CA1102065A - Flexible sheet material - Google Patents

Flexible sheet material

Info

Publication number
CA1102065A
CA1102065A CA295,042A CA295042A CA1102065A CA 1102065 A CA1102065 A CA 1102065A CA 295042 A CA295042 A CA 295042A CA 1102065 A CA1102065 A CA 1102065A
Authority
CA
Canada
Prior art keywords
sheet
temperature
pressing
sheet material
wear
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired
Application number
CA295,042A
Other languages
French (fr)
Inventor
Neville M. Sheldon
Alfred Stern
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
General Foam Products Ltd
Original Assignee
General Foam Products Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by General Foam Products Ltd filed Critical General Foam Products Ltd
Application granted granted Critical
Publication of CA1102065A publication Critical patent/CA1102065A/en
Expired legal-status Critical Current

Links

Classifications

    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C67/00Shaping techniques not covered by groups B29C39/00 - B29C65/00, B29C70/00 or B29C73/00
    • B29C67/20Shaping techniques not covered by groups B29C39/00 - B29C65/00, B29C70/00 or B29C73/00 for porous or cellular articles, e.g. of foam plastics, coarse-pored
    • B29C67/207Shaping techniques not covered by groups B29C39/00 - B29C65/00, B29C70/00 or B29C73/00 for porous or cellular articles, e.g. of foam plastics, coarse-pored comprising impregnating expanded particles or fragments with a binder
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C44/00Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
    • B29C44/02Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles
    • B29C44/10Applying counter-pressure during expanding
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29LINDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00Other particular articles
    • B29L2031/48Wearing apparel
    • B29L2031/50Footwear, e.g. shoes or parts thereof
    • B29L2031/504Soles
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10STECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10S264/00Plastic and nonmetallic article shaping or treating: processes
    • Y10S264/07Binding and molding cellular particles
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10STECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10S521/00Synthetic resins or natural rubbers -- part of the class 520 series
    • Y10S521/918Physical aftertreatment of a cellular product

Abstract

Title: Flexible Sheet Material ABSTRACT OF THE DISCLOSURE

A wear-resistant flexible sheet material, suitable for use as outer soles on footwear, is produced by pressing reconstituted polyurethane foam sheets in the substantial absence of air at temperatures above 150°C. The sheets should have a density exceeding 15 lb/ft2 and are further densi-fied by the hot pressing. The sheets are preferably pre-heated to 175-210°C and pressed under a pressure of 5 to 30 tons/ft2 for periods of up to 5 minutes.
The sheets may be embossed or smooth surfaced and may contain pigments, plasticisers and other additions.

Description

11~2~65 The present invention relates to flexible sheet material prepared from foamed polyurethane and exhibiting good wear resist-ance, making it suitable for such purposes as outer soles for footwear.
Reconstituted foam materials, in which communited foam is bonded together with a foamable binder, have been known for some considerable time and a method for their preparation has been de-scribed in our British Patent No. 976,26Q. These reconstituted materials are useful, for example, in packaging and upholstery.
More recently, materials of higher density have been pro-duced, as described in our British Patent No. 1,337,413, in which much of the cellularity of the comminuted foam is lost by reduction to a small particle size, and in which the binder exhibits little or no expansion owing to the pressure under which the product is moulded. Such denser materials are employed, for example, for in-soles in the footwear industry.
We have now discovered that if a relatively dense flexible reconstituted foam material composed wholly or predominantly of polyurethane and having a density exceeding 15 lb~ft3, is subjected to pressure of about 5 to 30 tons~ft at a temperature above 150C
in the substantial absence of air, it can be further densified and formed into a flexible sheet material having wear resistance significantly greater than that of ~'
- 2 - ,-~'''~'^,r$S

llQ2Q65 the or~inal recorlstitllted material. In this way it is possible to ~ake dense, yet flexible and resilient material suitable for use as outer soles c~nd exhibiting lon~ life -in such use.
I~ had previously been thouKht that heat-forming of polyurethane materials above about 160C would decompose the pol~lrethane structure and not give useful r~sults but we ha~e surpIisingly found that heat-forming of dense reconsti-tuted foam materials is possible in the substantial absence of air. It is not in all cases necessary to co~pletely enc?ose the material to be hot-formed; compression of sheet material between solid heating platens will often suffice~
~he platens exclude air from all but the peripheral edges of the sheet, while the high density of the starting material ~5 means that there is little air within the material~ Substan-tial amounts of entrappea air can hinder the transfer of heat and cause embrittlement of the product through oxidative decomposition.
During pressing th~ granular appearance of the material is lost ~nd any surface embossment on the heated pressure surfaces is i~pressed on the material and becomes a permanent feature o~ the product. An increase in density can also be observed.
DESCRI:~'rION O:F 5;~, ~1 ~:ltll:lLii'l ~ypical temperature and pressure conditions ~re about 210C and about 120 p.s~i. respectively. ~he time necessary - is of the order of a fe~ minutes, but varies with t-he thick-ness and density of ths starting material.

