U.S. patent application number 10/211683 was filed with the patent office on 2004-02-05 for foamed laminated construction.
Invention is credited to Bussey, Harry (Buddy) III, Bussey, Harry JR..
Application Number | 20040022973 10/211683 |
Document ID | / |
Family ID | 31187622 |
Filed Date | 2004-02-05 |
United States Patent
Application |
20040022973 |
Kind Code |
A1 |
Bussey, Harry JR. ; et
al. |
February 5, 2004 |
Foamed laminated construction
Abstract
A laminated construction is formed of at least one layer of
foamed mesh. In one embodiment, multiple layers of foamed mesh are
built up and provided with outer layers suitable to make an
insulation panel. In another embodiment, a block is formed of
laminated layers of the foamed mesh and cut out to form recesses to
receive items for packaging purposes. In another embodiment, a
foamed layer is secured along two longitudinal edges to a
non-porous layer and filled with loose fill elements for use as a
drainage pipe. In another embodiment, a foamed tube is secured at
one end to a non-porous layer to form a bag for use in planting
flowers and the like.
Inventors: |
Bussey, Harry JR.; (Marco
Island, FL) ; Bussey, Harry (Buddy) III; (Atlantic
Highlands, NJ) |
Correspondence
Address: |
Francis C. Hand Esq.,
c/o Carella, Byrne, Bain, Gilfillan, Cecchi,
Stewart & Olstein
6 Becker Farm Road
Roseland
NJ
07068
US
|
Family ID: |
31187622 |
Appl. No.: |
10/211683 |
Filed: |
August 2, 2002 |
Current U.S.
Class: |
428/35.2 ;
428/36.5; 428/36.91 |
Current CPC
Class: |
Y10T 428/1393 20150115;
Y10T 428/1334 20150115; B32B 2439/06 20130101; Y10T 442/10
20150401; B32B 5/18 20130101; Y10T 428/1362 20150115; B32B 15/14
20130101; Y10T 428/13 20150115; Y10T 428/1366 20150115; Y10T
442/184 20150401; Y10T 442/198 20150401; Y10T 428/1348 20150115;
Y10T 442/195 20150401; B32B 5/26 20130101; B32B 29/02 20130101;
B32B 5/04 20130101; B32B 27/12 20130101; Y10T 428/1376 20150115;
B32B 1/08 20130101; Y10T 428/139 20150115 |
Class at
Publication: |
428/35.2 ;
428/36.91; 428/36.5 |
International
Class: |
B32B 001/08 |
Claims
What is claimed is:
1. A laminated construction comprising at least one layer having a
plurality of criss-crossing foamed filaments adhered to each other
and defining a mesh-like structure; and at least a second layer
laminated to said one layer.
2. A laminated construction as set forth in claim 1 wherein said
layers are made of dissimilar materials.
3. A laminated construction as set forth in claim 2 wherein one of
said layers is made of polystyrene foam and the other of said
layers is made of polyethylene foam.
4. A laminated construction as set forth in claim 1 further
comprising a third layer of material laminated to at least one of
said layers.
5. A laminated construction as set forth in claim 4 wherein said
third layer is made of a material selected from the group
consisting of paper, plastic, and metal foil.
6. A laminated construction as set forth in claim 1 wherein each
said filament is of circular cross section with a diameter of 1/8
inch.
7. A laminated construction as set forth in claim 1 wherein each
said filament is of flattened cross section with a width of 1/4
inch.
8. A laminated construction as set forth in claim 1 wherein each
said layer has a weight of from 1/4 pounds to 10 pounds per cubic
foot.
9. A laminated construction as set forth in claim 1 wherein said
second layer is made of crisscrossing foamed filaments adhered to
each other and defining a mesh-like structure and said layers are
disposed in offset relation to each other whereby the filaments of
one layer are disposed in alignment with openings in the other of
said layers.
10. A laminated construction comprising a plurality of layers
disposed in overlying relation to form a one piece block, each said
layer having a plurality of crisscrossing foamed filaments adhered
to each other and defining a mesh-like structure with a
multiplicity of air spaces of predetermined size therein.
11. A laminated structure as set forth in claim 10 wherein said
block has at least one recess formed therein and passing through at
least some of said layers to receive an item therein.
12. A laminated structure as set forth in claim 10 further
comprising a plurality of laminations disposed in alternating
relation with said layers of foamed filaments, each said lamination
bonding a pair of adjacent layers of foamed filaments together
whereby said air spaces in each said layer of foamed filaments are
sealed.
13. A laminated structure as set forth in claim 12 wherein said
laminations are made of a plastic material and are heat sealed to
adjacent layers of foamed filaments.
14. A laminated structure as set forth in claim 12 wherein said
laminations are made of a plastic film of a thickness of 1 mil.
