Abstract: In a process for manufacturing a rigid-flex printed circuit wherein a rigid insulating layer supports one portion of the printed circuit and a flexible insulator supports another portion thereof to furnish flexible leads for connection the printed circuit to an operative device, a first assembly is provided comprising a curable prepreg insulator layer having an opening for the flexible leads. A flexible sheet spans the opening, and the assembly is pressed with one surface in contact with a smooth hard surface while the other surface is supported by a flowable curable prepreg layer. The insulator and flowable layers are a release layer which prevents bonding between the prepreg layers throughout most of the areas while permitting bonding along the edges. The assembly is maintained under heat and pressure to partially cure both prepreg layers and bond the flexible sheet to the edges of the opening and bond the edges of the prepregs together to form a flat rigid sandwich.

Abstract: An adhesive film comprising a ceramic powder and an adhesive composition having pressure-sensitive properties at room temperature (20.degree. C.), and a process for producing a multilayered ceramic structure, such as multilayered ceramic substrates, laminated ceramic capacitors, etc. using the adhesive film, are disclosed.

Abstract: A method of making a lightweight panel having a relatively soft foam-backed cover sheet supported on a relatively hard, self-supporting core in one simple step. An assembly of foam layers is built up comprising a core-forming foam layer, an intermediate foam layer, and a cover-backing foam layer, with a scrim sheet over the core-forming foam layer and a cover sheet over the cover-backing foam layer. The core-forming layer is impregnated with a heat-activatable hardening compound. The intermediate layer as well as the cover-backing layer may also, if desired, be impregnated with a heat-activatable hardening compound but usually in lesser amounts. The hardening compound coats the cell walls of the foam. The panel is formed by subjecting this layered assembly to heat and pressure between contoured dies in a single compression molding operation at a temperature at which the hardening compound is activated.

Abstract: A piece of fabric, preferably foam-backed, is laminated to a concave, rigid substrate, such as a fiberglass shell for an automobile headliner, by:a) coating the back of the fabric with a heat activable adhesive, e.g., a powdered polyamide;b) placing the adhesive side of the fabric against the concave side of the substrate;c) preheating a perforated male die having a complementary shape to that of the substrate;d) pressing the die against the fabric;e) ejecting a shot of superheated vapor, preferably steam, through the fabric, thereby activating the adhesive;f) cooling the adhesive until it sets; andg) releasing the laminated article from the die.The treatment with the superheated vapor permanently stretches the fabric in the concavities, preventing delamination after the article is released from the die.

Abstract: A fiber reinforced composite matrix that includes one or more layers of unidirectional fibers alternated with one or more layers of a porous fibrous material, all the fibers being embedded in a thermoplastic resin.

Abstract: A composite intermediate structure for joining two dissimilar materials together. The structure has a non-porous base with two bonding faces. A porous member is bonded to each of the faces. The base may be a metallic foil and the porous members may each be a metallic mesh.

Abstract: There is described an improved bipolar electrode comprised of an intermediate double-sided adhesive conductive plastic film or layer disposed between electronegative and electropositive layers wherein the intermediate layer has a volume resistivity of at least 0.5 ohm-cm. as well as a process for manufacturing same by passing a laminate of such layers through a pressure roller assembly at pressures between 30 to 500 psig.

Abstract: A method for the decorative coating of sheet-like materials, particularly laminated plastics and wood-derived panels is disclosed to achieve a marbled decor effect by pressing a support sheet, impregnated with a curable aminoplast resin and coateed with a thermoplastic or duroplastic synthetic resin, on the substrate to be coated at the melting or curing temperatures of the resins, in which(a) a support sheet is used which has two superimposed layers of a transparent, thermoplastic or duroplastic synthetic resin, which flows well under the pressing conditions, the layer facing the support sheet containing a flake or scale-like pigment in an amount of 2 to 40% by weight of the synthetic resin and the outer layer of synthetic resin being devoid of such pigments and(b) the pressing is carried out in a compression mold or tool, which has no surface profiling.The invention furthermore is directed to the synthetic resin-containing support sheets used in the inventive method.

