Flexible composite material

Abstract

To provide a flexible composite material that is curable to a solid.SOLUTION: There is provided a flexible composite material comprising: a fill material located in the space b between a first layer a and a second layer c opposing the first layer, which is curable to a solid on the addition of a liquid, gas or radiation; and a plurality of elements extending into the space from and connected to the first layer and / or the second layer, which may pass through the first layer and / or the second layer, and may connect together, thereby forming linking elements for joining the layers together; wherein an uncured first fill material is provided in the space at a pressure such that tension is applied to one or more of the linking elements, and wherein the flexible composite material further comprises a second fill material located in the space between the first layer and the second layer, and wherein the second fill material is separated from the first fill material by way of a separation layer located in the space between the first layer and the second layer.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] The present invention relates to flexible composite materials that can be solidified to become rigid or semi-rigid upon the addition of a liquid or by exposure to gas or radiation. [Background technology]

[0002] WO 2005 / 124063 describes a shelter including a ground sheet and a cover, where air can be pumped into the space between the ground sheet and the cover to expand the space and lift the cover and form the shelter. The cover is made of a cement-impregnated fabric, which may be a type of felt known as "wadding", which is an open non-woven fabric. The cover is wetted with water just before the interior space expands, so that after expansion, the cement in the cover hardens to form a rigid shell that acts as a self-supporting roof for the shelter. This is particularly useful for providing temporary accommodation in emergency areas.

[0003] WO 2007 / 144559 discloses a woven fabric comprising a pair of opposing surfaces, threads (also called connecting fibers) extending between and spacing the surfaces, and a solid powder material disposed in the space between the surfaces. The powder material can include a cement that can be solidified into a hard or semi-hard solid mass upon addition of a liquid, and that can be solidified into a solid cement or concrete upon addition of an aqueous liquid. The amount of solidifiable material in the spaces of the fabric is specifically such that when the material is solidified, it occupies substantially the entire space between the first and second surfaces. The fabric (without the powder material) can be a known spacer fabric that is commercially available. The thickness of the spacer fabric is determined during manufacture by selecting an appropriate length for the connecting fibers.

[0004] U.S. Patent No. 4,495,235 discloses a flat body including a core filler of gypsum or cement and aggregate disposed between a cover layer and a backing layer. The layers and core are needle-bonded together through the unset filler, thereby forming interlocking fibers within the core. The interlocking fibers hold the layers together in a deformable state. After the flat body is filled with the filler material, the filler is compressed by rollers after needling, thereby compressing the interlocking fibers and increasing the packing density of the filler.

[0005] WO 2010 / 086618 discloses a fabric impregnated with a material that solidifies when mixed with a liquid, the fabric being designed to prevent the filling material from spilling over the edges of the fabric by providing an edge extending laterally from one side of the fabric and an elastic thread pulling the extension towards the other side at least partially closing a space at the edge of the fabric to prevent the filling material from spilling over the fabric.

[0006] The fabric described in WO 2010 / 086618 represents an improvement over previous fabrics in that it provides a solution to the problem of the difficulty in controlling the amount of liquid added during the solidification process. The fabric described in WO 2010 / 086618 makes it easier to control the amount of liquid added during the solidification process by filling the fabric with a preset amount of filler, such that only a preset amount of liquid is allowed to enter the fabric and solidify the reagents in the filler.

[0007] The flexible fabrics described above have many uses and advantages. For example, the flexible composite material can be placed to form a structure and then cured to provide a rigid protective barrier. Similarly, the fabrics can be deployed to form, for example, temporary roads, temporary walls, erosion barriers, waste containment structures, temporary or permeable formwork, structural liners for piping, trenches or culverts, slope protection and stabilization layers, and many other applications. Multiple sheets of such fabrics may be used together, depending, for example, on the size of the application and the local environment.

[0008] One problem with existing filled flexible fabrics is that the powder filling cannot be packed into the fabric under significant pressure, resulting in limited powder packing density.