l~ZC)65 ~ioxe ~el~ally, the preferred tempe.rature range of the recon~.tituted foa~ material to be pressed is from 150 to 250C. lt hzs been found beneficial to pre-heat the material before p~essing si.~ce this makes possible greater throughput in the pressin~ stage. Preferred pre-heatin~; condltions c~e 1-5 minutes between i~fra-red radiators to a temperature of 150-250 and more especially 175 to 210C.
r~he preferred pressures employed i~ the pressing~ stage are in thè ran~e 5 to 30 tons/ft2, more especially from 10 to 25 tons/ft2. r~he dwell times of the foam material in -the press depend on the thickness of the starting material and on the type of emboss required~ Longer times are needed for deeply embossed surfaces as compared with smooth surfaces.
By way of exa~ple, the followin~ are typical pressing times for different thiclmesses of sheet:-For a deep embossO
2.5 mm thickness 2 minutes 2.8 mm " 2~ "
3.0 m~ " 3 "
3.5 mm " 3~ "
4.0 mm " 4 For a polished surface:
2.5 mm thickness 1 minute 3 r 0 ~m " 2 "
r~he process of the inventlcn is preferablv applied to achieve products of final sheet thickness from 1~2 mm to 18 mm, although these limits are not critical~ r~he most ~ .

}?~fer~ r a~ ,e of I)roduct thicl~ess is fro~ to 8 ~m.
~he proces~ can be applied t,o any predo~linantly poly-ureth~ne recorletituted fo~ material of the requisi1;e de~sity whether of the polyether or polysster'type. ~e effect achieved is particularl~ surprisin~ with the polyether type because this t~pe of pol~rethane has a]ways been considered to be essentially on-thermoplastic c~nd inc~apable of any kind of thermo-for~ing.
~he process c~oes not depend on the use of any particvlar kind of pol~rethane bincler in the preparation of the reconsti-tuted starting material. ~olylene di-isocyanate cold curing systems, tolylene di-isoc~anate prepolyrner systems and methylene di-isocyc~ate systems have all been successfully employed.
A variety of additions can be included in the reconsti-tuted foe~ starting material to modify its properties and hence the properties of the compressed product. Such additions include flame-retardants, colorants, deodorants, fungicides and plasticisers. ~hese can,extend the range of application ' of the product and improve its performance.
~he invention a]so provides shoe soles formed of the - flexible sheet material defined above or movlded to shapesr Such soles may be embossed with pattern~, by using engra~ed or otherwise figured platens, and colouring or surface lacquers may also be applied.
Soling materials prepared in this wa~ show increased wear resistance, good flexibility and high slip re~istance ~hen worn.

Thc fol1oY~ing are e~nples of the pre,sent ~referred practice of this invention? in which al' quantities are given in part,s by weight unless the context indicates otherwise.
~ _e~ple I
1. l'roduction of ~rim~ sheet.
Polyether based pol~ure-thane foam was ground to a particle size of less than 2 mm ana then mi.xed with a binder to a for.~ul3.tion as follows:
- Grou~d pol~urethc~e 78.2 parts Prepolymer formulation10.2 Ethyl acetate 1~4 ~ctivator solution 10.2 '~he prepolymer formulation is made up typically as follows:
Polyether polyol, rJol.wt. 5000 100.0 parts Amine catal.yst (N,~1-dimethyl-phenethylamine) 0O3 ~olylene diisocyanete (~0/20) 40.6 --An.activator solution may be made up as follows:
Water 100 parts ine catalyst (as above) '.~he resulting mixture was charged into a mould and cured under pressure to yield a material of 60 lb/ft3 density~
~heets were then cut from this material in a suitable thicXness.
29 Heat ~`reatment of Sheet.
A sheet of materjal cut from a piece of reconstituted material ~repc,.red as outlined in (1) ~nd of ~ ~m thicl~ness was pu-t in a pres3 bet~7eeIl embossed heated platens and sub-jectecl. to a pressuxe of 120 p.s~i.
The temperature of the.platens wa,s 210~ and the pressure was maintained for 2 minutes.
After this time the sheet ~as removed and. cooled. It had no~ lost its granular nature and increased its density while taking up a permanent impre3sion of the embossin~
pattern.
Example II
The follo~Jing i.s a formulation includin~ colour and plasticiser which can be substituted for that in ¢xample I
a~d used to produce a reconstituted foam which can thereafter be pressed to lorm a densified product as described in that ~xampleO
Ground polyuretb.ane foam 76.1 parts Pigmented prepolymer composition 9.8 Solvent 6.5 Plasticiser (di~isodecyl phthalate) 7.6 ~xample III
The follo~ring are test results on a typical product of the invention, made by a process substantially identical with that of Examples I and.II.
1. Flex Test r~he resistance of the produ~t to damage by flexirg is tested by the Ross Flex '~est carrled out in accoraance ~7ith the st~dard ~AT~A 'l'est Method Prf60 (Shoe & Allied Trades Research Association.).

