Laminated panel and process

• US 8,206,534 B2
• Filed: 12/21/2010
• Issued: 06/26/2012
• Est. Priority Date: 07/14/2004
• Status: Expired due to Fees

• Current Assignee: Sport Maska Incorporated (Adidas AG), Armfoam Inc.
• Original Assignee: Sport Maska Incorporated (Adidas AG), Armfoam Inc.
• Inventors: McDuff, Rodrigue, Koyess, Philippe, Murphy, Stephen, Vachon, Luc
• Primary Examiner(s): Lee, Katarzyna Wyrozebski
• Assistant Examiner(s): Dodds, Scott W
• Application Number:
  US12/974,161
• Publication Number:
  US 20110086205A1
• Time in Patent Office: 553 Days
• Field of Search: 156/219, 156/308.2, 156/308.4, 156/309.6, 156/581, 156/245, 156/290, 156/209, 156/213, 156/222, 156/323, 264/271.1, 264/273, 264/284
• US Class Current: 156/219
• CPC Class Codes: B32B 2262/0261 Polyamide fibres
• CPC Class Codes: B32B 2305/022 Foam
• CPC Class Codes: B32B 2305/38 Meshes, lattices or nets
• CPC Class Codes: B32B 2323/04 Polyethylene
• CPC Class Codes: B32B 2323/10 Polypropylene
• CPC Class Codes: B32B 2333/12 Polymers of methacrylic acid esters, e.g. PMMA, i.e. polymethylmethacrylate
• CPC Class Codes: B32B 2398/20 Thermoplastics
• CPC Class Codes: B32B 2459/00 Nets, e.g. camouflage nets
• CPC Class Codes: B32B 2479/00 Furniture upholstery B32B2601/00
• CPC Class Codes: B32B 2553/00 Packaging equipment or accessories not otherwise provided for
• CPC Class Codes: B32B 2607/00 Walls, panels
• CPC Class Codes: B32B 27/065 of foam
• CPC Class Codes: B32B 27/08 of synthetic resin
• CPC Class Codes: B32B 27/12 next to a fibrous or filamentary layer
• CPC Class Codes: B32B 27/308 comprising acrylic (co)polymers
• CPC Class Codes: B32B 27/32 comprising polyolefins comprising vinyl (co)polymers or acrylic (co)polymers B32B27/30
• CPC Class Codes: B32B 37/182 one or more of the layers being plastic
• CPC Class Codes: B32B 38/004 by physically contacting the layers, e.g. by the use of heated platens or rollers
• CPC Class Codes: B32B 38/06 Embossing
• CPC Class Codes: B32B 39/00 Layout of apparatus or plants, e.g. modular laminating systems
• CPC Class Codes: B32B 5/18 : characterised by features of a layer of foamed material
• CPC Class Codes: Y10T 156/1039 : Surface deformation only of sandwich or lamina [e.g., embossed panels]
• CPC Class Codes: Y10T 156/1041 : Subsequent to lamination
• CPC Class Codes: Y10T 428/22 : Nonparticulate element embedded or inlaid in substrate and visible
• CPC Class Codes: Y10T 428/23986 : With coating, impregnation, or bond
• CPC Class Codes: Y10T 428/24612 : Composite web or sheet

Abstract

A laminated panel (23) comprises a fusible layer (23A) having an upper surface. A mesh layer (23A, A1) has an encapsulated portion enclosed in the fusible layer so as to be below the upper surface of the fusible layer (23A). An embossed portion (A1) protrudes from the upper surface of the fusible layer (23A). A method (10) of forming a laminated panel with the fusible layer and the mesh layer comprises the steps of: i) heating the fusible layer (23A) to fuse a portion of the fusible layer; and ii) pressing only selected portion of the mesh layer against the fusible layer to provide for the formation of an embossed pattern (A1) on the resulting laminated panel (10).

Claims

1. A method of forming a laminated panel with at least a fusible layer and a mesh layer, comprising:

i) heating the fusible layer to fuse a portion of the fusible layer; and

ii) pressing only a selected portion of the mesh layer against the fusible layer to provide for the formation of an embossed pattern of mesh layer projecting above the adjacent fusible layer in which mesh layer is encapsulated, in the resulting laminated panel.

2. The method according to claim 1, wherein said pressing only a selected portion comprises pressing the mesh layer surrounding a periphery of the embossed pattern.

3. The method according to claim 1, further comprising securing a third layer to another surface of the fusible layer.

4. The method according to claim 3, comprising providing the third layer in at least one of a polymer, an expanded polymeric foam, and fabric.

5. The method according to claim 3, comprising providing the third layer in an expanded polymeric foam.

6. The method according to claim 1, comprising providing the fusible layer in any one of olefin, ionomeric resin, polypropylene, polyethylene, or thermoplastic olefin.

7. The method according to claim 1, comprising providing the fusible layer in an ionomeric resin.

8. The method according to claim 1, further comprising cooling the fused portion of the fusible layer while maintaining a pressure on the laminated panel after ii).

9. The method according to claim 1, further comprising cutting the resulting laminated panel with respect to the embossed pattern, so as to define at least one boot quarter panel.

10. The method according to claim 9, further comprising shaping the boot quarter panel into at least one boot quarter.

11. The method according to claim 1, wherein i) and ii) are performed concurrently by pressing a die with cut-outs on the assembly of the mesh layer and the fusible layer, with heat being transferred from the die through the mesh layer to the fusible layer, and with the cut-outs defining the embossed pattern.

12. The method according to claim 11, further comprising sandwiching the die, the fusible layer and the mesh layer between sheets of anti-adhesive material prior to said heating.

13. The method according to claim 1, wherein said pressing comprises forming a logo with the embossed portion, a periphery of the logo being the mesh layer projecting above the adjacent fusible layer.

14. A method of forming a laminated panel, comprising:

i) assembling product layers including a fusible polymeric layer, a mesh layer, and a core layer;

ii) heating the fusible polymeric layer to fuse a portion of the fusible polymeric layer; and

iii) pressing only a selected portion of the mesh layer against the fusible polymeric layer to provide for the formation of an embossed pattern of mesh layer projecting above the adjacent fusible polymeric layer in which mesh layer is encapsulated, in the resulting laminated panel.

15. The method according to claim 14, comprising providing the core layer in at least one of a polymer, an expanded polymeric foam, or fabric.

16. The method according to claim 14, comprising providing the core layer in an expanded polymeric foam.

17. The method according to claim 14, comprising providing the fusible polymeric layer in any one of olefin, ionomeric resin, polypropylene, polyethylene or thermoplastic olefin.

18. The method according to claim 14, comprising providing the fusible layer in an ionomeric resin.