# OAR Box 1413 Prepped by Ollie Stewart



## Document

Number: 

# 49 ) 11-1-4 9
Docket Number: 

# A-94-5 2

Printed 7/9/2008 3:11:22 PM Sheet 49 of 114 p. 1SCJN

I BT-U 3 ri U TAItlN l SALL S /-12-3 b; 15=2 5 

### P. 2 

### 19199410234:#30/5 0 

# Unite d State s Paten

tm Sche r e tsl . 

# Il

l US005IB360O

A 

## [ii ) Paten tNumber: [45 ] Dat e o f Patent : 5,183,60 0 -rpnya

Feb . 2,199 3 M 

## ~ J 

## ~ [54 ] METHO D AND APPARATU S FOR CONTINUOU S CASTIN G O P POLYMERIZABL E MATERIA L pS ] Inventors : Herb m L Seher.Tfteivillc ; Israe l S .

. Ihgar , RaadallKown ; Richar d R . Baehr , Jr , AnntpoHi . al l o f Md . • 

# m (21 ) 

### PJ J 

# rs u IS2 ) Assignee : Nevama

r Gorpomden

, Odenton , Md . App L No. : 732,66 2 Filed : JsLI«,19* l I M . CL * ««~. , Wstt » U » •IHIMMUIMUIWIMmMMMM t •
B39 C as/i o -...264/26 ; 264/73 ; 264/145 ; 264/148 ; 264/216 ; 264/236 ; 264/347 ; 264/331.18 ; 264/34 2 RE : 425/174. 1 ft
• 425/?24

j 425/445:425/7 5 [58 ] FWdofS«« h 264/216,13,22,212 , 264/26.331.18,166,16S . 148, 236,73,75,347 , 243,34 2 RE . 143 ; 429/174 4 R, 174. 1 E , 174.4 , 445,174.6,224,7 5 [56 ] Rcfercncea-Chc d US . PATEN T DOCUMENT S 2.13642 2 1379,24 a 

## isoa.-m 1979,13 1 2403,74 1 2.607.08 1 X663J00 2.U2J7 5 3.049.76 1 3.09U»1» 3£16J4 9 3437.67 4 MIU4 6 3419J1 7 3421,13 1 3.32942 5 3,392.88 2 3,600.49 0 3463.49 3 11/193 1 6/194 3 1/194 6 3/193 0 12/193 1 7/199 2 1/193 2 12/199 3 2/199 2 I/I96 2 6/196 3 11/196 9 1/196 7 •1/197 0 7/1970 9/1970 9/197 0 7/I9T 1 6/197 1 5/1972 - FIdds . 

## wnHaw . 244/236

,264 m 264/2 2 Burnet t«al . SdMcdfltaL . Taylo r — —264/16

9 Mrif f m, tl , Imbcr ta iL * . 429/174. 1 R Yakubik . Haekert. laeot o - 264/2 9 Smncbo m « a L -— —264/23 6 OuggilH . Deacf c ^ r ^—_

_425/174. 1 K DugfJm . Duggbtt . Menu . BtDlatdeycia

L . WillC T •«»••»•>—M«WMI»MMMMW a aw f #7 9 3.101,40

7 U»M H 3J72.I9 7 349M24 3,923,94 1 j.978.17 1 V9U.0 M 4j00146 t 4J0IM4 2 4,113.161 4.166A M 4J2I.299 429MI 3 4414/0 6 4.425.21 7 4^26,11 7 4.71033 3 4^39,12 9 4/197 4

6/197 * J/197 3 7/197 9 9/197 5 11/197 3 1/197 6 10/197 6 1/197 7 4/197 7 1/197 9 1/19( 0 9/198 0 11/198 1 2/198 2 9/1*8 3 1/19 M 12/191 6 12/198 7 6/19U OoUswonhyaiil. . fioncUrk a

tal . . Xatosta L . Kat o etal. . Henna . Weaver . OtUaeaai . Rat e eta L . MeUmctal . Fifcecta L . ttao. ' BredUyctaL. Sdbennr a • Teei* . Tfereaet i e L . Until- . Hotctta L . Manbodcta L Ida . FOREIG N PATEN T DOCUMENT S 003681 9 9/191 1 Earape n PW

. 6ft . 024680 6 11/198 7 Ewope w Pa tOff. . 394326 6 6/198 6 Fed . Rep . o f

Genuity . 149143 7 7/196 7 Fiao M . " 149770 8 9/196 7 494916 3 11/197 4 33-14036 2 9/197 1 Japan . 136638 5 9/197 4 Unite d Xhfdo n — —423/171 6 Primary JSmmMeN-JefFer y Thurio w • Attomty. Agtm er

f!rm-4oat% Day , Reavis * Fogu e

< ? [ST ] ABSTRAC T A metho d an

d apparatu

s fo r oortamoa tcadta f

o f poly i mrinbl taalsrielftha tshrin k durin g polymeriiatio n include * rapidl

y heating a movin g matri x sshstaotiall y •nUbrml y thranghoa

tit teros s sectio n b y radi o ft*-" fpency^cocrg

y t o initiat

e polymerisatio n ao d maintain ' q g di e matri

x thereafte

r fa substantia

l (bana l Isolation such thatsubstantiall

y adiabaO e polymerisatio n ocean . 7CUls»,SDra«iii e

### StEN l BY:U 5 ri O fAlt M SALti i : /-I2~\ib : Id^ S P. 3 

### lbiaa41U2i!4:#31/& U 

# U.S . Paten

t Feb . 2,199 3 Shee t1 of 5 

# 5,183,60 0

PF«JI M 

## niiP R . MONOMERS . RESI N FILLE R MODIFIERS , ETC .

PIGMENT S • CATALYSTS SYSTEM " COMPOUNDIN G SECTIO N

CAS T UQUI D MATRI X ONT O A MOVIN G CARRIE R WE B AN D ESTABUS H LEVE L SURFAC E 

# I HEA T MATRI X T O A POLYMERIZATIO N TEMPERATUR E THA T PERMIT S GELUN G WITHOU T SHRINKAGE .

HOL D A T A SOAKIN G TEMPERATUR E THA T I S CLOS E T O TH E TEMPERATUR E ATTAINE D FRO M TH E AUTOGENI C REACTIO N UNDE R ADIABATI C CONDITION S 

# Rg. 1 COO L SHEET S T O ROO M

TEMPERATUR E 

# 9,P. 4

JUV I DI*U O 

### n v THID M 

### iALL i : /-12-3t j : lb'-2 5 '• 

## 19193410234:#32/5 0 

# U.S . Paten

t Feb . 2,199 3 Sheet2 o f 5 

# 5,183,600Ui



### CONVENTIONAL HEATIN G O F UQUI D MATRI X B Y CONDUCTIO N

-X L . TEMPERATUR E 

# t C O 

### ro 

### a

VISCOSIT

Y 

# 2

& 

## 3

C O 

### t r &



# Rg 3 miE < (o r Distanc e Alon g BeK ) 

## tn C O

- < T l

— ) © T J r n

C D C D

c n t o a i



### 0 0 

## 0 *

mm . 

