GB1594350A - Flexible sheet material - Google Patents

Flexible sheet material Download PDF

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Publication number
GB1594350A
GB1594350A GB4998476A GB4998476A GB1594350A GB 1594350 A GB1594350 A GB 1594350A GB 4998476 A GB4998476 A GB 4998476A GB 4998476 A GB4998476 A GB 4998476A GB 1594350 A GB1594350 A GB 1594350A
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United Kingdom
Prior art keywords
foam
fibres
thermosettable
thermosettable powder
composition
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Expired
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GB4998476A
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Dunlop Ltd
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Dunlop Ltd
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Publication date
Application filed by Dunlop Ltd filed Critical Dunlop Ltd
Priority to GB4998476A priority Critical patent/GB1594350A/en
Priority to NZ18580177A priority patent/NZ185801A/en
Publication of GB1594350A publication Critical patent/GB1594350A/en
Expired legal-status Critical Current

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Classifications

    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J9/00—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof
    • C08J9/33—Agglomerating foam fragments, e.g. waste foam
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/02—Layer formed of wires, e.g. mesh
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/245—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it being a foam layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/02—Synthetic macromolecular fibres
    • B32B2262/0261—Polyamide fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/02—Synthetic macromolecular fibres
    • B32B2262/0276—Polyester fibres
    • B32B2262/0284—Polyethylene terephthalate [PET] or polybutylene terephthalate [PBT]
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/04—Cellulosic plastic fibres, e.g. rayon
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/06—Vegetal fibres
    • B32B2262/062—Cellulose fibres, e.g. cotton
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/10—Inorganic fibres
    • B32B2262/101—Glass fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/14—Mixture of at least two fibres made of different materials
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2266/00—Composition of foam
    • B32B2266/02—Organic
    • B32B2266/0207—Materials belonging to B32B25/00
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2266/00—Composition of foam
    • B32B2266/02—Organic
    • B32B2266/0214—Materials belonging to B32B27/00
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2266/00—Composition of foam
    • B32B2266/02—Organic
    • B32B2266/0214—Materials belonging to B32B27/00
    • B32B2266/0278—Polyurethane
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2437/00—Clothing
    • B32B2437/02—Gloves, shoes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2471/00—Floor coverings
    • B32B2471/02—Carpets
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2605/00—Vehicles
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J2205/00—Foams characterised by their properties
    • C08J2205/06—Flexible foams
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J2307/00—Characterised by the use of natural rubber
    • C08J2307/02—Latex
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J2309/00—Characterised by the use of homopolymers or copolymers of conjugated diene hydrocarbons
    • C08J2309/06—Copolymers with styrene
    • C08J2309/08—Latex
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J2311/00—Characterised by the use of homopolymers or copolymers of chloroprene
    • C08J2311/02—Latex
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J2375/00—Characterised by the use of polyureas or polyurethanes; Derivatives of such polymers
    • C08J2375/04—Polyurethanes
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J2461/00—Characterised by the use of condensation polymers of aldehydes or ketones; Derivatives of such polymers
    • C08J2461/04—Condensation polymers of aldehydes or ketones with phenols only
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J2463/00—Characterised by the use of epoxy resins; Derivatives of epoxy resins

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Materials Engineering (AREA)
  • Health & Medical Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Medicinal Chemistry (AREA)
  • Polymers & Plastics (AREA)
  • Organic Chemistry (AREA)
  • Manufacture Of Porous Articles, And Recovery And Treatment Of Waste Products (AREA)
  • Separation, Recovery Or Treatment Of Waste Materials Containing Plastics (AREA)

