Process for production of foam laminate product

Inventor: Neil P. Gehani (Mississauga, CA)

Assignee: PROPRIETECT L.P.

B32B5/18 B29C43/003 B29C44/5681 B29C66/73182 B32B5/245 B32B5/28 B32B37/04 B60R13/0212 B29K2075/00 B29K2105/128 B29L2031/3023 B32B2305/022 B32B2305/20 B32B2307/102 B32B2605/003 Y10T428/249953 Y10T428/249982

View Patent ↗

Loading inventors, assignments & file history…

Monitor This Case

Get email alerts when status or documents change.

Order Certified Copies

Most orders are placed with the USPTO same day — all within 24 business hours.

Order via The Patent Place →

Pre-filled with this patent's details

Quick Facts

Patent No.: US 12679065
App. No.: 14/948,981
Granted: Jul 14, 2026
Kind: B2

External Links

USPTO Patent Center↗ Full Patent PDF↗

Abstract

A laminate product comprising a foam core having a pair of opposed major surfaces and a cover layer secured with respect to each major surface is described. The cover layer contains a fibrous reinforcement layer that is substantially encapsulated by a polymer. It has been found that the use of a fibrous polymer layer (e.g., in place of conventional polyethylene film) results in a laminate product having significantly lower resistance to air flow resistance and significantly improved sound absorption properties.

Claims (26)

1 . A process for producing a laminate foam product having a pre-determined shape, the process comprising the steps of:

heating the blank at temperature above the melting point of the at least one spunbound fibrous polypropylene scrim layer for a period of time sufficient to cause polymer of the at least one spunbound fibrous polypropylene scrim layer to wet out, fully permeate and substantially encapsulate the at least one fiberglass reinforcing layer and make each cover layer adhere to the foam core, wherein the encapsulated at least one fiberglass reinforcing layer is configured to maintain an air flow resistance of the laminate foam product, as measured in accordance with ASTM C522, to be less than about 6,000 mks Rayls.

2 . The process defined in claim 1 , comprising the further step of: shaping the blank to assume pre-determined shape.

3 . The process defined in claim 2 , wherein said heating step and said shaping step are conducted concurrently.

4 . The process defined in claim 2 , wherein said heating step and said shaping step are conducted sequentially.

5 . The process defined in claim 2 , wherein said heating step is conducted prior to said shaping step.

6 . The process defined in claim 1 , wherein at least one of the cover layers on each major surface comprises two or more spunbound fibrous polypropylene scrim layers.

7 . The process defined in claim 1 , wherein each cover layer comprises two or more spunbound fibrous polypropylene scrim layers.

8 . The process defined in claim 1 , wherein at least one of the cover layers on each major surface comprises two or more fibrous reinforcement layers.

9 . The process defined in claim 1 , wherein each cover layer comprises two or more fibrous reinforcement layers.

10 . The process defined in claim 1 , wherein the at least one spunbound fibrous polypropylene scrim layer is non-woven.

11 . The process defined in claim 1 , wherein the heating step causes a first cover layer to adhere, by the spunbound fibrous polypropylene scrim layer, to a first major surface of the foam core and a second cover layer to adhere, by the spunbound fibrous polypropylene scrim layer, to a second major surface of the foam core.

12 . The process defined in claim 11 , wherein at least one of the first cover layer and the second cover layer comprises a single fibrous reinforcement layer.

13 . The process defined in claim 11 , wherein each of the first cover layer and the second cover layer comprises a single reinforcement layer.

14 . The process defined in claim 11 , wherein at least one of the first cover layer and the second cover layer comprises a plurality of fibrous reinforcement layers.

15 . The process defined in claim 11 , wherein each of the first cover layer and the second cover layer comprises a single fibrous reinforcement layer.

16 . The process defined in claim 11 , wherein at least one of the first cover layer and the second cover layer independently comprises from 1 to 15 fibrous reinforcement layers.

17 . The process defined in claim 11 , wherein each of the first cover layer and the second cover layer independently comprises from 1 to 10 fibrous reinforcement layers.

18 . The process defined in claim 11 , wherein each of the first cover layer and the second cover layer independently comprises from 1 to 5 fibrous reinforcement layers.

19 . The process defined in claim 1 , wherein the foam core comprises a thickness in the range of from about 3 mm to about 15 mm.

20 . The process defined in claim 1 , wherein the spunbound fibrous polypropylene scrim layer has the basis weight of from about 1.0 to about 2.3 oz/yd 2 .

21 . The process defined in claim 1 , wherein the spunbound fibrous polypropylene scrim layer has the basis weight of from about 0.8 to about 2.8 oz/yd 2 .

22 . A process for producing a laminate foam product having a pre-determined shape, the process comprising the steps of:

positioning a blank in a heating device, the blank comprising a foam core having a pair of opposed major surfaces and one or more cover layers disposed on each major surface, each cover layer comprising at least one fiberglass reinforcing layer, which is made of fiberglass containing a polymer material, and at least one spunbound fibrous polypropylene scrim layer arranged in an alternating fashion such that there are N fiberglass reinforcing layers, each of which is made of fiberglass containing a polymer material, and N+1 spunbound fibrous polypropylene scrim layers and Nis an integer equal to 1 or more, the spunbound fibrous polypropylene scrim layer having a basis weight of from about 0.8 to about 2.8oz/yd 2 , the blank being free of polyethylene film;