## Q S 

# s v ^ ^••^ H ^^ 1— •

C D C D C D #> . A—. O I O O J * » • * * o C O --^ , c n o0 

### c

RAD1 0 FREQUENC

Y HEATIN G O F LIQUI D MATRI X (Wooll y Unifor m Rodtotio n Field ) DURATIO N O F RADIATIO N

TEMPERATUR E TEMPERATURE v O F MATRI

X j

VISCOSIT

Y



# Rg. 4 D SETTIN G PERIO D O F FAIE R O R PARTICLE S (Muc h Shorte r Perio d wit h Radi o Frequenc y Heating )



## TIME ' 

# I fa 

# S PrtVISCOSIT

Y 

# 2

9

(J l O O c



## E p

t v I C l 

### a

t v a

a a C tv ; 

## o • p •if

### u



## ON E EMBODIMEN T O F TYPICA L HEATIN G SEQUENC E
T C

T A - TEMPERATUR E

^ N 

### G O 

# i ? 3
TEMPERATUR E RIS E DU E T O EXOTHERMI C REACTIO N 

# 1



# I (S.

c >

o r r r o r

i tv : C £ CT .

tv : cr



## HEATIN G PERIO D GELLIN G PERIO D

T A T C OPTIONA L SECON D HEATIN G PERIO D (no t shown ) 

## TIME - -•• » 

# 0

c n 

# a ,

GEUM G TEMPERATUR E fc CATALYS T ACTIVATIO N TEMPERATUR E CURIN G TEMPERATUR E (approidmot e temperatur e attaine d b y matri x reactin g under adrabatf c conditions ) At* 

### 0 0
C £

c c • P G : * > * * cr 

## a

•> l_P. 8 

### JU, , u.-u o n « imu u ML U • /-iz-a o • io-ZKm : " - ^ 13199410234:^6/5 0


## 3,183,600 1 2 o f reactio n an d actuall y i tcoole d b y dissipatin

g beal METHO D AN D APPARATU

S PO RCONTINUOU

S bac k t o tha tenvironment

. This proee a continue

s unti l CASTIN G O F POLYMERI&ABL

E MATERIA

L substantiall

y a U o f tb e unsaturate

d bond s o f di e mi n „.~«,«»,,,„., ~ ~« . •.. « ..».^v-.»^» . "^ monome r component

s at e consume

d an d tB e resi n BACKGROUN

D O F TH B INVENTIO

N 5 i s cured . Ib e mol d h the n opene d afte r ooplio f and a * ' J L Rd d ofth e Invention pon d ct f decomh * » ^ Tbe presen tinventio n relate s t o a ne w metho d an d plaine d bebw^tfepre^ i apparatu s far continuousl

y castin g certai n thic k shee t• ttm>d

j# ^ and material s sometime s use d a s turfad e overlay , ba

twhic h nuybtlw ^ als o eaa.b e used , withou

tunderlay , sucha s fb r a stand- !- * Suc h a batc h process- ha

s rigniflcanca ahoilonndngk alon e restauran ttabl e top . Mor

e particularly

, the pm - R h alow an

d inelQe^nquirin i a grea

tdea l o f mate cotinventio n relates t o t n improve

d metho d an d appa - rial handlin

g equipmen

tMoreover , i tpresent s dgnifi * ntn s for continuousl

y c-tttingpolymeri c material s can tproblem s wit h contra ^ dwmatrm'uniformit y t n • whfchihrin k durin g polymaization . di e mold , particularl y wher e decorative e*rtial a are a Description o f

di e Prio r Ar

tl s 

### use

d i n d m matrix. Fo r ekampb , flow pattern s sa d con -

. Polymeri c material s suc h i s thermosettm

g reaSns , veetio o ourent a in th e liqui d matri x whic h ma

y mul t diennophsric resins ; acryli c resin s an d di e lik e ai e com - durin

g pumpin g o r durin g di e beatin g an d early stage * manly , used.a a ratface txrverag materials. Sheet * o f o f polymerizatio

n ca n resu h i n aonunJibnnlt

y o f th e dies e material

s nr e use d ssdefcqredv

e finishing material

s dacomdv

e pattern, b addition

, snc h a bitc h proces s ianewbolldiBBconstntctioBa^inrcBwdeantforsuch M .|w»enM-Mgi>tfieM^ i «m wflr< 

### rtJ^|ytnffmattiw h n w application s a s bathroo

m vanit y tops , kitche

n oonhte r ltt«edv4t h proper uniformit y and , dms , doe s no tpoly * tops , furnitur

e components.restaurant.table * wal l pan- nerf ^ tt

### ft, „„ * rate 

### throughon tth e mel d cavity . din g an d other uses . TTt

e sheet s <ao be mad

e o f plai n Th tresul

t( » b e kicaliiedshriiddngwAlc h ma y cnai e *M crion>erca n b e patterne

d t o ha v tb a apomiaae c ernek s o r lea n h Ui

e final eundmMei U o f maiUe , granit

e o r othe r pattern

s o r textunl decora

* « dues residua

l stresses . - tion . Th e sheet

a ofte n ar e loade d widi decorativ

e parti * Bnwu i nrta

r mm m h». m 

### in, . m 

### «it « --••-*-—* — d a t o provid

e thes e characteristic

s an d di a ludn-oom * ^SS^^S^S^^^WgM&&&Z* ww * w |aw*w « MW * MiMKiiami

M «> M .U M iw u wuw

- eonunueu

s eastin tlechnlau

e a s an aftesiurth

M t o th e posftio n typically include

s minera l fillers indiesi^ . y^^pt^^^^ZSi^^mZS d m carbonat

e o r alwnfium

i Mfaydrate . I tI s prtiftmd ^ ^ U A ft

### j ^ 160O490 bsued t o BQIinxsefwanaae . band

s wwriakka.l ti s als o preferre d tha t«»wwy ta s i tBSI ^ doea, «r ^ ara m rf th e aaas a 

# TSLK^^ 

# S^To^^n^Sf'uSl^J ^ • o r machinin

g afte r th e shee tha s bee n cast. product

. T o avoi d th

e proble m o f wrinklin g o r tearin g aingletlKnna^gorilwnnopJKtkreSnorandflur e .tyt^tl*«^«tM»toand ^ • ofresi»suehttuiiutur»tedpolyester*andacry]IeKsi n f^"*? > slippag e tawttntbe $W * matri

x an d th e precursors. Sueh resin

s requir e a catalys tand/o r pro * • bdtofdKoonvevor.$pedfiedy.nillngiIeyteaehes « motersyjtentoiiutiatetl.eproca$offr«radlca1poly - P*oe«»ud^y^inat A rest s o n .laye r o f

a film mrrirwkff i Typira?r«Ttn«Trer*"'aCTCTfrtdbyha^tog a K wMc B 

### ahnnk

a duri m hcadni a

tth e aam e rat e as th e signiriean texothermi c reactio n durin g polymerbado

n *>*& •«*; . Bfflingsle

y teache s Ih a aa a o f of l o r a andaaubstantialincKaseofdensityduringdiatprecess . abnila r liqui d luttrican l betwee n di e fibn laye r aa

d di e Thus , a typica

l **mhturc« f 65 % filler an

d 33 % resin ( a ' ct 

### * VB 

### S' o r Bt 

### ' t

### * ° • * approach , th e film shrink

s wh h -matrU" ) shrink

s durin g di e polymerizatio

n procet f s o th e matri

x an d di e thi n fllm doe s no

than g up o o th t dia td w cure d solid compositio

n IM S a densit y abou t4 5 conveyo r belt

s as i tshrinks. S-8 % highe r tha n th e Uqui d matrix . This shrinkag

e Another conrinww

i cairin ! awtroaebcanb e fennd b pmrtit tprocessin g problem s relate d t o dw presen