15. A laminated structure as set forth in claim 12 wherein said
laminations are made of polyethylene.
16. A laminated structure as set forth in claim 10 wherein said
filaments are made of starch and said layers are bonded to each
other.
17. An insulation medium comprising a laminated structure including
a plurality of layers of net material disposed in overlying
laminated relation to each other, each said layer having a
plurality of crisscrossing foamed plastic filaments adhered to each
other and defining a mesh-like structure; a foil layer disposed
over one side of said laminated structure for reflecting heat; and
a paper layer disposed over an opposite side of said laminated
structure.
18. An insulation medium as set forth in claim 17 wherein said
laminated structure is of a width to fit in friction fit relation
between a pair of elongated supports and is characterized in having
a lateral stiffness sufficient to be frictionally held between the
pair of elongated supports.
19. An insulation medium as set forth in claim 17 wherein said
laminated structure includes four layers of said net material and
is of a thickness of 1/2 inch.
20. A laminated construction comprising a first layer having a
plurality of criss-crossing foamed filaments adhered to each other
and defining a mesh-like structure with a multiplicity of openings
therein; and a second layer of impermeable material laminated to
said first layer along two opposite longitudinal edges to form a
sleeve.
21. A laminated construction as set forth in claim 20 further
comprising a perforated pipe extending within said sleeve for
passage of fluid between a space within said pipe and said openings
in said first layer.
22. A laminated construction as set forth in claim 21 further
comprising a porous membrane about a portion of said sleeve to
prevent passage of soil into said openings in said first layer.
23. In combination, a laminated construction having a plurality of
layers disposed in overlying relation to form a block, each said
layer having a plurality of criss-crossing foamed filaments adhered
to each other and defining a mesh-like structure with a
multiplicity of air spaces of predetermined size therein; and a
porous layer disposed over a top surface of said block, said layer
being secured to said block along two longitudinal edges thereof
and being free of said block along a central longitudinal potion
thereof, said layer being of greater width than said block to allow
the insertion of a perforated pipe between said layer and said
block.
24. The combination as set forth in claim 23 wherein said layer is
a polyethylene film.
25. In combination, a laminated construction having a plurality of
layers disposed in overlying relation to form a block, each said
layer having a plurality of criss-crossing foamed filaments adhered
to each other and defining a mesh-like structure with a
multiplicity of air spaces of predetermined size therein; at least
one recess of predetermined size and shape in a surface of said
block to receive an item of larger size, said filaments of each
layer of said block defining a wall of said recess having ends
facing said recess; and an item of larger size than said
predetermined size received in said recess and deforming said ends
of said filaments to hold said item in a snug fit manner.
26. The combination as set forth in claim 25 wherein said recess
has a predetermined diameter and said item has a diameter greater
than said predetermined diameter.
27. The combination as set forth in claim 25 wherein said item has
a smaller height than the height of said block and is received in
said recess in spaced relation to the outer surfaces of said
block.
28. A cover comprising a translucent layer for passage of sunlight
therethrough; a second layer laminated to said translucent layer
and having a plurality of opaque crisscrossing foamed filaments
adhered to each other to receive sunlight passing through said
first layer for heating thereof, said filaments defining a
mesh-like structure with a multiplicity of openings therein to
contain air; and a third layer of opaque material laminated to said
second layer on a side opposite said first layer to seal said
openings in said second layer.
29. A bag comprising an outer paper layer; a second layer laminated
to said paper layer and having a plurality of crisscrossing foamed
filaments adhered to each other and defining a mesh-like structure
with a multiplicity of openings therein to contain air; and an
interior third layer of plastic material laminated to said second
layer on a side opposite said first layer to seal said openings in
said second layer.
30 In combination; a perforated pipe; a layer of porous material
wrapped around said pipe, said layer having a plurality of
criss-crossing foamed filaments adhered to each other and defining
a mesh-like structure with a multiplicity of openings therein to
contain air; and a porous membrane surrounding said sleeve to
prevent passage of soil into said openings in said layer of porous
material.
31. A concrete structure comprising a mass of concrete; and a block
of foamed material within said mass of concrete, said block
including a plurality of layers disposed in overlying relation,
each said layer having a plurality of crisscrossing foamed
filaments adhered to each other and defining a mesh-like structure
with a multiplicity of air spaces of predetermined size
therein.
32. A concrete structure as set forth in claim 31 wherein each said
layer has a weight of from 1/4 pound to 10 pounds per cubic
foot.
33. A concrete structure as set forth in claim 31 wherein each said
foamed filament of each said layer has a diameter of 1/8 inch.
34. A concrete structure as set forth in claim 32 is of elongated
shape with a rectangular cross-section and is characterized in
being bouyant.