Description

(54) FLEXIBLE SHEET MATERIAL (71) We, DUNLOP LIMITED, a British Company of Dunlop House, Ryder Street, St.
James's, London S W 1, do hereby declare the invention, for which we pray that a patent may be granted to us, and the method by which it is to be performed, to be particularly described in and by the following statement: This invention relates to flexible sheet material and to a method of making it.
According to the present invention, a method of making flexible sheet material comprises applying differential compression to a composition of granular flexible polymeric foam and a dry thermosettable powder the conditions of compression being such that the thermosettable powder is fused and forms a thermoset product and the thermosettable powder being present in an amount such that it will yield from 2 to 10 parts by weight, based on 100 parts by weight of foam, of the thermoset product.
By "dry" thermosettable powder is meant that the thermosettable powder is in a dry state and not e.g. in solution, dispersion or emulsion form, when it is combined with the foam.
Examples of thermosettable powders include resin precursors, a partially condensed resin a thermosettable resin (e.g. a phenolic or an epoxy resin) and mixtures of any of these. The thermosettable powder may be combined with the foam granules by tumbling them together. Examples of suitable thermoset products include cured resins e.g. phenolic and epoxy resins.
By "differential" compression is meant that compression is applied to the foam/ thermosettable powder composition such that certain areas of the product are highly compressed relative to the remaining areas and so that a flexible coherent product is produced. This differential compression may be achieved by the use of a profiled mould, one or more relief-patterned platens or, more simply, by locating a wire mesh at one or both sides of the composition before applying pressure to the assembly. The selection of mesh size and wire thickness usually depends on the foam particle size and the desired flexibility of the final product. Alternatively, a grid comprising a single set of a parallel wires may be used instead of a mesh, although this might tend to limit the flexibility of the product to one direction only.
Examples of suitable polymeric foams include those made from polyurethanes, natural or synthetic rubber latices (e.g. natural rubber, styrene/butadiene rubber [SBR] or polychloroprene rubber) and mixtures of these. Waste foam may be used. Foam having a non-compressed particle size such that it will pass through a B.S. 481 (Part 2:1972) 25 mm sieve may be used in the present invention. More preferably, foam having a noncompressed particle size such that it will pass through a 12. 5 mm sieve is used in the present invention.
It has been found, surprisingly, that a coherent flexible sheet material may be produced by the method of the present invention using only a small amount of thermosettable powder i.e. that amount which will yield from 2 to 10 parts by weight, based on 100 parts by weight of foam, of a thermoset product. Preferably, that amount of thermosettable powder which will yield about 5 parts by weight of thermoset product is used, based on 100 parts by weight of foam. In order to obtain a coherent product by the method of the present invention the thermosettable powder is preferably uniformly distributed throughout the granular flexible foam and therefore the smaller the amount of thermosettable powder used, the smaller its particle size will need to be and vice versa.The thermosettable powder may have a particle size of less than 100 microns and preferably less than 50 microns.
If desired, the composition of foam and thermosettable powder may also include textile fibres, the amount of thermosettable powder being such that it will yield from 2 to 10 parts by weight of a thermoset product and the amount of textile fibres suitably being from 20 to 50 parts by weight based on 100 parts by weight of foam. Examples of textile fibres include natural fibres (e.g. cotton); synthetic fibres (e.g. polyamides such as nylon); regenerated cellulose (e.g. rayon), polyesters (e.g. poly(ethylene terephthalate)); and mineral fibres (e.g. glass asbestos, metal). Preferred fibres are those of glass. Waste fibres, e.g. tyre lint or carpet clippings, may be used. By 'tyre lint' is meant the textile material which is a by-product of processes for reclaiming rubber from scrap tyres. Suitable fibres are those having lengths of from 2 to 25 mm.
A flexible sheet material having a backing and/or facing, of e.g. textile material or plastics or rubber sheet, may be made by assembling a layer of the required material in the appropriate position relative to the composition of foam, thermosettable powder and optionally also textile fibre before applying differential compression to the assembly. If a backing or facing is not present, the portion of the foam granules at the surface(s) of the composition of foam, thermosettable powder and optionally textile fibres may with advantage be fused.
The products of the present invention have a variety of uses depending on the types and proportions of materials used and the extent of compression. Examples of uses are as carpet underlay and, particularly when textile fibres are included, as interior trims such as a roof-lining for a vehicle (e.g. a car), packaging material and noise and heat-insulation generally. When the product is to be used as a roof-lining, the perimeter of the sheet and possibly also strip areas spaced across the sheet may suitably be compressed to a greater extent than the rest of the sheet.
