Patent US5540963A successfully refreshed from Google Patents.
US5540963A
Expired / Lapsed
US
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Expandable films and molded products therefrom
Assignee: Henkel Loctite Corp
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Filing: 1995-03-07
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Granted: 1996-07-30
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Expires: 2015-03-07
Abstract
Abstract A thin, tacky, non-pourable film of incompatible in situ-expandable thermoplastic particles and thermosettable matrix resin that contains an essentially uniform density and thickness across the breadth of the film. The in situ-expandable mass is not pourable yet can be easily dispensed in a uniform manner within a mold and thereafter expanded to the dimensions of the mold. Composites and reinforced compositions, as well as methods of molding, are disclosed.
Inventors
- 👤 Raymond S. Wong
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-04 03:16
CPC Classifications
C; C08; C08J; C08J9/00; C08J9/0085; B; B29; B29B; B29B15/00; B29B15/08; B29B15/10; B29B15/12; B29B15/122; B29C; B29C43/00; B29C43/22; B29C43/24; B29C43/28; B29C44/00; B29C44/34; B29C44/36; B29C44/38; B29C70/00; B29C70/02; B29C70/021; B29C70/025; B29C70/04; B29C70/28; B29C70/40; B29C70/50; B29C70/504; B29C70/58; B29C70/62; B29C70/66; C08J9/32; B29K; B29K2101/00; B29K2101/12; B29K2105/00; B29K2105/04; B29K2105/06; B29K2105/12; B29K2105/16; B29K2105/165; C08J2363/00; Y; Y10; Y10T; Y10T428/00; Y10T428/13; Y10T428/1352; Y10T428/1355; Y10T428/1359; Y10T428/1362; Y10T428/1366; Y10T428/1369; Y10T428/1372; Y10T428/1376; Y10T428/1386; Y10T428/139; Y10T428/1393; Y10T428/249921; Y10T428/249953; Y10T428/249954; Y10T428/249962; Y10T428/249971; Y10T428/249972; Y10T428/249981; Y10T428/249986; Y10T428/249987; Y10T428/249991; Y10T442/00; Y10T442/10; Y10T442/102; Y10T442/164; Y10T442/172; Y10T442/174; Y10T442/184; Y10T442/195; Y10T442/198; Y10T442/60; Y10T442/699
Claims Analysis
Total Claims: 18
Claim 1
Independent Claim
114 words
A method for the manufacture of a syntactic foam which comprises (1) placing in a predetermined configuration at least one tacky and drapeable, non-pourable film having a uniform thickness which is expandable under heating conditions and which contains uniformly distributed throughout the film (i) a non-pourable thermosettable resin matrix system and (ii) particles of a thermoplastic polymer which are in situ-expandable under heating conditions to form microcells in the expanded film, said thermoplastic polymer being incompatible with said thermosetting resin throughout the cycle of said in situ-expansion under heating conditions and (2) subjecting said at least one placed film to heating conditions to effect in situ-expansion and the obtainment of a cured syntactic foam.
Claim 2
Independent Claim
114 words
A method for the manufacture of a syntactic foam which comprises (1) placing in a predetermined configuration at least one tacky and drapeable, non-pourable film having a uniform thickness which is expandable under heating conditions and which contains uniformly distributed throughout the film (i) a non-pourable thermosettable resin matrix system and (ii) particles of a thermoplastic polymer which are in situ-expandable under heating conditions to form microcells in the expanded film, said thermoplastic polymer being incompatible with said thermosetting resin throughout the cycle of said in situ-expansion under heating conditions and (2) subjecting said at least one placed film to heating conditions to effect in situ-expansion and the obtainment of a cured syntactic foam.
Claim 3
Dependent Claim
38 words
The method of claim 1 wherein the placed film material is heated in a uneven manner to effect a thermal gradient and obtain a cured product having a density gradient throughout that is responsive to such thermal gradient.