35. A bag comprising a tube having a plurality of criss-crossing
foamed filaments adhered to each other and defining a mesh-like
structure, said tube being closed at one end; an impermeable layer
secured to an opposite end of said tube to form a pocket; and a
mass of loose fill elements disposed within said pocket and within
said tube.
36. In combination an elongated body of foamed material comprising
at least one layer having a plurality of crisscrossing foamed
filaments adhered to each other and defining a mesh-like structure;
and a sleeve receiving said body therein.
37. The combination as set forth in claim 36 wherein said layer is
wound on itself to form a cylindrical shape.
38. The combination as set forth in claim 36 wherein said body has
a plurality of said layers laminated to each other to form a block.
Description
[0001] This invention relates to a foamed laminated construction.
More particularly, this invention relates to a foamed laminated
construction for use in insulation, packaging, piping, pool covers
and other purposes.
[0002] As is known many types of foam materials have been employed
for insulation purposes. In some cases, foam materials have been
blown into spaces between the studs of a wall in order to provide
insulation. In other cases, panels have been formed of foam
materials and mounted in place between the studs of a wall or to
form a wall.
[0003] Foamed materials have also been used for packaging purposes.
For example, foamed polystyrene and similar materials have been
used to make loose fill materials of various shapes for packaging
purposes.
[0004] Foamed plastic materials have also been used in drainage
systems. For example, as described in U.S. Pat. No. 5,015,123
foamed plastic materials have been disposed around a perforated
pipe and held in place by a netting so that effluent may flow from
the pipe through the plastic materials and netting out of the
pipe.
[0005] It is an object of the invention to provide a laminated
construction that can be employed as a cushioning material and as
an insulation medium.
[0006] It is another object to the invention to provide a foamed
structural member that can be used as an insulation medium.
[0007] It is another object of the invention to provide a foamed
structural member that may be used for piping.
[0008] It is another object to the invention to provide a foamed
member that may be used for packaging purposes.
[0009] Briefly, the invention provides a laminated construction
employing a layer of net material formed of a plurality of
criss-crossing foamed filaments that are adhered to each other to
define a mesh-like structure.
[0010] The foamed filaments are made of any suitable material such
as a polymer material, e.g. polystyrene, polyethylene, and
polyurethane, a starch material or any material that can be
foamed.
[0011] In one embodiment, two or more layers of the same material
are laminated to one another with the openings of each layer in
alignment with the openings of the adjacent layer. The laminated
construction may be used in sheet form to form a cushioning sheet
for packaging purposes. The layers may also be built up to provide
a thickness suitable to form a cushion. Likewise, the layers may be
built up to provide a block of material which can be cut out to
form recesses to receive items for packaging purposes. In this
case, the block of material requires less material than presently
used blocks of foam plastic materials. This is due to the fact that
the laminations of the block have a generally controlled amount of
free space between the filaments. That is to say, each lamination
may be fabricated with a controlled thickness of filament and
spacing between filaments. Thus, the greater the spacing between
filaments, the less weight per lamination. The weight of the
resulting block of material can easily be less than one-half the
weight of a corresponding block of foam plastic material.
[0012] In another embodiment, a laminated construction may be
formed of a plurality of layers of foam filaments disposed in
alternating relation with a plurality of laminations that bond
adjacent layers of foamed filaments together whereby the air spaces
in each said layer of foamed filaments are sealed. These
laminations may be made of a plastic material, such as
polyethylene, that can be heated, for example to 300.degree. F., to
heat seal the adjacent layers of foamed filaments together. The
laminations may be relatively thin as compared to the layers of
foamed filaments, for example, being of a thickness of 1 mil.
[0013] In a case where the foamed filaments are made of starch, the
layers may be bonded to each other simply by applying steam to the
opposed surfaces of the layers to wet the surfaces and to bond the
filaments together.
[0014] The layers may also be laminated together with the openings
of each layer out of alignment in order to provide less cushioning
as the resistance to a compressive force is less.
[0015] In another embodiment, the layers may be made of dissimilar
materials. For example, some of layers may be made of polystyrene
foam and others of the layers may be made of polyethylene foam.
[0016] In still another embodiment, a layer of a different material
may be laminated to one or both sides of a foamed layer or to one
or both sides of a laminated construction. For example, the added
layer may be made of a material selected from the group consisting
of paper, plastic, and metal foil. In this embodiment, the
laminated construction may be employed for insulation purposes. For
example, rolls of the laminated construction may be used as a
substitute for conventional fiberglass insulation in the walls of a
building. In such a case, a foil layer disposed over one side of
the laminated construction is used for reflecting heat. Further,
the laminated construction and may be made of a width to fit in
friction fit relation between a pair of elongated supports, such as
studs, and is characterized in having a lateral stiffness
sufficient to be frictionally held between the pair of elongated
supports without the need for holders, such as staples, nails or
the like.
