IPC분류정보
국가/구분 |
United States(US) Patent
등록
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국제특허분류(IPC7판) |
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출원번호 |
US-0162116
(2002-06-04)
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발명자
/ 주소 |
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출원인 / 주소 |
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대리인 / 주소 |
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인용정보 |
피인용 횟수 :
11 인용 특허 :
40 |
초록
▼
A combination fastener and foam sheet having enhanced fastener retention and methods of forming a foam sheet are provided so that the fastener is not easily removed from the foam sheet when an outward force is applied thereto. The combination preferably includes a foam sheet including a fibrous mate
A combination fastener and foam sheet having enhanced fastener retention and methods of forming a foam sheet are provided so that the fastener is not easily removed from the foam sheet when an outward force is applied thereto. The combination preferably includes a foam sheet including a fibrous material and urethane foam material abuttingly contacting and substantially surrounding the fibrous material so that the fibrous material is substantially contained within and retained by the urethane foam material. The combination also, preferably includes a fastener having threaded portions positioned within the foam sheet so that the threaded portions are retained in the foam sheet and are not easily removed when an outward force is applied thereto. The foam sheet preferably also has a strengthening material such as glass also substantially surrounded by the urethane foam.
대표청구항
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1. A method of forming a urethane foam sheet having enhanced fastener retention so that a threaded fastener is retained within the urethane foam sheet and is not easily removed from the urethane foam sheet when an outward force is applied thereto, the method comprising:positioning at least one layer
1. A method of forming a urethane foam sheet having enhanced fastener retention so that a threaded fastener is retained within the urethane foam sheet and is not easily removed from the urethane foam sheet when an outward force is applied thereto, the method comprising:positioning at least one layer of a polyolefin blend and at least one layer of a glass material in a mold; supplying a non-polyolefin urethane foam material to the layers of the polyolefin blend and the glass material at a velocity so that the non-polyolefin urethane foam material is dispersed throughout the layers of the polyolefin blend and the glass material in the mold; pressing the layers of the polyolefin blend and the glass material and the non-polyolefin urethane foam material in the mold so that the materials are compacted to thereby increase the density of the materials and to enhance imbedding of the layers of the polyolefin blend and the glass material within the non-polyolefin urethane foam material; and controlling a temperature in a press during expansion of the non-polyolefin urethane foam material throughout the mold so that the layers of the polyolefin blend and the glass material are substantially contained within and retained by the non-polyolefin urethane foam material. 2. The method of claim 1, wherein the step of positioning at least one layer of a polyolefin blend and at least one layer of glass in a mold includes utilizing a polyolefin blend formed by the steps of:positioning a first fibrous material in a press; positioning a melted polyolefin in the press; positioning a second fibrous material in the press; compressing the melted polyolefin between the first and second fibrous materials within the press; and cooling the polyolefin blend prior to positioning the polyolefin blend in the mold. 3. The method of claim 2, wherein the utilizing step further includes removing the polyolefin blend from the press, and then cutting slits within the polyolefin blend to allow a non-polyolefin foam material to penetrate through the polyolefin blend.4. The method of claim 3, wherein supplying and placing a melted polyolefin in a press includes utilizing a melted polyolefin selected from the group consisting of polyethylene and polypropylene.5. The method of claim 4, wherein the step of supplying a non-polyolefin urethane foam material includes utilizing a non-polyolefin urethane foam material comprising a high density, high strength, and lightweight urethane foam, the high density being in the range of about 18 pounds per cubic foot to about 28 pounds per cubic foot.6. The method of claim 4, wherein the urethane foam sheet has a fastener torque test in the range of about 20 inch-pounds to about 45 inch-pounds.7. The method of claim 6, wherein the urethane foam sheet has a density in the range of about 20 pounds per cubic foot to about 28 pounds per cubic foot.8. The method of claim 2, wherein the steps of positioning a first and a second fibrous material in a press include utilizing a fibrous material comprising at least one sheet of fibrous material to enhance bonding of the polyolefin to the non-polyolefin urethane foam material.9. The method of claim 4, wherein the step of positioning at least one layer of a glass material in a mold includes utilizing a glass material selected from the group consisting of a sheet of woven glass and a sheet of non-woven glass.10. A method of forming a urethane foam sheet having enhanced fastener retention so that a threaded fastener is retained within the urethane foam sheet and is not easily removed from the urethane foam sheet when an outward force is applied thereto, the urethane foam sheet having a fastener torque test in the range of about 20 inch-pounds to about 45 inch-pounds, the method comprising the steps of:positioning at least one layer of a fibrous material and at least one layer of a glass material in a mold; supplying a non-polyolefin urethane foam material to the layers of the fibrous material and the glass material at a velocity wherein the non-polyolefin urethane foam material is dispersed throughout the layers of the fibrous material and the glass material in the mold; pressing the layers of the fibrous material and the glass material and the non-polyolefin urethane foam material in the mold so that the materials are compacted, thereby increasing the density of the materials and enhancing imbedding of the layers of the fibrous material and the glass material within the non-polyolefin urethane foam material; and controlling a temperature in a press while the non-polyolefin urethane foam material expands throughout the mold so that the layers of the fibrous material and the glass material are substantially contained within and retained by the non-polyolefin urethane foam material. 