Patents by Inventor Michael John Block
Michael John Block has filed for patents to protect the following inventions. This listing includes patent applications that are pending as well as patents that have already been granted by the United States Patent and Trademark Office (USPTO).
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Patent number: 11850809Abstract: According to one embodiment, a system for manufacturing a fully impregnated thermoplastic prepreg includes a mechanism for moving a fabric or mat and a drying mechanism that removes residual moisture from at least one surface of the fabric or mat. The system also includes a resin application mechanism that applies a reactive resin to the fabric or mat and a press mechanism that presses the coated fabric or mat to ensure that the resin fully saturates the fabric or mat. The system further includes a curing oven through which the coated fabric or mat is moved to polymerize the resin and thereby form a thermoplastic polymer so that upon exiting the oven, the fabric or mat is fully impregnated with the thermoplastic polymer. During at least a portion of the process, humidity in the vicinity of the coated fabric or mat is maintained at substantially zero.Type: GrantFiled: November 11, 2021Date of Patent: December 26, 2023Assignee: Johns ManvilleInventors: Mingfu Zhang, Klaus Friedrich Gleich, Asheber Yohannes, Michael John Block, Jawed Asrar, Derek Cooper Bristol, Christopher P Sandoval, Matthew Walp, Edwing Chaparro-Chavez, Stanislav O Kukatin, Albert Patrick Faulkinbury, Christopher McBride, Bradley Ray Lockwood, Nicholas Gene Fitzpatrick
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Patent number: 11772336Abstract: According to one embodiment, a system for manufacturing a polymethyl methacrylate (PMMA) prepreg includes a mechanism for continuously moving a fabric or mat and a resin application component that applies a methyl methacrylate (MMA) resin to the fabric or mat. The system also includes a press mechanism that presses the fabric or mat during the continuous movement subsequent to the application of the MMA resin to ensure that the MMA resin fully saturates the fabric or mat. The system further includes a curing oven through which the fabric or mat is continuously moved. The curing oven is maintained at a temperature of between 40° C. and 100° C. to polymerize the MMA resin and thereby form PMMA so that upon exiting the curing oven, the fabric or mat is fully impregnated with PMMA.Type: GrantFiled: August 11, 2020Date of Patent: October 3, 2023Assignee: Johns ManvilleInventors: Mingfu Zhang, Klaus Friedrich Gleich, Asheber Yohannes, Michael John Block, Jawed Asrar, Derek Cooper Bristol, Christopher P Sandoval
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Publication number: 20230234305Abstract: According to one embodiment, a system for manufacturing a fully impregnated thermoplastic prepreg includes a mechanism for moving a fabric or mat and a drying mechanism that removes residual moisture from at least one surface of the fabric or mat. The system also includes a resin application mechanism that applies a reactive resin to the fabric or mat and a press mechanism that presses the coated fabric or mat to ensure that the resin fully saturates the fabric or mat. The system further includes a curing oven through which the coated fabric or mat is moved to polymerize the resin and thereby form a thermoplastic polymer so that upon exiting the oven, the fabric or mat is fully impregnated with the thermoplastic polymer. During at least a portion of the process, humidity in the vicinity of the coated fabric or mat is maintained at substantially zero.Type: ApplicationFiled: April 3, 2023Publication date: July 27, 2023Inventors: Mingfu Zhang, Klaus Friedrich Gleich, Asheber Yohannes, Michael John Block, Jawed Asrar, Derek Cooper Bristol, Christopher P Sandoval
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Publication number: 20230234306Abstract: According to one embodiment, a system for manufacturing a fully impregnated thermoplastic prepreg includes a mechanism for moving a fabric or mat and a drying mechanism that removes residual moisture from at least one surface of the fabric or mat. The system also includes a resin application mechanism that applies a reactive resin to the fabric or mat and a press mechanism that presses the coated fabric or mat to ensure that the resin fully saturates the fabric or mat. The system further includes a curing oven through which the coated fabric or mat is moved to polymerize the resin and thereby form a thermoplastic polymer so that upon exiting the oven, the fabric or mat is fully impregnated with the thermoplastic polymer. During at least a portion of the process, humidity in the vicinity of the coated fabric or mat is maintained at substantially zero.Type: ApplicationFiled: April 3, 2023Publication date: July 27, 2023Inventors: Mingfu Zhang, Klaus Friedrich Gleich, Asheber Yohannes, Michael John Block, Jawed Asrar, Derek Cooper Bristol, Christopher P. Sandoval