tUS . Fax

. N a *,9tfc09

B Issue d t e Kat o e ta L Kat o faventioa whic

h at e discusse

d bdow . • ' , ' teache s a dua l beltsyste m whie h n m d w force o f

a A vavi^b f prior madiod

k have bee n uae d m achiev e eeadbedtpawmeontrddwtaadeiideaofd w mani a t o - syntheti c shee tmaterial s havfa g a decorativ

e patiem/5 0 distor

to r tea r itsel f apar tdurin g tba polymerisatio

n O&mid&iwlvasab* ^ -proen&Tlwmatri x fapais^'through aoonAnadapnoe th e matri x i s prepare

d by mixin g th e tesias wh

h th a o>Aoe d b y uppe r an d bwerbtlt»whk*forwU w matri x filler an d di e desire d decorariv e partides o r colorin

g » mdntaf

a a flatrectangula

r croa a sedio n despit

e th e n»teria h en d wid i a auwlar

d quantif y o f catalyst . The - presenc e o f interna l force s brough tabortb y toeaBxod amoun to f catalysttypically recommended i n th e prio r 5 5 curin g whic h wonld adietwii e eaua

e th e matri x t o pu B ar ti s oo e halft o tw o percen

tbase d c a di e liqui

d resi n apart , war p o r bend . flactioo o f d w matrix . Tbiamani a fc th m poere

d o r - Pro

m tb e foregoing i tean b e seen tha tth e prior ar

t ptape d imo a large , caidn g mold'an d seale d iaitlM ^ contmuou

s easting processe

s involv e expensive and aoMFlh e mol

d i s the n subjecte d t o snfllden

thea tt o oomplicate

d amngenknt s t o eootru

l d w curing o f

d w tegt a deeompoaido

n e f dw caulyst , whic

h initiate s C O polymeri c materia L Thiea e prio r ar tcaadn g mediod s 

# K yaarizedon o f

dw resin. Beeana

a d w polymerisatio

n ala s po m qualit y problems, b corivendonalheltcatrih g ^ nexoi^enni c process . d » reactio n contribute s to th a equ^menttdj e liqui

d matri x b fa therma

l contactwit

h hea to f d w system , leadin

g t o Ambe r catalys tdacompo- • th

e bchs an d ma y b e heate d b y d w conduction o f

beal anio n aa d an increase

d rat e o f polymerisation. This . tlvough th e bdt twhic h a m enclose d i n a s environmen

t follows th e typica l prio r ar tapproac h whereb y th e M o f heate d fluid o r gaa

. Wid i d & arrangement

, th e mol d oonduedv e e r convective hea

tenvironmen

tapplie d to o r ba

h auriae e ca n cam * Initiatio

n ef. a rapi d accelerai di e matri x i s war m enoug h t o *1cic k off " th e polymeriza

* .b g reactio

n befor e curin g i s complete, b extrem

e case s do n reactio n whic h the n sustain s itael f b y i u ow n hea tdii s ca n cause loca

l boding, o r a

tleast, irregula

r cure •<w » 

# 7

### SfcWrBT:U S fl' O fA'l'tN T SALt S _ _P£_ /-i2-a b : lb:2 b : " 1313341uzo*»*p//o u



## 5,183,600 3 4 wid i shrinkag

e stresses , cracking , ripple, craz e layers , goin g polymerization occur s In a substanddl y adiabati c etc . mamier . Optionally , additioo d hea tma y b e supplie d t o I f th e heatin g were t o b e done o n a singl e supportin g th e mixtur e t o iocreaa

e di e reactio n rale . Accordin g l o bel t(withou ta to p bell) , th e botto m o f di e matri x laye r di e presen

tmveotion , h ha

s bee n bun d dwtd w matri x ma y polymeriz e befor

e d w top , cantin g sever e warp , 3 ca a shrin k uniforml

y withou tcausin g wrinkles o n tb e concav e upward . Also , excessiv e temperatur e differ * botto

m sufftc e an

d widiou tdevelopin g problemati c ence s betwee n di e matri x cente r aa

d surfac e coul d stresse

s o r deformities . caus e flpw pattern

s t o develo p which reau

h i n obje c * Th e presen tinventio n ha

s th e benefi to f

providin g a

n tioaablea|>pearance o f

moldin g o r streaks . Th e us e o f efficien

tuncomplicated metho d o f continuou s cattin g typicdbdt.'tysiems , panicularly togethe r withconvee-1 0 dia tavoid s destructive intenw l an d exten d force s do n heat , ma

y resu h i n di e nee d t o limh d w rat e o f which tend t o produc e distortion . I tab o has th e benefit beating , resultin g In a lon g heatin g time . Thi s i n tur n o f producing n cured homogeneou s matri x wit h uni ma y requir e a highe r matri

x vbcont y t o reduce panicl e for m properties aad appearance . I tals o ba s d w benefi t setding . an

d longe r equipmen

tin th e cas e o f

continuou s o f

providing a shee twhie h shrink s uniformly througb easting . Problems arise because , wid i d w longe r heatin g 1 5 ou td w shee tmateria

L diu s avoidin g warpage , wevi time , th e viscosity o f

d w matri x ud D b e reduced fo r a ness , o r odie r rigns o f ipegula r shrinkag e durin g cur e longe r perio d o f

time befor

e i trapidl y dimb s jus tprio r even dioug h n o externall y applie d pressure b provided , t o gelling . Thi s i s illustrate d i n HG . 3 . Th e lowe r vfc . Addition d advantages an d benefits wil l b e apparea tt o entity fo r a

n extende d time wil l permi

tdi e minera

l filler thos e skilled in d w a n upon readin g thi s tttsdotore . t o settl e an

d als o an y dense partide s used for decorativ e 3 0

_" nasruivnaN rat TH Rn v AWMfi c effctmaysettfeimdtioginaaontamogenomshee i BRIE F DESCRIPTIO N O F TH E DRAWING S bod i i n physk d propertie s an d i n appearanc

e a ta cu tFIO . I

h a schemati c flow diagra m whic h depicts th e proces s step s accordin g t o on e embodimento f d w pres * SUMMAR

Y O F TH E INVENTIO N ^ n a Jisadiagmmadesldeelevatlondvfcwofim e I ti ta n objec to f d w presen

tinventio n t o provid e a n embodimen to f a n apparatu

s o f th e presentfatvendoo. efficientand simpl e medio d and apparatu s for cootinu - FIO . 3 i s a diagra m showin g di e rdarienshi p betwee n ou s castin g o f

polymeri c material

s whic h shrin k upon d w settling o f th e filler an d th e beatin g time o f d w curing . I tb a

n obje a t o provid e a mediod whic h over - matri x prior t o d w gellin g fa • conventional heatin g comadwprebienuafpanicleKtdemeD tandsuriac e 3 0 arrangemen

tusin g conductiv e o r convectiv e heating. ' distortio n during th e curin g process . I

ti s a n objec tt o FK3. 4 i s a diagra m showin g tb e improve d retadoo provid e a metho d which wil l preventd w creatio n o f ' shi p betwee n sealin g e f d w filler en d th e shortene d hterna l stresses (an

d th e assodated problem

s o f warp , beatin

g time made possibl e b y th e improve d medio d tt cu d au d craefcfag. ) I tfa a farther objectiv e t o provid e a d w presen tinvention . medio d whic h wil l avoi d th e tendenc y o f th e shrinking J

