Polymeric and fibrous laminate and methods of forming and using same
First Claim
1. A method of forming a laminate sheet having high strength and enhanced fastener retention so that a threaded fastener is retained within the laminate sheet and is not easily removed from the laminate sheet when an outward force is applied thereto, the method comprising:
- heating a polyolefin blend resulting in a gelatin mass;
positioning a first bonding veil in a press;
positioning the gelatin mass in the press;
positioning a second bonding veil in the press; and
compressing the gelatin mass between the first and second bonding veils within the press to imbed the gelatin mass within the first and second bonding veils so that the first and second bonding veils abuttingly contact and substantially adhere to the gelatin mass and so that the gelatin mass fills the press and penetrates a short distance into the first and second bonding veils.
1 Assignment
0 Petitions
Accused Products
Abstract
A polymeric and fibrous laminate is preferably formed of a polyolefin having fillers, such as ground glass, shredded cloth, polypropylene, scrap urethane, or other materials which are heated, mixed, and made into a high viscosity gelatin mass. The polyolefin is combined with a fibrous material in the form of a veil of some type such as Trevira (or other synthetic material), glass (such as fiberglass or other mineral origin materials), or natural fibers, or combinations thereof. The laminate advantageously enhances retainment of fasteners when inserted into the laminate and superior adhesion properties to bond to other substrates that would normally not bond to recycled or virgin polyolefins.
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Citations
56 Claims
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1. A method of forming a laminate sheet having high strength and enhanced fastener retention so that a threaded fastener is retained within the laminate sheet and is not easily removed from the laminate sheet when an outward force is applied thereto, the method comprising:
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heating a polyolefin blend resulting in a gelatin mass;
positioning a first bonding veil in a press;
positioning the gelatin mass in the press;
positioning a second bonding veil in the press; and
compressing the gelatin mass between the first and second bonding veils within the press to imbed the gelatin mass within the first and second bonding veils so that the first and second bonding veils abuttingly contact and substantially adhere to the gelatin mass and so that the gelatin mass fills the press and penetrates a short distance into the first and second bonding veils. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10)
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11. A method of forming a laminate sheet having high strength and enhanced fastener retention so that a threaded fastener is retained within the laminate sheet and is not easily removed from the laminate sheet when an outward force is applied thereto, the method comprising:
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positioning a layer of a polyolefin material on a surface;
overlying and positioning an adhesive polymer emulsion upon an upper surface of the layer of polyolefin material;
heating the adhesive polymer emulsion and the layer of polyolefin material to thereby form a heated adhesive polymer emulsion;
positioning a layer of a bonding veil upon the heated adhesive polymer emulsion; and
pressing the layers of the polyolefin material and the bonding veil in a press so that the materials are compacted to thereby increase the density of the materials and to enhance adherence of the bonding veil to the polyolefin material.
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12. A method of retaining a threaded fastener within a laminate sheet having high strength and enhanced fastener retention, the method comprising the steps of:
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providing a laminate sheet having a density in the range of about 35 pounds per cubic foot to about 65 pounds per cubic foot; and
positioning the threaded fastener therein so that the threaded fastener is retained within the laminate sheet and is not easily removed when an outward force is applied. - View Dependent Claims (13, 14, 15, 16, 17, 18)
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19. A method of retaining enhanced fastener retention properties in a laminate sheet comprising the steps of:
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providing a laminate sheet, the laminate sheet comprising a polyolefin blend and a bonding veil;
twisting a threaded fastener into the laminate sheet, so that the fastener becomes engaged within the laminate sheet; and
removing the threaded fastener from the laminate sheet so that the laminate sheet retains its enhanced fastener retention properties.
