US 11,701,815 B2
Lamination process and using coated fiber cores to create an adhesive layer and/or a reinforcement layer
Dale Barnes, Tuscaloosa, AL (US)
Assigned to Phifer Incorporated, Tuscaloosa, AL (US)
Filed by Dale Barnes, Tuscaloosa, AL (US)
Filed on Aug. 6, 2020, as Appl. No. 16/987,189.
Claims priority of provisional application 62/913,841, filed on Oct. 11, 2019.
Claims priority of provisional application 62/883,895, filed on Aug. 7, 2019.
Prior Publication US 2021/0039307 A1, Feb. 11, 2021
Int. Cl. B29C 64/147 (2017.01); B29C 64/118 (2017.01); B33Y 10/00 (2015.01); B33Y 70/00 (2020.01); B33Y 80/00 (2015.01); B29K 27/06 (2006.01); B29L 23/00 (2006.01); B29K 105/00 (2006.01)
CPC B29C 64/118 (2017.08) [B29C 64/147 (2017.08); B29K 2023/06 (2013.01); B29K 2027/06 (2013.01); B29K 2105/0008 (2013.01); B29K 2105/0026 (2013.01); B29K 2105/0044 (2013.01); B29K 2105/0097 (2013.01); B29K 2995/0016 (2013.01); B29K 2995/0026 (2013.01); B29L 2023/005 (2013.01); B33Y 10/00 (2014.12); B33Y 70/00 (2014.12); B33Y 80/00 (2014.12)] 21 Claims
OG exemplary drawing
 
1. In a lamination process using heat, vacuum and/or pressure to laminate a series of layers and adhesives into a monolithic bonded product in the lamination process, a method of providing an adhesive layer between two adjacent layers in the structure to be laminated, an upper layer and a lower layer, the method comprising the steps of:
positioning an intermediary layer between the upper and lower layers, where the intermediary layer comprises at least one fiber comprising an inner core and an outer surface comprising an extrusion coated polymer, comprising a solidified extruded polymer that is meltable and flowable when melted, the extruded polymer adapted to bind the upper and the lower layers,
the process further comprising the steps of continuing the lamination process to thereby melt the extruded polymer coating and cause the melted polymer to flow between the upper and lower layers, thereby forming an adhesive intermediary layer therebetween, such that at the completion of the lamination process, the upper and lower layers are bonded together in the laminated structure.