S FIO . S i s a grap h Showing a n embodimen to f th e matri x t o detach itidfdu e t o shrinkag e from th e liquid heatin g sequence accordin g t o th e presentinvention . ^^SStt^^Snovdfc«ure.o f »*TAIL£ D MNUffjON;O P TH E RESEC T th e inventio n wU

l b e setfort

h i n par ti n th e descriptio n INVENTIO N whic h follows, an

d i n pan wil l becom e apparen tt o 4 0 Th e proces s step s o f

th e presentinventio n ar e ache thoae skille d i n di e ar

tupo n examinatio

n o f th e follow * maticdl y illustrate d in FIO . I . A s show n i a FIG . L t o in g o r ma y b e teamed b

y practic e o f th e invention . Th e begin , d w matri x b prepare

d usin g a mixtur

e o f redo , objects an

d advantages ofth e inventio n ma y b e realize d filter an

d cpdona l mooomers , modifiers o r ethe r mgre * an d attaine d b y mean

s o f the instrumentalitie

s an d com * dJents

. Th e matri

x fa unprepare d for eastin g witi i ti» Mnation s particularl

y pointe d ou ti n th e appende

d 4 5 aadhlonofpigmeaUindcatdysu.Tlwdecerative'Shee t claims . materid ma y b e mad e o f an y polynwrixabl e materia l T o achiev e th e foregoing an d odie r objecttand in - having flu, desired propertie s o f heatassistanc e colo r accordance wit

h th e purpos

e o f di e presen

tinvention , stability , clarity , chamic d aa d stat e resistance , sa d d u inventio n provide s a metho d an d apparatu

s fo r eon - edwrphydedpiopMtimsuilsbk'for'Cav'nwclrinnbilli y rinuous castin g o f

a polymerizable materi d whic h 5 0 an d fabricatio

n i n d w polymerixe d Hum . Tb e present shrink s upon curing . Aeeordla g t o d w praen tfovea- inventio n i s particularl

y wel l suite d l o materials whic h ti^E th e mnpotitioa'Eia^an^u^E^usbi g a controlle d "shrin

k upo n curing . Suc

h material s ar e discjissr

d fat emcmtfjftl ^ greate r deuf i below . piSfj| ^ a we b which b travd - '" „ - A oatdys tsystem typically consistin g o f oa a o r mor

a n^l u a p^ ^ whic h b i n a 5 5 caulys tgroup s b used . Th e oatdys tahould b e selecte d laj^statc.isallowedtcitn ^ t o permi tgdlin g widioutsignifican tshrinkage . Th e ^lmti^'M:ti^'io'i»ooiB* leve l and sinoot h b y \, specifi c eatdyatselecte d and it s concentratio a wil l de > dw||piCe^ ^ devio e coul d - ' pen d o n tb e test a used . IK:UM&E& ^ A s explaine d more folly below , h ha s bee n found that , £ thenqnieid y Iwatir

f a ta poin tdownstrea

m o f d w 4 0 b y d w prope

r us e o f radio frequency eactgy , th s matri x ..dcjj$t|!itt. ^ ma y b e partiall

y jjoliymeriredquk ^ an d uniforml y to • : ta&''iecikiaW''i-v-m\6

fteoncocy energy t o a tempera* d w poin tc f crestin g a soli d rubber

y materi d suitabl e on e di d initiatespdyncnaarion . ) thas been found i n for furthe r processing in accordanc e wid i d w Invention accordance widi th e presen tinventio n dia

td w matri

x befor

e a a excessiv e amoun

to f shrinkag e ooeutt . Exces eanbe ! awd a t e partiall

y polyinerit

e quickl y t o a rub - 4

5 rive duiakag e b tha

tamoun twhich , fa d w eas e e f

th e berygdbeforeaignificamshrinkageeccura.Thereafter , give n matrix , cause s th e matri

x t o form surfte e wrin d w mixtur

e b mafaidne

d in subitaniisl thcrm d bolatio a kles , residua l stresses , war

p or . l a extrem e cases , t o tea r from i u auneundin g environment . A s a mult , th e on - Itsel f apart . 

# 9>i. i u i • v* > i i v i niru M Ortl-1— 3 I-It.-OK) • i.0-^.1 P.1 0 

### 13iaa410234:#38/5 0



## • s,i83,rt o § <§ Eeitaraim g t o JF30._H , sh e liqui d aaccaft a syM i 8&

a tdi&S c^sgsm

8 © sfesc e -idDsg S

n -Jk ? D Ktes t&ere'or o Eaoa y eaKoSyn j systsss i S

Q <8fepeaE@

d i a eoa&r©!!J@$ osaeira s ©au o cfenaosaw s omiagGssewit

e psai&f e •©Mat

e ok ? cs®g 2 © f ass^rageamOT's^c^liiao^oH A fegj'S^sifa'ygailtaintei^^ (kscyjoE ? a Beve

l aarfoce

. levelle d feyostenassosoDagljios ssfl ^ to t°M&s£

to® flss® c@aara l CSSSSS D fe \p®s$&zx, o peto*

. SE D tfjie ae » Meg e f sh

e jpifesoso , depig»s

S te 3 <^fe'&B5@E)

. TS s tei fc D csstifea ) & a "ofeSg& i oik s EsoSfef e PB©§

. 2 ca& Si , th s laourf n fo gisfa&lly.cn d DBifessiSs f

. b eos

j W& MtikMy

0s*jte& "ffSx

s cssss^ fe a csgst o fc tessS VAQ

EQ$ © (Sre^sssie y esaj ^

D ® o BGrapsjosw

e •cSM i & 3 saoffio

a b Mty ^S^mshcS

cs£ sas!fc & ••d ^ ^swsrisot o llj ^ essoi n EK^fe3$iw^

^ Aei'OTtoGafflp^iasre&.'f e (tefc-ata^feteac^ ^ • ^sss8^1^8E'^& ^

q?^oij&toE33<3 ^ so^<^§8®24^aq|ai!@ ^ & ,-&aggnfe o t ® fe gsrer-a i feggaateaa 62 3 dtesr^ a Bosses ? 20=4

8 E3sgic2BS

& Keaaeib e OTsfa fe M^Jta i -safcsfc^CT^I!^ ^ saSaaagto B i&ssd l fcsJaaoaa a&& oSfews S 8®t?Gc§(ioa£b

> O S Essaaoatei i oe^Sgi a
_

. A D aa @3^eso

3 c«^ ? oftscoellaisis , a&

s sote' s sea

y ESS S toeaifea cfesr o te Pzl@

. 2 s°a®^c 3 c a oac^ l o^B 2 to EEs^steae S 8

© fc@8oGs iks

oefc Q osgsfe

a fijsea B& @ ^sfiasSbecKteDS'^tf.^ ^ 5G)fe'jiS'@'93£5.A3G8g & 8 9 De5 8 ©fgD^XS b &S

S 2 8 SSaSBl S fcg OSff

l fflPMSS/ 1 gf

f tSD^fe g feeCffifes^bpSS^

Gdly B08O8£° ) OSSWG'pi'-l^li o IT

® B& 2 tnlr^Jig ^

^Vg £j@3

D 8 saotote ' ESeao

, to gsSte d naoari a b j^&s^eollly " S^aSG

d cSl^bi'sradi^QgBa'- ^ fitaBitei^sireo®!^

QMS@ S3S88 & ©fet e tea csaf e <°4

? (t o q^coolto

. "1^

2 wori^^«aifc?&ffli ^

2S.@ai«^^ , gfa8feaO'^!® ^ •*^aQSG@fiBSra

@ QQs o c^iag&v s Gb¥@@s & ®f f a TSsv s oss d a css@s

S <Erc & 0 b peSte S i b E! b god&i g ^SSKSOS

. Irt e ©sERfi^s ?

