Fabric (woven – knitted – or nonwoven textile or cloth – etc.) – Woven fabric – Including a foamed layer or component
Reexamination Certificate
1998-09-08
2001-04-10
Jones, Deborah (Department: 1775)
Fabric (woven, knitted, or nonwoven textile or cloth, etc.)
Woven fabric
Including a foamed layer or component
C442S224000, C442S269000, C442S283000, C428S086000, C428S119000, C428S219000
Reexamination Certificate
active
06214753
ABSTRACT:
BACKGROUND OF THE INVENTION
This invention relates to a layered composite construction material which can be shaped and formed for use throughout the marine, transportation, and building industries and which essentially reduces the reliance on wood and metal for certain products which are traditionally made out of such materials. This construction material has been proven to be stronger than plywood and other types of wood and is waterproof and quite resistant to expansion due to changes in the temperature.
For years, certain types of building materials traditionally have been made out of wood, plastics, steel or metal, and cement can be replaced with the present invention which also can be used in other industries. The prior art illustrates the use of other materials which can be used as building materials and other useful products.
One known prior art include PREFAB PANELS AND SYSTEM FOR BUILDING CONSTRUCTION, U.S. Pat. No. 4,154,030, issued on May 15, 1979 and invented by Rafael R. Hugue, which comprises a plurality of columns and beams adapted to one another to form a rigid load-bearing structural frame and a plurality of inexpensive lightweight non-load-bearing panels spanning the frame components, the panels comprising a main portion of molded waste material and a resinous binder forming a polymer and the minor portion of open cell material in spaced parallel cylindrical shafts embedded within the main portion of molded waste material.
Another known prior art includes A WALL MATERIAL AND METHOD OF PREPARING A WALL MATERIAL OF SOILS AND VEGETABLE MATERIALS, U.S. Pat. No. 4,947,611, issued on Aug. 14, 1990 and invented by Michlo Otsuka and which comprises pulverized straw, pulverized chaff and pulverized palm material all of which are mixed with a substantially equal quantity of clay and added to a fibrous material. This mixture is poured into a form and then dried.
Another known prior art includes a HIGHLY FILLED SUBSTANTIALLY SOLID POLYURETHANE, UREA AND ISOCYANNURATE COMPOSITES FOR INDOOR AND OUTDOOR APPLICATION FOR LOAD BEARING, STRUCTURAL AND DECORATIVE PRODUCTS, U.S. Pat. No. 5,053,274, issued on Oct. 1, 1991 and invented by Arthur E. Jonas and which comprises a mixture of solid polyurethane, polyisocyanurate and/or polyurea binder with a preponderance of a solid or liquid filler.
Another known prior art includes REINFORCED FOAM CORES AND METHOD AND APPARATUS OF PRODUCTION, U.S. Pat. No. 5,589,243, issued on Dec. 31, 1996 and invented by Stephen W. Day and which comprises rigid foam boards and alternating fibrous web sheets adhered to form core panels or billets wherein the web sheets have porous openings through which resin is filled.
Another known prior art is a METHOD OF PRODUCTION OF REINFORCED FOAM CORES, U.S. Pat. No. 5,462,623, issued on Oct. 31, 1995 and invented by Stephen W. Day and which comprises rigid foam insulation boards and thin flexible fibrous sheets or strips stacked in alternating layers with adhesive between the layers and the stack being compressed while the adhesive cures to form a rectangular core panel or billet.
None of the prior art discloses or suggests a perfectly layered construction material which comprises many differently constructed and/or configured fiberglass layers which are bonded together with a rigid foam to essentially form highly useable construction material which serves as a replacement of many products traditionally made of wood, plastics, or metal.
SUMMARY OF THE INVENTION
The present invention comprises a pair of distinct outer layers of material essentially comprising continuous strand fiberglass mats which are separated by a pair of distinct intermediate sandwich layers of material each of which is adjacent to a respective one of the outer layers of material and essentially comprises eighteen ounce woven roving fiberglass mat and which is further separated by at least one distinct internal layer of material which is sandwiched between the intermediate sandwich layers and which comprises a layer of spun fiberglass blanket with all the layers being bonded with a foam which is dispersed throughout the layers. This construction material can be used to replace wood products such as plywood and even metal products and cement.
One objective of the present invention is to provide a layered composite construction material which is ultra lightweight as compared to similarly sized plywood or metal structural components.
Another objective of the present invention is to provide a layered composite construction material which is waterproof and resistant to salt and chemicals.
Also, another objective of the present invention is to provide a layered composite construction material which is stronger than that of similar sized plywood.
Further, another objective of the present invention is to provide a layered composite construction material which has a higher insulation value of approximately 14 times greater than that of plywood.
Yet, another objective of the present invention is to provide a layered composite construction material which has a closed cell structure for eliminating bacterial penetration and contamination.
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patent: 4927684 (1990-05-01), Asensio et al.
patent: 4983442 (1991-01-01), Patel et al.
patent: 5667866 (1997-09-01), Reese, Jr.
patent: 5741574 (1998-04-01), Boyce et al.
Althoff Arnold G.
Brenot Stephen E.
Schneider Randy M.
Jones Deborah
Lingbeck David A.
Savage Jason
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