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20. A method of forming a laminate sheet having high strength and enhanced fastener retention so that a threaded fastener is retained within the laminate sheet and is not easily removed from the laminate sheet when an outward force is applied thereto, the method comprising:
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heating a non-adhesive material resulting in a melted non-adhesive material;
positioning a first bonding veil in a press;
positioning the melted non-adhesive material in the press;
positioning a second bonding veil in the press; and
compressing the melted non-adhesive material between the first and second bonding veils within the press to imbed the melted non-adhesive material within the first and second bonding veils so that the first and second bonding veils abuttingly contact and substantially adhere to the melted non-adhesive material. - View Dependent Claims (21)
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22. A method of retaining a threaded fastener within a laminate sheet having high strength and enhanced fastener retention, the method comprising the steps of:
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providing a laminate sheet having a density in the range of about 35 pounds per cubic foot to about 65 pounds per cubic foot, the laminate sheet comprising a non-adhesive material and a bonding veil, the bonding veil contacting and substantially adhering to the non-adhesive material; and
positioning a threaded fastener therein so that the threaded fastener is retained within the laminate sheet and is not easily removed when an outward force is applied. - View Dependent Claims (23, 24, 25)
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26. A combination fastener and laminate sheet having high strength and enhanced fastener retention so that the fastener is not easily removed from the laminate sheet when an outward force is applied thereto, the combination comprising:
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a laminate sheet having a polyolefin blend and a bonding veil, the bonding veil contacting and substantially adhering to the polyolefin blend; and
a fastener having threaded portions positioned within the laminate sheet so that the threaded portions are retained in the laminate sheet and are not easily removed when an outward force is applied thereto. - View Dependent Claims (27, 28, 29, 30, 31, 32, 33, 34)
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35. A laminate sheet having high strength and enhanced fastener retention so that when a fastener, having threaded portions, is positioned within the laminate sheet, the fastener is not easily removed from the laminate sheet when an outward force is applied thereto, the laminate sheet comprising:
- a polyolefin blend and a bonding veil, the bonding veil contacting and substantially adhering to the polyolefin blend.
- View Dependent Claims (36, 37, 38, 39, 40, 41, 42)
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43. A combination fastener and laminate sheet having high strength and enhanced fastener retention so that the fastener is not easily removed from the laminate sheet when an outward force is applied thereto, the combination comprising:
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a laminate sheet having a polyolefin blend, a glass material, and a bonding veil, the laminate sheet having a density in the range of about 35 pounds per cubic foot to about 65 pounds per cubic foot, the bonding veil contacting and substantially adhering to the polyolefin blend and the glass material; and
a fastener having threaded portions positioned within the laminate sheet so that the threaded portions are retained in the laminate sheet and are not easily removed when an outward force is applied thereto. - View Dependent Claims (44, 45, 46, 47, 48)
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49. A laminate sheet having high strength and enhanced fastener retention so that when a fastener, having threaded portions, is positioned within the laminate sheet, the fastener is not easily removed from the laminate sheet when an outward force is applied thereto, the laminate sheet having a density in the range of about 35 pounds per cubic foot to about 65 pounds per cubic foot, the laminate sheet comprising:
- a polyolefin blend, a glass material, and a bonding veil, the bonding veil contacting and substantially adhering to the polyolefin blend and the glass material.
- View Dependent Claims (50, 51, 52)
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53. A laminate sheet having high strength and enhanced fastener retention so that when a fastener, having threaded portions, is positioned with the laminate sheet, the fastener is not easily removed from the laminate sheet when an outward force is applied thereto, the laminate sheet comprising:
- a bonding veil and a non-adhesive material, the bonding veil contacting and substantially adhering to the non-adhesive material.
- View Dependent Claims (54)
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55. A combination fastener and laminate sheet having high strength and enhanced fastener retention so that the fastener is not easily removed from the laminate sheet when an outward force is applied thereto, the combination comprising:
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a laminate sheet having a non-adhesive material and a bonding veil, the bonding veil contacting and substantially adhering to the non-adhesive material; and
a fastener having threaded portions positioned within the laminate sheet so that the threaded portions are retained in the laminate sheet and are not easily removed when an outward force is applied thereto. - View Dependent Claims (56)
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Specification