[0017] When used for insulation purposes, the laminated
construction may be easily put in place since there is no need for
holders. Likewise, the laminated construction may be easily removed
when no longer needed. This is particularly advantageous when the
laminated construction is used as insulation in the walls and
ceiling of a chicken coop that requires substantial cleaning and
removal of the insulation on the walls and ceilings after a flock
of chickens has been removed for processing and a fresh flock is to
be housed.
[0018] In still another embodiment, a layer of foamed material in
strip form may be laminated to an impermeable layer of strip form
along two longitudinal edges to form a sleeve which may be opened
to form a pipe or a conduit or into which a perforated pipe may be
slid for use in a drainage or septic tank environment.
[0019] In still another embodiment, a layer of foamed material may
be sandwiched between a transparent layer and an opaque layer for
use as a cover for a swimming pool. In this case, the spaces formed
in the foamed layer become sealed by the transparent layer and
opaque layer so that air is trapped in the spaces. Advantageously,
the layer of foamed material would be made, for example, of
recycled foamed plastic material that is opaque and preferably
black in color. In use, the transparent layer would be positioned
as the top layer of the pool cover so that sunlight may pass
through and heat the foamed layer. The heat generated in the foamed
layer would permeate into the bottom layer and would also heat the
air trapped in the spaces or cells defined by the foamed layer.
Thus, when a pool is not in use, the pool cover can be used to
retain heat within the water in the pool while also transferring
heat from sunlight into the water. Further, the heat that is
trapped in the air spaces of the foamed layer can be transferred to
the pool water at a later time.
[0020] Such a laminated construction may also be used as a ground
cover in order to keep the ground warm, particularly where plants,
shrubs and trees are planted.
[0021] The laminated construction may be fabricated so that each
layer has a weight of from 1/4 pounds to 10 pounds per cubic foot.
As such, the laminated construction is of relatively low
weight.
[0022] In still another embodiment, a layer of the foamed material
may be sandwiched between a plastic film and a sheet of paper for
use in making a bag. In this case, the laminated construction may
be folded over on itself and secured along two sides in a
conventional manner to form a bag with an open end. The resulting
bag would have soft cushioning characteristics. The layer of foamed
material would take the place of plastic films that have pockets or
bubbles formed therein.
[0023] In still another embodiment, one or more layers of the
foamed material may be used for wrapping about a perforated pipe,
for example for use in a drainage system or in a septic tank
system. In this embodiment, a wrapped pipe could be placed against
a foundation wall so that water might permeate through the openings
of the foamed material and then into the pipe for transfer away
from the foundation wall. Also, when used in a septic tank system,
effluent may pass from the pipe outwardly through the openings of
the foamed material and into a leaching field or the like. In
either case, in order to prevent sediments from passing into and
clogging the openings of the foamed material, a porous membrane
such as a silk sock may be placed about the layer of foamed
material to prevent passage of the sediments into the openings of
the following material.
[0024] In still another embodiment, a layer of foamed material may
be wound on itself to form a cylinder that could be placed in a
sleeve of permeable or impermeable. For example, such a cylinder
could be used as a boom to contain an oil slick on a body of water.
Alternatively, a plurality of layers of foamed material may be
formed into a block that is then cut to size to form a boom. In
either case, the resulting structure is of less weight than a
conventional foamed plastic material. For example, the resulting
structure may be less than one-half the weight of a conventional
foamed plastic material.
[0025] In still another embodiment, a plurality of layers may be
disposed in overlying relation and fabricated to form a one piece
block with each layer having a plurality of criss-crossing foamed
filaments adhered to each other and defining a mesh-like structure
with a multiplicity of air spaces of predetermined size therein.
Such a foamed block may have one or more recesses formed therein to
pass through at least some of the layers to receive an item
therein, for example for packaging purposes. Such a block would be
of substantially less weight than a conventional foamed block of
similar shape and dimensions.
[0026] The foamed block may also be used in the construction of
floating concrete docks. For example, a laminated block of the
foamed material, for example 12 feet by 6 feet by 16 inches, may be
placed in a plastic bag or wrapped in a sheet of plastic and used
as a core about which concrete may be poured so that upon setting
of the concrete, the resulting concrete dock is of substantially
less weight than a solid concrete block. In this case, the amount
of free space that is contained within the laminated block of
foamed material serves to reduce the overall weight from the
concrete block. Where used, the plastic wrapping serves to prevent
the concrete from entraining into the pores of the laminated
block.
[0027] In still another embodiment, the foamed material may be used
as a protective sheet between items that are being shipped together
in a stack in order to avoid scratching of the items on each other
and/or slippage of the items on each other since the foamed
material has a coefficient of friction that prevents the items from
sliding. In such cases, a plastic film may be laid over a layer of
the foamed material to protect the items from each other while the
foamed material provides for cushioning. Also, a layer of the
foamed material may be sandwiched between two highly polished
sheets. Thus, a relatively high stack of items may be shipped with
a reduced risk that the items will slide relative to each
other.