Abstract: A continuous process for producing reinforced resin laminates comprising the steps of impregnating a fibrous substrate with a liquid resin which is free of volatile solvent and is capable of curing without generating liquid and gaseous byproducts, laminating a plurality of the resin-impregnated substrates into a unitary member, sandwiching the laminate between a pair of covering sheets, and curing the laminate between said pair of covering sheets without applying appreciable pressure. The improvement comprises adjusting the final resin content in said resin impregnated substrate at 10 to 90% by weight based on the total weight of said impregnated substrate.

Abstract: A vehicular powertrain mount assembly comprising two metal bracket members and a volume of a resilient elastomeric material sandwiched between and adhesively bonded to the two brackets. An epoxy adhesive is used in bonding the metal to the elastomer producing a bond having a minimum tensile rupture strength of 3,000 Newtons when tested by ASTM D-429.

Abstract: Disclosed herein is a method of producing a trim board, which comprises by steps: (a) hot-pressing trimming and piercing a resin-impregnated substrate at the same time to produce a shaped substrate; (b) laying an outer skin member onto one surface of the shaped substrate with an interposal of a hot-melt sheet therebetween; (c) pressing the outer skin member against the shaped substrate while the shaped substrate is still hot, thereby to produce a skin covered unfinished trim board; (d) trimming and piercing the outer skin member at portions which correspond to the portions of the shaped substrate at which the trimming and piercing have been carried out at the step (a), the step (d) being so made that a peripheral portion of the outer skin member at which the trimming and piercing have been effected protrudes by a certain degree beyond a peripheral edge of the shaped substrate at which the trimming and piercing have been effected; and (e) turning back the protruding peripheral portion of the outer skin member

Abstract: A method is disclosed for forming a coated metal object comprises preparing a laminate of an unformed metal substrate and a fabric having a thermoplastic adhesive layer interposed between and adhered to the metal substrate and fabric; forming the laminate into the desired metal object; and coating the formed metal object with a suitable coating material.

Abstract: Substrates are coated by a process which comprises co-extruding onto the substrate, e.g. aluminium foil, a layer of an olefin terpolymer and a layer of polypropylene, the olefin terpolymer being adjacent to the substrate and the polypropylene being adjacent to the olefin terpolymer. The olefin terpolymer is a terpolymer of an olefin, e.g. ethylene, an unsaturated carboxylic acid or anhydride, e.g. acrylic acid, and an unsaturated ester, e.g. methyl acrylate, in which the amount of carboxylic acid or anhydride groups in the terpolymer is at least 3 mole % and the amount of ester groups in the terpolymer is at least 3 mole %.

Abstract: A thermally conductive adhesive, and processes for formulating the same, are provided for bonding an electrical device package, such as an integrated circuit (IC) package, to a surface of a substrate, such as a printed circuit board. The thermally conductive adhesive comprises a polyurethane-based resin material and a predetermined amount of thermally conducting, electrically insulating material, such as alumina, mixed therewith. With such arrangement, a thermally conductive adhesive is provided having a low modulus of elasticity. Thus, such adhesive is soft and pliable rather than rigid, and thus deforms in response to the different amounts of thermal expansion, or contraction, of the IC package and PCB against, or away from, the thermally-conductive adhesive, thereby preventing damage to either the IC package or PCB, or separation of solder joints therebetween, due to such thermal expansion or contraction.

Abstract: In order to make a synthetic membrane for a gas meter of the measuring chamber type, an initial structure of polyester fibers, which are preferably woven, is placed between two films of hot meltable elastomer (polyurethane). The hot meltable material is raised to its softening temperature and pressure is applied to cause the films to adhere to the woven structure.

Abstract: A nail file comprises a core of stiff sheet material and a layer of abrasive material laminated to at least one surface of the sheet material.

Abstract: In the joining of silicone-coated fabrics in the present invention, a silicone rubber adhesive, which is plastic at room temperature and is an addition-curing type containing platinum-type catalyst or a radical-curing type containing organoperoxide, is inserted into the overlap region of said silicone rubber-coated fabrics. This overlap region is then hot-cured after press-adhering or is hot-cured while press-adhering. As a consequence, the silicone-coated fabrics are tightly bonded in an accurate, watertight and airtight manner.