Q~;S

T~e t;est i s carried out at -5C c~nd for a material to pass i.t r,lust exhihit growth o~ a st~mdard cut not exceeding .5 mm.
~he p~oducts of this invention over a r~l~e of 2.5 to 3 ~m thickness showed cut growths of only 1.5 to 2.5 ~.
2 Miscellane~ roperties ~, _ Other physical properties for a material of 2~5 mm thic~ess were:
Densi'y 57 lb/ft3 q`ensile strength 4000 KPa ~lon~ation 70%
q'ear resistance 3 Kg/cm Hardness (Shore A) 60-80 Abrasion resistance (Weight loss after 1000 cycles in ~aber-~I22 test) 2-2.~/o : Cold flex at -~5C ~o cracking (after 18 hours exposure) - .

Claims (8)

THE EMBODIMENTS OF THE INVENTION IN WHICH AN EXCLUSIVE
PROPERTY OR PRIVILEGE IS CLAIMED ARE DEFINED AS FOLLOWS:
1. A process for making wear-resistant flexible sheet material comprising the steps of:
providing a sheet of dense flexible reconstituted poly-urethane foam material having a density exceeding about 15 lb/ft3;
and subjecting said sheet to pressure of about 5 to 30 tons/ft2 at a temperature above about 150°C in the substantial absence of air whereby said sheet is densified and its wear re-sistance enhanced.
2. The process of claim 1 wherein said pressing is carried out at a temperature in the range of about 150 to 250°C.
3. The process of claim 1 wherein said sheet is preheated to a temperature in the range of about 150 to 250°C for a period of about 1 to about 5 minutes prior to pressing.
4. The process of claim 1 wherein said pressing is carried out for a period of 1 to 4 minutes depending on the thickness of said sheet.
5. The process of claim 1 wherein the polyurethane is of the polyether type.
6, A process for making wear-resistant flexible sheet material comprising the steps of:
providing a sheet of dense flexible reconstituted foam composed at least predominantly of polyurethane and having a density exceeding about 15 lb/ft3;

heating said sheet to a temperature in the range of about 150 to 250°C;
and compressing said sheet at said temperature between platens to the substantial exclusion of air under a pressure in the approximate range 5 to 30 tons/ft2 for a period of about 1 to about 4 minutes to a final sheet thickness in the approximate range of 1.2 to 18 mm.
7. The process of claim 6 wherein said sheet is heated to a temperature of 175 to 210°C over a period of 1 to 5 minutes prior to said pressing.
8. Wear-resistant flexible sheet material made by the process of claim 1.
CA295,042A 1977-02-02 1978-01-16 Flexible sheet material Expired CA1102065A (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
GB4282/77 1977-02-02
GB4282/77A GB1595223A (en) 1977-02-02 1977-02-02 Flexible polyurethane sheet material

Publications (1)

Publication Number Publication Date
CA1102065A true CA1102065A (en) 1981-06-02

Family

ID=9774194

Family Applications (1)

Application Number Title Priority Date Filing Date
CA295,042A Expired CA1102065A (en) 1977-02-02 1978-01-16 Flexible sheet material

Country Status (7)

Country Link
US (1) US4241189A (en)
AU (1) AU3291178A (en)
CA (1) CA1102065A (en)
DE (1) DE2804489A1 (en)
FR (1) FR2379368A1 (en)
GB (1) GB1595223A (en)
IT (1) IT1111443B (en)