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Publication number: 20220063217Abstract: According to one embodiment, a system for manufacturing a fully impregnated thermoplastic prepreg includes a mechanism for moving a fabric or mat and a drying mechanism that removes residual moisture from at least one surface of the fabric or mat. The system also includes a resin application mechanism that applies a reactive resin to the fabric or mat and a press mechanism that presses the coated fabric or mat to ensure that the resin fully saturates the fabric or mat. The system further includes a curing oven through which the coated fabric or mat is moved to polymerize the resin and thereby form a thermoplastic polymer so that upon exiting the oven, the fabric or mat is fully impregnated with the thermoplastic polymer. During at least a portion of the process, humidity in the vicinity of the coated fabric or mat is maintained at substantially zero.Type: ApplicationFiled: November 11, 2021Publication date: March 3, 2022Inventors: Mingfu Zhang, Klaus Friedrich Gleich, Asheber Yohannes, Michael John Block, Jawed Asrar, Derek Cooper Bristol, Christopher P Sandoval, Matthew Walp, Edwing Chapparo-Chavez, Stanislav O Kukatin, Albert Patrick Faulkinbury, Christopher McBride, Bradley Ray Lockwood
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Patent number: 11198259Abstract: According to one embodiment, a system for manufacturing a fully impregnated thermoplastic prepreg includes a mechanism for moving a fabric or mat and a drying mechanism that removes residual moisture from at least one surface of the fabric or mat. The system also includes a resin application mechanism that applies a reactive resin to the fabric or mat and a press mechanism that presses the coated fabric or mat to ensure that the resin fully saturates the fabric or mat. The system further includes a curing oven through which the coated fabric or mat is moved to polymerize the resin and thereby form a thermoplastic polymer so that upon exiting the oven, the fabric or mat is fully impregnated with the thermoplastic polymer. During at least a portion of the process, humidity in the vicinity of the coated fabric or mat is maintained at substantially zero.Type: GrantFiled: April 3, 2018Date of Patent: December 14, 2021Assignee: Johns ManvilleInventors: Mingfu Zhang, Klaus Friedrich Gleich, Asheber Yohannes, Michael John Block, Jawed Asrar, Derek Cooper Bristol, Christopher P Sandoval
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Patent number: 11091598Abstract: Fiber-containing polymethyl methacrylate (PMMA) prepregs are described that include a first and second plurality of fibers. The second plurality of fibers is made from a different material than the first plurality of fibers. The PMMA prepregs also contain a polymerized resin that includes polymethyl methacrylate that has been formed from a reactive resin composition that includes methyl methacrylate. Methods of making fiber-containing PMMA prepregs are also described.Type: GrantFiled: May 13, 2020Date of Patent: August 17, 2021Assignee: Johns ManvilleInventors: Mingfu Zhang, Klaus Friedrich Gleich, Asheber Yohannes, Michael John Block, Jawed Asrar, Derek Cooper Bristol, Christopher P Sandoval
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Patent number: 10954349Abstract: This invention relates to a process of making a fiber-reinforced composite. Glass fibers may be provided. These glass fibers may be treated with a sizing composition that has a coupling-activator compound with the formula: S—X-(A)n, where S represents a silicon-containing coupling moiety capable of bonding to the surface of glass fibers, X represents a linking moiety, and (A)n, represents one or more polymerization activator moieties. The treated glass fibers may be combined with a resin to make a fiber-resin mixture. The resin may have a monomer, a catalyst, and an activator compound capable of initiating a polymerization of the monomer. The monomer may be a lactam or lactone having 3-12 carbon atoms in the main ring. The fiber-resin mixture may then be cured so that the monomer polymerizes to form a thermoplastic polymer matrix of the fiber-reinforced composite. The thermoplastic polymer matrix may be formed by in situ polymerization initiated from both the surface of the glass fibers and the resin.Type: GrantFiled: May 29, 2019Date of Patent: March 23, 2021Assignee: Johns ManvilleInventors: Mingfu Zhang, Klaus Friedrich Gleich, Asheber Yohannes, Michael John Block, Jawed Asrar