[0009] There are several techniques used to manufacture flexible fabrics. Bonding a first layer to a second layer can be effectively done using needling or stitchbonding techniques, which involve carrying fibers or yarns through one layer into the filler material and wholly or partially to the opposing layer to bond the layers together. Needling and stitchbonding techniques are well known across industries such as the textile industry and can be used to efficiently manufacture large quantities of flexible fabrics. There are several drawbacks to using needling and stitchbonding techniques to manufacture flexible filled fabrics. Fabrics made by needling or stitchbonding through the filler material cannot have a high density of the filler material because the needle carrying the fibers or yarns has a certain volume. That is, the volume of the needle causes powder to be expelled as the needle passes through the filler material, resulting in a density of the filler material that is lower than the maximum filler density after the needling or stitchbonding process. To overcome this limitation, after filling and needling or stitch-bonding the filling material, the filled and needled or stitch-bonded fabric is often further densified by applying pressure to the filled fabric between rollers to recompress the filling material. The recompression of the filled fabric under pressure has the disadvantage that the connecting fibers are broken and cannot be tensioned, and the outer surface is flattened and cannot support the internal pressure, i.e., when the unconsolidated fabric is manipulated to apply internal pressure to the fabric, the broken connecting fibers tend to return to their pre-pressurized state, and the density of the filling material becomes lower than its optimal filling density. For the reasons mentioned above, applying pressure to the filled fabric to break the connecting fibers means that the increased packing density created by the rollers is lost when the unconsolidated flexible fabric is manipulated. Therefore, the filled flexible fabric produced in this way has difficulty maintaining a constant density at the high density of the unconsolidated powder filling when it is manipulated during handling, transportation and use, because the connecting fibers are easily straightened to allow the powder filling to move within the material.

[0010] Another method of producing filled flexible fabrics is to fill the powder through the holes in the outer surface of a preformed three-dimensional structure by vibration or brushing, and then seal the holes. One drawback of this type of filled flexible fabric is that the preformed three-dimensional structure needs to be sufficiently stiff in the z-direction (thickness direction) so that it does not collapse during the filling process. Such stiff three-dimensional structures are expensive and also require thicker fibers and / or more connecting fibers between the two outer layers to allow the connecting fibers to support sufficient compressive loads to maintain the internal volume of the material during filling with the filling material and during use. Their outer surface is also flat, so the stiff connecting fibers must be closely spaced to maintain this shape when the unconsolidated material is manipulated during use. As a result, a very large number of stiff connecting fibers are required per unit volume to allow the powder to be filled with sufficient density, which makes the fabrics produced in this way expensive and difficult to manufacture. Additionally, powder fillers can act as a mold release agent, making it difficult to seal the surfaces through which the powder filler passes during filling, and difficult to bond or form sealing surfaces to close open pores.

[0011] No. 5,401,552 discloses a geocomposite liner material having first and second fibrous layers and a non-fibrous layer of bentonite clay between the first and second layers. The liner of U.S. Pat. No. 5,401,552 is formed by placing bentonite clay between the first and second layers and needle punching the second layer so that the fibers from the second layer pass from the second layer into the bentonite clay and through the first layer. The fibers from the second layer extend from the first layer and are heat fused to the exterior of the first layer to hold the first layer, the bentonite clay layer and the second layer together. DE-A-4122993 and U.S. Pat. No. 5,346,566 disclose similar materials and methods of manufacture, but the fibers extending from the first layer are secured to the exterior of the first layer with an adhesive.

[0012] One problem with existing methods for manufacturing geocomposites containing swelling clays such as bentonite is that the needle punching process causes wear on the needles as they pass through the clay, resulting in frequent replacement of worn or bent needles and limiting the density of the dry clay before expansion.

[0013] The present invention aims to provide an alternative to flexible fabrics, and also to provide a solution to the problems mentioned above.