Abstract: A mounting entity comprises, in layered order, a pressure sensitive adhesive, a foam spacer, a second pressure sensitive adhesive, a filler, and a heat sensitive adhesive. The first pressure sensitive adhesive is attached to an electrical component which is then mounted upon a printed circuit with the heat sensitive adhesive in contact therewith. The passing of the board over a solder wave heats the top surface of the board to a temperature high enough to activate the heat sensitive adhesive and adhere the component to the board. The intermediate foam layer dampens shock and vibration.

Abstract: A method of forming a tube is disclosed which has the strength and stiffness required for a tampon applicator tube and which can rapidly disintegrate in water. A method including the steps of directing a web of paper, a web of adhesive film and a web of superabsorbent material on to a mandrel. Wrapping said webs on the mandrel to form a laminate, and then heating the laminate to form a seal between the various layers to produce a finished tube.

Abstract: An article of manufacture and method for assisting the lamination of printed circuits in a flat bed press, in which a stratiform sheet has a thermoplastic layer, a polymeric release layer on one side, a polymeric stabilizing layer having a melting point higher than the laminating temperature peak on the other side, both bonded to the middle thermoplastic layer which has a glass transition point lower than the laminating temperature peak, and a melting point higher than the peak, and the sheet is characterized by substantial freedom from creases, trapped gases, and contaminants between the layers, and the improved method using the stratiform sheet in a flat bed press operation.

Abstract: The invention provides a method of bonding into an integral structure a unit formed by disposing therein a heating wire and a temperature detecting wire, a surface cloth material of an electric carpet to be manufactured, and an insulating material of the same, wherein a metallic foil is used in the unit, the metallic foil itself is caused to generate heat by electromagnetic induction, at least one heat-fuseable film layer is melted by the generated heat, and the carpet elements are integrally bonded by pressing. The method provides for efficient bonding as well as the elimination of pile-collapsing of the surface cloth material, thus producing electric carpets of high quality.

Abstract: Lamination of a tufted, primary carpet backing to a secondary backing is conducted using a composite hot melt adhesive in sheet form. The composite adhesive overcomes the unfavorable temperature-viscosity gradient within the carpet structure during the lamination process, yielding tufted pile carpets with good tuft encapsulation, tuft bind strength and delamination strength. Also disclosed are hot melt adhesive compositions suitable for use in sheet form in such a process.

Abstract: A dimensionally stable composite wood panel having wood veneer sheets with their grains disposed in the same direction, and a core of adhesively-bonded biomass particles is improved by including a third wood veneer sheet having its grain substantially perpendicular to the grains of the surface veneer sheets. Additional veneer sheets may lie intermediate the surface sheets and the intermediate sheet, with its grain structure oriented parallel to the surface sheets. The panel produced may be ripped or sawed to form laminated veneer lumber of such dimensions that is may be substituted for structural lumber. The laminated veneer lumber of the present invention has improved dimensional stability and may be nailed without splitting or cracking. A process of manufacturing continous or indefinite lengths of the composite wood panel is disclosed.

Abstract: An improved method of chemical bonding wherein a bonding polymer and its corresponding curing agent are deposited on plastic strips with adhesive backings. When bonding is desired, then these strips are applied to the bondable structural surfaces and the exposed deposits are brought together through agitation, mixing the two components and initiating the bonding action.

Abstract: Crossbanding of veneered or laminated panels with vulcanized fiber sheets that can be of multiple thin plies vulcanized together and colored. The finished vulcanized fiber crossband sheets have both surfaces coated with adhesive adherently dried in place so that they can be very simply assembled with the remaining panel constituents and hot pressed to produce desired panel.

Abstract: There is disclosed a synthetic sheet composite that is tear resistant and has paper-like aesthetic qualities. The composite comprises two spun filament polymer webs of unbonded continuous filaments with a binder web sandwiched between. The binder has a melting point below that of the spun filament webs. When the composite is subjected to heat and pressure the binder melts, and fills the interstital space between the filaments, and binds the filaments together. The filaments are encapsulated within the composite but retain their discrete identity. The filaments at the surface are exposed, flattened, discrete, and adhered to the binder.

