US5134014A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Moldable foam composite
Assignee: BASF SE
•
Filing: 1991-01-28
•
Granted: 1992-07-28
•
Expires: 2011-01-28
Abstract
Abstract A heat moldable composite panel is particularly useful as an automotive headliner and other as structural parts which must have heat and sound insulating properties as well as sound absorbing properties. The panel comprises a corrugated core which is advantageously dual arched core or corrugated metal foil, with opposite sides. One side is covered by a linerboard and is attached to the core through thermoplastic adhesive. The opposite side is covered by a thermoformable foam layer which is attached to the core by heat activatable adhesive. The entire structure is formable in a molding die at relatively low temperatures.
Inventors
- 👤 Harold H. Zaima
- 👤 J. Christopher Landry
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-03 02:03
CPC Classifications
B; B32; B32B; B32B3/00; B32B3/26; B32B3/28; B29; B29C; B29C51/00; B29C51/14; B32B15/00; B32B15/04; B32B15/046; B32B15/12; B32B15/20; B32B29/00; B32B29/08; B32B7/00; B32B7/04; B32B7/12; G; G10; G10K; G10K11/00; G10K11/16; G10K11/162; G10K11/168; B29C51/08; B29C51/082; B29L; B29L2009/00; B29L2009/001; B32B2266/00; B32B2266/02; B32B2266/0214; B32B2266/0278; B32B2311/00; B32B2311/24; B32B2605/00; B60; B60R; B60R13/00; B60R13/02; B60R13/0212; B60R13/0225; B60R13/08; B60R13/0815; Y; Y10; Y10T; Y10T428/00; Y10T428/24; Y10T428/24628; Y10T428/24669; Y10T428/24694; Y10T428/24711; Y10T428/24727; Y10T428/24802; Y10T428/24826; Y10T428/249921; Y10T428/249953; Y10T428/249982; Y10T428/249985; Y10T428/249987
Claims Analysis
Total Claims: 21
Claim 1
Independent Claim
54 words
A moldable composite panel for use as an automotive headliner and the like, comprising: a corrugated core having first and second opposite sides; a linerboard adhered to the first side of the core by a thermoplastic; and a thermoformable foam layer adhered to the second side of the core by a heat activatable adhesive.
Claim 2
Dependent Claim
54 words
A moldable composite panel for use as an automotive headliner and the like, comprising: a corrugated core having first and second opposite sides; a linerboard adhered to the first side of the core by a thermoplastic; and a thermoformable foam layer adhered to the second side of the core by a heat activatable adhesive.
Claim 3
Dependent Claim
20 words
A panel according to claim 1, wherein the foam layer is directly adhered to the second side of the core.
Claim 4
Dependent Claim
33 words
A panel according to claim 1, wherein the core comprises a dual arch core made of at least two layers of material, at least one layer of material of the core being paperboard.
Claim 5
Dependent Claim
20 words
A panel according to claim 3, wherein at least one layer of the material of the core is metal foil.
Claim 6
Dependent Claim
24 words
A panel according to claim 3, wherein both layers of material of the core are paperboard which are adhered to each other with adhesive.
Claim 7
Dependent Claim
15 words
A panel according to claim 1, wherein the corrugated core is made of metal foil.
Claim 8
Dependent Claim
12 words
A panel according to claim 6, wherein the metal foil is aluminum.
Claim 9
Dependent Claim
16 words
A panel according to claim 7, wherein the aluminum has a thickness of approximately 0.0007 inches.
Claim 10
Dependent Claim
13 words
A panel according to claim 1, wherein the heat activatable adhesive is thermoplastic.
Claim 11
Dependent Claim
34 words
A panel according to claim 1, wherein the foam layer comprises polyurethane foam and is directly connected by the adhesive to the second side of the core, the corrugated core comprising dual arch core.
Claim 12
Dependent Claim
34 words
A panel according to claim 1, wherein the foam layer comprises polyurethane foam and is directly connected by the adhesive to the second layer of the core, the corrugated core comprising corrugated metal foil.
Claim 13
Independent Claim
93 words
A method of constructing a thermoformable composite panel for use as automotive headliners and the like, comprising: positioning a panel in a molding die, the panel comprising a corrugated core having opposite sides, one side covered by a linerboard with a thermoplastic between the linerboard and the core, and the opposite side covered by a thermoformable foam layer with a heat activatable adhesive between the foam layer and the core; closing the mold die to heat and shape the panel into a shaped panel; and opening the die to release the shaped panel.
Claim 14
Independent Claim
93 words
A method of constructing a thermoformable composite panel for use as automotive headliners and the like, comprising: positioning a panel in a molding die, the panel comprising a corrugated core having opposite sides, one side covered by a linerboard with a thermoplastic between the linerboard and the core, and the opposite side covered by a thermoformable foam layer with a heat activatable adhesive between the foam layer and the core; closing the mold die to heat and shape the panel into a shaped panel; and opening the die to release the shaped panel.
Claim 15
Dependent Claim
24 words
A method according to claim 12, including connecting the linerboard to the core through the thermoplastic before the panel is placed in the die.
Claim 16
Dependent Claim
28 words
A method according to claim 13, wherein the foam layer is not attached to the core through the heat activatable adhesive until after the molding die is closed.
Claim 17
Dependent Claim
17 words
A method according to claim 12, wherein the corrugated core is made of dual arch corrugated medium.
Claim 18
Dependent Claim
18 words
A method according to claim 15, wherein the dual arch corrugated medium has at least one paperboard layer.
Claim 19
Dependent Claim
18 words
A method according to claim 16, wherein the dual arch corrugated has at least one metal foil layer.
Claim 20
Dependent Claim
16 words
A method according to claim 12, wherein the corrugated medium is made of corrugated metal foil.
Claim 21
Dependent Claim
12 words
A method according to claim 18, wherein the metal foil is aluminum.
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) | 1995-07-28 | 1996-01-27 | 1996-07-28 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1999-07-28 | 2000-01-27 | 2000-07-28 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2003-07-28 | 2004-01-27 | 2004-07-28 | $7700.00 | Window Closed / Lapsed |