US5824246A — Method of forming a thermoactive binder composite

Claim 1

Independent Claim 161 words

A method of forming a thermoactive binder composite product comprising the steps of: choosing a base material including a thermoactive binder component; forming the base material into a mat having at least one surface expanse; providing jet structure for delivering a pressurized hot non-condensable gas toward and into the base material through the surface expanse, the jet structure including a plurality of jets adapted to be disposed in a predetermined distribution over the surface expanse with the plurality of jets having an average opening size and being spaced apart in the predetermined distribution by an average distance substantially greater than the average opening size; injecting, via the provided jet structure, the hot non-condensable gas into the base material, where the pressure of the gas is substantially dissipated in passage through the jets prior to entry into the base material at least during a portion of the step of injecting; and pressing the base material to compress it to a first density.

Claim 2

Independent Claim 161 words

A method of forming a thermoactive binder composite product comprising the steps of: choosing a base material including a thermoactive binder component; forming the base material into a mat having at least one surface expanse; providing jet structure for delivering a pressurized hot non-condensable gas toward and into the base material through the surface expanse, the jet structure including a plurality of jets adapted to be disposed in a predetermined distribution over the surface expanse with the plurality of jets having an average opening size and being spaced apart in the predetermined distribution by an average distance substantially greater than the average opening size; injecting, via the provided jet structure, the hot non-condensable gas into the base material, where the pressure of the gas is substantially dissipated in passage through the jets prior to entry into the base material at least during a portion of the step of injecting; and pressing the base material to compress it to a first density.

Claim 3

Dependent Claim 20 words

The method of claim 1 wherein the jets are positioned in contact with the surface expanse of the base material.

Claim 4

Dependent Claim 21 words

The method of claim 2 wherein the jets are separated from the surface of the base material by a short distance.

Claim 5

Dependent Claim 17 words

The method of claim 1 further comprising the step of selecting a base material including filler particles.

Claim 6

Dependent Claim 19 words

The method of claim 4 further comprising the step of selecting filler particles generally in the form of strands.

Claim 7

Dependent Claim 33 words

The method of claim 4 further comprising the step of selecting filler particles from the group including sawdust, shredded paper, wood chips, wood shavings, peanut shells, glass fibers, boron fibers, or Kevlar™ fibers.

Claim 8

Dependent Claim 25 words

The method of claim 4 further comprising the step of preheating the thermoplastic portion of the base material prior to combination with the filler particles.

Claim 9

Dependent Claim 44 words

The method of claim 1, further including the step of forming the base material into a press charge that includes opposing sides, and wherein the providing set including providing jets positioned to deliver gas toward and into the opposing sides of the press charge.

Claim 10

Independent Claim 82 words

A method of forming a thermoactive binder composite product comprising the steps of: supplying a base material including a thermoactive binder component; providing a platen press with a pair of opposed platens to compress a press change formed from the base material; choosing platens having an insulating inner face for contacting the press charge to thereby substantially limit conductive heat transfer between the platens and the press charge; injecting a hot dry gas into the press charge; and compressing the press charge.

Claim 11

Independent Claim 82 words

A method of forming a thermoactive binder composite product comprising the steps of: supplying a base material including a thermoactive binder component; providing a platen press with a pair of opposed platens to compress a press change formed from the base material; choosing platens having an insulating inner face for contacting the press charge to thereby substantially limit conductive heat transfer between the platens and the press charge; injecting a hot dry gas into the press charge; and compressing the press charge.

Claim 12

Dependent Claim 22 words

The method of claim 9 further comprising the step of choosing hot air as the hot gas for the step of injecting.

Claim 13

Dependent Claim 26 words

The method of claim 10 further comprising the step of heating the hot air to between 400° and 600° F. prior to the step of injecting.

Claim 14

Dependent Claim 17 words

The method of claim 9 further comprising the step of choosing thermoplastic fluff as the thermoactive binder.

Claim 15

Independent Claim 119 words

A method of forming a thermoactive binder composite product comprising the steps of: selecting a gas permeable base material including a thermoactive binder component; forming the base material into a press charge having a pair of opposing sides; and infusing a substantially dry hot gas into the base material through a first region on one of the opposing sides and through a second region on the other of the opposing sides simultaneously, with at least a substantial portion of the regions being opposed to each other across the press charge in a direction generally normal to the sides, where the temperature of the gas is greater than the activation temperature of the thermoactive binder component of the base material.

Claim 16

Independent Claim 119 words

A method of forming a thermoactive binder composite product comprising the steps of: selecting a gas permeable base material including a thermoactive binder component; forming the base material into a press charge having a pair of opposing sides; and infusing a substantially dry hot gas into the base material through a first region on one of the opposing sides and through a second region on the other of the opposing sides simultaneously, with at least a substantial portion of the regions being opposed to each other across the press charge in a direction generally normal to the sides, where the temperature of the gas is greater than the activation temperature of the thermoactive binder component of the base material.