[0014] The term "flexible composite material" or "composite material" is used herein to refer to a spacer material having an internal space containing a solidifiable fill material. A "spacer material" is a material having a first layer and a second layer separated from each other by an internal space, and also has a connecting element extending between the first and second layers that maintains the first and second layers in a spaced apart arrangement. The solidifiable fill material is also called a "fill", and this fill can include both materials that react with liquid or radiation to solidify the fill, called "reagents", and materials that do not react with liquid or radiation, e.g., inert substances such as auxiliaries and fillers. The term "first layer" refers to the portion of the composite material between the upper exterior surface and the internal space. This first layer may be liquid and / or radiation transparent and is usually at the top of the product when installed. The term "element" is used to indicate a separate material component, which may be combined with other elements to form a product layer. The first layer may be composed of two or more individual elements bonded together. The term "second layer" refers to the portion of the composite material between the interior space and the lower exterior surface. This second layer is usually the side that will not be exposed to weathering once installed. The second layer can also be composed of several individual elements bonded together. The term "intermediate surface" refers to a plane that is equidistant from the surfaces of the first and second layers if they were idealized planes. Summary of the Invention

[0015] That is, the present invention provides a flexible composite material that can be solidified to become rigid or semi-rigid, the flexible composite material comprising a first layer, a second layer opposite the first layer, the second layer separated from the first layer by a space, a filler material disposed in the space between the first and second layers, the filler material being capable of solidifying to a rigid or semi-rigid solid upon application of a liquid, gas or radiation, and a plurality of elements extending substantially from the first and / or second layer into the space and connected to the first and / or second layer, the plurality of elements being capable of passing through the first and / or second layer and being capable of connecting to one another, thereby forming connecting elements that bond the layers to one another, wherein one or more of the connecting elements are placed under tension, and unsolidified filler material is provided in the space with a pressure such as to bulge the first and / or second layer outwardly between adjacent connecting elements that are under tension.

[0016] The pressure applied by the powder charge, in combination with the tension in the one or more connecting elements, causes the first layer and / or second layer to bulge outwardly relative to an interface between the first and second layers between the one or more connecting elements that are under tension and forms one or more points of minimal thickness in the composite material between the first layer and / or second layer at the locations where the one or more connecting elements are connected to the first layer and / or second layer.

[0017] The first layer and / or the second layer can include a plurality of pores that are small enough to retain the filler material but allow the passage of liquid or gas.

[0018] The solidifiable filler material disposed in the space is filled into the space with a positive pressure differential in order to compress the filler material and maximize the internal volume of the structure occupied by the filler at a given filling pressure differential and mechanical properties of the first and second layers. The bonded connecting elements are tensioned as a result of the pressure exerted by the filler material on the first and second layers, thereby forming a series (multiple) of three-dimensional curved tensile microstructures (bumps) with a length scale of 0.1-50 mm (e.g., 2-30 mm) that preferably have a minimum at the point where the bonded connecting elements are connected to the first and second layers. This is observed when the material is in an unsolidified state and placed on a flat surface without any external load. When flattened, the individual connecting elements are tensioned, and the presence of the compressed filler material causes the first and second layers to bulge outward between the connecting elements, placing their surfaces in tension between the attachment points of the connecting elements.

[0019] The positive pressure difference as the fill is packed into the space is a hydrostatic pressure in the fluidized powder (fluidized by aeration and / or vibration), induced mechanically or by a pressurized gas or liquid carrier, which then leaks through the first and / or second layers. The volume of the space between two layers of composite material is limited by the connecting elements that constrain how far apart the layers can be. The pressurized packing results in a compression of the powder fill between the layers, and this compression is substantially maintained because the connecting elements and the first and second layers are under tension to maintain the internal volume. Substantially maintaining the compression level is important to minimize the movement of the fill material (and the resulting loss of density) during transportation and placement of the unconsolidated material, and to ensure the correct ratio of liquid to settable powder during the solidification of the fill material.

[0020] The first layer of the flexible composite material may comprise a nonwoven fabric. The nonwoven fabric may comprise fibers bonded by needle punching, adhesives, heat and pressure, hydroentanglement, stitch bonding or ultrasonic welding. Preferably, the nonwoven fabric comprises fibers bonded by needle punching.

[0021] Providing a nonwoven in the first layer allows the flexible composite to retain the filler material within the spaces while at the same time allowing the passage of liquids such as water into the composite, thereby allowing the liquid to permeate or be drawn in by capillary action by the connecting elements, or fill the spaces with the filler material and solidify it. They also retain the filler material in the composite while allowing the pressurized carrier gas or liquid used to introduce the filler material during manufacture to exit the composite.

