Aluminum based laminate member and process for producing the same

Claim 1

A COMPOSITE LAMINATED MEMBER COMPOSED OF (A) A BODY SHEET OF ALUMINUM OF A THICKNESS OF AT LEAST 0.02 INCH, (B) A FACE LAMINATE COMPRISING AT LEAST TWO SHEETS OF FIBROUS MATERIAL COEXTENSIVE OVER AT LEAST ONE FACE OF THE SHEET OF ALUMINUM AND OF A THICKNESS NOT SUBSTANTIALLY EXCEEDING THE THICKNESS OF THE SHEET OF ALUMINUM, THE FACE LAMINATE HAVING AN OUTER SHEET OF FIBROUS MATERIAL IMPREGNATED WITH A RESIN SELECTED FROM THE GROUP CONSISTING OF THERMOSET MELAMINE-ALDEHYDE AND UREAALDEHYDE RESINS AND AN INNERMOST SHEET OF FIBROUS MATERIAL IMPREGNATED WITH A THERMOSET PHENOL-ALDEHYDE RESIN, AND (C) A BINDER SHEET COEXTENSIVE WITH THE SHEET OF ALUMINUM AND DISPOSED BETWEEN THE SHEET OF ALUMINUM AND THE FACE LAMINATE, THE BINDER SHEET COMPRISING SHEET FIBROUS MATERIAL COATED ON THE SIDE IN CONTACT WITH THE SHEET OF ALUMINUM WITH AT LEAST 50% OF ITS WEIGHT OF A THERMOSET RESIN HIGHLY ADHERENT TO ALUMINUM, THE THERMOSET RESIN COMPRISING ESSENTIALLY FROM 25 TO 80 PARTS BY WEIGHT OF POLYVINYL BUTYRAL AND FROM 75 TO 20 PARTS BY WEIGHT OF A PHENOLIC RESIN DERIVED BY REACTING AT ABOUT THE BOILING POINT OF THE MIXTURE 1.0 MOL OF A PHENOL AND FROM 0.8 TO 1.2 MOLS OF FORMALDEHYDE WITH FROM ABOUT 1/6% TO 1% OF THE WEIGHT OF THE PHENOL OF AN ALKALI HYDROXIDE CATALYST TO EFFECT AN INITIAL REACTION, EVACUATING TO REMOVE UNREACTED FORMALDEHYDE AND WATER, THE INITIAL REACTION BEING CONDUCTED FOR A PERIOD OF TIME INVERSELY PROPORTIONAL TO THE AMOUNT OF CATALYST AND CORRESPONDING TO ABOUT ONE-HALF HOUR FOR 1/3%, INTRODUCING AN AMMONIUM SALT AND AMMONIUM HYDROXIDE INTO THE PARTIALLY REACTED MIXTURE, THE AMMONIUM SALT CHEMICALLY REACTING WITH THE ALKALI HYDROXIDE TO PRODUCE AND ALKALI SALT, WHICH WILL PRECIPITATE, AND AMMONIUM HYDROXIDE, THE TOTAL AMMONIUM HYDROXIDE EFFECTING A SECONDARY CATALYTIC REACTION TO PRODUCE A RESINIFIED MATERIAL, DISSOLVING THE RESINIFIED MATERIAL IN A SOLVENT AND CENTRIFUGING THE RESIN SOLUTION TO REMOVE THE ALKALI SALT PRECIPITATE AND TO EFFECT CLARIFICATION.