[0028] The foamed material may also be used for expansion joints in
sidewalks, insulation in automobile doors, and many other uses.
[0029] These and the other objects and advantages of the invention
will become a more apparent from the following detailed description
taken in conjunction with the accompanying drawings wherein:
[0030] FIG. 1 illustrates a schematic view of a manner of making a
layer of foamed material in accordance with the invention;
[0031] FIG. 2 illustrates a layer of foamed material in accordance
with the invention;
[0032] FIG. 3 illustrates an enlarged view of a layer of foamed
material with a laminated layer on two sides;
[0033] FIG. 4 illustrates a cross-section view taken on line 4-4 of
FIG. 3;
[0034] FIG. 5 illustrates a cross-sectional view of a laminated
construction in accordance with the invention;
[0035] FIG. 6 illustrates a view similar to FIG. 5 with the
openings of adjacent layers of the laminated construction out of
alignment with each other;
[0036] FIG. 7 illustrates a view similar to FIG. 5 of a laminated
construction of multiple layers;
[0037] FIG. 8 illustrates a cross-sectional view of a foamed a
laminated construction for use as insulation;
[0038] FIG. 9 illustrates a cross-sectional view of a foamed
laminated construction for use as a pipe;
[0039] FIG. 10 illustrates a part cross-sectional view of a foamed
member for use in a flower pot;
[0040] FIG. 11 illustrates a view of a perforated pipe wrapped with
multiple convolutions of a foamed sheet in accordance with the
invention;
[0041] FIG. 12 illustrates a part perspective view of a web of the
foamed sheet wond on itself and placed in a sleeve in accordance
with the invention; and
[0042] FIG. 13 illustrates a part cross-sectional view of a
concrete dock constructed in accordance with the invention.
[0043] Referring to FIG. 1, a foamed tube 10 is made in a
conventional manner. In this respect, a plurality of filaments 11
of foamable material, such as polyethylene, polystyrene, starch and
the like, are extruded through a die 12 having openings 13, for
example of circular shape, that are disposed in the circular array.
At a point downstream of the die 12, the filaments 11 are crossed
over each other. During this time, the individual filaments 11
become integral with each other at the points of crossing to form
the tube 10. Subsequently, the tube 10 is slit longitudinally and
flattened in order to form a rectangular sheet 14 of net material
as indicated in FIG. 2, for example of a width of 4 feet.
[0044] Where the filaments 11 are made of a thermoplastic material,
the filaments 11 bond to each other at the points of crossing.
[0045] Where the filaments 11 are made of a foamable starch
material, a mist may be applied at the points where the filaments
cross in order to enhance securement of the filaments to each
other.
[0046] Referring to FIG. 2, the individual filaments 11 of the
sheet 14 cross over each other on a relatively small acute angle
relative to a longitudinal axis such that the mesh openings are of
an elongated diamond shape with the walls of equal length that are
at acute angles to each other at the leading and trailing ends of
the opening. Thus, the sheet 14 is characterized in being laterally
stretchable with limited longitudinal stretchability. The crossing
angle of the filaments 11 may be greater or less to obtain mesh
openings lying between an elongated diamond shape as shown in FIG.
2 or a square shape as shown in FIG. 3.
[0047] Referring to FIG. 6, the filaments 11 of the sheet 14 are
disposed in two layers with the filaments of each layer being
parallel to each other and angularly disposed to the filaments 11
of the other layer. For purposes of simplicity, the cross-section
of each sheet 14 is illustrated in the remaining Figs. as that of a
single layer of filaments but is to be understood that each sheet
14 has a cross-section as shown in FIG. 6.
[0048] The die 12 is provided with a circular array of openings 13,
for example of circular shape, to produce filaments 11 having a
circular cross-section. The openings are sized so that each
filament 11 has a diameter of 1/8 inch. Alternatively, each opening
13 may be rectangular to produce a filament with a flattened
cross-section with a width of 1/4 inch. The size of the mesh
openings may be made of greater or less dimension depending upon
the ultimate use of the member fabricated from the sheet 14.
Likewise, the size of the filaments may be greater or less than in
the above example.
[0049] The sheet 14 may be sub-divided into sections in order to
fabricate a structural member with the sections laminated one over
the other or may be used as is.
[0050] Referring to FIGS. 3 and 4, the sheet 14 may have a layer
15, for example, of plastic film, paper, foil or the like laminated
to one or both sides to form a laminated construction. In an
embodiment where a laminated layer 15 is used on only one side, the
layer 15 may be a protective layer with holes or perforations 16
for use in packaging and, particularly, for protection of hard
goods that have a finish thereon. In this case, the foamed sheet 14
is placed over the surface of the hard goods while the protective
layer 15 protects against damage from the surrounding environment.
