FIBER FOAM AND PROCESS

摘要

A method of forming a foam article having a predetermined distribution of randomly oriented fiber filaments of staple length throughout the article and a substantially uniform weight ratio of fiber filaments to foam resin throughout comprising:(a) adding fibers of staple length to at least one major component of a foamable resin composition thereby forming a fiber slurry;(b) pumping said slurry through a circulating line for a time sufficient to separate the fibers into discrete fiber filaments and to wet said fiber filaments with said major component while maintaining the structural integrity of said fiber filament thereby forming a substantially uniform dispersion of randomly oriented fibers in said component;(c) mixing said dispersion with the balance of components necessary to form a foamable resin composition;(d) thereafter allowing the resin composition to foam in an appropriate mold whereby a foam article is provided having a substantially uniform weight ratio of fiber filaments to foam resin throughout. The resulting foam is of substantially improved mechanical strength over conventional foams.