feKsRsa 8

© OESK S -idffisa fe &3

ts%, t s gsssjf^ l OE I oggaso& n felMSI^dk^^'ei^Sbodk) (tesfe(®c^(a»iteifee , jQ^(^i£gfea^^t e gsofesniatei l &$$? & ^1 ^ (§30 ^ c ^ < > © caf e (if a ggsiiG t b (i&^a&s rccoS a feda & i osfescias^ l t&aiiEr f tea @ ? Q sssntests s jpa , Ha zM fcj sferafe a fis G&fc@c

3 bsfott5© B •CJEESS I oSte w JS

s p ® j^ss i 0(2^2 ? oateaiEill ^ 5 3 cfflb S fe to OB

Q tea sst o csaa b @ss2i l Ib.ECsi) G s c^HdfeofiB g ©ssi^ligCssaQ

. lIMaf c ©§©

3 i^ p l^gMsca c sBc a isoe^ J •gs®«^ o q^s^gfeit e G°1GS 3 fi® (& 5 •»d^teC33Aife3'3! > t a o csaCsfo

Q D<a5ap2SD8EiB

Q DpjpsigpfeDSoil

y ^jtso O 0 ® te isss

. ©sdssgs'Es a ®^l& 5 teS^SEC q5g3cS2 S ttte3 b ip®= %ks!$3?attimG

gSigcfas ^ tea to-Esos ef

f soosit o ®2&i ? v^s 3 o ecsA c SKS S 0 ferot e EgaK J Ecatrfa

. E^ss = cito8fe@©^itef^intemtifiafe&(^Q8 ^ £2ff^3S

3 ffc®sa fiEa Ks8Sai

G ^ic S O Bfca?

3 to gsss^^b a Q ®®S> » as © 0 8 tee! eaaffl sit e oMa&oge' b caikSDQi!ib % @gss ° <? 9 •waaitenBEi^DStoQ^CsssjfeKa ^ (ofese

. '

. ( ?^©(&3!in**ffi^B3i ^ <g^^w^*>^l^@'W8l!!s^^8soE^i!te8aa^ ^ toa &238&

0 eo« ^ 8 & ihS s Cx3d!8E

O @b'*»S(?s ? S 3 b q?^!!©' "

s^^»i^d«^@Da'a^^©rfi«tes ^ offisS

a Cssq p 8E& 3 papa ? G^3 3 cjs^ic a cfisd a to ^3JS> » n S i ragi fe^i!©» SEE

S et e ooosdSat

e Gsa^iipteJQ

. T®to(^^bi^tofe8S^e3<^!)2'0[k ^ " • TTtoia^^^l^'di^fc&yoBc&'fc^'^ ^ -«?^osiS2lSte8!nfe^§di^stoI! ^ D y sSal o E2Site 4 to 2^=3

^ EacEsf a @0 8 6 3 Esose

S wa y fca@sfess3 # db®fe D C «!bc2 Q ( b j^s-^fei l 0 3 c^faf e

. R^^S y o M tssaSfesirfj

? DSSSS S Ss o ©seo cssife a Alcsi o 9

3 esok&o ^ksata ? SO

. "SMj-bBE^afcsiGi l ossl b Gt o Q& s gas^tl^t^SD&ISs'pgt^E^b''^ ^ 63^3C®o@7Bfes^®cs^^cs3p®^ ^ •afegsfie^oas^arat^e ^ b -csfkaz i @ 3 cJ.[jfe'[rj l e&zh£Mp E^arn't e fescS Olb

S O C&®n ! Ib08fcC.C^Qfes i tet$ S©iBfe8£§S 3 (§3 ^SCM^fci^Cl^'SQ'Je^b^S^ ^ E3D!!!?f c <»ls§d!82'o ES^S^f e D*3S& C ^ ffifeo O ^

QQ§i!»-C§

> foQ ,fls & ' fe 8 te^®s£l (&3 ®2 & dd l @3t!!«

3 C§o!^@£2E > .Eafta^^jsgaaj^^easfeooBQ- ^ 1 ^ S ^ o cso=dywis ) *^.£3oEiro£fCK^^S3ai22ps G b [jiodKl g i®

©aam?§ 3 i& s g^Ss^nssssSscsste

a 8 ® '•jstsSess o ps^/y^s S ••iSfes A to ijfefes a G-t. a (gsafifeBifQfe ) D S & t&ssa csafecteBiaiDBJs ' J&S 3 -sf f esto^ls o ga * (SstesMs i c&E^dte'fcQ'^'? ^ •CTtea s 8&

o ®t£& fe o a ©»BBteD^ I fesStt e@ > geajcsBnia BSk

s st e 8123

8 QC J caj^liSc J c « bfe o 2f l a & B D b tgDac^ l c s ©a o Giate^iEsisa B ® f os a appaBQim

DeoasA o 0

© aEc a Oigro o ©CafcacaDSffS

n 5 a & , ^ig5sMc3ffi!r'& j fcifcsiOj s-^fei b b ijasaa s Cawaafe a b drsssyia te HQ

. 2

. ITMa'G^agSlef o &8gbs e QSC ^ alfe s fiaSeo DD^ti^

^ fisiESi 20

. E^'sScnS^siSs^ i (£a e s® 3 oaeoii s 0

® Hcai t sfeo-goocss i aa-vi^fe a a&& J a wil l Ik s IsSr a $2 5 o a o 8@« y •yoBesSij? csi

ssJkm^Q

d a a t 0 gs& 8

• ^oc m DIU J n u rrtiuv i JHLX. O • I-I<C-OQ > io-^ o p.1 1 A 0 1 OO I 1 U<iO<

i • #-00 / Q U

5,183,60 0 7 8 between inlet

s 1 1 sn d 19 ; ib e mstri

x i s blankete

d alon g polymeriz e unde r adiabati c condition s a

tleas tt o th e h s lengt h b y a g o whic

h approximate

s th e temperatur

e poin twhe n shrinkag

e U substantiall

y complete , ofth e matrix. Th e matri

x i s thu a maintaine

d in subitan * I n th e embodimen to f HO . 2 , th e gelle d matri

x shee t tia l therma l isolation and polymerizatio n proceed s i n a • 4 2 i i carried o n th e we b 4 and emerge s from soakin g substantiall

y adiabati c manner . 5 chambe r M . There , th e we b 4 i s peele d from th e botto m Th e apparatu

s o r th e presen

tinvention in on e em* o f th e matri

x shee t43 . The n travelin g ss w 26 , whos e bodimen twoul d en

d wii h soakin

g chambe r 18 . In th e machin

e directiona

l velocit y i s carefully synchronise d embodimen

to f HO . 2 . however , additiona l optiona l «* h thewe b 4 velocity , make s a transvers e cu tthroug h item s ar e included as drmftwr

i bdow . th e matri x 42 . Th b separation b y cuttin g physicall y l a th e regio n where th e matri x aa d we b at e sepa* » W« w tb e delicate an d dtfonnibl e -portions i

f th e nied , there h provided a travelin g ss w 2 & Thi s « • gelle d niuin x ftom shnhk y stresse s produce d te th e nngemen tfcr separatin

g th e sheetinto individua l downstrea

m curin g step . Sw * astejpJsjptanaTan d piece s i s optional . Alternat e way s t o contro

l shrinkag e othe r mean

s C M b e provide d at

> anrioned I ahwe . force s include th e w e o f

pinc h roll s o r by advancing IniteembodinitttofITO.2.^indiv^ ^ web4^«aughay>)ower > mtrth.nweb4o r b y othe r » nheet t44.« » de,»sne d y A e swfa y y^^Tfc ; ^d s techniques know

n l o thos e skilled i n th e si t* • »° * *»"•• » "WOrtin g tt e gdle d star t44 . id * Dewnstreem ofth e travelin g u w % ther e i s pro - ^ces ^ th e ^ttonslse^httO^^a i Bet e vide d a secon d sectio n o f

conveyo r platfor

m 3 1 havin g lnogeIledSh^44optionanyma^liea«toasawn| l 

### t m i twe h 4' . Jus tbeyon d th e secon d sectio n of eon - ^^^SJ^^^SS^SJS ^ veyo r platfor m 28 , ther e i s provide d a secon d radi o » ^^J^^i^»S^lSl^SS S wsveintcrfcrcncecbokeMuiJacentanoptioiuJsecOD d TMS^* ^ lS32^KSL?STM ! heatin g chambe r 3 1 Again , th e heatin g ebaabe r 32 b JSS^?Jffi^£2KStee K 