[0022] The fibers of the nonwoven fabric may be one or more of polyester fibers, polyethylene terephthalate fibers, polyvinyl alcohol fibers, nylon fibers, silnylon fibers, vinyl fibers, basalt fibers, carbon fibers, alkali resistant fiberglass, glass fibers, coated glass fibers, polyvinyl chloride fibers, aramid fibers, jute fibers, cotton fibers, viscose fibers, and mixtures thereof. The fibers may further include a heat activated binder or other form of binder that relies on chemical, radiation or oxidative activation.

[0023] The fibers of the nonwoven fabric have an average linear density of 0.1-100 dtex (measured in g / m), preferably 0.2-100 dtex, more preferably 0.5-100 dtex, even more preferably 1-100 dtex, preferably 2-50 dtex or 3-30 dtex, or may comprise a blend of fibers of different weights. The fibers of the nonwoven fabric may have a staple length of 10-200 mm, preferably 30-150 mm or 40-100 mm, for example, the fibers of the nonwoven fabric may have a staple length of 20, 30, 40, 50, 60, 70, 80, 90, 100, 110, 120, 130, 140, 150, 160, 170, 180, 190 or 200 mm.

[0024] The first layer may be permeable to gas and / or liquid, but substantially impermeable to the filler material. This allows gas and / or liquid to pass through the first layer and into the space while preventing the filler material from escaping or flowing out of the space. Providing such a permeable first layer allows excess gas and / or liquid to escape from the space. Preferably, the first layer is permeable to gas sufficiently to allow the pressurized gas carrying the solidifiable powder into the space to escape, but prevents the solidifiable powder from escaping, allowing the solidifiable powder to be trapped in the material at a higher density than it was during transport into the space. The first layer is preferably highly permeable to gas, since when the carrier gas expands to atmospheric pressure, the volume of the carrier gas can be much larger than the volume of the solidifiable powder. A higher conveying gas pressure can be used to increase the transport rate of the material and therefore the filling rate, increasing the density of the solidifiable powder filling trapped between the layers and increasing the tension and elongation acting on the connecting elements. Connecting elements with higher tensile capacity (tensile strength), either due to stronger fibers, better attachment to other layers, or more elements per square centimeter, allow the material to be filled at higher pressures. Providing connecting elements with higher tensile capacity can advantageously allow the filling material to be filled more densely inside the space, thereby improving the properties of the consolidated composite material. Thus, a higher tensile capacity can reduce the porosity of the consolidated composite material and also prevent the movement of the unconsolidated powder filling during transportation and when the material is used before solidification.

[0025] The material of the first layer can be substantially the same color as the filler material when solidified. Having the first layer be a similar color to the solidified filler material immediately below it helps prevent staining from the filler material permeating the first layer, or staining or visible markings caused by the first layer becoming worn or damaged during use. Alternatively, the first layer and / or the filler material can be colored to blend in or stand out from its surroundings, or can be its natural color to avoid fading over time and minimize costs.

[0026] The flexible composite material may include a wear element or one or more coatings on the outermost side of the first layer opposite the filler material to improve wear characteristics in an abrasive environment.

[0027] The wear element (or coating) may be an additional element incorporated into the material of the first layer itself, or may be applied as a coating to the first layer. If the first layer comprises a nonwoven fabric, the application of the wear element or coating may act to bond the fibers of the nonwoven fabric to one another. The wear element or coating must not prevent the first layer from being permeable to the packing solidification agent, and thus may be, for example, perforated or in the form of a grid. Providing such a wear coating may improve the wear and durability of the composite in an abrasive environment (e.g., when the composite is used as a temporary road surface, a reinforcing lining for a mine wall, or a trench lining), as well as prevent fibers (e.g., non-biodegradable synthetic fibers) from detaching from the composite and leaking into the environment.

[0028] The wear element or coating is selected from the list of materials including polyester, polyethylene terephthalate, polyvinyl alcohol, nylon, silnilon, vinyl, basalt, carbon fiber, fiberglass, coated fiberglass, rubber, latex, HDPE, polyvinyl chloride, aramid, jute, cotton, viscose, polypropylene, styrene block polymers or acrylics, polyesters, polysulfides or polyurethanes, lignin or mixtures thereof. Preferably, the wear element or coating comprises one or more layers of polypropylene.

