Nonfoaming process for bonding foam to porous substrates

• US 3,228,820 A
• Filed: 05/14/1962
• Issued: 01/11/1966
• Est. Priority Date: 05/14/1962
• Status: Expired due to Term

• Current Assignee: Richard D. Samson
• Original Assignee: Richard D. Samson
• Inventors: Samson, Richard D.
• Application Number:
  US04/194,661
• Time in Patent Office: 1,338 Days
• US Class Current: 156/307.3
• CPC Class Codes: B29C 65/485 Multi-component adhesives, i.e. chemically curing as a result of the mixing of said multi-components
• CPC Class Codes: B29C 66/71 characterised by the composition of the plastics material of the parts to be joined welding bar compositions B29C65/125
• CPC Class Codes: B29C 66/727 being porous, e.g. foam
• CPC Class Codes: B29C 66/729 Textile or other fibrous material made from plastics
• CPC Class Codes: B29C 66/7294 Non woven mats, e.g. felt
• CPC Class Codes: B29K 2001/00 Use of cellulose, modified cellulose or cellulose derivatives, e.g. viscose, as moulding material
• CPC Class Codes: B29K 2027/06 PVC, i.e. polyvinylchloride
• CPC Class Codes: B29K 2027/08 PVDC, i.e. polyvinylidene chloride
• CPC Class Codes: B29K 2063/00 Use of EP, i.e. epoxy resins or derivatives thereof, as moulding material
• CPC Class Codes: B29K 2075/00 Use of PU, i.e. polyureas or polyurethanes or derivatives thereof, as moulding material
• CPC Class Codes: B32B 27/00 Layered products comprising a layer of synthetic resin fibrous or filamentary layer made of a synthetic resin B32B5/02; particulate layer made of a synthetic resin B32B5/16; foamed layer made of a synthetic resin B32B5/18
• CPC Class Codes: C08G 18/10 Prepolymer processes involving reaction of isocyanates or isothiocyanates with compounds having active hydrogen in a first reaction step
• CPC Class Codes: C08G 18/285 Nitrogen containing compounds
• CPC Class Codes: C09J 175/04 Polyurethanes
• CPC Class Codes: Y10T 428/249981 Plural void-containing components
• CPC Class Codes: Y10T 428/249985 Composition of adhesive or bonding component specified
• CPC Class Codes: Y10T 428/31554 Next to second layer of polyamidoester
• CPC Class Codes: Y10T 442/3366 Woven fabric is coated, impregnated, or autogenously bonded
• CPC Class Codes: Y10T 442/652 Nonwoven fabric is coated, impregnated, or autogenously bonded

Claims

1. A NONFOAMING PROCESS INTERRUPTABLE AT ANY POINT THEREIN AND SUBSEQUENTLY CONTINUABLE TO PROVIDE LAMINATES OF A PLURALITY OF LAYERS OF FOAM AND POROUS SUBSTRATES WITH CURED NONFOAMED URETHANE INTERLAYERS THEREBETWEEN COMPRISING (A) APPLYING FROM ABOUT 0.5 TO 4 OUNCES BY WEIGHT OF A LIQUID ADHESIVE COMPOSITION SO AS TO WET AT LEAST ONE OF EACH TWO CONTACT INTERFACILA SURFACES OF AT LEAST ONE LAYER OF EXTANT FOAM AND AT LEAST ONE POROUS SUBSTRATE LAYER PER SQUARE YARD OF CONTACT INTERFACIAL SURFACE, SAID ADHESIVE COMPOSITION COMPRISING A NONAQUEOUS ORGANIC SOLUTION OF AURETHANE PREPOLYMER BLOCKED WITH A BLOCKING AGENT SELECTED FROM THE GROUP CONSISTING OF IMINES, OXIMES AND KETOXIMES, SAID BLOCKED PREPOLYMER HAVING A MOLECULAR WEIGHT OF ABOUT 400 TO 6000 AND A RATIO OF EQUIVALENTS OF ISOCYANATE BY WEIGHT OF SAID PREPOLYMER TO EQUIVALENTS BY WEIGHT OF ACTIVE HYDROGEN OF SAID BLOCKING AGENT IN THE RANGE OF ABOUT 1 TO 2 AND SUFFICIENT QUANTITIES OF AT LEAST ONE ORGANIC CURING AGENT TO PROVIDE A RATIO OF EQUIVALENTS BY WEIGHT OF ISOCYANATE OF SAID PREPOLYMER TO EQUIVALENTS BY WEIGHT OF ACTIVE HYDROGEN OF SAID CURING AGENT IN THE RANGE ABOUT 0.5 TO 2.0;

(B) JOINING SAID LAYERS OF EXTANT FOAM AND POROUS SUBSTRATE UDNER PRESSURE SUCH THAT THEIR CONTACT INTERFACIAL SURFACES ARE MUTUALLY WETTED BY SAID ADHESIVE COMPOSITION AND SUCH THAT AN ADHERENCE IS THEREBY EFFECTED BETWEEN EACH TWO LAYERS OF EXTANT FOAM AND POROUS SUBSTRATE SO JOINED BY SAID LIQUID ADHESIVE COMPOSITION INTERLAYER THEREBETWEEN;

AND (C) HEATING THE THUS JOINED AND ADHERING PLURALITY OF LAYERS OF EXTANT FOAM AND POROUS SUBSTRATE AND LIQUID ADHESIVE INTERLAYERS THEREBETWEEN SO AS TO VOLATILIZE SAID SOLUTION'"'"''"'"'S SOLVENT, UNBLOCK AND DISASSOCIATE SAID PREPOLYMER AND SAID BLOCKING AGENT, VOLATILIZE SAID BLOCKING AGENT, INTERACT SAID PREPOLYMER AND SAID CURING AGENT SO AS TO CURE SAID PREPOLYMER TO A SOLID INTERLAYER AND THUS PERMANENTLY BOND THEREWITH SAID PLURALITY OF EXTANT FOAM TO POROUS SUBSTRATE LAYERS.