# US 2017/0282499 A1 · Foam Reefer Wall Using "Loop" Scrim Fabric Backing

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- Number: US 2017/0282499 A1
- Document ID: US20170282499A1
- Status: Published application
- Kind: A1
- Application number: 15/475,486
- Filed: 2017-03-31
- Published: 2017-10-05
- Earliest claimed: 2016-04-01
- Inventors: Michael C. LaRocco
- Web page: https://patentgrep.com/patent/US20170282499A1

## CPC

- B32B 5/06: characterised by a fibrous {or filamentary} layer {mechanically connected, e.g. by needling} to another layer, e.g. of fibres, of paper
- B32B 1/00: Layered products having a non-planar shape
- B32B 1/08: Tubular products
- B32B 3/08: characterised by added members at particular parts {(layer formed of separate pieces of material which are juxtaposed side-by-side B32B3/14, B32B3/18)}
- 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 5/022: {Non-woven fabric}
- B32B 5/024: {Woven fabric}
- B32B 5/028: {Net structure, e.g. spaced apart filaments bonded at the crossing points}
- B32B 5/20: foamed in situ
- B32B 5/245: {another layer next to it being a foam layer}
- B32B 7/12: using interposed adhesives or interposed materials with bonding properties
- B32B 15/046: {of foam}
- B65D 90/022: {Laminated structures (B65D90/029 takes precedence)}
- B32B 2250/05: 5 or more layers
- B32B 2260/021: Fibrous or filamentary layer
- B32B 2260/046: Synthetic resin
- B32B 2262/0253: Polyolefin fibres
- B32B 2262/0261: Polyamide fibres
- B32B 2262/0276: Polyester fibres
- B32B 2262/101: Glass fibres
- B32B 2266/0228: Aromatic vinyl resin, e.g. styrenic (co)polymers
- B32B 2266/0235: Vinyl halide, e.g. PVC, PVDC, PVF, PVDF
- B32B 2266/025: Polyolefin
- B32B 2266/0257: Polyamide
- B32B 2266/0264: Polyester
- B32B 2307/304: Insulating
- B32B 2307/50: having particular mechanical properties
- B32B 2439/62: Boxes, cartons, cases
- B32B 2605/00: Vehicles
- B32B 2605/08: Cars
- B32B 2605/10: Trains
- B32B 2607/00: Walls, panels
- B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B65D: CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES

## Abstract

An improved fabric backing for the manufacture of glass-reinforced thermoplastic panels that exhibits significantly greater foam adhesion than its scrim counterpart. That fabric backing includes a plurality of looped section extending upwardly (and inwardly) from its base for enhancing adhesion thereto. The combination is subjected to lamination for making an improved glass-reinforced thermoplastic interior wall panel. That wall panel can be used in a storage unit, such as a refrigerated trailer, railcar, shipping container and/or box truck.

## Claims

### Claim 1

An improved fabric using loops for connecting to a back side of a wall during manufacture of a glass-reinforced thermoplastic wall panel, said loop fabric comprising:
a plurality of fully looped sections adhered at both loop ends into a polymer woven wall substrate, said looped sections adapted for extending outwardly above the polymer woven wall substrate prior to having a thermoplastic resin injected thereabout to form an improved, laminated wall panel therefrom.

### Claim 2 (depends on 1)

The loop fabric of claim 1 wherein the looped sections extend between about 3-6 mm above the polymer woven wall substrate.

### Claim 3 (depends on 2)

The loop fabric of claim 2 wherein the looped sections extend at a substantially consistent height above the polymer woven wall substrate.

### Claim 4 (depends on 1)

The loop fabric of claim 1 wherein the fully looped sections consist essentially of a polyester blend.

### Claim 5 (depends on 1)

The loop fabric of claim 1, which includes between about 40 to 75 loops/sq. inch of fully looped sections.

### Claim 6 (depends on 1)

The loop fabric of claim 1, which includes between about 100 to 140 loops/sq. inch of fully looped sections.

### Claim 7 (depends on 1)

The loop fabric of claim 1, which connects to a backside of the wall panel by: lamination, gluing or combinations thereof.

### Claim 8

A composite sheet comprised of:
a) a base layer of reinforcing woven or non-woven fibers for impregnating with a thermoplastic resin, said base layer having a substrate into which a plurality of fully looped sections are interwoven for extending about 0.5 to 6 mm outwardly beyond the substrate; and
b) a thermoplastic resin injected about the base layer to create an improved mechanical bond between the injected thermoplastic resin and the base layer.

### Claim 9 (depends on 8)

The composite sheet of claim 8, which exhibits at least about 50% greater thermoplastic resin adhesion than its scrim counterpart.

### Claim 10 (depends on 8)

The composite sheet of claim 8 wherein the thermoplastic resin is a resin selected from the group consisting of ABS, nylon, polyester, polyolefin, polypropylene, PVC and polystyrene and the looped sections are made from a material selected from the group consisting of polypropylene, fiberglass, polyester, and nylon.

### Claim 11 (depends on 8)

The composite sheet of claim 8 wherein the mat includes between about 40 to 180 loops/sq. inch of fully looped sections.

### Claim 12 (depends on 11)

The composite sheet of claim 11, which includes between about 40 to 75 loops/sq. inch of fully looped sections.

### Claim 13 (depends on 11)

The composite sheet of claim 11, which includes between about 100 to 140 loops/sq. inch of fully looped sections.

### Claim 14

An improved storage unit made from a plurality of glass-reinforced interior wall panels, said interior wall panels being made from a thermoplastic foam adhered to a wall backing having a substrate which includes a plurality of fully looped sections which extend outwardly beyond the wall backing for greater adhesion of the thermoplastic foam thereto.

### Claim 15 (depends on 14)

The storage unit of claim 14 wherein the fully looped sections extend about 0.5-6 mm outwardly beyond the wall backing.

### Claim 16 (depends on 14)

The storage unit of claim 14 wherein the fully looped sections are adhered at both ends to the wall backing at a rate between about 40 to 180 loops/sq. inch.

### Claim 17 (depends on 14)

The storage unit of claim 14, which is selected from the group consisting of: a refrigerated trailer, a railcar, a shipping container and a box truck.

### Claim 18 (depends on 14)

The storage unit of claim 14 wherein the fully looped sections consist essentially of a polyester blend.

### Claim 19 (depends on 18)

The storage unit of claim 18 wherein the fully looped sections consist essentially of polypropylene.

### Claim 20 (depends on 14)

The storage unit of claim 14 wherein the wall backing adheres to an interior wall of the storage unit by: lamination, gluing or combinations thereof.