# US 10,766,239 B2 · Composite panel, composite material, impregnator and method for manufacturing a composite panel

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- Number: US 10,766,239 B2
- Document ID: US10766239B2
- Status: Granted
- Kind: B2
- Application number: 16/407,147
- Filed: 2019-05-08
- Published: 2019-08-29
- Granted: 2020-09-08
- Earliest claimed: 2017-12-04
- Assignees: Annexair Inc.
- Applicants: Annexair Inc.
- Inventors: François Lemieux; Rhéal Comte; Raymond Marcoux
- Web page: https://patentgrep.com/patent/US10766239B2

## CPC

- B32B 37/18: involving the assembly of discrete sheets or panels only
- B29C 70/50: for producing articles of indefinite length, e.g. prepregs, sheet moulding compounds [SMC] or cross moulding compounds [XMC]
- B32B 5/02: characterised by structural features of a {fibrous or filamentary} layer {(layer formed of metallic wires B32B15/02; layer formed of natural mineral fibres B32B19/02; layer formed of wood fibres B32B21/02)}
- B32B 5/18: characterised by features of a layer {of} foamed material
- B32B 5/26: another layer {next to it} also being fibrous or filamentary {(relative arrangement of fibres or filaments of different layers B32B5/12)}
- B32B 27/04: as impregnant, bonding, or embedding substance {(not used)}
- B32B 27/10: of paper or cardboard
- B32B 29/007: {next to a foam layer}
- B32B 29/02: next to a fibrous or filamentary layer
- B32B 38/0004: {Cutting, tearing or severing, e.g. bursting; Cutter details (cutting in general B26D; laminating combined with punching or perforating B32B38/04; removing all or part of the layers B32B38/10; cutting in combination with laying up and registration B32B38/185 takes precedence)}
- B32B 37/20: involving the assembly of continuous webs only
- B32B 38/08: Impregnating
- B32B 2250/40: Symmetrical or sandwich layers, e.g. ABA, ABCBA, ABCCBA
- B32B 2260/021: Fibrous or filamentary layer
- B32B 2260/023: Two or more layers
- B32B 2260/028: Paper layer
- B32B 2260/046: Synthetic resin
- B32B 2266/0264: Polyester
- B32B 2305/18: Fabrics, textiles
- B32B 2307/3065: Flame resistant or retardant, fire resistant or retardant
- B32B 2307/718: Weight, e.g. weight per square meter
- B32B 2307/732: Dimensional properties
- B32B 2317/122: Kraft paper
- B32B 2419/00: Buildings or parts thereof
- B32B 2439/00: Containers; Receptacles
- B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00)

## Abstract

A method for manufacturing a composite material, the method comprising: positioning a first fabric layer between a first Kraft paper layer and a second Kraft paper layer; impregnating the first fabric layer with a binding composition while maintaining the first Kraft paper layer and the second Kraft paper layer dry; assembling the impregnated first fabric layer, the first Kraft paper layer and the second Kraft paper layer together to form a first pre-impregnated multilayer assembly; applying pressure on the first pre-impregnated multilayer assembly to diffuse the binding composition from the first fabric layer to the first Kraft paper layer and the second Kraft paper layer; and curing the first pre-impregnated multilayer assembly.

## Claims

### Claim 1

A method for manufacturing a composite material, the method comprising:
a) positioning a first fabric layer between a first Kraft paper layer and a second Kraft paper layer;
b) impregnating the first fabric layer with a binding composition in fluid state while maintaining the first Kraft paper layer and the second Kraft paper layer dry and separate from the first fabric layer;
c) after a) and b), assembling the impregnated first fabric layer, the first Kraft paper layer and the second Kraft paper layer together to form a first pre-impregnated multilayer assembly;
d) after c), applying pressure on the first pre-impregnated multilayer assembly to diffuse the binding composition from the first fabric layer to the first Kraft paper layer and the second Kraft paper layer; and
e) after d), curing the first pre-impregnated multilayer assembly.

### Claim 2 (depends on 1)

The method of claim 1, wherein impregnating the first fabric layer comprises translating the first fabric layer through an impregnator containing the binding composition.

### Claim 3 (depends on 2)

The method of claim 2, wherein impregnating the first fabric layer is conducted while the first Kraft paper layer and the second Kraft paper layer are bypassing the impregnator.

### Claim 4 (depends on 3)

The method of claim 3, wherein the impregnated first fabric layer, the first Kraft paper layer and the second Kraft paper layer are assembled downstream of the impregnator.

### Claim 5 (depends on 1)

The method of claim 1, further comprising, prior to applying pressure on the first pre-impregnated multilayer assembly:
f) cutting up the first pre-impregnated multilayer assembly;
g) after f), laying the first pre-impregnated multilayer assembly on a first surface of a foam core;
h) forming a second pre-impregnated multilayer assembly from the impregnated first fabric layer, the first Kraft paper layer and the second Kraft paper layer;
i) after h), laying the second pre-impregnated multilayer assembly on a second surface of the foam core; and
j) after i), cutting up the second pre-impregnated multilayer assembly.

### Claim 6 (depends on 5)

The method of claim 5, wherein applying pressure on the first pre-impregnated multilayer assembly further comprises applying pressure on the foam core and the second pre-impregnated multilayer assembly so that the binding composition penetrates the first Kraft paper layer and the second Kraft paper layer of the first pre-impregnated multilayer assembly and penetrates the first Kraft paper layer and the second Kraft paper layer of the second pre-impregnated multilayer assembly.

### Claim 7 (depends on 6)

The method of claim 6, wherein curing the first pre-impregnated multilayer assembly further comprises curing the foam core and the second pre-impregnated multilayer assembly so as to form a composite panel.

### Claim 8 (depends on 1)

The method of claim 1, wherein positioning the first fabric layer between the first Kraft paper layer and the second Kraft paper layer further comprises positioning a first veil layer between the first fabric layer and the first Kraft paper layer and positioning a second veil layer between the first fabric layer and the second Kraft paper layer.

### Claim 9 (depends on 1)

The method of claim 1, wherein positioning the first fabric layer between the first Kraft paper layer and the second Kraft paper layer comprises unrolling a first roll comprising the first fabric layer, unrolling a second roll comprising the first Kraft paper layer and unrolling a third roll comprising the second Kraft paper layer.