Families Citing this family (11)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR2442642A1 (en) * 1978-11-29 1980-06-27 Recticel PROCESS FOR THE REALIZATION OF A GYMNASTICS MAT CALLED "RECEPTION MAT"
US4438220A (en) * 1981-06-18 1984-03-20 Wm. T. Burnett & Co., Inc. Polyurethane foam-filled foam resistant to combustion and method of producing same
US4396568A (en) * 1981-07-17 1983-08-02 Firma Carl Freudenberg Method for the manufacture of a relief-like profiled outer sole of a cross-linked ethylene-co-vinyl acetate (EVA) foamed with closed cells
GB2116572B (en) * 1982-03-05 1985-10-30 Kun Huang Chang High density flexible polyurethane foam
US4990396A (en) * 1986-06-18 1991-02-05 Dana Corporation Gasket having multiple regions of different densities and thicknesses
US4810454A (en) * 1986-06-18 1989-03-07 Dana Corporation Method of manufacturing a gasket having multiple regions of different densities and thicknesses
GB2240978A (en) * 1990-02-01 1991-08-21 Psychopax Limited Improved packaging materials
US5273698A (en) * 1992-05-28 1993-12-28 Creme Art Corporation Method for shaping cover materials
US5296182A (en) * 1992-05-28 1994-03-22 Creme Art Corporation Method for making formed laminate
US5457139A (en) * 1993-07-26 1995-10-10 Monsanto Company Flexible water-blown polyurethane foams
US6623676B1 (en) 1999-07-14 2003-09-23 Wm. T. Burnett & Co. Process for forming a continuous web from polyurethane foam pieces

Family Cites Families (12)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
NL113523C (en) * 1955-02-03 1900-01-01
US3035280A (en) * 1956-08-16 1962-05-22 Agricola Reg Trust Method of working expanded plastic and articles made by the method
US2994110A (en) * 1957-05-10 1961-08-01 Mobay Chemical Corp Surfacing process for isocyanate foam and product
US3004293A (en) * 1959-09-15 1961-10-17 Werner H Kreidl Method of treating a foamy material having a high water content and product obtained thereby
GB976260A (en) * 1962-09-18 1964-11-25 Gen Foam Products Improvements relating to the moulding of articles of foam material
NL297232A (en) * 1962-10-31 1900-01-01
US3354578A (en) * 1964-07-24 1967-11-28 Mattel Inc Figure toy having compressed elastomeric stuffing and bonded cover
GB1134751A (en) * 1965-01-22 1968-11-27 Gen Foam Products Improvements relating to foamed materials
US3452127A (en) * 1965-12-28 1969-06-24 Henry H Lovette Method of making an innerspring body supporting article
DE6750189U (en) * 1968-03-01 1969-01-02 Rudolph Koepp & Co Chem Fab Ag PRESSED FORMED PARTS ON A POLYURETHANE BASE.
GB1337413A (en) * 1970-04-10 1973-11-14 Gen Foam Products Flexible moulded product
US3746610A (en) * 1971-01-29 1973-07-17 Du Pont Composite boards prepared from foam sheeting

Also Published As

Publication number Publication date
IT1111443B (en) 1986-01-13
US4241189A (en) 1980-12-23
AU3291178A (en) 1979-08-09
FR2379368A1 (en) 1978-09-01
DE2804489A1 (en) 1978-08-03
GB1595223A (en) 1981-08-12
IT7867189A0 (en) 1978-02-01

Similar Documents

Publication Publication Date Title
CA1102065A (en) Flexible sheet material
US2994110A (en) Surfacing process for isocyanate foam and product
US3844862A (en) A method of coating fabrics with polyurethane
US3061885A (en) Treatment of polyurethane foams
GB1379898A (en) Method of making transparent polyurethane and siad product
US3101242A (en) Process of making flexible absorbent material
EP0278622A2 (en) Shaping of syntactic foam
CN106436341A (en) Solvent-free ultrafine fiber mirror synthetic leather
US4014826A (en) Process for preparing rebonded foam structures
JP2603905B2 (en) Manufacturing method of molded products
US3263010A (en) Non-cellular unitary structures and preparation thereof
US4504338A (en) Methods of producing composite foamed thermoplastic resin articles
US2296305A (en) Manufacture of thin sheets of chemically blown rubber
US4396568A (en) Method for the manufacture of a relief-like profiled outer sole of a cross-linked ethylene-co-vinyl acetate (EVA) foamed with closed cells
CA2027894A1 (en) Process for preparing a sheet of polymer-based foam
US2267316A (en) Pressed fibrous product and process
SU1623568A3 (en) Method of producing leather blanks for making footwear and leather articles
US2723934A (en) Porous rubber materials
US5397417A (en) Process for producing sponge rubber stamp having open cell
US4975515A (en) Polyurethanes
CA1158817A (en) Foam composites of polyurethane integral skin foam and non-polyurethane foam and a process for their manufacture
CN100575381C (en) The method for making of formed polyurethane foam material
EP0193229B1 (en) Thermoplastic leather material and its preparation
JPS5934499B2 (en) Manufacturing method of thermo-press molded fiberboard
JPS58145431A (en) Heat-and water-resistant molding with flame-retardant expansible adhesive

Legal Events

Date Code Title Description
MKEX Expiry