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Publication number: 20200368979Abstract: According to one embodiment, a system for manufacturing a polymethyl methacrylate (PMMA) prepreg includes a mechanism for continuously moving a fabric or mat and a resin application component that applies a methyl methacrylate (MMA) resin to the fabric or mat. The system also includes a press mechanism that presses the fabric or mat during the continuous movement subsequent to the application of the MMA resin to ensure that the MMA resin fully saturates the fabric or mat. The system further includes a curing oven through which the fabric or mat is continuously moved. The curing oven is maintained at a temperature of between 40° C. and 100° C. to polymerize the MMA resin and thereby form PMMA so that upon exiting the curing oven, the fabric or mat is fully impregnated with PMMA.Type: ApplicationFiled: August 11, 2020Publication date: November 26, 2020Inventors: Mingfu Zhang, Klaus Friedrich Gleich, Asheber Yohannes, Michael John Block, Jawed Asrar, Derek Cooper Bristol, Christopher P. Sandoval
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Patent number: 10773474Abstract: According to one embodiment, a system for manufacturing a polymethyl methacrylate (PMMA) prepreg includes a mechanism for continuously moving a fabric or mat and a resin application component that applies a methyl methacrylate (MMA) resin to the fabric or mat. The system also includes a press mechanism that presses the fabric or mat during the continuous movement subsequent to the application of the MMA resin to ensure that the MMA resin fully saturates the fabric or mat. The system further includes a curing oven through which the fabric or mat is continuously moved. The curing oven is maintained at a temperature of between 40° C. and 100° C. to polymerize the MMA resin and thereby form PMMA so that upon exiting the curing oven, the fabric or mat is fully impregnated with PMMA.Type: GrantFiled: July 11, 2018Date of Patent: September 15, 2020Assignee: Johns ManvilleInventors: Mingfu Zhang, Klaus Friedrich Gleich, Asheber Yohannes, Michael John Block, Jawed Asrar, Derek Cooper Bristol, Christopher P Sandoval
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Publication number: 20200277460Abstract: Fiber-containing polymethyl methacrylate (PMMA) prepregs are described that include a first and second plurality of fibers. The second plurality of fibers is made from a different material than the first plurality of fibers. The PMMA prepregs also contain a polymerized resin that includes polymethyl methacrylate that has been formed from a reactive resin composition that includes methyl methacrylate. Methods of making fiber-containing PMMA prepregs are also described.Type: ApplicationFiled: May 13, 2020Publication date: September 3, 2020Inventors: Mingfu Zhang, Klaus Friedrich Gleich, Asheber Yohannes, Michael John Block, Jawed Asrar, Derek Cooper Bristol, Christopher P Sandoval
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Patent number: 10683406Abstract: Fiber-containing polymethyl methacrylate (PMMA) prepregs are described that include a first and second plurality of fibers. The second plurality of fibers is made from a different material than the first plurality of fibers. The PMMA prepregs also contain a polymerized resin that includes polymethyl methacrylate that has been formed from a reactive resin composition that includes methyl methacrylate. Methods of making fiber-containing PMMA prepregs are also described.Type: GrantFiled: October 9, 2017Date of Patent: June 16, 2020Assignee: Johns ManvilleInventors: Mingfu Zhang, Klaus Friedrich Gleich, Asheber Yohannes, Michael John Block, Jawed Asrar, Derek Cooper Bristol, Christopher P Sandoval