11. The method of claim 10, wherein the step of supplying a non-polyolefin urethane foam material includes utilizing a non-polyolefin urethane foam material comprising a high density, high strength, and lightweight foam, and wherein the high density is in the range of about 18 pounds per cubic foot to about 28 pounds per cubic foot.12. The method of claim 10, wherein the urethane foam sheet has a density in the range of about 20 pounds per cubic foot to about 28 pounds per cubic foot.13. A method of forming a urethane foam sheet having enhanced fastener retention so that a fastener, having threaded portions positioned and retained within the urethane foam sheet, is not easily removed from the urethane foam sheet when an outward force is applied thereto, the urethane foam sheet having a fastener torque test in the range of about 20 inch-pounds to about 45 inch-pounds, the method comprising the steps of:positioning at least one layer of a fibrous material in a mold; supplying a non-polyolefin urethane foam material to the layer of the fibrous material at a velocity wherein the non-polyolefin urethane foam material is dispersed throughout the layer of the fibrous material; pressing the layer of the fibrous material the non-polyolefin urethane foam material in the mold so that the materials are compacted, thereby increasing the density of the materials and enhancing imbedding of the layer of the fibrous material within the non-polyolefin urethane foam material; and controlling a temperature in a press while the non-polyolefin urethane foam material expands throughout the mold so that the layer of the fibrous material is substantially contained within and retained by the non-polyolefin urethane foam material. 14. The method of claim 13, wherein the step of supplying a non-polyolefin urethane foam material includes utilizing a non-polyolefin urethane foam material comprising a high density, high strength, and lightweight urethane foam, and wherein the high density is in the range of about 18 pounds per cubic foot to about 28 pounds per cubic foot.15. The method of claim 13, wherein the urethane foam sheet has a density in the range of about 20 pounds per cubic foot to about 28 pounds per cubic foot.16. A method of retaining a fastener within a urethane foam sheet having enhanced fastener retention, the urethane foam sheet having a fastener torque test in the range of about 20 inch-pounds to about 45 inch-pounds, the method comprising the steps of:providing the urethane foam sheet, the urethane foam sheet comprising a polyolefin blend, a glass material, and a non-polyolefin urethane foam material, the non-polyolefin urethane foam material contacting and substantially surrounding the polyolefin blend and the glass material; and positioning a threaded fastener therein so the fastener is retained by the urethane foam sheet and is not easily removed from the urethane foam sheet when an outward force is applied to the threaded fastener. 17. The method of claim 16, wherein the step of providing a urethane foam sheet includes utilizing a urethane foam sheet comprising a foam material, the foam material comprising a high density, high strength, and lightweight foam, and wherein the high density is in the range of about 18 pounds per cubic foot to about 28 pounds per cubic foot.18. The method of claim 16, wherein the step of providing a urethane foam sheet includes utilizing a urethane foam sheet having a density in the range of about 20 pounds per cubic foot to about 28 pounds per cubic foot.19. The method of claim 16, wherein the step of providing a urethane foam sheet includes utilizing a urethane foam sheet comprising a polyolefin blend, the polyolefin blend comprising a polyolefin and a fibrous material and wherein the polyolefin is selected from the group consisting of polyethylene and polypropylene.20. The method of claim 19, wherein the step of providing a urethane foam sheet includes utilizing a urethane foam sheet comprising a polyolefin blend comprising a fibrous material comprising at least one sheet of fibrous material to enhance bonding of the polyolefin to the foam material.21. The method of claim 16, further comprising positioning another layer of material between the urethane foam sheet and the fastener.22. The method of claim 16, wherein the step of providing a urethane foam sheet includes utilizing a urethane foam sheet comprising a fibrous material, a glass material, and a non-polyolefin urethane foam material, the non-polyolefin urethane foam material contacting and substantially surrounding the fibrous material and the glass material.23. The method of claim 22, wherein the step of providing a urethane foam sheet includes utilizing a urethane foam sheet comprising a foam material, the foam material comprising a high density, high strength, and lightweight foam, and wherein the high density is in the range of about 18 pounds per cubic foot to about 28 pounds per cubic foot.24. The method of claim 22, further comprising positioning another layer of material between the urethane foam sheet and the fastener.25. The method of claim 16, wherein the step of providing a urethane foam sheet includes utilizing a urethane foam sheet comprising a foam material, the foam material comprising a high density, high strength, and lightweight foam, and wherein the high density is in the range of about 18 pounds per cubic foot to about 28 pounds per cubic foot.26. The method of claim 25, wherein the step of providing a urethane foam sheet includes utilizing a urethane foam sheet having a density in the range of about 20 pounds per cubic foot to about 28 pounds per cubic foot.27. The method of claim 26, wherein the step of providing a urethane foam sheet includes utilizing a urethane foam sheet having a density in the range of about 20 pounds per cubic foot to about 28 pounds per cubic foot.28. The method of claim 21, further comprising positioning another layer of material between the urethane foam sheet and the fastener.29. The method of claim 16, further comprising twisting the threaded fastener within a location so that the threaded fastener remains tightened when an outward force is applied.30. A method of retaining a fastener within a urethane foam sheet having enhanced fastener retention, the urethane foam sheet having a fastener torque test in the range of about 20 inch-pounds to about 45 inch-pounds, the method comprising the steps of:providing the urethane foam sheet, the urethane foam sheet comprising a fibrous material and a non-polyolefin urethane foam material, the non-polyolefin urethane foam material contacting and substantially surrounding the fibrous material; and positioning a threaded fastener therein so the fastener is retained by the urethane foam sheet and is not easily removed from the urethane foam sheet when an outward force is applied to the threaded fastener.
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