Claim 17

Dependent Claim 43 words

The method of claim 13, further including the step of providing jet structure for infusing the substantially dry hot gas toward and into the base material through the opposing sides, the jet structure including a plurality of jets disposed over both opposing sides.

Claim 18

Dependent Claim 38 words

The method of claim 14, further including the step of forcing an amount of gas through the jets sufficient to create a substantial pressure drop across the jets prior to entry of the gas into the base material.

Claim 19

Independent Claim 137 words

A method of forming a thermoplastic binder composite product comprising the steps of: selecting a gas permeable base material including a thermoplastic binder component, where the gas permeability of the base material varies upon activation of the thermoplastic binder; injecting a substantially dry hot gas into the base material from a plurality of discrete locations, where the temperature of the gas is greater than the activation temperature of the thermoplastic binder component of the base material; regulating the gas flow among the plurality of discrete locations so that variations in the permeability of the base material in the proximity of one or more of the plurality of discrete locations does not substantially affect gas flow into the base material from one of the one or more discrete locations relative to another of the plurality of discrete locations.

Claim 20

Independent Claim 137 words

A method of forming a thermoplastic binder composite product comprising the steps of: selecting a gas permeable base material including a thermoplastic binder component, where the gas permeability of the base material varies upon activation of the thermoplastic binder; injecting a substantially dry hot gas into the base material from a plurality of discrete locations, where the temperature of the gas is greater than the activation temperature of the thermoplastic binder component of the base material; regulating the gas flow among the plurality of discrete locations so that variations in the permeability of the base material in the proximity of one or more of the plurality of discrete locations does not substantially affect gas flow into the base material from one of the one or more discrete locations relative to another of the plurality of discrete locations.

Claim 21

Dependent Claim 39 words

The method of claim 16, further including the step of forming the base material into a press charge that includes opposing sides, and wherein the plurality of discrete locations includes locations on both opposing sides of the press charge.

Claim 22

Dependent Claim 20 words

The method of claim 17, further comprising the step of compressing the base material into a substantially compact, solid product.

Claim 23

Dependent Claim 21 words

The method of claim 18, further including the step of choosing a base material including thermoplastic material as the thermoactive binder.

Claim 24

Dependent Claim 21 words

The method of claim 18, further including the step of choosing a base material including thermoset material as the thermoactive binder.

Claim 25

Dependent Claim 20 words

The method of claim 16, further comprising the step of compressing the base material into a substantially compact, solid product.

Claim 26

Dependent Claim 29 words

The method of claim 16, further including the step of choosing a substantially dry hot gas for the step of injecting with a temperature of at least 400° F.

Claim 27

Independent Claim 82 words

A method of forming a thermoactive binder and cellulosic composite product comprising the steps of: selecting a gas permeable base material including a thermoactive binder component and a cellulosic component; injecting a substantially dry hot gas into the base material where the temperature of the gas is greater than 400° F., where the gas consists essentially of air; and limiting the exposure of the base material to gas with a temperature greater than 400° F. in step of injecting to avoid combustion.

Claim 28

Independent Claim 82 words

A method of forming a thermoactive binder and cellulosic composite product comprising the steps of: selecting a gas permeable base material including a thermoactive binder component and a cellulosic component; injecting a substantially dry hot gas into the base material where the temperature of the gas is greater than 400° F., where the gas consists essentially of air; and limiting the exposure of the base material to gas with a temperature greater than 400° F. in step of injecting to avoid combustion.

Claim 29

Dependent Claim 20 words

The method of claim 23, further comprising the step of choosing a gas temperature between 400° F. and 600° F.

Claim 30

Dependent Claim 15 words

The method of claim 23, further comprising the step of selecting a thermoplastic thermoactive binder.

Claim 31

Dependent Claim 26 words

The method of claim 23, further including the step of spiking the temperature for a predetermined interval when the gas is first injected into the mat.

Claim 32

Dependent Claim 17 words

The method of claim 23, further including the step of choosing a base material including thermoplastic fluff.

Claim 33

Dependent Claim 59 words

The method of claim 27, further including the step of forming the base material into a mat prior to the step of injecting and the step of compressing the mat to a first density of not more tan fifteen pounds per cubic foot at least during part of the step of injecting so that the mat remains substantially porous.

Annuity Stage	Window Opens	Payment Deadline	Surcharge Period Until	Estimated Fee	Status
3.5 Years (Year 4)	2001-10-19	2002-04-20	2002-10-20	$2000.00	Window Closed / Lapsed
7.5 Years (Year 8)	2005-10-19	2006-04-20	2006-10-20	$3760.00	Window Closed / Lapsed
11.5 Years (Year 12)	2009-10-19	2010-04-20	2010-10-20	$7700.00	Window Closed / Lapsed

Method of forming a thermoactive binder composite

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