US3859401A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Process for fabricating structural panels
Assignee: Fibre-Thane Inc
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Filing: 1971-08-09
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Granted: 1975-01-07
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Expires: 1991-08-09
Abstract
Abstract A process and apparatus are disclosed for fabricating a laminated structural panel useful for forming a portion of a dwelling or the like. The panel has a foam core and outer skins of a hard weather-resistant resin. The laminate is formed by spraying a liquid resin on two generally horizontal mold surfaces which are maintained under conditions which allow the liquid resin to gain structural integrity but which prevent a substantially complete curing of the resin. Next, a material capable of forming a foam is placed on the exposed surface of one or both of the resin layers which cover the mold surfaces. The mold is provided with movable sides and the apparatus is next closed to form a substantially closed cavity. The material capable of forming a foam is then permitted to foam within the closed cavity thereby filling the cavity and pressing the resin against the mold surfaces. The outer resin is then caused to cure thereby forming a finished, cured laminate. In a preferred embodiment, the outer skin is formed from a polyester-fiberglass resin mixture and the inner foam is formed from a polyurethane rigid foam. The process can be adapted to permit the integral molding of the windows, doors, electrical conduit, piping and the like. The process may be performed in a hinged mold having one stationary horizontal mold surface and a second hinged mold surface which opens 180* thereby forming two substantially horizontal mold surfaces. Movable sides may be provided along the edge of these surfaces.
Inventors
- 👤 Francis Gallap
- 👤 Reginald V Tunstall
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-02 22:42
CPC Classifications
B; B29; B29C; B29C44/00; B29C44/34; B29C44/3415; Y; Y10; Y10T; Y10T428/00; Y10T428/249921; Y10T428/249953; Y10T428/249987; Y10T428/249991; Y10T428/249992
Claims Analysis
Total Claims: 16
Claim 1
Independent Claim
196 words
A PROCESS FOR FABRICATING A STRUCTURAL LAMINATE COMPRISING: BRINGING THE SURFACE OF A FIRST MOLD AND THE SURFACE OF A SECOND MOLD TO A PREDETERMINED TEMPERATURE; COVERING BOTH SURFACES WITH A GELLABLE, HEAT CURABLE LIQUID RESIN LAYER; INCREASING THE TEMPERATURE OF BOTH SURFACES TO BRING THE RESIN LAYERS THEREON TO A GELLED STATE; CONTROLLING THE TEMPERATURE OF BOTH SURFACES TO PREVENT A SUBSTANTIALLY COMPLETE CURING OF THE GELLED RESIN LAYERS; ADDING A FOAMABLE LIQUID RESIN DIRECTLY ONTO AT LEAST A PORTION OF THE EXPOSED SURFACE OF AT LEAST ONE OF THE GELLED RESIN LAYERS; CREATING A CLOSED CHAMBER BY MOVING THE COVERED SURFACES INTO AN OPPOSING POSITION WHEREBY THE SURFACES ARE SPACED APART A PREDETERMINED DISTANCE AND THE EDGES THEREOF ARE IN AN ABUTTING RELATIONSHIP; CREATING A PRESSURIZED ENVIRONMENT WITHIN THE CLOSED CHAMBER BY ALLOWING THE FOAMABLE LIQUID RESIN TO EXPAND IN SAID CHAMBER WHILE IN DIRECT CONTACT WITH THE RESIN LAYERS WITH THE PRESSURE EFFECTING AN IMPROVED BOND AT THE INTERFACE BETWEEN THE EXPANDED FOAMABLE LIQUID RESIN AND THE GELLED RESIN LAYERS AND FORCING THE EXTERIOR SURFACE OF THE LAMINATE INTO A DEFINED CONFIGURATION; AND, CURING THE GELLED RESIN LAYERS AND THE EXPANDED FOAMABLE RESIN.
Claim 2
Dependent Claim
196 words
A PROCESS FOR FABRICATING A STRUCTURAL LAMINATE COMPRISING: BRINGING THE SURFACE OF A FIRST MOLD AND THE SURFACE OF A SECOND MOLD TO A PREDETERMINED TEMPERATURE; COVERING BOTH SURFACES WITH A GELLABLE, HEAT CURABLE LIQUID RESIN LAYER; INCREASING THE TEMPERATURE OF BOTH SURFACES TO BRING THE RESIN LAYERS THEREON TO A GELLED STATE; CONTROLLING THE TEMPERATURE OF BOTH SURFACES TO PREVENT A SUBSTANTIALLY COMPLETE CURING OF THE GELLED RESIN LAYERS; ADDING A FOAMABLE LIQUID RESIN DIRECTLY ONTO AT LEAST A PORTION OF THE EXPOSED SURFACE OF AT LEAST ONE OF THE GELLED RESIN LAYERS; CREATING A CLOSED CHAMBER BY MOVING THE COVERED SURFACES INTO AN OPPOSING POSITION WHEREBY THE SURFACES ARE SPACED APART A PREDETERMINED DISTANCE AND THE EDGES THEREOF ARE IN AN ABUTTING RELATIONSHIP; CREATING A PRESSURIZED ENVIRONMENT WITHIN THE CLOSED CHAMBER BY ALLOWING THE FOAMABLE LIQUID RESIN TO EXPAND IN SAID CHAMBER WHILE IN DIRECT CONTACT WITH THE RESIN LAYERS WITH THE PRESSURE EFFECTING AN IMPROVED BOND AT THE INTERFACE BETWEEN THE EXPANDED FOAMABLE LIQUID RESIN AND THE GELLED RESIN LAYERS AND FORCING THE EXTERIOR SURFACE OF THE LAMINATE INTO A DEFINED CONFIGURATION; AND, CURING THE GELLED RESIN LAYERS AND THE EXPANDED FOAMABLE RESIN.