Claim 4
Dependent Claim
20 words
The method of claim 2 wherein the placement step involves deposition of said at least one film in a mold.
Claim 5
Dependent Claim
40 words
The method for the manufacture of a syntactic foam of claim 1 wherein the placement step involves deposition of said at least one film in a mold and wherein in situ-expansion is continued until the desired foam density is achieved.
Claim 6
Dependent Claim
112 words
A tacky and drapable, non-pourable film having a uniform thickness which is expandable without liquefication under heating conditions and which contains uniformly distributed throughout the film (i) a non-pourable thermosettable resin matrix system and (ii) particles of a thermoplastic polymer which are in situ-expandable under heating conditions to form microcells in the expanded film, said thermoplastic polymer being incompatible with said thermosetting resin throughout the cycle of in situ-expansion under heating conditions, each said film being capable of expanding in the thickness dimension about 1.01 to about 3.5 times upon in situ-expansion under heating conditions and said at least one film being composited with at least one layer of a different material.
Claim 7
Dependent Claim
112 words
A tacky and drapable, non-pourable film having a uniform thickness which is expandable without liquefication under heating conditions and which contains uniformly distributed throughout the film (i) a non-pourable thermosettable resin matrix system and (ii) particles of a thermoplastic polymer which are in situ-expandable under heating conditions to form microcells in the expanded film, said thermoplastic polymer being incompatible with said thermosetting resin throughout the cycle of in situ-expansion under heating conditions, each said film being capable of expanding in the thickness dimension about 1.01 to about 3.5 times upon in situ-expansion under heating conditions and said at least one film being composited with at least one layer of a different material.
Claim 8
Dependent Claim
27 words
The thin and drapable, in situ-expandable tacky film of claim 5 wherein the different material strengthens the film prior to expansion and conversion to the thermoset state.
Claim 9
Dependent Claim
20 words
The thin and drapable, in situ-expandable tacky film of claim 6 wherein the different material is calendared to the film.
Claim 10
Dependent Claim
23 words
The thin and drapable, in situ-expandable tacky film of claim 7 wherein the different layer of material comprises scrims, foils and plastic films.
Claim 11
Dependent Claim
18 words
The thin and drapable, in situ-expandable tacky film of claim 7 wherein the different material sandwiches the film.
Claim 12
Dependent Claim
29 words
The thin and drapable, in situ-expandable tacky film of claim 7 wherein the bond of the film to the different material is effected through the tackiness of the film.
Claim 13
Dependent Claim
19 words
The thin and drapable, in situ-expandable tacky film of claim 7 wherein the different material is an open scrim.
Claim 14
Dependent Claim
26 words
The thin and drapable, in situ-expandable tacky film of claim 11 wherein the open scrim is one or more of a woven, nonwoven or knitted scrim.
Claim 15
Dependent Claim
38 words
The thin and drapable, in situ-expandable tacky film of claim 5 wherein the film is composited with an uncured syntactic foam that comprises thin films of uniform thickness which contain rigid microballoons uniformly dispersed in a resin matrix.
Claim 16
Dependent Claim
25 words
The thin and drapable, in situ-expandable tacky film of claim 13 wherein the resin matrix in the film and the uncured syntactic foam are co-curable.
Claim 17
Dependent Claim
26 words
The thin and drapable, in situ-expandable tacky film of claim 5 wherein the thin and drapable, tacky film is composited with a layer of a prepreg.
Claim 18
Dependent Claim
35 words
The thin film of claim 5 scrolled into a tube about which is adhered one or more prepeg layers comprising carbon fiber reinforcement to form a composite tube containing a small hole in the center.
References Cited (Backward Citations)
US5234757A
Cited
US5397611A
Cited
USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1999-07-30 | 2000-01-29 | 2000-07-30 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 2003-07-30 | 2004-01-29 | 2004-07-30 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2007-07-30 | 2008-01-29 | 2008-07-30 | $7700.00 | Window Closed / Lapsed |