# ItlBmAtSX^^ enSSte5SSS&^5 ^ ehunb^Sathenkpn^mida.teteribenceehc ^ 3Btf5Stt^JSw5S22 ^ 3&A4iace«tothaexhteterieren«ch^Mbaseeond - ;£^JJS3££SL^ ^ a^^d^SSissuedwMcbisco * „ S^^T^E^ ^ structed an

d operates i n essentially th e sam e manne r a s ,b « th e surToundin a ta s ao d surwonln a member a i n adi^ticsoatoa^bwll.lXwM.t^rfthesnc . a * chambe r iTtf-eh^tteann ^ and soaking chambe

r 31 , ther e i s a coolin g section . atsodate d regio n o f tl » cwm g intfri x shee t44 , th t ^mtionofiheapparatoofttapre^iinventioo , ^trftdfeeiivei y kt e thenndbolatio n fron It s envi f iUuaia^bthemtejdin^tfHO. * follows. Xdcae n coate d paper sheets 4 i s pulled from an d web s 4 an

d 4'hav e a lo w bea tcapacit y and lo w tol l % and threade

d throug h th e equipmen

tlin e t o th e tfcenna

l conductivity . Thes e wrihkn tprovid e n wimotorized rewind ro 0 2 L A s th e we b 4 advances , Jus tfa^. temperatur

e profil e l a a

D .direction * unifor

m prio r t o th e entranc

e t o th e castin g section , th e edge s o f «ross-section d shrinkag e and mntaaxatio a o f

wans , th e we b 4 arc folde

d sharpl y uprigh tt o for m a moving ^ y^»int w and wifr^ftmr d strptu s troug h wit h vertica l edges . •yj u pieaeo tinventio n relies , i n part , upo n certai n A Iiquidnwtrix42which has bee n heate d toatemper > reUrionthips aiures twhic h th e hairiif

c ofth e caulys ti s such tha tth e enie i o f

polymrrf

c w h matirrial

tsn d thri r raHyi* ' matri x wQ I no tpolymeriz e I

n lh e pip e leading t o th e eystem s discovere d t o b e advantageou s te th e continu * cantin g hea d 8 and whic h ha s bee n passe d through, a 4

5 p ^ t*wfag o f

polymeri c imrt

triab **»c h shrin

k duHhg stati c mixe

r i s pumpe

d a ta constan

tflow rat e throug h polymerisation . Various materials wer e ne d i n lh e th e castin g hea

d 8 onto th e movin g we b 4 . Th e relation * WQ ^ repone d and th e Wmiff r o f th e presen

ttevm* sU p amon g th e matri

x flow rate , ih e we b velodt y and tio n sr e characterized a s follow s butar tno tmesn tton s th e we b widt

h establishes'th e averag e thickness o f th e limited b y th e following description . Thoe e eklDe d te Bqol d matri x 42 . Tb e we b 4 advance s a sufficien tlengt h J O ibea n wil l recogniz e tb a variou s dasa o o f polymeri e t o allo w tb e liqui

d nutrix C t o fle w t o a levdsurfiice : material s an d eoanposite

s whic h ca n b e used fa accer* * Thev ^ 4 the

n euer s th e heatin g cavit

y 1 2 threug

h th e dau e wit h flie presen tfeverition. faterierence chok e 10 . I a tha thatin g cavit

y U , th e , iqul d matri

x i s heate d quickly an

d uniforml

y un g Folyealc r Bea m radio frequenc

y energ y t o a temperatur

e selecte d l o 55 A n unsaturate d polyeste r cartin g resi n i s prepare d b y activat e th e catalys tgroup an

d 1 0 caus e polymeriratio o a condensation resctiaaofo^ydrfcaleQbQ l an d dibasi c t o a g d stat

e withoa tcawin g a strongl

y exothermic adds . Th e viscou s reaction product a ar e ti m dissolve d reaction an d withoutcansing execuiv e shrinkage . fa viny l o r acryli c mooomei a such a s styrena , viny l Web4ibcnadvancesthrougheshfaterferettechek e toluen e o r methyl methacrylat e (MMA) . Tb e rates I S aa d throug

h adiabati c aoakb g chambe

r 1 8 whie h i s s o used containe d abou t30 % styren e monomer , about mctmaine d a tth e sam e temperatur

e as th e aasociate

d • MSf tMM A monomer an d hav e a viaoadqr o f

dbou t sectio n o f th e matri x throughou

tit s lengt h a s describe

d 50 0 t o 2^0 0 c p at2 0 degree s C above , fa thi s manner

, th e combinstio n o f

startin g resin . Thes e ream

s typicall y contai n n steal ! amoun to f ia * estslyat , heating temperatur e an d rat e o f advanc e o f d w hibitor , sue h a s hydroquteone t e preven tprematur e we b ca a b e adjuste

d t o provid e a fir

m rubber y g d exh * 4

S gellin g durin g storage . The y di o typicall y contai n anti in g ih e soaking chambe

r 1 8 whic h g d ha s notye tunder

* oxidan u an

d U V absorber

a t o hd p contro l agln f

and gon e exces s v e shrinkage. I n on e embodiment , th e ma * U V degradation ofth e cure d put s whic h caus e yellow * tri x remain s i n aoakia

g chamber 1 8 lon g enoug h t o lag . embrittlemen tan d othe r physica

l deterioration . 

# IVP.1 2 5LIN I CT-U 5 ft U TAILIN

I 5ALH 5 • I-U---0 • iO-^ O 

### laiaa'iiuzo^.ftiu/o u



## 5,183,60 0 9 1 0 d d re^pplSsan' d ihS'exac tcompositio n i s p! £ "HLPOIN T 90 " (Wite

o Cheraic d Co. ) prietar y t o th e supplier . A wid e variet y cf resin s ea n be Mediy

l ethy l keton e peroxid e (MEKP ) i s n catdyst use d accordin

g t o di e presen

tinvention

. However

, typiedlyuaedtoiainawftemdicd'reacriaos'iapdyes* ' thos e found particularl

y wel l suite d t o be adapte

d for * . teirresins . Whe n i tisused donat e th e resin; itbegin s t o usete the presen

tinventionihaveth

e following charac

- toomiwie a

ta toly hig

h taaperntur

e abov e 200 » P . teristics : (I ) The

y ca n be pdymerize

d t o a thermoset

- * Wenuarfwimasmdl^BiDOinrtofn^inphiher ^ 

### ti««ateby«fteradicdreKtle»iri^faycatdys * -^^^!^^SS}S^SmS ^ an d (Z ) tb e densit y of th e cure d test e i s substantiall

y Thus , polyeste r iwfaconwnte

g abou t1- ^ o f MEKP , lttgberthantheIiquidretJn.U n 

### theretbshrinfa<farin

g , 0 

### ^J*"*!*^ 0 

### ^ ^Accord^tepublishedmdtne^mddend S ^^^^^1^..%^! ^ th e infilled mt e typicaU

y ea n shrin k u p t o abou t15 % ^S^i^J^SSSt 50 

### * ,ed 

### ^ m,BB n 

### dur^i^vmerizatiooofr^eateranduptoaboul20 % *•"««" te dimethy l p&tbtiate . te th e ease o f unfille d acryli c teste . Th e mixture s o f w 

