Patent US6416613B1 successfully refreshed from Google Patents.
US6416613B1
Expired / Lapsed
US
⏱️ 0.0 years remaining
Products of and method for improving adhesion between substrate and polymer layers
Assignee: Nextec Applications Inc
•
Filing: 1998-06-23
•
Granted: 2002-07-09
•
Expires: 2018-06-23
Abstract
Abstract The present invention relates to a method for improving both adhesion between substrate and polymer layers and the durability of such composite structures; while maintaining the malleability and preferred characteristics of the original substrate. Quite unexpectedly, the application of a layer or film upon an uncured, encapsulated base substrate which has been encapsulated by the shear thinning methods of the present invention, results in superior adhesion of multiple layers when compared to conventional layering, coating or composite manufacturing methods. Moreover, the uncured or at most, semi-cured, polymer composition applied to the base substrate ensures that the substrate maintains maximum flexibility for subsequent shaping into composite articles prior to curing. The methods described herein produce multiple layer composite articles that are lighter, stronger, more flexible and utilize less material, than composite articles produced by conventional techniques. The method comprises applying an uncured, substantially solvent free, polymer composition exhibiting thixotropic or pseudoplastic characteristics, onto a base substrate having structural elements and interstices therebetween; shear thinning the polymer composition to place it into the base substrate, thereby encapsulating most of the structural elements while leaving a plurality of interstitial spaces open; overlaying a layer or film of polymer or thermoplastic material to at least one surface of the uncured encapsulated base substrate; pressuring the layer or film into the interstices of the uncured encapsulated base substrate to form a chemical and mechanical interlocking bond between the polymer composition of the base substrate and the overlay material; and optionally shaping the multi layer composite and curing the completed composite. This method produces multi layer composite articles and medical garments exhibiting increased adhesion and durability with excellent malleability and flexibility over conventional methods.
Inventors
- 👤 Rodney Lane Patrick
- 👤 James Michael Caldwell
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-24 13:24
CPC Classifications
B; B32; B32B; B32B38/00; B32B38/08; B29; B29C; B29C37/00; B29C37/0078; B29C37/0082; B29C70/00; B29C70/04; B29C70/06; B29C70/08; B29C70/086; B29C70/28; B29C70/30; B29C70/54; B29C70/546; B32B37/00; B32B37/12; C; C09; C09J; C09J5/00; C09J5/02; B29K; B29K2313/00; B29K2313/02; B32B2038/0052; B32B2038/0076
Claims Analysis
Total Claims: 41
Claim 1
Independent Claim
116 words
A method of preparing a composite comprising the steps of: applying an uncured, substantially solvent free, polymer composition exhibiting thixotropic or pseudoplastic characteristics, onto a base substrate wherein said base substrate comprises structural elements with interstices therebetween; shear thinning the polymer composition to place it into the base substrate and encapsulate most of the structural elements while leaving substantially all interstitial spaces open; overlaying a layer of polymer or thermoplastic material on at least one surface of the uncured, encapsulated base substrate; and pressuring the layer into the interstices of the uncured encapsulated base substrate to form chemical surface interactions and mechanical interlocking bonds between the polymer composition of the base substrate and the overlay material.
Claim 2
Independent Claim
116 words
A method of preparing a composite comprising the steps of: applying an uncured, substantially solvent free, polymer composition exhibiting thixotropic or pseudoplastic characteristics, onto a base substrate wherein said base substrate comprises structural elements with interstices therebetween; shear thinning the polymer composition to place it into the base substrate and encapsulate most of the structural elements while leaving substantially all interstitial spaces open; overlaying a layer of polymer or thermoplastic material on at least one surface of the uncured, encapsulated base substrate; and pressuring the layer into the interstices of the uncured encapsulated base substrate to form chemical surface interactions and mechanical interlocking bonds between the polymer composition of the base substrate and the overlay material.
Claim 3
Dependent Claim
36 words
The method of claim 1 wherein the shear thinned polymer composition is selected from the group consisting of silicones, polyurethanes, fluorosilicones, silicone-modified polyurethanes, acrylics, polytetrafluoroethylene (PTFE), PTFE-containing materials, neoprenes, high consistency rubbers (HCR), and combinations thereof.
Claim 4
Dependent Claim
70 words
The method of claim 1 wherein the material of the base substrate is selected from the group consisting of cotton, wool, silk, jute, linen, rayon, acetate, polyesters, polyethyleneterephthalate, polyamides, nylon, acrylics, olefins, aramids, azlons, glasses, fiberglass, modacrylics, novoloids, nytrils, rayons, sarans, spandex, vinal, vinyon, foams, films, foamed sheets, natural leathers, split hydes, synthetic leathers, vinyl, urethane, filtration membranes, polysulfones, polyimides, nitrocellulose, cellulose acetate, cellulose, and regenerated cellulose, and combinations thereof.
