Polymeric and fibrous laminate and methods of forming and using same

• US 20030143366A1
• Filed: 01/10/2003
• Published: 07/31/2003
• Est. Priority Date: 01/17/2002
• Status: Abandoned Application

• Current Assignee: E.L.F. Products, Inc.
• Original Assignee: E.L.F. Products, Inc.
• Inventors: Foley, Jerry
• Application Number:
  US10/340,450
• Publication Number:
  US 20030143366A1
• Time in Patent Office: Days
• US Class Current: 428/67
• CPC Class Codes: B29B 17/0042 for shaping parts, e.g. multilayered parts with at least one layer containing regenerated plastic
• CPC Class Codes: B29C 70/467 and impregnating the reinforcements during mould closing B29C70/465 takes precedence
• CPC Class Codes: B29K 2023/065 HDPE, i.e. high density polyethylene
• CPC Class Codes: B29K 2023/083 EVA, i.e. ethylene vinyl acetate copolymer
• CPC Class Codes: B29K 2023/12 PP, i.e. polypropylene
• CPC Class Codes: B29K 2105/16 Fillers
• CPC Class Codes: B29K 2423/12 PP, i.e. polypropylene
• CPC Class Codes: B32B 2305/70 Scrap or recycled material
• CPC Class Codes: B32B 37/24 with at least one layer not being coherent before laminating, e.g. made up from granular material sprinkled onto a substrate B32B37/15 takes precedence
• CPC Class Codes: Y02W 30/62 Plastics recycling; Rubber recycling
• CPC Class Codes: Y10T 428/22 Nonparticulate element embedded or inlaid in substrate and visible

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.

Claims

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.

2. A method as defined in claim 1, further comprising cooling the laminate sheet, and wherein the step of heating the polyolefin blend includes heating the polyolefin blend to a temperature in the range of about 300°

F. to about 425°

F.

3. A method as defined in claim 1, wherein the step of heating the polyolefin blend includes utilizing a polyolefin selected from the group consisting of polyethylene and polypropylene and other polyolefin groups and combinations thereof.

4. A method as defined in claim 3, wherein the laminate sheet has a density in the range of about 35 pounds per cubic foot to about 65 pounds per cubic foot.

5. A method as defined in claim 4, wherein the laminate sheet has a density in the range of about 40 pounds per cubic foot to about 63 pounds per cubic foot.

6. A method as defined in claim 1, wherein the steps of positioning a first and a second bonding veil include utilizing a bonding veil selected from the group consisting of a synthetic material, a glass material, urethane, natural fibers, and combinations thereof.

7. A method as defined in claim 1, wherein the step of heating a polyolefin blend includes utilizing a polyolefin blend comprising a polyolefin and a filler selected from the group consisting of glass, natural fibers, shredded cloth, urethane, various powders for antimicrobial and flame retardant properties, and combinations thereof.

8. A method as defined in claim 7, wherein the step of heating a polyolefin blend includes utilizing a polyolefin comprising a high density, recycled polyethylene, the high density being in the range of about 50 pounds per cubic foot to about 55 pounds per cubic foot, and the recycled polyethylene comprising a scrap polyethylene and at least one filled selected from the group consisting of glass, shredded cloth, polypropylene, scrap urethane with glass, scrap urethane without glass, and combinations thereof.

9. A method as defined in claim 1, further comprising positioning at least one layer of a urethane material in the press before compressing the gelatin mass between the first and second bonding veils.

10. A method as defined in claim 1, further comprising positioning at least one layer of a glass material in the press before compressing the gelatin mass between the first and second bonding veils.

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:

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.

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:

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.

13. A method as defined in claim 12, wherein the step of providing a laminate sheet having a density in the range of about 35 pounds per cubic foot to about 65 pounds per cubic foot includes utilizing a laminate sheet having a density in the range of about 40 pounds per cubic foot to about 63 pounds per cubic foot.

14. A method as defined in claim 12, further comprising positioning another layer of material between the laminate sheet and the threaded fastener.

15. A method as defined in claim 12, wherein the step of providing a laminate sheet includes utilizing a laminate sheet comprising a polyolefin blend and a bonding veil, the bonding veil contacting and substantially adhering to the polyolefin blend.

16. A method as defined in claim 15, wherein the step of utilizing a laminate sheet comprising a polyolefin blend includes utilizing a polyolefin blend comprising a polyolefin and a filler selected from the group consisting of glass, natural fibers, shredded cloth, urethane, various powders for antimicrobial and flame retardant properties, and combinations thereof.

17. A method as defined in claim 15, wherein the step of providing a laminate sheet includes utilizing a laminate sheet comprising a polyolefin, the polyolefin comprising a high density, recycled polypropylene, wherein the high density is in the range of about 50 pounds per cubic foot to about 55 pounds per cubic foot, and the recycled polypropylene comprising a scrap polyethylene and at least one filled selected from the group consisting of glass, shredded cloth, polypropylene, scrap urethane with glass, scrap urethane without glass, and combinations thereof.

18. A method as defined in claim 12, further comprising twisting the threaded fastener within a location so that the threaded fastener remains tightened when an outward force is applied.

19. A method of retaining enhanced fastener retention properties in a laminate sheet comprising the steps of:

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.

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:

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.

21. A method as defined in claim 20, further comprising cooling the laminate sheet, and wherein heating a non-adhesive material includes utilizing a non-adhesive material selected from the group consisting of plastics, resins, a glass material, and combinations thereof.

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:

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.

23. A method as defined in claim 22, wherein the step of providing a laminate sheet having a density in the range of about 35 pounds per cubic foot to about 65 pounds per cubic foot includes utilizing a laminate sheet having a density in the range of about 40 pounds per cubic foot to about 63 pounds per cubic foot.

