Appeal 2006-2300
Application 10/615,746
8) Londrigan discloses that reinforcing web(s) may be introduced
above and/or below the foamable chemicals (Londrigan, col. 13, ll. 52-
57).
9) The reinforcing web may be fed from a roll 49 toward the nip
between the two rotating metering rolls 32 and 33 (Londrigan, col. 14, ll.
1-3).
10) “The nip or gap 47 formed between the rolls 32 and 33 is
accurately adjustable so as to insure contact of the foamable mixture
with the facing sheets and any reinforcing material and cause the desired
uniform distribution of the mixture across the width of the sheets. Rolls
32 and 33 thus serve as a device to meter the amount of chemicals being
passed downstream for formation of the desired board thickness”
(Londrigan, col. 14, ll. 40-46).
11) According to Londrigan, a preferred reinforcing web material is
fiberglass fibers, for example, the type of expandable glass mat used in
producing the structural laminate of U.S. Pat. No. 4,028,158, i.e., a thin
mat of long, generally straight glass fibers (Londrigan, col. 13, ll. 57-62).
12) Londrigan further states that “[b]y generally following the method
of foam reinforcement described in Example 1 of U.S. Pat. No.
4,028,158 and utilizing a foam-forming mixture having the consistency
of the liquid foamable mixture of this example, the glass mat becomes
distributed within the foam core” (Londrigan, col. 13, ll. 62-67).2
2 Example 1 of U.S. Pat. No. 4,028,158 discloses the use of a mat of glass
fibers which is substantially incompressible and has an overall thickness of
0.030 inches. The glass fibers forming the mat are described as “long,
straight fibers having an average diameter of less than 25 microns and
lengths varying from 5 to 12 feet with an average length of over 5 feet.”
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