The perforations 16 in the protective layer 15 also allow air to
pass through into the foamed sheet 14. The foamed sheet 14 of the
laminated construction allows the surface of the hard goods to
breathe and allows the finish to cure faster.
[0051] Referring to FIG. 5, a pair of foamed sheets 14 or a pair of
sections sub-divided from a single sheet 14 are laminated over each
other to form two layers of net material of a laminated
construction. As illustrated, the sheets 14 are disposed with the
mesh openings in alignment with each other. Alternatively, the
sheets 14 may be stacked with the filaments of the overlying sheets
offset relative to each other. This embodiment allows less
cushioning since the filaments 11 of the layers are out all
alignment with each other. Also, the two sheets 14 may be stacked
with one sheet rotated 90.degree. relative to the other sheet so
that the elongated mesh openings of the sheets 14 are not aligned.
In this case, the filaments of one sheet 14 cross laterally over
the filaments of the other sheet 14.
[0052] The sheets 14 may be made of dissimilar materials, For
example, one sheet 14 may be made of polyethylene while the other
sheet is made of polystyrene. In this way, different
characteristics may be given to a structural unit that is formed of
sheets 14 of dissimilar materials.
[0053] Referring to FIG. 4, a layer of foamed material 14 may be
sandwiched between a transparent layer 15 and an opaque layer 24
for use as a cover for a swimming pool. In this case, the spaces
formed in the foamed layer 14 become sealed by the transparent
layer 15 and opaque layer 24 so that air is trapped in the spaces.
Advantageously, the layer of foamed material 14 would be made, for
example, of recycled foamed plastic material that is opaque and
preferably black in color. In use, the transparent layer 15 would
be positioned as the top layer of the pool cover so that sunlight
may pass through and heat the foamed layer 14. The heat generated
in the foamed layer 14 would permeate into the bottom layer 24 and
would also heat the air trapped in the spaces or cells defined by
the foamed layer 24. Thus, when a pool is not in use, the pool
cover can be used to retain heat within the water in the pool while
also transferring heat from sunlight into the water. Further, the
heat that is trapped in the air spaces of the foamed layer 14 can
be transferred to the pool water at a later time.
[0054] In another embodiment, a layer of the foamed material 14 may
be sandwiched between a plastic film 15 and a sheet of paper 24 for
use in making a bag. In this case, the laminated construction may
be folded over on itself and secured along two sides in a
conventional manner to form a bag with an open end. The resulting
bag would have soft cushioning characteristics. The layer of foamed
material 14 would take the place of plastic films that have pockets
or bubbles formed therein.
[0055] In still another embodiment, sheets of plastic 15,24 may be
secured to opposite sides of a layer of foamed material 14 to form
a blank that can be scored for folding, for example in the manner
of corrugated paperboard into a carton.
[0056] Referring to FIG. 7, a multiplicity of sheets 14 may be
stacked on each other in alternating relation with a plurality of
laminations 17 of impermeable material. For example, four sheets 14
may be stacked with three laminations 17 to form a laminated
construction 18 having an increased rigidity. In this case, the
filaments 11 of the adjacent sheets 14 may be out of alignment as
illustrated or in alignment in a manner as illustrated in FIG.
5.
[0057] In order to form the laminated construction 18, after a
foamed tube 10 has been cut and formed into a continuous web, the
web is rolled up into a roll and delivered to a laminating machine.
Four such rolls and then be unwound along with three rolls of
impermeable material to supply continuous webs of the layers of
foamed filaments in alternating manner with the webs of impermeable
material in a stacked manner. Where the webs of impermeable
material are made of a plastic, such as polyethylene, heat is
applied to cause the plastic to melt or become sufficiently tacky
to bond the layers of foamed filaments together. Typically, for a
web of polyethylene of 1 mil thickness, the webs are heated to 300
degrees Fahrenheit.
[0058] After the layers of foamed filaments 14 and laminations of
plastic 17 are bonded together, the resulting laminated structure
18 may be cut into desired lengths and/or widths.
[0059] One of the characteristics of the laminated structure 18 is
that the air spaces in each layer of foamed filaments 14 become
sealed between two laminations of plastic 17. This adds to the
rigidity of a laminated structure 18.
[0060] The laminated structure 18 is particularly useful for
packaging items in recesses that are cut out of a laminated
structure 18, for example, in a shape to receive an item in a snug
manner.