24. A method as defined in claim 22, wherein the step of providing a laminate sheet comprising a non-adhesive material includes utilizing a non-adhesive material selected from the group consisting of plastics, resins, a glass material, and combinations thereof.

25. A method as defined in claim 22, further comprising positioning another layer of material between the laminate sheet and the threaded fastener.

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:

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.

27. A combination as defined in claim 26, wherein the polyolefin blend comprises a polyolefin and a filler selected from the group consisting of glass, natural fibers, shredded cloth, urethane, various powders for antimicrobial and flame retardant properties, and combinations thereof.

28. A combination as defined in claim 27, wherein the polyolefin comprises a high density, recycled polyethylene, wherein the high density is in the range of about 50 pounds per cubic foot to about 55 pounds per cubic foot, and the recycled polyethylene comprising a scrap polyethylene and at least one filled selected from the group consisting of glass, shredded cloth, polypropylene, scrap urethane with glass, scrap urethane without glass, and combinations thereof.

29. A combination as defined in claim 28, wherein the laminate sheet has a density in the range of about 35 pounds per cubic foot to about 65 pounds per cubic foot.

30. A combination as defined in claim 27, wherein the laminate sheet has a density in the range of about 40 pounds per cubic foot to about 63 pounds per cubic foot.

31. A combination as defined in claim 27, wherein the polyolefin is selected from the group consisting of polyethylene and polypropylene.

32. A combination as defined in claim 27, wherein the laminate sheet further comprises a glass material, the bonding veil contacting and substantially adhering to the polyolefin blend and the glass material.

33. A combination as defined in claim 27, wherein the laminate sheet further comprises a urethane material, the bonding veil contacting and substantially adhering to the polyolefin blend and the urethane material.

34. A combination as defined in claim 27, further including a layer of material between an outer surface of the laminate sheet and the fastener, wherein the fastener is not easily removed from the layer of material.

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.

36. A laminate sheet as defined in claim 35, wherein the polyolefin blend comprises a polyolefin and a filler selected from the group consisting of glass, natural fibers, shredded cloth, urethane, various powders for antimicrobial and flame retardant properties, and combinations thereof.

37. A laminate sheet as defined in claim 36, wherein the polyolefin comprises a high density, recycled polyethylene, wherein the high density is in the range of about 50 pounds per cubic foot to about 55 pounds per cubic foot, and the recycled polyethylene comprising a scrap polyethylene and at least one filled selected from the group consisting of glass, shredded cloth, polypropylene, scrap urethane with glass, scrap urethane without glass, and combinations thereof.

38. A laminate sheet as defined in claim 36, wherein the laminate sheet has a density in the range of about 35 pounds per cubic foot to about 65 pounds per cubic foot.

39. A laminate sheet as defined in claim 38, wherein the laminate sheet has a density in the range of about 40 pounds per cubic foot to about 63 pounds per cubic foot.

40. A laminate sheet as defined in claim 36, wherein the polyolefin is selected from the group consisting of polyethylene and polypropylene.

41. A laminate sheet as defined in claim 36, further comprising a glass material, the bonding veil contacting and substantially adhering to the polyolefin blend and the glass material.

42. A laminate sheet as defined in claim 36, further comprising a urethane material, the bonding veil contacting and substantially adhering to the polyolefin blend and the urethane material.

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:

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.

44. A combination as defined in claim 43, wherein the laminate sheet has a density in the range of about 40 pounds per cubic foot to about 63 pounds per cubic foot.

45. A combination as defined in claim 43, wherein the polyolefin blend comprises a polyolefin and a filler selected from the group consisting of glass, natural fibers, shredded cloth, urethane, various powders for antimicrobial and flame retardant properties, and combinations thereof.

46. A combination as defined in claim 43, wherein the polyolefin blend comprises a high density, recycled polyethylene, wherein the high density is in the range of about 50 pounds per cubic foot to about 55 pounds per cubic foot, and the recycled polyethylene comprising a scrap polyethylene and at least one filled selected from the group consisting of glass, shredded cloth, polypropylene, scrap urethane with glass, scrap urethane without glass, natural fibers, and combinations thereof.

47. A combination as defined in claim 43, further including a layer of material between an outer surface of the laminate sheet and the fastener, wherein the fastener is not easily removed from the layer of material.

48. A combination as defined in claim 43, wherein the laminate sheet further includes a layer of urethane material, the bonding veil contacting and substantially adhering to the polyolefin blend, the glass material, and the urethane material.

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.

50. A laminate sheet as defined in claim 49, wherein the laminate sheet has a density in the range of about 40 pounds per cubic foot to about 43 pounds per cubic foot.

51. A laminate sheet as defined in claim 49, wherein the polyolefin blend comprises a polyolefin and a filler selected from the group consisting of glass, natural fibers, shredded cloth, urethane, various powders for antimicrobial and flame retardant properties, and combinations thereof.

52. A laminate sheet as defined in claim 49, wherein the polyolefin blend comprises a high density, recycled polyethylene, wherein the high density is in the range of about 50 pounds per cubic foot to about 55 pounds per cubic foot, and the recycled polyethylene comprising a scrap polyethylene and at least one filled selected from the group consisting of glass, shredded cloth, polypropylene, scrap urethane with glass, scrap urethane without glass, natural fibers, and combinations thereof.

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.

54. A laminate sheet as defined in claim 53, wherein the non-adhesive material is selected from the group consisting of plastics, resins, a glass material, and combinations thereof.

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:

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.

56. A combination as defined in claim 55, wherein the non-adhesive material is selected from the group consisting of plastics, resins, a glass material, and combinations thereof.