Abstract: A microwavable package, comprising a folded package for use in holding a variety of cookable items, such as popcorn, other food products, or other substances, all to be heated within a microwave oven, the package being formed of a polymer material, comprising one or more liners of such laminated material, with the package being formed into the tubular configuration, and having a paper or paper-like web of material located and adhesively secured within its manufacturer's joint; the formed tubular like material is then folded at its bottom segments, adhered temporarily through the usage of a hot melt of other adhesive, and having a paper or paper like seal applied thereover, to form a fully integrated and foldable package which is capable of functioning and maintaining its structural integrity even when exposed to the energy of a microwave oven.

Abstract: A carpet and pad installation avoids the need for stretching and tackless strips by utilizing a pad with pressure-sensitive adhesive on one surface. The pad is first laid on the floor surface and trimmed as required, with either the adhesive surface down to adhere to the floor, or with the adhesive surface up and another adhesive applied to the floor prior to laying the pad. A removable release film may cover the pressure-sensitive adhesive on the pad, so that with the adhesive side up the carpet may be unrolled over the release film and then cut and seamed as required. The seamed carpet is folded back and the release film is removed from the exposed area of the carpet cushion, then the carpet is pressed down onto the exposed area of adhesive. Then another portion of the carpet is folded back, the release film is removed from that area, and that portion of the carpet is pressed onto the exposed pressure-sensitive adhesive of the carpet cushion.

Abstract: Objects may be bonded to target surfaces of a variety of materials, including rough surfaces, surfaces at temperatures down to -40.degree. F. and surfaces submerged under water, by securing a sheet of compliant material to the object, applying cyanoacylate to the exposed surface of compliant material and pressing the object against the target surface for a time sufficient to establish a cure of the cyanoacrylate adequate to support the object from the target surface.

Abstract: A machine for laminating fabric (123) to open cell cushion foam (124) while forming design lines in the foam is disclosed. The machine comprises a top hollow die (21) having perforations (38) and a complementary, hollow bottom die (54) which also has perforations (130). Hot melt adhesive (125) is interleaved between fabric (123) and foam (124). Top die (21) is preheated to just below the melt point of adhesive (125); then dies (21) and (54) are closed against the layered workpiece, with top die (21) contacting the face of fabric (123). A shot of superheated steam, e.g., at 80 psig and 700.degree. F., is ejected from perforations (38) and (130) to melt adhesive (125). Then a vacuum is applied to the perforations to pull ambient air through the workpiece and cool it. The resolidified ashesive (125) holds foam (124) in its deformed shape and laminates fabric (123) to the foam.

Abstract: Laminates particularly useful in vertical blind slat assemblies, and vertical blind slat assemblies utilizing the laminates are disclosed. The laminates comprise strand material which is not free hanging and in which there are substantial spaces between the strands to allow light to pass through the material, and a sheet-like layer to which the strand material is secured so that the strands of the laminate are fixed. The laminates allow the color or other characteristics of a slat member or insert to be seen. The laminates can have differing surface characteristics, (e.g. texture) and strand colors, sizes and patterns. The sheet-like layer can be transparent or translucent. A laminate can be secured directly, for example by adhesive, to a slat member having light-transmitting properties (e.g. opaque or translucent), surface characteristics (e.g. texture) and/or color which affect the overall appearance of the slat.

Abstract: A lightweight energy-absorbing structure is comprised of a laminate including a plurality of fabrics, pre-impregnated with a thermosetting resin, abutting against a core of cellular foam treated with a charge of filled bonding material. The resulting mixed materials are compressed between two die members while heat is applied to the dies thereby single curing the thermosetting resin and bonding material. Individual sheets of fabric may have a predetermined orientation to increase impact resistance. In a preferred embodiment polyimide open-cell foam may be employed.

Abstract: A reinforcing composite for bituminous roofing membranes is made by combining as a first layer an open network of non-woven adhesive-free continuous filament yarns and as second and third layers, placed one on each side of the first layer, lightweight preformed mats or networks, and thereafter impregnating them with an adhesive resin which is then dried or cured.