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Patent number: 10569483Abstract: According to one embodiment, a system for manufacturing a polymethyl methacrylate (PMMA) prepreg includes a mechanism for continuously moving a fabric or mat and a resin application component that applies a methyl methacrylate (MMA) resin to the fabric or mat. The system also includes a press mechanism that presses the fabric or mat during the continuous movement subsequent to the application of the MMA resin to ensure that the MMA resin fully saturates the fabric or mat. The system further includes a curing oven through which the fabric or mat is continuously moved. The curing oven is maintained at a temperature of between 40° C. and 100° C. to polymerize the MMA resin and thereby form PMMA so that upon exiting the curing oven, the fabric or mat is fully impregnated with PMMA.Type: GrantFiled: May 8, 2019Date of Patent: February 25, 2020Inventors: Mingfu Zhang, Klaus Friedrich Gleich, Asheber Yohannes, Michael John Block, Jawed Asrar, Derek Cooper Bristol, Christopher P Sandoval
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Patent number: 10449735Abstract: According to one embodiment, a system for manufacturing a polymethyl methacrylate (PMMA) prepreg includes a mechanism for continuously moving a fabric or mat and a resin application component that applies a methyl methacrylate (MMA) resin to the fabric or mat. The system also includes a press mechanism that presses the fabric or mat during the continuous movement subsequent to the application of the MMA resin to ensure that the MMA resin fully saturates the fabric or mat. The system further includes a curing oven through which the fabric or mat is continuously moved. The curing oven is maintained at a temperature of between 40° C. and 100° C. to polymerize the MMA resin and thereby form PMMA so that upon exiting the curing oven, the fabric or mat is fully impregnated with PMMA.Type: GrantFiled: May 8, 2019Date of Patent: October 22, 2019Inventors: Mingfu Zhang, Klaus Friedrich Gleich, Asheber Yohannes, Michael John Block, Jawed Asrar, Derek Cooper Bristol, Christopher P Sandoval
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Publication number: 20190284352Abstract: This invention relates to a process of making a fiber-reinforced composite. Glass fibers may be provided. These glass fibers may be treated with a sizing composition that has a coupling-activator compound with the formula: S-X-(A)n, where S represents a silicon-containing coupling moiety capable of bonding to the surface of glass fibers, X represents a linking moiety, and (A)n, represents one or more polymerization activator moieties. The treated glass fibers may be combined with a resin to make a fiber-resin mixture. The resin may have a monomer, a catalyst, and an activator compound capable of initiating a polymerization of the monomer. The monomer may be a lactam or lactone having 3-12 carbon atoms in the main ring. The fiber-resin mixture may then be cured so that the monomer polymerizes to form a thermoplastic polymer matrix of the fiber-reinforced composite. The thermoplastic polymer matrix may be formed by in situ polymerization initiated from both the surface of the glass fibers and the resin.Type: ApplicationFiled: May 29, 2019Publication date: September 19, 2019Inventors: Mingfu Zhang, Klaus Friedrich Gleich, Asheber Yohannes, Michael John Block, Jawed Asrar
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Publication number: 20190263078Abstract: According to one embodiment, a system for manufacturing a polymethyl methacrylate (PMMA) prepreg includes a mechanism for continuously moving a fabric or mat and a resin application component that applies a methyl methacrylate (MMA) resin to the fabric or mat. The system also includes a press mechanism that presses the fabric or mat during the continuous movement subsequent to the application of the MMA resin to ensure that the MMA resin fully saturates the fabric or mat. The system further includes a curing oven through which the fabric or mat is continuously moved. The curing oven is maintained at a temperature of between 40° C. and 100° C. to polymerize the MMA resin and thereby form PMMA so that upon exiting the curing oven, the fabric or mat is fully impregnated with PMMA.Type: ApplicationFiled: May 8, 2019Publication date: August 29, 2019Inventors: Mingfu Zhang, Klaus Friedrich Gleich, Asheber Yohannes, Michael John Block, Jawed Asrar, Derek Cooper Bristol, Christopher P. Sandoval
