# US 4,095,008 A · Syntactic foam matrix board

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- Number: US 4,095,008 A
- Document ID: US4095008A
- Status: Granted
- Kind: A
- Application number: 05/604,187
- Filed: 1975-08-13
- Granted: 1978-06-13
- Earliest claimed: 1975-08-13
- Assignees: Rogers Corporation
- Inventors: Donald W. Sundstrom; Richard L. Maine
- Web page: https://patentgrep.com/patent/US4095008A

## CPC

- B32B 5/18: characterised by features of a layer {of} foamed material
- B32B 5/245: {another layer next to it being a foam layer}
- B32B 27/065: {of foam}
- B32B 27/42: comprising condensation resins of aldehydes, e.g. with phenols, ureas or melamines
- B32B 29/007: {next to a foam layer}
- C08J 9/32: from compositions containing microballoons, e.g. syntactic foams
- B32B 2309/105: Thickness
- Y10S 264/06: Molding microballoons and binder
- Y10S 428/908: Impression retention layer, e.g. print matrix, sound record
- Y10T 428/24504: Component comprises a polymer [e.g., rubber, etc.]
- Y10T 428/24967: Absolute thicknesses specified
- Y10T 428/249974: Metal- or silicon-containing element
- Y10T 428/252: Glass or ceramic [i.e., fired or glazed clay, cement, etc.] [porcelain, quartz, etc.]
- Y10T 428/2996: Glass particles or spheres
- B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- C08J: WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H (working, e.g. shaping, of plastics B29)
- Y10S: TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION

## Abstract

A matrix board and the method of manufacture thereof are presented wherein the board has a relatively thin carrier sheet, a relatively thick layer of syntactic foam on the carrier sheet and a relatively thin layer of phenolic resin and filler over the relatively thick syntactic foam layer. The matrix board is capable of being molded at low pressures on the order of fifty psi, thus making it particularly suitable for use with rubber and photopolymer pattern or master plates and also making it particularly suitable for formation of deep relief matrix boards.

## Claims

### Claim 1

A matrix board for molding printing plates including:
a carrier sheet; and
a layer of syntactic foam on said carrier sheet, said layer of syntactic foam including, by weight, from 25-50% thermosetting resin, said thermosetting resin being not more than partially cured, from 25-75% hollow particles and from 5-25% an aqueous latex dispersion binder;
said matrix board being deformable under pressure of from 25 psi to 125 psi and curable on exposure to heat to form a matrix board for the molding of printing plates.

### Claim 2 (depends on 1)

A matrix board as in claim 1, wherein said layer of syntactic foam further includes:
from 0-5% release agent; and
from 0-1.5% alkaline buffer.

### Claim 3 (depends on 1)

A matrix board as in claim 1 wherein:
said carrier sheet is a relatively thin layer of from 0.004 to 0.020 inches; and
said syntactic foam layer is a relatively thick layer of from 0.060 to 0.500 inches.

### Claim 4 (depends on 3)

A matrix board as in claim 3 wherein:
the thickness of said syntactic foam layer is greater than 0.015 inches; and wherein
said matrix board is deformable to form deep relief areas having depths of at least 0.15 inches.

### Claim 5 (depends on 1)

A matrix board as in claim 1 wherein:
said thermosetting resin is a phenolic resin.

### Claim 6 (depends on 1)

A matrix board as in claim 1 further including:
a cover layer including phenolic resin and binder.

### Claim 7 (depends on 6)

A matrix board as in claim 6, wherein said layer of syntactic foam further includes:
from 0-5% release agent; and
from 0-1.5% alkaline buffer.

### Claim 8 (depends on 6)

A matrix board as in claim 6 wherein:
said carrier sheet is a relatively thin layer of from 0.004 to 0.020 inches;
said syntactic foam layer is a relatively thick layer of from 0.060 to 0.500 inches; and
said cover layer is a relatively thin layer of from 0.015 to 0.040 inches.

### Claim 9 (depends on 8)

A matrix board as in claim 8 wherein:
the thickness of said syntactic foam layer is greater than 0.15 inches; and wherein
said matrix board is deformable to form deep relief areas having depths of at least 0.15 inches.

### Claim 10 (depends on 6)

A matrix board as in claim 6 wherein:
said thermosetting resin is a phenolic resin.