[0061] The laminated constructions of FIGS. 6 and 7 may be used in
sheet form to form a cushioning sheet for packaging purposes. The
layers may also be built up to provide a thickness suitable to form
a cushion. Likewise, the layers may be built up to provide a block
of material which can be cut out to form recesses to receive items
for packaging purposes. In this case, the block of material
requires less material than presently used blocks of foam plastic
materials. This is due to the fact that the laminations 14 of the
block have a generally controlled amount of free space between the
filaments. That is to say, each lamination 14 may be fabricated
with a controlled thickness of filament and spacing between
filaments. Thus, the greater the spacing between filaments, the
less weight per lamination. The weight of the resulting block of
material can easily be less than one-half the weight of a
corresponding block of foam plastic material.
[0062] The laminated constructions of FIGS. 6 and 7 may be built up
of several layers and may have one or recesses of predetermined
size and shape formed therein, for example, a two and one-half inch
diameter recess, to receive an item of larger size, for example, a
three inch diameter bottle. In this embodiment, the wall of the
recess is defined by the ends of the filaments 11 of each sheet 14
so that when an item of larger size is placed in the recess, the
ends of the filaments deform inwardly or flex downwardly to receive
the item. Because of the resilient nature of the filaments, the
item is thus held in a snug fit manner. Thus, the recess is able to
adapt to the size of the item being received. This embodiment is
particularly useful in packaging figurines since the figurines can
be held in a snug-fit manner rather than in a simple slide fit
manner as occurs with previously known foamed plastic blocks that
are hollowed out to receive an item.
[0063] The recess or recesses formed in a laminated construction of
the FIG. 6 or FIG. 7 type to receive an item to be packaged may
also pass completely through the laminated construction. In this
embodiment, the laminated construction may be made relatively thick
to receive an item of lesser thickness in a floating manner, i.e.
with the item spaced inwardly of the top and bottom surfaces of the
laminated construction.
[0064] A laminated construction of the FIG. 6 or FIG. 7 type may
also be provided with one or more recesses that are to receive an
item or items as above and may be used with a solid foam block or
another laminated construction that is not recessed. In this case,
the solid foam block or unrecessed laminated construction would be
placed on the bottom of a carton and then the recessed laminated
construction would be placed on top thereof to receive the item or
items to be packaged. In this way, the solid block may provide a
stronger base for the packaged items.
[0065] Referring to FIG. 5, a laminated construction may be built
up of a plurality of sheets 14 for piping purposes, for example to
a thickness of 2 inches, a width of 18 inches and a length of 10
feet. In this embodiment, a porous layer in the form of a thin
sheet, for example, a 1 mil thick polyethylene film (not shown) is
placed over an upper side of the laminated construction and secured
only along two longitudinal edges to the laminated construction.
The polyethylene film would have a greater width than that of the
laminated construction so that the central longitudinal portion of
the film is free of the laminated construction. Once this unit is
delivered to a site, a perforated pipe would be slid into place
between the laminated construction and the film, i.e. the central
longitudinal portion of the film. Where water is to pass through
the film into or from the perforated pipe, the film would be made
porous, for example, in the manner of a silk sock, for the passage
of water but not for the passage of soil.
[0066] Referring to FIG. 8, a plurality of sheets 14 or
sub-divisions thereof, for example, 8 layers, each 1/2 inch in
thickness, may be laminated together with or without alternating
impermeable laminations and then provided with outer layers 19, 19'
to form a panel of insulation 20. One layer 19 may be paper while
the other layer 19' is a heat reflective foil. Due to the stiffness
of the laminated sheets 14, the resulting insulation panel 20 is
relatively stiff in a lateral direction. As such, the panel 20 may
be sized of a width to fit between a pair of studs or beams 21 in a
friction fit manner so as to avoid a need for fasteners, such as
nails, staples or the like. Further, should a need arise to remove
a panel 20 from a wall or the like, the panel 20 may be easily
removed by hand without interference from any fasteners.
[0067] The insulation panel 20 may be made in standard lengths of,
for example, 6, 7 or 8 feet to provide insulation for walls, floors
and ceilings of a building. Further, the insulation panel 20 may be
fabricated in a flat state or in a rolled state so as to provide a
longer length.
[0068] The insulation panel 20 provides a large volume of dead air
space between the outer layers 19,19'. Further, by fabricating
foamed sheets 14 with controlled sizes of filaments and mesh
openings, the amount of dead air space may be increased or
decreased to thereby control the heat insulation factor of the
panel. Likewise, fire retardant additives may be added to the
extrudate used to make the filaments 11 to thereby increase the
fire retardant qualities of the panel 20.
