Adhesive bonding and miscellaneous chemical manufacture – Methods – Surface bonding and/or assembly therefor
Reexamination Certificate
1998-02-27
2001-05-01
Watkins, III, William P. (Department: 1772)
Adhesive bonding and miscellaneous chemical manufacture
Methods
Surface bonding and/or assembly therefor
C156S213000, C156S214000, C156S215000, C156S216000, C156S285000, C156S286000, C156S282000, C362S382000, C428S073000, C428S099000, C428S076000, C428S071000, C428S074000, C428S068000, C428S131000, C428S137000, C428S138000
Reexamination Certificate
active
06224706
ABSTRACT:
The present invention relates to fabrication of inherently strong articles from inherently weak materials and is directed to a modification to, or improvement in, the subject matter disclosed in International Patent Application No. PCT/AU95/00100 assigned to the present applicants which is unpublished as of the priority date of this application. The contents of that international patent application are hereby incorporated into the present specification by cross-reference.
BACKGROUND INFORMATION
The disclosure of the above-mentioned PCT application is essentially concerned with the fabrication of structurally strong articles from an inherently weak material such as expanded polystyrene (EPS) which is coated with one or more layers of a thermoplastic sheet material such as APET (amorphous polyethylene terphalate). By themselves such materials have a negligible strength, however, by carrying out the processes described in the above-mentioned PCT specification, a structural article of very substantial strength can be fabricated. Some examples of various structural articles are disclosed in that PCT specification.
The object of the present invention is to further improve upon the above-mentioned disclosures, in particular by the provision of a number of interior members each of either inherently fluid permeable or perforated to become fluid permeable. The interior members are provided, for example for the purposes of decoration and/or additional strength and/or their individual properties, and are sandwiched or encapsulated by the heat deformable outer layer(s).
SUMMARY OF THE INVENTION
In accordance with a first aspect of the present invention there is disclosed a method of forming a layered structural article having load bearing capabilities formed from a plurality of shape defining interior members and at least one external skin, each of said plurality of shape defining interior members being not inherently load bearing and being at least partially fluid permeable, said method comprising the steps of:
(1) locating said plurality of members one above the other to form a stack;
(2) heating a thermoplastics sheet intended to form said external skin;
(3) moving said heated sheet relative to said stack to bring the heated sheet into a position overlying said stack;
(4) applying a fluid pressure differential between that side of said sheet remote from said stack and that side of said stack remote from said sheet, to compress the members of said stack and conform said sheet to the shape of said compressed stack and mutually engage said sheet and compressed stack, air initially trapped between said stack and sheet and within said stack passing through said stack; and
(5) cooling said thermoplastics sheet, or allowing same to cool, whereupon tensional forces arise in said sheet in all directions.
In accordance with a second aspect of the present invention there is disclosed a layered structural article having load bearing capabilities formed from a plurality of shape defining interior members located one above the other to form a stack, each of said plurality of members being not inherently load bearing and being at least partially fluid permeable, said stack being at least partially encapsulated by at least one sheet of thermoplastic material which compresses said members of said stack together and conforms to the compressed shape of said stack.
REFERENCES:
patent: 3929536 (1975-12-01), Maughan
patent: 4024309 (1977-05-01), Pender
patent: 4337116 (1982-06-01), Foster et al.
patent: 4880588 (1989-11-01), Brault et al.
patent: 4980214 (1990-12-01), Charriere
patent: 5051144 (1991-09-01), Kistner
patent: 5201981 (1993-04-01), Whiteside
patent: 5252164 (1993-10-01), Mills
patent: 5346571 (1994-09-01), Condon et al.
patent: 5833796 (1998-11-01), Matich
patent: 68979 (1995-02-01), None
patent: 361823 (1990-04-01), None
patent: 389456 (1990-09-01), None
patent: 2103468 (1983-02-01), None
patent: WO9117040 (1991-11-01), None
patent: WO9323236 (1993-11-01), None
patent: WO9523682 (1995-09-01), None
Armacel Pty. Limited
Leydig , Voit & Mayer, Ltd.
Watkins III William P.
LandOfFree
Method of making a layered structural articles does not yet have a rating. At this time, there are no reviews or comments for this patent.
If you have personal experience with Method of making a layered structural articles, we encourage you to share that experience with our LandOfFree.com community. Your opinion is very important and Method of making a layered structural articles will most certainly appreciate the feedback.
Profile ID: LFUS-PAI-O-2556728