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Publication number: 20180319105Abstract: According to one embodiment, a system for manufacturing a polymethyl methacrylate (PMMA) prepreg includes a mechanism for continuously moving a fabric or mat and a resin application component that applies a methyl methacrylate (MMA) resin to the fabric or mat. The system also includes a press mechanism that presses the fabric or mat during the continuous movement subsequent to the application of the MMA resin to ensure that the MMA resin fully saturates the fabric or mat. The system further includes a curing oven through which the fabric or mat is continuously moved. The curing oven is maintained at a temperature of between 40° C. and 100° C. to polymerize the MMA resin and thereby form PMMA so that upon exiting the curing oven, the fabric or mat is fully impregnated with PMMA.Type: ApplicationFiled: July 11, 2018Publication date: November 8, 2018Inventors: Mingfu Zhang, Klaus Friedrich Gleich, Asheber Yohannes, Michael John Block, Jawed Asrar, Derek Cooper Bristol, Christopher P. Sandoval
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Patent number: 10105871Abstract: According to one embodiment, a system for manufacturing a polymethyl methacrylate (PMMA) prepreg includes a mechanism for continuously moving a fabric or mat and a resin application component that applies a methyl methacrylate (MMA) resin to the fabric or mat. The system also includes a press mechanism that presses the fabric or mat during the continuous movement subsequent to the application of the MMA resin to ensure that the MMA resin fully saturates the fabric or mat. The system further includes a curing oven through which the fabric or mat is continuously moved. The curing oven is maintained at a temperature of between 40° C. and 100° C. to polymerize the MMA resin and thereby form PMMA so that upon exiting the curing oven, the fabric or mat is fully impregnated with PMMA.Type: GrantFiled: September 3, 2015Date of Patent: October 23, 2018Assignee: Johns ManvilleInventors: Mingfu Zhang, Klaus Friedrich Gleich, Asheber Yohannes, Michael John Block, Jawed Asrar, Derek Cooper Bristol, Christopher P Sandoval
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Publication number: 20180229399Abstract: According to one embodiment, a system for manufacturing a fully impregnated thermoplastic prepreg includes a mechanism for moving a fabric or mat and a drying mechanism that removes residual moisture from at least one surface of the fabric or mat. The system also includes a resin application mechanism that applies a reactive resin to the fabric or mat and a press mechanism that presses the coated fabric or mat to ensure that the resin fully saturates the fabric or mat. The system further includes a curing oven through which the coated fabric or mat is moved to polymerize the resin and thereby form a thermoplastic polymer so that upon exiting the oven, the fabric or mat is fully impregnated with the thermoplastic polymer. During at least a portion of the process, humidity in the vicinity of the coated fabric or mat is maintained at substantially zero.Type: ApplicationFiled: April 3, 2018Publication date: August 16, 2018Inventors: Mingfu Zhang, Klaus Friedrich Gleich, Asheber Yohannes, Michael John Block, Jawed Asrar, Derek Cooper Bristol, Christopher P. Sandoval
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Patent number: 9993945Abstract: According to one embodiment, a system for manufacturing a fully impregnated thermoplastic prepreg includes a mechanism for moving a fabric or mat and a drying mechanism that removes residual moisture from at least one surface of the fabric or mat. The system also includes a resin application mechanism that applies a reactive resin to the fabric or mat and a press mechanism that presses the coated fabric or mat to ensure that the resin fully saturates the fabric or mat. The system further includes a curing oven through which the coated fabric or mat is moved to polymerize the resin and thereby form a thermoplastic polymer so that upon exiting the oven, the fabric or mat is fully impregnated with the thermoplastic polymer. During at least a portion of the process, humidity in the vicinity of the coated fabric or mat is maintained at substantially zero.Type: GrantFiled: July 8, 2015Date of Patent: June 12, 2018Assignee: Johns ManvilleInventors: Mingfu Zhang, Klaus Friedrich Gleich, Asheber Yohannes, Michael John Block, Jawed Asrar, Derek Cooper Bristol, Christopher P Sandoval