The invention is illustrated in the following examples: Example I 20 g of granular polyurethane foam was tumbled with 1 g of Resin 0222/2 (a phenolic resin available from BXL Limited). The resulting composition was placed on a 15 cm x 15 cm square steel plate. A sheet of steel wire mesh (15 mm mesh, 3 mm diameter wire) was placed on top of the composition, followed by a second steel plate. This assembly was pressed for 5 minutes at 1600C under a pressure of approximately 1 kg/cm2. The product was a flexible, resilient sheet material, 6 mm thick, with an average density of about 0.15 g/cc.
Example II 180 g of granular mixed flexible polyether-urethane foam of nominal size 10 mm were blended by tumbling with 72 g of chopped staple glass fibre (12 mm length) and 18 g of phenolic resin powder (Resin R0222/2, Bakelite Limited). This composition was transferred to the bottom half of a mould of approximate size 30 cm x 30 cm, which had been lined with a laminate of brushed nylon fabric having a thin backing layer of polyurethane foam of about 1 mm thickness. The upper half of the mould was put in place and was closed in a press under sufficient pressure to fully close the mould (see NOTE below). The sample was held in the press for 5 minutes at 1600C and then de-moulded. The product was a 5 mm thick uniform coherent sheet.
Note The mould used in this operation was provided with a distance piece which could be varied to control the final thickness of the product and hence its modulus of rigidity and compressibility.
Exnmples 111 and IV These were as Example 1I except that the distance piece was such as to give a final sheet thickness of 10 mm and 3 mm respectively.
The modulus of rigidity of each of the products of Examples Il-IV was measured by the bending beam method on a sample 25.5 cm in length to give a deflection of 5 cm. The hardness of each sample was determined using a Shore A gaugc. Results are given in Table 1.
TABLE I Simple Modulus of thickness rigidity Shore A Example (mien) (MN/m2 hardness II 5 109 70 III 10 7.3 40 IV 3 432 85 Ev~z le V Example II was repeated cxcept that the 72 g of glass fibre were replaced by 36 g of nylon 66 flock of approximately 4 mm length and 20 denier. The product was similar in stiffness (subjectively assessed) to that of Example II.
WHAT WE CLAIM IS: 1. A method of mixing flexible sheet material comprises applying differential compression to a composition of granular flexible polymeric foam and a dry thermosettable powder as hereinbefore defined. the conditions of compression being such that the thermosettable powder is fused ind forms a thermoset product, the thermosettable powder being present in an amount such that it will yield from 2 to l() parts by weight, based on 100 parts by weight of foam. of the thermoset product.
2. A method according to claim I wherein the foam has a non-compressed particle size such that it will pass through a B.S. 481 (Part 2; 1972) 25 mm sieve.
3. A method according to claim I wherein the foam has a non-compressed particle size such that it will pass thn'ugh a B.S. 481 (Part 2: 1972) 12.5 mm sieve.
4. A method according to any of claims 1 to 3, wherein the foam comprises a polyurethane foam, a natural or synthetic rubber latex foam or a mixture of any of these.
5. A method according to claim 4 wherein the foam comprises a styrene/butadiene rubber (SBR) foam. a polychloroprene foam or a mixture thereof.
6. A method according to any of the preceding claims wherein the foam comprises Waste foam.
7. A method according to any of the preceding claims wherein the particle size of the thermosettable powder is less than 100 microns.
8. A method according to any of claims 1 to 6 wherein the particle size of the thermosettable powder is less than 50 microns.
9. A method according to any of the preceding claims wherein the thermosettable powder is present in an amount such that it will yield 5 parts by weight, based on 100 parts by weight of foam, of the thermoset product.
10. A method according to any of the preceding claims wherein the thermosettable powder comprises resin precursors.
11. A method according to any of claims 1 to 9 wherein the thermosettable powder comprises a partially condensed resin.
12. A method according to any of claims 1 to 9 wherein the thermosettable powder comprises a thermosettable resin.
13. A method according to claim 12 wherein the resin comprises a phenolic or epoxv resin or a mixture thereof.
A A method according to any of the preceding claims wherein the composition of granular flexible foam and a dry thermosettable powder contains textile fibres.
15. A method according to claim 14 wherein the fibres comprise mineral fibres.
16. A method according to claim 15 wherein the fibres comprise glass fibres.
17. A method according to claim 14 wherein the fibres comprise natural fibres.
18. A method according to claim 17 wherein the fibres comprise cotton fibres.
19. A method according to claim 14 wherein the fibres comprise polyamide.
regenerated cellulose, polyester or a mixture of any of these fibres.
20. A method according to claim 19 wherein the fibres comprise nylon, rayon.
poly(ethylene terephthalate) or a mixture of any of these fibres.
**WARNING** end of DESC field may overlap start of CLMS **.

