Composite laminate material and process for making the same
First Claim
1. A process for making a composite laminate material which comprises the steps of(a) providing an unbonded fibrous batt of desired thickness having a thermosetting binder material dispersed therethrough;
- (b) applying a layer of desired thickness of a cureable latex to at least one side of said fibrous batt;
(c) drying said layer to a predetermined moisture level to provide a dried composite material; and
(d) heating and compression molding said dried composite material to simultaneously mold said composite, cure said layer and cure said binder material by embossing a pattern into the exposed side of said layer before said layer and said binder material are cured to cause said layer to be contoured with said pattern substantially throughout the thickness thereof and thereby cause said pattern to be substantially impressed into said one side of said batt so that the resulting embossed and cured layer has a substantially uniform thickness and said one side of said cured batt substantially conforms to the embossed contour of said layer.
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Accused Products
Abstract
A composite laminate material and a process for making the same are provided, the process comprising the steps of providing an unbonded fibrous batt of desired thickness having a thermosetting binder material dispersed therethrough, applying a layer of desired thickness of a curable latex to at least one side of the fibrous batt, drying the layer to a predetermined moisture level to provide a dried composite material, and heating and compression molding the dried composite material to simultaneously mold the composite, cure the layer and cure the binder material by embossing a pattern into the exposed side of the layer before the layer and the binder material are cured to cause the layer to be contoured with the pattern substantially throughout the thickness thereof and thereby cause the pattern to be substantially impressed into one side of the batt so that the resulting embossed and cured layer has a substantially uniform thickness and the one side of the cured batt substantially conforms to the embossed contour of the layer.
This application is a continuation patent application of copending parent application, Ser. No. 167,294, filed Jul. 10, 1980, now abandoned.
33 Citations
14 Claims
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1. A process for making a composite laminate material which comprises the steps of
(a) providing an unbonded fibrous batt of desired thickness having a thermosetting binder material dispersed therethrough; -
(b) applying a layer of desired thickness of a cureable latex to at least one side of said fibrous batt; (c) drying said layer to a predetermined moisture level to provide a dried composite material; and (d) heating and compression molding said dried composite material to simultaneously mold said composite, cure said layer and cure said binder material by embossing a pattern into the exposed side of said layer before said layer and said binder material are cured to cause said layer to be contoured with said pattern substantially throughout the thickness thereof and thereby cause said pattern to be substantially impressed into said one side of said batt so that the resulting embossed and cured layer has a substantially uniform thickness and said one side of said cured batt substantially conforms to the embossed contour of said layer. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14)
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Specification