Claim 5
Dependent Claim
14 words
The method of claim 1 wherein the overlaying comprises coating the encapsulated base substrate.
Claim 6
Dependent Claim
12 words
The method of claim 1 wherein the pressuring is provided by calendaring.
Claim 7
Dependent Claim
10 words
The method of claim 1 further comprising curing the composite.
Claim 8
Dependent Claim
32 words
The method of claim 6 wherein the curing is provided by an energy source selected from the group consisting of thermal energy, an electron beam, microwave energy, electromagnetic radiation and ultrasonic energy.
Claim 9
Dependent Claim
20 words
The method of claim 1 wherein said chemical surface interactions include Van der Waal forces, dipole/dipole interactions or Hydrogen bonding.
Claim 10
Dependent Claim
26 words
The method of claim 1 wherein said mechanical interlocking bonds arise when the applied polymer layer is pressed through the interstitial spaces left open after encapsulation.
Claim 11
Dependent Claim
30 words
The method of claim 1 wherein the base substrate is threaded through an application head comprising a brake nip, a series of shearing blades, idler rolls, and a pull nip.
Claim 12
Dependent Claim
18 words
The method of claim 10 wherein the base substrate is fiberglass and the applied polymer layer is silicone.
Claim 13
Dependent Claim
25 words
The method of claim 1 further comprising the step of creating a multiple ply composite layer by stacking one composite layer on top of another.
Claim 14
Dependent Claim
20 words
The method of claim 12 wherein the base substrate is fiberglass and the applied polymer layer is high consistency rubber.
Claim 15
Dependent Claim
20 words
The method of claim 13 wherein the multiple ply composite layer has a burst strength of at least 180 psi.
Claim 16
Independent Claim
158 words
A method of preparing a composite structure article comprising the steps of: preparing a plurality of one-ply composite layers by: applying an uncured, substantially solvent free, polymer composition exhibiting thixotropic or pseudoplastic characteristics, onto a base substrate wherein said base substrate comprises structural elements with interstices therebetween; shear thinning the polymer composition to place it into the base substrate and encapsulate most of the structural elements while leaving substantially all interstitial spaces open; overlaying a layer of polymer or thermoplastic material on at least one surface of the uncured, encapsulated base substrate; forming a composite structure shape by wrapping said one-ply composite layers so that the one-ply composite layers overlap; pressuring the one-ply composite layers of said composite structure into the interstices of adjacent one-ply composite layers to form chemical surface interactions and mechanical interlocking bonds between the polymer composition of the base substrate and the overlay material in adjacent one-ply composite layers; and curing the composite structure.
Claim 17
Independent Claim
158 words
A method of preparing a composite structure article comprising the steps of: preparing a plurality of one-ply composite layers by: applying an uncured, substantially solvent free, polymer composition exhibiting thixotropic or pseudoplastic characteristics, onto a base substrate wherein said base substrate comprises structural elements with interstices therebetween; shear thinning the polymer composition to place it into the base substrate and encapsulate most of the structural elements while leaving substantially all interstitial spaces open; overlaying a layer of polymer or thermoplastic material on at least one surface of the uncured, encapsulated base substrate; forming a composite structure shape by wrapping said one-ply composite layers so that the one-ply composite layers overlap; pressuring the one-ply composite layers of said composite structure into the interstices of adjacent one-ply composite layers to form chemical surface interactions and mechanical interlocking bonds between the polymer composition of the base substrate and the overlay material in adjacent one-ply composite layers; and curing the composite structure.
Claim 18
Dependent Claim
19 words
The method of claim 15 wherein the pressuring step consists of tightly wrapping said composite layers with a non-adhesive.
Claim 19
Dependent Claim
49 words
The method of claim 15 wherein preparing the one-ply composite layers further comprises the additional step of pressuring the layer into the interstices of the uncured encapsulated base substrate to form a chemical and mechanical interlocking bond between the polymer composition of the base substrate and the overlay material.
Claim 20
Dependent Claim
17 words
The method of claim 17 wherein the pressuring of said one-ply composite layer is provided by calendaring.
Claim 21
Dependent Claim
36 words
The method of claim 15 wherein the shear thinned polymer composition is selected from the group consisting of silicones, polyurethanes, fluorosilicones, silicone-modified polyurethanes, acrylics, polytetrafluoroethylene (PTFE), PTFE-containing materials, neoprenes, high consistency rubbers (HCR), and combinations thereof.
