corrugations of each said kraft paper skin.
Claim 12
Dependent Claim
73 words
A foam composite forming an insulating panel, said composite comprising first and second oppositely disposed skins of corrugated kraft paper having inwardly facing corrugations and a core of cured foam material therebetween, and first and second layers of particulate material at each interface between said corrugations and said foam, said foam extending between the particles of said material and bonding to said particles and to the corrugations of each said kraft paper skin.
Claim 13
Dependent Claim
73 words
A foam composite forming an insulating panel, said composite comprising first and second oppositely disposed skins of corrugated kraft paper having inwardly facing corrugations and a core of cured foam material therebetween, and first and second layers of particulate material at each interface between said corrugations and said foam, said foam extending between the particles of said material and bonding to said particles and to the corrugations of each said kraft paper skin.
Claim 14
Dependent Claim
23 words
A foam composite as claimed in claim 9, wherein each said porous mat is wadding paper or a low density flexible urethane foam.
Claim 15
Dependent Claim
14 words
A foam composite as claimed in claim 10, wherein said reinforcement material is sawdust.
Claim 16
Dependent Claim
20 words
A foam composite as claimed in claim 11, wherein each said porous mat has a thickness of about 2 mm.
Claim 17
Dependent Claim
20 words
A foam composite as claim in claim 12, wherein each said sawdust layer has a thickness of about 2 mm.
Claim 18
Dependent Claim
30 words
A foam composite as claimed in claim 9, wherein each said continuous porous mat is perforated at selected intervals to provide additional communication between said foam and each said skin.
Claim 19
Dependent Claim
47 words
A foam composite as defined in claim 1, wherein said continuous porous mat is provided on its surface adjacent said foam material with anchor points for said foam, said anchor points being secured to said mat and providing locally increased adhesion between said foam and said mat.
Claim 20
Dependent Claim
34 words
A foam composite as defined in claim 16, wherein said anchor points are small pieces of material selected from cellulosic felt, Velcro, perforated beadboard, closed cell phenolic foam and epoxy or catalysed resin adhesive.
Claim 21
Dependent Claim
57 words
A phenolic foam composite comprising first and second oppositely disposed corrugated skins and a core of phenolic foam material between said skins, and a reinforcement medium located at the interface between said foam core and each said skin, said foam extending through interstices or pores in said medium and bonding to said medium and each said skin.
Claim 22
Dependent Claim
57 words
A phenolic foam composite comprising first and second oppositely disposed corrugated skins and a core of phenolic foam material between said skins, and a reinforcement medium located at the interface between said foam core and each said skin, said foam extending through interstices or pores in said medium and bonding to said medium and each said skin.
Claim 23
Dependent Claim
16 words
A phenolic foam composite as defined in claim 18, wherein said skins are corrugated kraft paper.
Claim 24
Dependent Claim
29 words
A phenolic foam composite as defined in claim 18, wherein said medium is a continuous porous mat or a particulate or fibrous material having interstices between the particles thereof.
Claim 25
Dependent Claim
14 words
A phenolic foam composite as defined in claim 20, wherein said medium is sawdust.
Claim 26
Dependent Claim
22 words
A phenolic foam composite as defined in claim 20, wherein said medium is selected from low density urethane foam and wadding paper.
Claim 27
Dependent Claim
35 words
A phenolic foam composite as defined in claim 18, wherein said medium is a continuous porous mat which is perforated at selected intervals to provide additional communication between said foam and each of said skins.
Claim 28
Dependent Claim
24 words
A phenolic foam composite as defined in claim 18, wherein said medium is a particulate material layer having a thickness of about 2 mm.
Claim 29
Dependent Claim
24 words
A phenolic foam composite as defined in claim 18, wherein said medium is a continuous porous mat having a thickness of about 1-2 mm.
Claim 30
Dependent Claim
80 words
A phenolic foam composite forming an insulating panel, said composite comprising first and second oppositely disposed skins of corrugated kraft paper having inwardly facing corrugations and a core of phenolic foam material therebetween, and first and second porous mats of reinforcement material located between said foam core and the respective corrugations of said skins, said foam extending through the pores of each said mat and bonding to said reinforcement material and to the corrugations of each said kraft paper skin.
Claim 31
Dependent Claim
80 words
A phenolic foam composite forming an insulating panel, said composite comprising first and second oppositely disposed skins of corrugated kraft paper having inwardly facing corrugations and a core of phenolic foam material therebetween, and first and second porous mats of reinforcement material located between said foam core and the respective corrugations of said skins, said foam extending through the pores of each said mat and bonding to said reinforcement material and to the corrugations of each said kraft paper skin.
Claim 32
Dependent Claim
77 words
A closed cell phenolic foam composite forming an insulating panel, said composite comprising first and second oppositely disposed skins of corrugated kraft paper having inwardly facing corrugations and a core of closed cell phenolic foam therebetween, and first and second layers of particulate material at each interface between said corrugations and said foam, said foam extending between the particles of said material and bonding to said particles and to the corrugations of each said kraft paper skin.
Claim 33
Dependent Claim
77 words
A closed cell phenolic foam composite forming an insulating panel, said composite comprising first and second oppositely disposed skins of corrugated kraft paper having inwardly facing corrugations and a core of closed cell phenolic foam therebetween, and first and second layers of particulate material at each interface between said corrugations and said foam, said foam extending between the particles of said material and bonding to said particles and to the corrugations of each said kraft paper skin.
Claim 34
Dependent Claim
24 words
A phenolic foam composite as claimed in claim 26, wherein each said porous mat is wadding paper or a low density flexible urethane foam.
Claim 35
Dependent Claim
15 words
A phenolic foam composite as claimed in claim 27, wherein said reinforcement material is sawdust.
Claim 36
Dependent Claim
21 words
A phenolic foam composite as claimed in claim 28, wherein each said porous mat has a thickness of about 2 mm.
Claim 37
Dependent Claim
21 words
A phenolic foam composite as claim in claim 29, wherein each said sawdust layer has a thickness of about 2 mm.
Claim 38
Dependent Claim
31 words
A phenolic foam composite as claimed in claim 26, wherein each said continuous porous mat is perforated at selected intervals to provide additional communication between said foam and each said skin.
Claim 39
Dependent Claim
48 words
A phenolic foam composite as defined in claim 18, wherein said continuous porous mat is provided on its surface adjacent said foam material with anchor points for said foam, said anchor points being secured to said mat and providing locally increased adhesion between said foam and said mat.
Claim 40
Dependent Claim
35 words
A phenolic foam composite as defined in claim 33, wherein said anchor points are small pieces of material selected from cellulosic felt, Velcro, perforated beadboard, closed cell phenolic foam and epoxy or catalysed resin adhesive.
Claim 41
Dependent Claim
26 words
A foam composite as defined in claim 1, wherein said foam is selected from a closed-cell phenolic foam, an open-celled phenolic foam, urethane and polyisocyanurate foams.
Claim 42
Dependent Claim
27 words
A foam composite as defined in claim 9, wherein said foam is selected from a closed-cell phenolic foam, an open celled phenolic foam, urethane and polyisocyanurate foams.
Claim 43
Dependent Claim
27 words
A foam composite as defined in claim 10, wherein said foam is selected from a closed-cell phenolic foam, an open celled phenolic foam, urethane and polyisocyanurate foams.
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1992-10-30 | 1993-05-01 | 1993-10-31 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1996-10-30 | 1997-05-01 | 1997-10-31 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2000-10-30 | 2001-05-01 | 2001-10-31 | $7700.00 | Window Closed / Lapsed |