Adhesive bonding and miscellaneous chemical manufacture – Methods – Surface bonding and/or assembly therefor
Patent
1996-09-09
1998-03-10
Aftergut, Jeff H.
Adhesive bonding and miscellaneous chemical manufacture
Methods
Surface bonding and/or assembly therefor
156324, 156500, 156538, 156547, 156549, 156550, 427138, 427139, 427186, B32B 3100, B32B 3106, B32B 3108, B32B 3112
Patent
active
057257167
DESCRIPTION:
BRIEF SUMMARY
This invention relates to a novel continuous structure forming method and apparatus and to a new continuous structure produced thereby.
The inventions of the applicant's early patents listed above provide novel methods and apparatus to produce at a job site structures such as liners and pipe for the collection, storage and/or distribution of water and other liquids. The apparatus employed, which normally is transported to a job site, is complex and sophisticated requiring major capital investment.
The invention of applicant's latest application listed above, Ser. No. 870,927, filed Apr. 20, 1992, provides a novel method and structure that can be produced with a minimum of machinery at the job site. Thus, the structure and method of the invention can be employed efficiently and economically for patching and for small jobs even at remote locations.
While the applicant's earlier patents mention the use of recycled or waste materials as additives in structures, most efforts of others have been directed to separating the waste into its primary components and the combining of similar materials into the same product again. Various governmental and private agencies have provided incentives such as subsidies and grants in attempting to develop commercially feasible products and procedures for recycling waste. To date, only very few waste materials are routinely recycled on an economical basis.
The present invention provides a novel method, apparatus and structure which overcome the shortcomings of previous expedients. In addition, the method, apparatus and structure provide features and advantages not found in earlier technology.
The structure produced with the method and apparatus of the invention can include major proportions of recycled, waste or other materials which are readily available at a job site. These structures are of high quality and may exhibit properties not usually found in products formed with conventional ingredients.
The method of the present invention may be conducted by individuals with only limited mechanical skills and experience. Structures can be produced by such individuals safely and efficiently without supervision. The configuration and composition of the structure can be changed easily.
The method of the invention can be modified to form a variety of different structures. Variations in physical dimensions, composition and surface appearance, etc. can be achieved. Even with such changes, uniform high quality can be maintained without difficulty.
A novel method of the present invention for forming a continuous structure includes the steps of preselecting a liquid reactive resin forming material, a particulate solid additive material, a porous blanket and a thin fibrous sheet. The additive particles are mixed with the liquid resin forming material substantially continuously in a proportion significantly greater than that of the liquid resin forming material. Substantially all of the additive particles are encapsulated with the resin forming material to a preselected thickness.
A pool of the resulting mixture is formed between the porous blanket and the fibrous sheet. The blanket and the sheet are advanced at a rate sufficient to create movement of the additive particles within the pool and maintain the additive particles in suspension. Part of the liquid resin forming material is migrated through the blanket and the sheet substantially uniformly prior to gelling of the liquid resin forming material to form a continuous resin matrix within the structure.
The additive particles advantageously are mixed with the liquid resin forming material as it is passed continuously through anelongated mixing chamber. Preferably, the mixture is deposited between the blanket and the sheet in a reciprocating motion across the width of the materials. The pool of the mixture advantageously is confined between the blanket and the sheet with an elongated barrier positioned close thereto and substantially transverse to the direction of the advance. The fibrous sheet which advantageously is a spot bonded fibrous
REFERENCES:
patent: 2193472 (1940-03-01), Bothe et al.
patent: 2648619 (1953-08-01), Alderfer
patent: 3245329 (1966-04-01), Nagin et al.
patent: 4955760 (1990-09-01), Payne
patent: 5496434 (1996-03-01), Payne
Aftergut Jeff H.
Urban Arthur L.
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