Abstract: A laminated structural panel which is especially well suited for the construction of a bulkhead used to partition a trailer or other cargo container. The center of the panel is formed by a polyurethane foam core panel sandwiched between a pair of flexible plastic reinforcing sheets adhesively bonded to opposite sides of the core panel. Additional layers of foam are adhesively bonded to the reinforcing sheets, and the outer foam layers are covered by puncture and abrasion resistant skins which are adhesively bonded to the foam. The reinforcing sheets provide the structural foam with tensile strength and with both beam and column strength because of their ability to resist being stretched. The outer foam layers provide impact resistance and enhanced strength due to the effect of the added laminations.

Abstract: Floor covering, such as carpets or other covering materials for residential and general furnishing, are fixed to a floor or other surface by means of an applied bonding layer. Embedded into the bonding layer are adhesive particles which are made chemically passive and the cohesive forces of which are greater in the thermoplastic state than their adhesive forces and which are converted, only after the carpet has been laid and adjusted in position, from their non-adhesive state into a malleable tacky phase of the layer as a result of the effect of temperature, after which a firm bond is produced in a cooling phase as a result of the lowering of this temperture. Alternatively, the bonding layer may be provided by a separate interlayer.

Abstract: A hydraulic unit for a waterbed mattress is provided, along with a method for constructing the unit. The usual lower sheet having a plurality of chambers is covered with the usual upper sheet, and the fibrous bat is placed over the upper sheet. The assembly can be welded together, and plastic from the lower and upper sheets encases the fibrous bat to hold the bat to the hydraulic unit. The upper sheet, which is normally thin, should have about the same thickness as the lower sheet to prevent degradation. Otherwise, the upper sheet can remain thin, and a porous sheet is interposed, so the plastic from the lower and upper sheets flows through the porous sheet and encases the fibrous bat without degrading the thin upper sheet.

Abstract: A light-transmissive touch panel is disclosed which comprises a substrate, upper and lower electrode sheets, and a transparent double adhesive tape at least between the lower electrode sheet and the substrate so as to be superposed all over their surfaces, the transparent double adhesive tape having a refractive index proximate to those of the lower sheet of the substrate.

Abstract: A method of producing an open, triaxial woven, acoustic face sheet useful in acoustic energy absorbing panels for aircraft engines or the like. The composite face sheet is formed from carbon fibers in an epoxy resin matrix and has about 25 to 33% open area. This face sheet has lower weight and superior and more uniform strength and stiffness than biaxial composite face sheets. The face sheet is made by first weaving carbon fiber tows at warp angles of +30.degree. and -30.degree. and a fill angle of 90.degree.. The woven sheet is impregnated with epoxy as other resins in a manner which produces no rich or starved areas and no blocked openings. The resulting prepreg material may be stored for extended periods at reduced temperatures. The prepreg material is shaped on a suitable mold surface and the resin is fully cured, preferably in a vacuum bag assembly in an autoclave. The resulting sheet has very light weight, an excellent percentage of openings and high strength and stiffness.

Abstract: A novel polyurethane can be used to form asymmetrical laminates with glass and plastics such as polycarbonate at temperatures below 150.degree. F. The polyurethane is a reaction product of a diisocyanate, a high molecular weight polyether glycol or polyester glycol, and at least two different diols.

Abstract: The present invention relates to a printed circuit board and to a method of manufacturing the same.The printed circuit board of the present invention consists of a metal board glued to a resin board which is provided with at least one circuit layer. The metal board is provided with holes which are filled with resin, and lead wire holes are provided at the centers of the resin filled holes. The resin board is provided with through holes. The center of the lead wire holes and the centers of the through holes are on identical lines.Further, the method of manufacturing a printed circuit board under the present invention is to provide resin holes on a metal board, filling the holes with resin, and providing lead wire holes at the centers of the resin filled holes. In this process, an identical hole position designating means is used for providing the resin holes and the lead wire holes. At least one circuit layer and through holes are to be provided on the resin board.

Abstract: A continuous process for producing reinforced resin laminates is disclosed. A plurality of fibrous substrate is continuously and sequentially subjected to the steps of (a) impregnating with resin, (b) laminating into a unitary member, (c) sandwiching between a pair of covering sheet, at least one of which is a cladding metal foil, and (d) curing the resin while supporting between said covering sheets without applying pressure on the laminate surface.

