Claims
- 1. A method of forming a cut-resistant compressed seat covering material comprising at least one layer of a substantially incompressible flexible matrix material embedded within a compressed flexible foam polymer material, comprising the steps of:
- a) providing ingredients to form an expanded thermosetting flexible foam polymer material and mixing the ingredients;
- b) introducing a substantially incompressible flexible matrix material into a mold;
- c) introducing the mixed ingredients into the mold;
- d) reacting the mixed ingredients to produce gas and cause the ingredients to foam and expand to form an uncured expanded thermosetting flexible foam polymer material completely surrounding the matrix material;
- e) following step d), compressing the matrix-foam combination to remove substantially all of the gas produced during formation of the expanded thermosetting flexible foam polymer material in step d) to form a compressed matrix-foam product; and
- f) concurrently with or subsequently to step e), fully curing the compressed matrix-foam product produced in step e) to form a cut-resistant compressed seat covering material, whereby substantially all of the gas produced during formation of the expanded thermosetting flexible foam has been removed from the cut-resistant compressed seat covering material.
- 2. The method of claim 1, said step b) comprising introducing the matrix material into a mold, introducing the flexible foam polymer material into the mold, and causing or allowing the foam polymer material to foam and expand to form a green or uncured expanded foam material completely surrounding the matrix material.
- 3. The method of claim 2, in which the matrix material is a woven wire mesh.
- 4. The method of claim 2, in which the matrix material is a stainless steel woven wire mesh.
- 5. The method of claim 2, in which the matrix material is a metal.
- 6. The method of claim 2, in which the matrix material is a non-metal.
- 7. The method of claim 2, in which the matrix material is a woven mat of metal fibers.
- 8. The method of claim 2, in which the matrix material is a woven mat of metal wires.
- 9. The method of claim 2, in which the matrix material is a non-woven mat of metal fibers.
- 10. The method of claim 2, in which the matrix material is a non-woven mat of metal wires.
- 11. The method of claim 2, in which the matrix material a mesh of 6 mesh 20 gauge 304 woven stainless steel wire.
- 12. The method of claim 2, in which the flexible foam polymer material is a fire retardant foam polymer material.
- 13. A method of forming a cut-resistant compressed seat covering material comprising at least one layer of a substantially incompressible flexible matrix material embedded within a compressed flexible foam polymer material, comprising the steps of:
- a) forming a partially cured expanded thermosetting flexible foam polymer material having gas therein produced during the formation of the expanded thermosetting flexible foam polymer material;
- b) following step a), surrounding a substantially incompressible flexible matrix material with the partially cured expanded thermosetting flexible foam polymer material to form a matrix-foam combination;
- c) following step b), compressing the matrix-foam combination in a ratio of uncompressed thickness to compressed thickness of from 3:1 to 30:1 to remove substantially all of the gas produced during formation of the expanded thermosetting flexible foam polymer material in step a) to form a compressed matrix-foam product; and
- d) concurrently with or subsequently to step c), curing the compressed matrix-foam product produced in step c) to form a cut-resistant compressed seat covering material, whereby substantially all of the gas produced during formation of the expanded thermosetting flexible foam has been removed from the cut-resistant compressed seat covering material.
- 14. A method of forming a cut-resistant compressed seat covering material comprising at least one layer of a substantially incompressible flexible matrix material embedded within a compressed flexible, fire-retardant, foam polymer material, comprising the steps of:
- a) providing ingredients to form an expanded thermosetting flexible, fire-retardant, foam polymer material and mixing the ingredients;
- b) introducing a substantially incompressible flexible matrix material into a mold;
- c) introducing the mixed ingredients into the mold;
- d) reacting the mixed ingredients to produce gas and cause the ingredients to foam and expand to form an uncured expanded thermosetting flexible, fire-retardant, foam polymer material completely surrounding the matrix material;
- e) following step d), compressing the matrix-foam combination to remove substantially all of the gas produced during formation of the expanded thermosetting flexible, fire-retardant foam polymer material in step d) to form a compressed matrix-foam product; and
- f) concurrently with or subsequently to step e), fully curing the compressed matrix-foam product produced in step e) to form a cut-resistant compressed seat covering material, whereby substantially all of the gas produced during formation of the expanded thermosetting flexible, fire-retardant foam has been removed from the cut-resistant compressed seat covering material.
Parent Case Info
The present application is a continuation application of U.S. application Ser. No. 07/353,242, filed May 17, 1989, now U.S. Pat. No. 5,259,896.
US Referenced Citations (6)
Continuations (1)
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Number |
Date |
Country |
Parent |
353242 |
May 1989 |
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