Source: https://patents.google.com/patent/US20040235379A1/en
Timestamp: 2019-04-21 18:58:35+00:00

Document:
This application is a continuation-in-part of pending U.S. application Ser. No. 09/955,395 filed on Sep. 18, 2001, which is a continuation-in-part of U.S. patent application Ser. No. 09/663,255, filed on Sep. 15, 2000, which claims priority under 35 U.S.C. § 119(e) to Provisional Application No. 60/168,057, filed on Nov. 30, 1999, now U.S. Pat. No. 6,586,353; of pending U.S. application Ser. No. 10/354,216, filed on Jan. 29, 2003, which claims priority under 35 U.S.C. §119(e) to Provisional Application No. 60/352,691; of pending U.S. application Ser. No. 10/354,220, filed on Jan. 29, 2003, which claims priority under 35 U.S.C. §119(e) to Provisional Application No. 60/352,692; and of pending U.S. application Ser. No. 10/354,219, which claims priority under 35 U.S.C. §119(e) to Provisional Application No. 60/352,693.
To produce the composite materials of the present invention, the applicant formulated the coating using just three major components, water, filler and binder (see Table I above). The amounts of the major constituents were as follows: approximately 27.42% water, 25% Hycar 2679, and 34.60% clay (dry percentages are 0%, 29.43% and 55.40% respectively). The binders Cymel  373 (approximately 3.70% wet/6.97% dry) and Rhoplex TR-407 (approximately 4.50% wet and 5.30% dry) were also used. In total, the binder and filler made up 67.80% wet and 97.10% dry of the total coating. Dye and defoaming agent made up less than 1.00% of the dry formulation, water repellant made up less than 2.00% of the dry formulation, ionic material (ammonium hydroxide) made up less than 1.00% of the dry formulation. The defoaming agent was Drew Plus Y-250. The materials were mixed in a reaction or mixing kettle for 45 minutes.
The coating was used to coat woven and non-woven fiberglass mats on one and both sides. The woven mat was manufactured by Elk Corporation of Ennis, Texas and had a basis weight in the range of 1.4 lb./sq. to 2.0 lb./sq. The mat had a porosity in the range of 800 to 1,000 cfm/ft 2. The non-woven mat comprises from about 80% to 97.5% H glass filaments, from about 2.5% to 20% Evanite microglass, from about 0-15% polyester fiber (50/50 mix of ¼ inch and ½ inch length, and from about 5-30% acrylic based binder. Generally, when such highly porous mats have been coated on one side only, the coating bleeds through to the other side. In accordance with the present invention however, the novel coating comprising clay coated the surface of the fiberglass mat very well and did not bleed through to the other side of the mat. The coated article was durable and flexible and did not crack on bending. Typical tensile strength measurements for uncoated versus coated were 75 lbs/3″ and 217 lbs/3″ respectively. Typical Elmendorff tear strength measurements were ≧3200 grams without the sample tearing.
Coating of the fiberglass substrates was accomplished using a hand-held coater which can be obtained from the Gardner Company, but any conventional method, such as dipping and flow coating from aqueous dispersion, and the like, followed by drying and baking, may be employed to coat the substrate as is well known in the art. Best coating results were observed using a Gardner profile  10 blade. While the coating was still wet, aluminum foil was laid on top of the coating. Then, the samples were placed in an oven at approximately 400° F. about 2.0 minutes to achieve drying and curing. When the coating was dry, an adhesive bond was formed between the aluminum foil and the coating. Additionally, the coating may be separately formed as a film of one or more components for subsequent combination with the substrate.
5. The composite material according to claims 3 or 4 wherein said metallic component is adhered to one side of said coated substrate.
6. The composite material according to claims 3 or 4 wherein said metallic component is adhered to both sides of said coated substrate.
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References: § 119
 Application No. 60
 §119
 Application No. 60
 §119
 Application No. 60
 §119
 Application No. 60