### "U5F*245 " (Witc o Chemica l Co. ) rah an d fDIe r use d (abou tJS * resi n an d 63%miner

d *Mte*«h*l.2 J U s OethjMexnnoyl perox y hex * 

# ^ t,H 

# WTT^ 4md 

# %^Lf^I^ 4bhDqS^^t£«dSo» ^ M*"^*^/W~Tte*ir.te8lat o «torobata*mlVF.Iib^S«aWbaSv e cocunlvnropically.Le

, th e sam e amoun tm eac h diree * n 

### \wt» ' tJon , a volum e shrinkage'o

f 7 % woul d be cause d b y M 

### linea r shrinkag e o f 241%. - Lowe

r filler rate s wiO'hav e • "PERCADO

X It T (AKZO Cbemied

s Inc. ) correspondingl

y highe r shrinkage

. DH4-t-butyl<cycIobexyl)»perox y dtearbonat

c i s a fa tb e cu e o f

a minerd-nOc

d resi n matri x i n whic h powde

r tha tdissolve s in. styren e pionoimr, aa

d decomthe ADe r ha s a substanti

d bea tcapacity , muc h ofth e pose

s rapidl y in thamrina

tabou t110 * P . J tha a bee n fine energ

y chang e durin g polymerizatio

B resuh s fa a n 3 3 .£ ^ W 

### produeeagdtimBOf4- 3 aunutesn l 130 " P. * facreased temperatur

e o f th e fiUe r a s waf l a s th e resin . ja d diu

s ca a be use d s s a a alternativ

e t o th s cerabtea

* The redn s mos tpreferabl y adapte d for th e presen tfa* tio n o f MEK P an d cobdtnaphthenato.ltI

s supplie d as venrknshOM

M be cnrabl

e in a reasonabl

y shor tperio d a a 100 % activ e ingredient

. durin g whid i the find cur

e b conducte

d in a n essan * m~*<***nar*» «*• * /*«*<•;•. #•»

. I„I . « .

% tidlydieimdlyisdattdcnvironnmtwitfao w TRIGONO X C (AXZO Cbemieds Inc. ) a d hea to f reactio n causin g enoug h temperatur

e rise t o t>buty]perexkfabenzoattbali«iMthatdecooipoec s caus e therm d degradatio

n o f th e polymer . - rapidl

y i n polyeste

r a tabou t250 * P . I tIs supplie

d a s a n 100 % activ e ingredien

t EXAMPLE

S

OSumiirtrnjnin i Mttfcy ) wnhaayta u MH W A1HPb«* r Pte»m » Fantefc

t I U

4 1 41 4 30 9 

### Aluminu m Trihydrat

e (ATH ) Aluminu m Trihydrate(ATH) b a naturall y oocunfa g 3 5 miner d derive d froa processin

g o f bauxit e or e use d te Aspect

s o f the presen

tfavendon nr

e show n b y th e the manufactur

e o f dununummeta

L Its'inolecula

r fbr * followin

g example s for puipose

s o f fllustratioo. .Thes

e nuIsisAbQi3H20.SBdhihspure,refinedstste,itba a example * an d cmhodinwM

x ar e n w mean tl o limi tth e almos twhit e t o yellowis

h granula r soUd . fa a finely favendon i

n an y way. Thos

e skille d fa th e ar

twin reegroundfomv AT

H ha s bee n widel y use d a s a fillerfa * ° Qgniz

e dia tchanges , addition s an d modification

s ma y b e •|a»sticsloimpfOVerirerwisUnce.IibmoHU«fttlwhe n irade,a

U withi n the . spiri tan d scop e o f tb e invention

, groun d t o a n averag e partid e siz e belo w shou t3 0 mt - EXAMPL E 1 croas , bu tno tto o muc h bdo w abou

t5 microns

. Th e lo w practie

d limi to f particl e siz e b se tb y th e viscosit y A matri

x rnlxtur e b prepare

d eoatppae

d of t ofth e resi n * AT H matrix

. Thai : b , a s the AT H particl e .•». . dsc : 

### '" 6 reduced, it

s highe r surfac e are a resulo te te* crease d visoosit y ofth e matrix

, makin g itk m suitabl e te the presen tinvention

. A tabov e shou t20-50000 cp , i t become s ver y difficul tt o process, pum

p an d pou r th e - _ nurrixVVjt

h a deiire d mixtur e of^Slf c ATH , 35% min , * th b vbcosit

y rang e occur s wit h AT H parddeds e o f

Th e matri x b pumpe d a ta rat e of44#/W n throug

h abou t1CV-2 0 micron s dependin g o n die processin

g con * a modifie

d hea texchange r t o prehea tth e matri x t o 125 * dittoe s an d the .particula

r bran d o f ATH. The.Ugh F . Onc e preheated

, caldya tan d pigmen tar e adde d an d Heede d Hmi

te f particl e size woul

d be determine

d by « . 1 

### * iu 

### * b

y us e o f a stati c mise r assembly . Th e eompod* its settlin g rat e andthus b dependen

ton th e coneentra

* tio n o f th e catdys tsdutionjs.asfoBo*s : . tknf o th e seri n an d th e g d time ofth e matrix

. Fo r 45 %

____________ — — 

### -'^_______

_ AT H 33 % i«ri

n mixtures , h b prefer ^ te di e ftfesea trmAatf

c . is * inventio n tha tparticl e siz e no texcee d abou t3 0 nderons

. Tn>an C is* . Th e preferre d filler ratio

s ar e from abou

t40 % 1 0 40 tymmt4mtmm io » abou t15% , an d die mor e preierre d rsri o b from abou

t 50% re 65% . tlw lower rede, of<»unc.befe g th e mos tTl w catalyr tsdutlo n b a~ctera

d a ta rat e o f 02 3 difficul trelativ e t o hea to f reaction . Tb e lowe r pre * (Mat e Int o die matri x stream . Tin s provide s ncoooau * /erre d redo o f AT H b appYoximatd

y ths minimu

m trado

a o f 0\2 % Percado

x I6S , 02 % Trigono

x C base d oeneanrado

n tha tsti U provide s goo d fire-hazard char*

. *4 S o n th e liqui d portio n ofth e matri

x mixture . Th a matri x acicristlc s suitabl e fo r buildin g applications

, bu tlower • b then-dispense

d o a t o th e we b travelin g a tthre e fee t ratioscoul d b e use d iffirereriuanceisofn o concern , or pe r minut e wii h s widd i o f 38 " t o produc

e a aomia d i f othe r mean s ar e wed t p provid e fire resistance

. 0.300 " sheet

. Th e matri x trsyd s a suffleien

i distanc e t oP.1 3 

### SEN T BY:U S PT O PATEN T SALE S ; 7-12-9 6 : 15:2 9 ; - 19199410234:#41/5 0


## 5,183,60 0 1 1 1 2 giv e approximatel

y 2 minutes levelin g time prio r t o aomin d 0.500 " sheet . Th e liquid b then heate d t o initi enterin g a n RFduunbe r where abou

