US 12,083,773 B2
Method for producing cured polymeric skins
Aldino Albertelli, Dublin (IE)
Assigned to Acell Industries Limited, Dublin (IE)
Appl. No. 16/635,185
Filed by ACELL INDUSTRIES LIMITED, Dublin (IE)
PCT Filed Jul. 31, 2018, PCT No. PCT/GB2018/052181
§ 371(c)(1), (2) Date Jan. 30, 2020,
PCT Pub. No. WO2019/025783, PCT Pub. Date Feb. 7, 2019.
Claims priority of application No. 1712320 (GB), filed on Jul. 31, 2017.
Prior Publication US 2021/0053300 A1, Feb. 25, 2021
Int. Cl. B32B 27/12 (2006.01); B29C 35/08 (2006.01); B29C 70/46 (2006.01); B32B 5/02 (2006.01); B32B 5/16 (2006.01); B32B 27/14 (2006.01); B32B 27/42 (2006.01); C08J 5/12 (2006.01); C08J 5/18 (2006.01); E04F 13/14 (2006.01); B29K 61/04 (2006.01); B29K 105/00 (2006.01); B29K 105/08 (2006.01); B29K 267/00 (2006.01); B29L 31/10 (2006.01)
CPC B32B 27/12 (2013.01) [B29C 35/0805 (2013.01); B29C 70/465 (2013.01); B32B 5/022 (2013.01); B32B 5/16 (2013.01); B32B 27/14 (2013.01); B32B 27/42 (2013.01); C08J 5/121 (2013.01); C08J 5/18 (2013.01); E04F 13/142 (2013.01); B29C 2035/0855 (2013.01); B29K 2061/04 (2013.01); B29K 2105/0863 (2013.01); B29K 2105/0872 (2013.01); B29K 2105/251 (2013.01); B29K 2267/00 (2013.01); B29L 2031/108 (2013.01); B32B 2262/101 (2013.01); B32B 2264/1021 (2020.08); B32B 2419/06 (2013.01); C08J 2361/04 (2013.01)] 21 Claims
OG exemplary drawing
 
1. A method of forming a cured polymeric skin, the method comprising:
providing a sheet-form curable material including a thermosetting material, the thermosetting material including
uncured phenolic resin,
filler, and
a catalyst in an amount of less than 1 wt. % relative to the content of the uncured phenolic resin,
wherein the filler is present in a ratio of filler to uncured phenolic resin in an amount of 3:1 and greater, and further wherein the filler comprises a transition metal hydroxide and/or aluminium hydroxide in a ratio of metal hydroxide to uncured phenolic resin in an amount of 2:1 to 3:1;
providing a substrate in particulate form;
contacting the particulate substrate with a first surface of the sheet-form curable material;
pressing the particulate substrate to the sheet-form curable material; and
at least partially curing the sheet-form curable material to form a skin,
wherein the configuration of the substrate is such that gas and/or vapour can be displaced from the pressing region, and a portion of the sheet-form curable material flows into the particulate substrate.