Claim 22
Dependent Claim
70 words
The method of claim 15 wherein the material of the base substrate is selected from the group consisting of cotton, wool, silk, jute, linen, rayon, acetate, polyesters, polyethyleneterephthalate, polyamides, nylon, acrylics, olefins, aramids, azlons, glasses, fiberglass, modacrylics, novoloids, nytrils, rayons, sarans, spandex, vinal, vinyon, foams, films, foamed sheets, natural leathers, split hydes, synthetic leathers, vinyl, urethane, filtration membranes, polysulfones, polyimides, nitrocellulose, cellulose acetate, cellulose, and regenerated cellulose, and combinations thereof.
Claim 23
Dependent Claim
14 words
The method of claim 15 wherein the overlaying comprises coating the encapsulated base substrate.
Claim 24
Dependent Claim
32 words
The method of claim 15 wherein the curing is provided by an energy source selected from the group consisting of thermal energy, an electron beam, microwave energy, electromagnetic radiation and ultrasonic energy.
Claim 25
Dependent Claim
20 words
The method of claim 8 wherein said chemical surface interactions include Van der Waal forces, dipole/dipole interactions or Hydrogen bonding.
Claim 26
Dependent Claim
26 words
The method of claim 15 wherein said mechanical interlocking bonds arise when the applied polymer layer is pressed through the interstitial spaces left open after encapsulation.
Claim 27
Dependent Claim
30 words
The method of claim 8 wherein the base substrate is threaded through an application head comprising a brake nip, a series of shearing blades, idler rolls, and a pull nip.
Claim 28
Dependent Claim
18 words
The method of claim 25 wherein the base substrate is fiberglass and the applied polymer layer is silicone.
Claim 29
Dependent Claim
20 words
The method of claim 15 wherein the base substrate is fiberglass and the applied polymer layer is high consistency rubber.
Claim 30
Dependent Claim
18 words
The method of claim 27 wherein the composite structure has a burst strength of at least 180 psi.
Claim 31
Independent Claim
156 words
A method of preparing a composite comprising the steps of: applying an uncured polymer composition exhibiting thixotropic or pseudoplastic characteristics, onto a base substrate wherein said base substrate comprises structural elements with interstices therebetween, defining an untreated base substrate ratio of surface area to total volume; shear thinning the polymer composition to controllably place it into the base substrate and encapsulate most of the structural elements while leaving substantially all interstitial spaces open, thereby controllably effecting a change in the surface area available for chemical surface interactions and mechanical interlocking bonds between the polymer composition of the base substrate and the overlay material; overlaying a layer of polymer or thermoplastic material on at least one surface of the uncured, encapsulated base substrate; and pressuring the layer into the interstices of the uncured encapsulated base substrate to form chemical surface interactions and mechanical interlocking bonds between the polymer composition of the base substrate and the overlay material.
Claim 32
Independent Claim
156 words
A method of preparing a composite comprising the steps of: applying an uncured polymer composition exhibiting thixotropic or pseudoplastic characteristics, onto a base substrate wherein said base substrate comprises structural elements with interstices therebetween, defining an untreated base substrate ratio of surface area to total volume; shear thinning the polymer composition to controllably place it into the base substrate and encapsulate most of the structural elements while leaving substantially all interstitial spaces open, thereby controllably effecting a change in the surface area available for chemical surface interactions and mechanical interlocking bonds between the polymer composition of the base substrate and the overlay material; overlaying a layer of polymer or thermoplastic material on at least one surface of the uncured, encapsulated base substrate; and pressuring the layer into the interstices of the uncured encapsulated base substrate to form chemical surface interactions and mechanical interlocking bonds between the polymer composition of the base substrate and the overlay material.
Claim 33
Dependent Claim
16 words
The method of claim 29 wherein the applied uncured polymer composition is substantially free of solvent.
Claim 34
Dependent Claim
10 words
The method of claim 29 further comprising curing the composite.
Claim 35
Dependent Claim
20 words
The method of claim 29 wherein said chemical surface interactions include Van der Waal forces, dipole/dipole interactions or Hydrogen bonding.
Claim 36
Dependent Claim
26 words
The method of claim 29 wherein said mechanical interlocking bonds arise when the applied polymer layer is pressed through the interstitial spaces left open after encapsulation.
Claim 37
Dependent Claim
30 words
The method of claim 29 wherein the base substrate is threaded through an application head comprising a brake nip, a series of shearing blades, idler rolls, and a pull nip.
Claim 38
Dependent Claim
18 words
The method of claim 34 wherein the base substrate is fiberglass and the applied polymer layer is silicone.
Claim 39
Dependent Claim
25 words
The method of claim 29 further comprising the step of creating a multiple ply composite layer by stacking one composite layer on top of another.
Claim 40
Dependent Claim
20 words
The method of claim 36 wherein the base substrate is fiberglass and the applied polymer layer is high consistency rubber.
Claim 41
Dependent Claim
20 words
The method of claim 37 wherein the multiple ply composite layer has a burst strength of at least 180 psi.
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