Claims (36)

**WARNING** start of CLMS field may overlap end of DESC **. bending beam method on a sample 25.5 cm in length to give a deflection of 5 cm. The hardness of each sample was determined using a Shore A gaugc. Results are given in Table 1. TABLE I Simple Modulus of thickness rigidity Shore A Example (mien) (MN/m2 hardness II 5 109 70 III 10 7.3 40 IV 3 432 85 Ev~z le V Example II was repeated cxcept that the 72 g of glass fibre were replaced by 36 g of nylon 66 flock of approximately 4 mm length and 20 denier. The product was similar in stiffness (subjectively assessed) to that of Example II. WHAT WE CLAIM IS:
1. A method of mixing flexible sheet material comprises applying differential compression to a composition of granular flexible polymeric foam and a dry thermosettable powder as hereinbefore defined. the conditions of compression being such that the thermosettable powder is fused ind forms a thermoset product, the thermosettable powder being present in an amount such that it will yield from 2 to l() parts by weight, based on 100 parts by weight of foam. of the thermoset product.
2. A method according to claim I wherein the foam has a non-compressed particle size such that it will pass through a B.S. 481 (Part 2; 1972) 25 mm sieve.
3. A method according to claim I wherein the foam has a non-compressed particle size such that it will pass thn'ugh a B.S. 481 (Part 2: 1972) 12.5 mm sieve.
4. A method according to any of claims 1 to 3, wherein the foam comprises a polyurethane foam, a natural or synthetic rubber latex foam or a mixture of any of these.
5. A method according to claim 4 wherein the foam comprises a styrene/butadiene rubber (SBR) foam. a polychloroprene foam or a mixture thereof.
6. A method according to any of the preceding claims wherein the foam comprises Waste foam.
7. A method according to any of the preceding claims wherein the particle size of the thermosettable powder is less than 100 microns.
8. A method according to any of claims 1 to 6 wherein the particle size of the thermosettable powder is less than 50 microns.
9. A method according to any of the preceding claims wherein the thermosettable powder is present in an amount such that it will yield 5 parts by weight, based on 100 parts by weight of foam, of the thermoset product.
10. A method according to any of the preceding claims wherein the thermosettable powder comprises resin precursors.
11. A method according to any of claims 1 to 9 wherein the thermosettable powder comprises a partially condensed resin.
12. A method according to any of claims 1 to 9 wherein the thermosettable powder comprises a thermosettable resin.
13. A method according to claim 12 wherein the resin comprises a phenolic or epoxv resin or a mixture thereof.
A A method according to any of the preceding claims wherein the composition of granular flexible foam and a dry thermosettable powder contains textile fibres.
15. A method according to claim 14 wherein the fibres comprise mineral fibres.
16. A method according to claim 15 wherein the fibres comprise glass fibres.
17. A method according to claim 14 wherein the fibres comprise natural fibres.
18. A method according to claim 17 wherein the fibres comprise cotton fibres.
19. A method according to claim 14 wherein the fibres comprise polyamide.
regenerated cellulose, polyester or a mixture of any of these fibres.
20. A method according to claim 19 wherein the fibres comprise nylon, rayon.
poly(ethylene terephthalate) or a mixture of any of these fibres.
21. A method according to any of claims 14 to 20 wherein the fibres comprise waste
fibres.
22. A method according to any of claims 14 to 21 wherein the amount of textile fibres is from 20 to 50 parts by weight based on 100 parts by weight of foam.
23. A method according to any of claims 14 to 22 wherein the fibres are of a length from 2 to 25 mms.
24. A method according to any of the preceding claims wherein the composition of foam and thermosettable power is made by tumbling them together.
25. A method according to any of the preceding claims wherein the thermosettable powder is distributed uniformly throughout the granular foam.
26. A method according to any of the preceding claims wherein a backing and/or a facing layer is assembled in the appropriate position relative to the composition of foam and thermosettable powder before applying differential compression to the assembly.
27. A method according to any of the preceding claims wherein a portion of the foam at at least one of the surfaces of the composition of foam and thermosettable powder is fused during differential compression.
28. A method according to any of the preceding claims wherein the differential compression is applied by pressing the composition in a profiled mould.
29. A method according to any of claims 1 to 27 wherein the differential compression is applied using relief-patterned platens.
30. A method according to any of claims 1 to 27 wherein the differential compression is applied by locating a wire mesh or a grid arrangement at one or both faces of the composition before applying pressure to the resulting assembly.
31. A method according to claim 1 and substantially as herein described.
32. A method according to claim 1 and substantially as described in any of Examples I to V.
33. A flexible sheet material made by the method according to any of claims 1 to 32.
34. A flexible sheet material according to claim 33 when used as a vehicle roof-lining.
35. A flexible sheet material according to claim 33 when used as a car roof-lining.
36. A flexible sheet material according to claim 33 when used as an insulation material.
GB4998476A 1976-11-30 1976-11-30 Flexible sheet material Expired GB1594350A (en)