t1 3 K W b applie d at e th e polymerization an

d b dlowe d t o exother

m t o a t o lh e matrix

, th b yidd s a temperatur

e o f approxi* . temperatur

e o f approximatel

y 230 * F . t o 240 * F . Durin g maid y 150 * F . t o 160 * F . whic h start

s di e polymerize * th e exother m perio d th e shee

ti thel d i n ib e adiabati c don . l n approximatel

y 6 minute s th e materia

l ha s gelle d s section'i o bolat e h from th e outride environment. Tb e t o a nibbersut e an

d the pape r b removed . Th e continu - • pape r b the n remove d an

d tb e sheetbeu tt o b e depos ou s shee tb cu tt o the desire d lengdi . A tdu s pan tth e ite d om o di e r*^ii f bdt . Th e shee tb the n pesse d matri x ha s increase d in temperatur

e du e t o th e exother * throug h di e secon d R F cavit

y sn d heated t o apptoxi mi e polymerizatio

n reaction t o approximatel

y 210 * F . tnatd y 250 ' F . Afte r passing throug h th e soakin g area bu thas no tye tha d sigmfican tchang e to density . 1

0 & sheetb dlowe d t o coo l t o soot n temperature . Th e Th e w tmatri

x sheets ar e deposited ont o s second d^et tar e observe d t o b e free ofwar p an d othe r defcets . 5 * S^uf^J? 6 

### J?" TM *•*•• * • *? c m d 

### * f Upo n physic d tesdn g i ti s found tha tth e residu d ity . d 

### ^ , 

### ^!S^^ d 

### ^I?»" ^ taeb^herUwthdofeznnxpteLItteiwftiiedtli t wil l hav e bee n heate d t o approximatel

y 265*F. I tb t^t-a^usotionwIiemfafa^lmaeetheBseof n die n psse d tea secon

d soakin g clumbe r where,I * i s X,E^J!ns^^ ^ ^per«ureinciearatoappre^dy^F..»(rF . 3 e 

### ^ e 

### S 3 

### ^ < 

### SSSSw " do e t o the hea

tofreaetion . Th e fully cure d sheetb the n *"?.

_r"^-„T.L^T£^7r_T7Lj.,_ t_•*«*« . coole d evenl y an

d slowl y t o roo

m tempenture . Th e ^iHSiSSS ^ IKSlTS S

b e exhaustiv e o r t o lfau tth e inventio n t o tli e precb e EXAMPL E 2 fonn disclosed . Obviously , man y modifications aad A shee tU prepare d accordin g t o example 1 wit

h th a ^tion s ar

e possibl e fa Hgh

to f th e abov e teaching , exception dia

tdi e cuttin g ste p b omitted . Tha tb . onc e j 5 2^^? M 

### ^L5^ e M 

### ^ fff^T^T!!!!^ th e idcer e pape

r we b has bee

n removed, th e continuous chosen an d described i n orde r t o bes texplain th e princt gelle d shee tbredepotite d ont o a continuous bd tTh e P 1 

### * * o f th e inventio n an

d it s prettie d apptieario

n t o bd tb constructe

d wths tftdot * it trestrictsBpnag e thsr* y enable other s skilled fa th e si tt o bestutiliz e th a betwee n th e shee

tsnd itself . Th e spee d o f

th b bd tpre f

bveado o te variou s embodiment s and wh h variou s errably n independentl

y controllabl e s o (ha

ti tca n ru n n 

### modification

s s s nre suite d t o th e particula

r us e oontcn v slighd y slowe r du n th e initl d web . I a dd a manne r plated , ahrfafcag c ca n b e accounte

d for . Wha tb claimed is : Th e eondnuou

s matri x shee tb die n passe

d throug h LAmethodofooottenoudycssttegapolyxKrizahl e th e second R F cavit

y an d soakin g section . Onc e th e .Squi d materi d whic h contain s a particulat e filler an d ahee texit tth e ove n i tb then cu tt o th e desired lengdi u 

### which shrink s during polymerization t o produce a shee t an d allowed t o coo

L Th e sheets ar

e Observe d t o hav e n o substantiall

y free o f ware*, eonsbtin g essentiall y of t rignificamififrereneeinappeafanceorphysicdpropcfw (a ) depadtin g a controlle d amoun to f a Uqui d mixtur e ties tha n thos e o f example 1 . containing sai d materi d o n a we b having a a up~ pyiwp i -p « sticsi n directio n sn d a downstrea m directio n and 4 0 movin g s ta predetermine d spee d t o provid e a A dieet b prepare

d accordin g t o exampl e I wit

h th e movin g mixtur

e *o f containe d thickness ; exception tha

ta secon d R F cavity b no tused . Onc

e th e (b ) heating ad d mixtur e substantiall

y uattbrady idle d materi

d ha s been cu tan

d redeperited ont o th e throughou tH s cros s sectio n b y radi o frequency secon d bd ti tbellowe d t o rise i n temperatur e unde r i u energy downstrea

m o f sai d deporitte g ste p o tleas t ow n hea to f reaction , during whie h dm e th e sheetb 4 } 

### ten temperatur e »v**yfr«» » t o labiate polymerize * TnvtKn g throug h th e secon d adiabatic soakin g are&andlitm ; ' reaches a-maximu

m temperatur

e o f approxfmatd

y 2S0* ^ providing CftndWtm twhif h fabHste ahrfakag

e F . Th e duet s exitth e ove n an d ar e coole d t o roo

m forces tha

toccu r ta said mixtur

e furthe r down * temperature. Ther

e b a o significan

tdifference fa np* p^m ft^ ^ y t^t, , fop, traasstdasfa n ap pearanc e o r physic d propenie s whe n compare d t o M 

### stream : sheet a o f example I . (d)matotabte g ad d botae d mixtur e foretime da-re afte r i n substanti d Ihenn d bdatte a an d free o f substanti d conStrdnin g forces suc h tha tpelymeri -

- astio n an d Ambe r shrinkag

e ocea n te a sabstan * 3 5 dail y adiabatic meaner ; whereby a shee tb provide d free o f eobatantid warp . 2 . Th e metho d sccordin g t o dafa n 3 wherei n ad d radi o frequency energ y bfad w rang e o f abou t4t o 245 0 megahartx . 31 A medio d o f

continuousl y oustin

g a nolymcrisabl e Bqul d materi d whic h contain s a paideulate lille r an d which shrink

s during polymerization to-produc e n shee t substandaO y free o f warp , eonsbtin g esscadaDy of t 0 0 depositing a controlle d amoun to f a liquid mixtur

e 4 5 containing ad d materi d o n n we b havin g a a up * a o tha tthe Percado

x concentration b 04 % base

d o n strea

m directio n an

d a downstrea

m direction an

d EXAMPL E 4 e matri x b prepare d compose d of t thuwttc d Vttfmtt

Ke n AT M SM I

an d b pumpe

d s t 2 0 #/mt n an d mixe d wid i a catalys t mtptn f ffft* * fning *

SkRaduIS S liytt M IS « SS * 

### liquid . Th e matri

x b the n disperse d ont o a we b movin g movin g a ta predetermine

d epee d t o provid e tw o fee tpe r minut e wit h a widt h o f 30 " t o produc

e a moving mixtur

e o f controlle d thickness; - 

# n