Stock material or miscellaneous articles – Web or sheet containing structurally defined element or... – Composite having voids in a component
Reexamination Certificate
1998-12-09
2001-05-15
Gupta, Yogendra (Department: 1751)
Stock material or miscellaneous articles
Web or sheet containing structurally defined element or...
Composite having voids in a component
C428S304400, C428S308400, C428S309900, C428S311110, C428S314400, C428S315900, C428S317500, C428S317700, C428S317900, C428S320200, C428S322700, C428S325000, C428S326000
Reexamination Certificate
active
06231961
ABSTRACT:
FIELD OF THE INVENTION
The present invention relates to forming a product mixture from a foamable substance (e.g. a liquid binder), a dry binder and a number of particles and, particularly, where the product mixture is joined to one or more relatively rigid outer members.
BACKGROUND OF THE INVENTION
Packaging products are produced in many forms and sizes. Such packaging products are used to contain and support the contents thereof. Packing materials may be included within or may be part of the packaging products. Such packing materials can cushion, absorb or otherwise safeguard the contents against pressures or forces that the packaging product might be subject to during handing or use. A common packaging product is made from cardboard. On many occasions, it is necessary to provide additional packing materials in the cardboard box or construction to safeguard the contents of the box against forces that experiences as it is shipped. Often times it is not feasible to recycle or re-use these additional materials provided in such cardboard boxes because of their compositions.
It would be desirable to provide a packaging structure from materials that are not environmentally detrimental or burdensome, while keeping the packaging lightweight and of sufficient strength to support the contents. Such a packaging product should be readily and cost competitively fabricated and formed. Cardboard packaging is essentially a layered unit that has been suitably configured or folded to a desired size and shape. In view of this packaging construction, other applications can be identified for a layered structure that is lightweight and relatively strong. These applications might include doors, room dividers, panels generally and other enclosures or supports.
SUMMARY OF THE INVENTION
A layered structure is provided for a number of applications including packaging, such as cardboard packages or boxes. The layered structure includes a sub-combination of a product mixture that is combined with one or more outer members or layers. The product mixture includes a number of particles. These particles may be organic, fibrous particles such as made from paper or other cellulosic materials, although other particle components can be employed so long as they are relatively low density and have suitable strength. The mixture also includes a dry binder material or adhesive and a foamable substance, such as a liquid binder material or adhesive that may have a foaming agent. The dry binder must properly react with the liquid binder when they come in contact to produce a sufficiently strong adhesion or binding among the numerous particles, particularly after the product mixture cures or has dried. The dry binder preferably has greater adhesion characteristics or properties than does the liquid binder or other foamable substance. The dry binder is preferably added to the particles before being contacted by the liquid binder. Such contact also occurs after the combination of dry binder and particles are lofted or spread apart using a suitable force or pressure, such as supplied by pressurized air that carries the combination of the dry binder and particles along a hose. The liquid binder is provided or formed into a foamed adhesive. This can be accomplished, for example, by means of a foaming agent that is part of the liquid binder. The foaming occurs when the liquid adhesive is subject to a force or agitation such as that induced by pressurized air or some mechanical device or other machinery that causes the liquid adhesive to properly foam. In another embodiment, the foamable substance is primarily water. In the preferred embodiment, the foamed liquid binder that includes air pockets or air bubbles contacts the spread apart particles with dry binder before being output from the apparatus that is used in combining these materials. In so doing, the foamed liquid binder not only acts to maintain the separation among the particles to provide a lower density product but also reacts with the dry binder so that the reacted dry binder provides greater or stronger adhesion among the particles. Consequently, when the product mixture cures or drys and the foam dissipates, a stronger, low density product is produced as the particles remain spread from each other but in an interconnecting relationship due to the reacted dry binder, together with the liquid binder.
Preferably, the dry binder is less than about 50% by weight of the total weight of the liquid and dry binders. Preferably also, the reacted dry binder in the product mixture is located inwardly relative to, or in comparison with, the liquid binder. That is, a majority of the reacted dry binder is disposed inwardly of outer portions or surfaces of the product mixture, while the liquid binder has portions that are part of the outer surfaces of the product mixture when it is prepared for an outer layer to be joined to the product mixture. In that regard, the layered structure has at least a first outer member that is laminated or otherwise joined to outer surface portions of the product mixture. This joining together preferably is conducted before the product mixture of liquid and reacted dry binders, together with the particles, completely drys or cures, although the outer member could be joined to the product mixture after such drying and the dissipation of foam associated with the liquid binder. In one embodiment, the product mixture is sprayed or otherwise provided on an inner wall or surface of the first outer member. The product mixture can be provided in a form, size or shape appropriate for the outer member. For example, the product mixture can be uniformly or evenly displaced along the entire area of the inner surface or wall of the first outer member. A second outer member can then be placed over opposite portions of a second outer surface of the product mixture. The second outer member is preferably joined using at least some of the adhesive properties of the liquid binder of the product mixture that is found on this opposite outer surface of the product mixture.
It should be understood that the outer members can be formed from a variety of materials for a number of applications, with the usual common characteristic of such outer members being that each is relatively more rigid and has a greater density than the product mixture after it cures. The layered structure can be formed into a packaging product or material, such as the foldable parts of a cardboard box or package. It should be further understood that the product mixture can be used in other applications and with other types of materials joined thereto for such items or products as wall panels, panels generally, room dividers, doors, as well as various types of enclosure and/or support structures.
Based on the foregoing summary, a number of salient aspects of the present invention can be readily identified. A light, lower density layered structure is provided for a number of applications, such as boxes or other packaging materials, doors, portable or mobile enclosures, insulation constructions, dividers and panels. The present invention can utilize recyclable or environmentally advantageous materials as an intermediate layer between two relatively rigid pieces. The particles are made of a suitable material that, when formed into a desired shape, meet required weight or load bearing requirements but can also be re-cycled for producing the same or a similar product. The product mixture of the present invention can be readily adapted to strength requirements for a particular application by controlling the amount of particles and/or dry adhesive per unit volume. In that regard, the weight and density of the resulting layered structure can be regulated by using relatively fewer particles by weight, while still providing sufficient strength for the desired application. Furthermore, the reacted dry binder is located relatively inwardly of the product mixture to provide desired product strength. When utilized, the liquid foamed binder, on the other hand, is located outwardly thereof, such as the liquid binde
Boyer Charles
Gupta Yogendra
Sheridan Ross PC
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