Abstract: Methods of bonding a printing plate on a base film and an apparatus therefor are disclosed. The apparatus includes a pair of support mechanisms, one of which is horizontally located and the other of which is disposed at a right angle with respect to the horizontal one. A strip of paper is reeved around the horizontal support mechanism, while a strip of film is reeved around the vertical one. A plotter is provided above and in conjunction with the horizontal support mechanism for marking the location on which to place a printing plate, on the paper reeved around the horizontal support mechanism. A half mirror is disposed in close proximity to both of said horizontal and vertical support mechanisms for projecting the location marked on the paper onto the film reeved around the vertical support mechanism. Using a lifter, the operator looks down the half mirror to view the location of a printing plate as projected onto the film, and bonds the printing plate to the base film in that projected location.

Abstract: A composition for fixing a metal powder molding at sintering, which is used, in the case of disposing a metal powder molding formed by rolling a mixture of a metal powder and a synthetic resin-based binder on a metal base material and sintering the metal powder molding in a non-oxidizing atmosphere, by interposing between the metal powder molding and the base material, comprising a thermosetting resin composition containing a thermosetting resin as the essential component, the amount of the residual carbon of which after the completion of sintering is at least about 0.5% by weight.

Abstract: The present invention relates to a system for packaging and a method of using double-faced adhesive tape. A strip of waxed or otherwise non-stick material is folded to form a pocket in which a piece of double-faced tape having a hold tab at one end thereof is inserted such that the hold tab projects from without the pocket. To apply the tape, the wrapper and projecting hold tab are positioned between two pieces of material that are intended to be taped together. A pull tab, which is connected to the wrapper, extends out from between the two pieces of material. Pressure is then applied to the material surrounding the hold tab in order to retain the hold tab in position, and the pull tab is pulled away from the hold tab and tape. As a result, the non-stick wrapper is removed from the tape, leaving the double-faced tape and the attached hold tab in position between the two materials that are being taped together.

Abstract: A method for providing a product which has a simulated embossed effect wherein a first wear layer is applied in a pattern and a second wear layer is deposited over the total surface that receives the first wear layer so that some areas of the surface have two wear layers and other areas of the surface have one wear layer to produce an embossed impression.

Abstract: A novel polyurethane can be used to form asymmetrical laminates with glass and plastics such as polycarbonate at temperatures below 150.degree. F. The polyurethane is a reaction product of a diisocyanate, a high molecular weight polyether glycol or polyester glycol, and at least two different diols.

Abstract: An improved method of adhering a waterproofing membrane to an underlayment and substrate is disclosed. A perforated underlayment comprising a tough, fibrous reinforcing base layer or matting impregnated with a bitumen/polymer mixture substantially similar to the bitumen/polymer mixture of the waterproofing membrane is placed on a substrate. The exposed underside of the waterproofing membrane is heated until it reaches a softening point. Thereafter, the membrane is unrolled onto the underlayment whereby the membrane and the underlayment are bonded essentially into a single ply. Additionally, when the membrane is unrolled, the bitumen/polymer mixture is sufficiently molten to flow and pass through the openings of the perforations thereby bonding the final waterproofing membrane to the substrate.

Abstract: A continuous process for producing reinforced resin laminates comprising the steps of impregnating a fibrous substrate with a liquid resin which is free of volatile solvent and is capable of curing without generating liquid and gaseous byproducts, laminating a plurality of the resin-impregnated substrates into a unitary member, sandwiching the laminate between a pair of covering sheets, and curing the laminate between said pair of covering sheets without applying appreciable pressure. The improvement comprises adjusting the final resin content in said resin impregnated substrate at 10 to 90% by weight based on the total weight of said impregnated substrate.

Abstract: The present invention provides a method and primer composition to increase the adherence of a polydiorganosiloxane-polycarbonate block copolymer lamina or layer to adjoining thermoplastic laminae or layers in a consolidated laminate or composite.

Abstract: A plywood is manufactured by applying an aqueous plywood adhesive fluid to the peripheral surface of a heating roll rotating at a given speed by means of a roll coater to form an adhesive fluid film, drying the adhesive fluid film into a tacky-dry film while it is carried on the surface of the heating roll, stripping the tacky-dry adhesive film from the roll surface by pulling it under tension with or without the aid of a stripping knife, interposing the adhesive film between a pair of veneers, and pressing the veneers to each other to bond them.