Claim 3
Dependent Claim
22 words
The process of claim 1 wherein said gellable, heat-curable liquid resin layers are layers of polyester resin containing a strength-reinforcing material therein.
Claim 4
Dependent Claim
12 words
The process of claim 2 wherein said reinforcing material comprises glass fibers.
Claim 5
Dependent Claim
24 words
The process of claim 1 wherein said placing a gellable, heat-curable liquid resin step is carried out by spraying said gellable, heat-curable liquid resin.
Claim 6
Dependent Claim
15 words
The process of claim 1 wherein said foamable liquid resin forms a rigid urethane foam.
Claim 7
Dependent Claim
24 words
The process of claim 5 wherein said foamable liquid resin is partially but completely expanded at the time it is placed on said layer.
Claim 8
Dependent Claim
18 words
The process of claim 1 wherein at least a portion of said mold surface has a textured surface.
Claim 9
Dependent Claim
108 words
A process for fabricating a structural laminate comprising: covering a surface of a mold with a layer of gellable heat curable liquid resin; controlling the temperature of the mold surface to effect a predetermined transfer of heat between the mold surface and the liquid resin to bring the resin layer to a gelled state; reducing the temperature of the mold surface to retard the curing of the resin layer; adding a foamable liquid resin directly onto at least a portion of the exposed surface of the gelled resin layer and allowing the foamable liqud resin to expand; and curing the gelled resin layer and the expanded foamable resin.
Claim 10
Dependent Claim
108 words
A process for fabricating a structural laminate comprising: covering a surface of a mold with a layer of gellable heat curable liquid resin; controlling the temperature of the mold surface to effect a predetermined transfer of heat between the mold surface and the liquid resin to bring the resin layer to a gelled state; reducing the temperature of the mold surface to retard the curing of the resin layer; adding a foamable liquid resin directly onto at least a portion of the exposed surface of the gelled resin layer and allowing the foamable liqud resin to expand; and curing the gelled resin layer and the expanded foamable resin.
Claim 11
Dependent Claim
101 words
A process for fabricating a structural laminate comprising: bringing the surface of a mold to a predetermined temperature; covering the mold surface with a layer of heat gellable curable liquid resin; increasing the temperature of the mold surface to bring the liquid resin to a gelled state; reducing the temperature of the mold surface to retard the curing of the resin layer; adding a foamable liquid resin directly onto at least a portion of the exposed surface of the gelled resin layer and allowing the foamable liquid resin to expand; and curing the gelled resin layer and the expanded foamable resin.
Claim 12
Dependent Claim
101 words
A process for fabricating a structural laminate comprising: bringing the surface of a mold to a predetermined temperature; covering the mold surface with a layer of heat gellable curable liquid resin; increasing the temperature of the mold surface to bring the liquid resin to a gelled state; reducing the temperature of the mold surface to retard the curing of the resin layer; adding a foamable liquid resin directly onto at least a portion of the exposed surface of the gelled resin layer and allowing the foamable liquid resin to expand; and curing the gelled resin layer and the expanded foamable resin.
Claim 13
Dependent Claim
28 words
The process of claim 9 wherein the temperature of the mold surface is increased during the step of curing the gelled resin layer and the expanded foamable resin.
Claim 14
Dependent Claim
28 words
The process of claim 10 wherein the temperature of the mold surface is reduced after the step of curing the gelled resin layer and the expanded foamable resin.
Claim 15
Dependent Claim
37 words
The process of claim 6 wherein said partial expansion is accomplished by the addition of a low boiling halocarbon to said foamable liquid resin prior to placing said foamable liquid resin on a surface of said layers.
Claim 16
Dependent Claim
19 words
The process of claim 12 wherein when said foamable liquid resin is polyurethane said low boiling halocarbon is dichlorodifluoromethane.
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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) | 1978-01-06 | 1978-07-08 | 1979-01-07 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1982-01-06 | 1982-07-08 | 1983-01-07 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1986-01-06 | 1986-07-08 | 1987-01-07 | $7700.00 | Window Closed / Lapsed |