[0069] Referring to FIG. 9, a foamed sheet 14 or a strip thereof
may be secured to a film 22 of impermeable plastic or the like
along two longitudinal edges either by use of adhesives, sewing,
crimping, or heat sealing. The resulting structure may then be
shaped into a generally cylindrical or oval shape to form a pipe
23. The interior of the pipe 23 may be provided with suitable
supports to maintain the foamed sheet 14 and film 22 in the opened
state. For example, the space within the pipe 23 may be filled with
loose fill elements so as to form a pipe suitable for drainage
purposes. For example, such a pipe 23 may be provided alongside a
foundation, for example a house foundation, in order to provide for
drainage away from the foundation.
[0070] Alternatively, a perforated pipe (not shown) may be slid
between the foamed sheet 14 and film 22. The resulting construction
may be used for drainage purposes of alongside a foundation in
order to provide for drainage away from the foundation for may be
used in a septic tank system to convey effluent out of the pipe and
through the foamed sheet 14 into a leaching field.
[0071] Referring to FIG. 10, a bag 25 may be formed from a foamed
tube 26 and an impermeable or non-porous layer 27, for example of a
plastic. The tube 26 is formed in a manner as described above with
respect to FIG. 1 and is closed off at the upper end in any
suitable manner as by heat sealing or by a staple (not shown) while
the open lower end is secured to the non-porous layer 27, such as
by heat sealing, crimping, sewing and the like. As illustrated the
non-porous layer 27 is of a size to form a pocket that extends from
the tube 26.
[0072] The bag 25 may be filled with loose fill elements 28 of
expandable polystyrene or other suitable aggregate to function as
plant growing medium. That is, the bag 25 may be placed in a flower
pot 29 or other like container with the non-porous layer 27 facing
down and seated at the bottom of the pot 29. A layer of soil may
then be placed over the bag and a plant embedded in the soil in a
conventional manner.
[0073] The use of the bag 25 in the flower pot 29 reduces the
amount of water needed for the plant to grow since water is not
lost by drainage out of the pot 29. Further, the plant is not
immersed in a pool of water since the loose fill elements 28 keep
the plant above the water line and allow only the roots of the
plant to grow down through the elements 28 to the water line. The
bag 25 also keeps water in the pot as a reserve water supply.
[0074] Referring to FIG. 11, a web 30 of the foamed sheet may be
wrapped about a perforated pipe 31 for use in a drainage system or
a septic tank system. In addition, a porous or permeable membrane
32, such as a silk sock, is placed about a portion of the upper
outer surface of the web 30 to prevent sediment from passing into
the web 30. In this respect, the web 30 takes the place of foamed
aggregate that has been placed about a perforated pipe in prior art
constructions. Consequently, the web 30 not only provides a porous
structure but also allows easy fabrication of the web 30 about the
pipe 31. That is to say, there is no need to blow the foamed
aggregate into a mesh-like membrane fitted about a porous pipe as
in the prior art constructions.
[0075] Referring to FIG. 12, a layer of foamed material 14 may be
wound on itself to form a cylinder 33 that is placed in a sleeve 34
of permeable or impermeable material. For example, such a cylinder
33 could be used as a boom to contain an oil slick on a body of
water.
[0076] Alternatively, a plurality of layers of foamed material 14
may be formed into a block, for example as indicated in FIG. 7 that
is then cut to size to form a boom. In either case, the resulting
structure is of less weight than a conventional foamed plastic
material. For example, the resulting structure may be less than
one-half the weight of a conventional foamed plastic material.
[0077] Referring to FIG. 13, a laminated block 35 formed of
multiple layers 14 of the foamed material, with or without
alternating laminations of an impermeable material, may be used in
the construction of a floating concrete dock 36. For example, a
laminated block 35 of the foamed material, for example 12 feet by 6
feet by 16 inches, may be used as a core about which concrete may
be poured so that upon setting of the concrete, the resulting
concrete dock 36 is of substantially less weight than a solid
concrete block. In this case, the amount of free space that is
contained within the laminated block of foamed material serves to
reduce the overall weight of the concrete block. In addition, the
concrete is able to enter into the mesh openings of the laminated
block 35 to form a secure bonding of the concrete to the block 35.
Alternatively, the block 35 may be encased in a sleeve or bag or
the like to preclude the concrete from entering into the mesh
openings of the block 35. The resulting concrete block would have
even less overall weight and a greater amount of voids within the
block 35.
[0078] As described above, a laminated construction formed in part
of the foamed layer of crisscrossing foamed filaments has many uses
and may be made of various foamed plastic materials. For example,
the foamed layer may be made of polyethylene that has a high slip
characteristic. The foamed layers may also be provided with fire
retardants and/or anti-static additives.
[0079] A stack of foamed layers may be laminated on one or both
sides with suitable materials to function as insulation. Also,
laminations may be added to the outside and/or in alternating
manner to stiffen the laminated construction for use as a
structural element.
[0080] The invention thus provides a laminated construction that
can be made in a relatively inexpensive manner and that can be
fabricated into multilayer constructions to provide multiple
uses.
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