Priority Applications (2)

Application Number Priority Date Filing Date Title
GB4998476A GB1594350A (en) 1976-11-30 1976-11-30 Flexible sheet material
NZ18580177A NZ185801A (en) 1976-11-30 1977-11-28 Flexible sheet material produced from a composition comprising granular flexible foam and dry thermosettable powder

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
GB4998576 1976-11-30
GB4998476A GB1594350A (en) 1976-11-30 1976-11-30 Flexible sheet material

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GB1594350A true GB1594350A (en) 1981-07-30

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NZ (1) NZ185801A (en)

Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2141722A (en) * 1983-06-20 1985-01-03 Secretary Industry Brit Urethane composites
GB2161812A (en) * 1984-07-07 1986-01-22 Wardle Storeys Plc Particulate cross-linked polymer mixtures
EP0528456A1 (en) * 1991-06-25 1993-02-24 HP-CHEMIE PELZER RESEARCH & DEVELOPMENT Ltd. Recycling of duroplastic polyurethane foam articles
EP0829588A2 (en) * 1996-09-17 1998-03-18 Helmut Wedi Semi-finished product, namely insulation panel for a floor, ceiling or wall
WO2012091557A1 (en) * 2010-12-31 2012-07-05 Holland Composites Innovation B.V. Composite materials and shaped articles

Cited By (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2141722A (en) * 1983-06-20 1985-01-03 Secretary Industry Brit Urethane composites
GB2161812A (en) * 1984-07-07 1986-01-22 Wardle Storeys Plc Particulate cross-linked polymer mixtures
EP0528456A1 (en) * 1991-06-25 1993-02-24 HP-CHEMIE PELZER RESEARCH & DEVELOPMENT Ltd. Recycling of duroplastic polyurethane foam articles
EP0829588A2 (en) * 1996-09-17 1998-03-18 Helmut Wedi Semi-finished product, namely insulation panel for a floor, ceiling or wall
EP0829588A3 (en) * 1996-09-17 1998-08-12 Helmut Wedi Semi-finished product, namely insulation panel for a floor, ceiling or wall
WO2012091557A1 (en) * 2010-12-31 2012-07-05 Holland Composites Innovation B.V. Composite materials and shaped articles

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