[0029] The first and / or second layers of the flexible composite material may further include a reinforcing element, which may include a woven, nonwoven, continuous membrane, or knitted fabric configured to improve the tensile strength and / or increase the stiffness of the first and / or second layers. Preferably, the reinforcing element is a continuous geomembrane with good strength and stiffness, such as 1 mm linear low density polyethylene (LLDPE). The reinforcing element may also include a ductile layer, such as a ductile metal lath, grid, or mesh, to achieve two purposes: to provide reinforcement and to make the unset flexible composite material sufficiently stiff to bendable to form into a three-dimensional shape, and to ensure that the ductile layer is sufficiently stiff to support the weight of the composite material in that shape before the material sets. This is advantageous because it eliminates the need for a formwork. This is because the material can be easily formed into a free-standing three-dimensional shape, where the material can be easily solidified into a three-dimensional form by adding a liquid solidifying agent to a flexible composite material with limited strength. Conventional settable fabrics must be placed over a pre-existing shape, form, or expandable object to obtain the three-dimensional shape before curing.

[0030] The reinforcing elements may perform the functions of other elements and may include polyvinyl chloride (PVC), polypropylene, high density polyethylene (HDPE), medium density polyethylene (MDPE), low density polyethylene (LDPE), LLDPE, flexible polypropylene, chlorosulfonated polyethylene, polyurethane, ethylene propylene diene monomer rubber (EPDM) rubber, butyl rubber, neoprene, polyurea coating, silicone, latex, natural or synthetic rubber, polyester, melt spun polyethylene fibers, nylon, silnylon, vinyl, basalt fibers, boron fibers, carbon fibers, polyvinyl alcohol fibers, alumina fibers, glass fibers, aramid fibers, jute, cotton, viscose or mixtures thereof, metals such as stainless steel, steel, aluminum alloys, etc. Suitable forms of reinforcing elements include extruded meshes, e.g., biaxially oriented HDPE grids, laths, knitted or woven fabrics, geogrids, membrane sheet materials that are themselves reinforced, nonwoven fabrics, etc. Preferably, the reinforcing layer comprises polypropylene. Most preferably, the reinforcing layer is a woven polypropylene tape.

[0031] Preferably, the inner portion of the reinforcing element (adjacent to the filler material) includes a textured surface for the filler material to adhere to upon solidification. This textured surface can be an integral part of the reinforcing element or an additional element bonded onto the surface to contact the solidifiable filler material. For example, the reinforcing element can include an open structure, such as a knitted mesh or open weave, configured for the filler material to pass through the open structure and bond to the first layer and / or second layer beyond the reinforcing layer upon solidification.

[0032] The ultimate tensile strength of the first layer and / or the second layer is determined by the following formula: TIFF2024170406000002.tif14170, where σ f is the ultimate tensile stress of the filling material when solidified (N / m 2 ), and t fis the average thickness (m) of the solidified fill material (measured along the crack line when the material is loaded to failure in a three-point bend test as described in BS EN 1849:2001), and T r is the ultimate tensile strength (N per metre width) of the first or second ply, tensioned in either bending direction. The ultimate tensile strength of a ply is the combination of all elements that make up the ply, substantially dominated by the reinforcing elements (if included).

[0033] Equation I can be derived as follows: Figure 15, 1000, shows the force (per unit depth into the plane of Figure 11) acting on a consolidated sample of flexible composite undergoing a three-point bending test according to BS EN 196-1:2005. The first ply is shown at 19, the consolidated filler material at 20 and the second ply at 21. The failure mode of the sample is believed to be that the consolidated filler material breaks under tension, cracking multiple times at discrete points progressively further away from an initial central crack, with final failure occurring when the second ply breaks under tension. This is in contrast to other failure modes such as failure of the bulk consolidated filler in compression or delamination of the reinforcement. For example, the first and second plies may be interchanged if the flexible composite is loaded from opposite sides such that the first ply becomes the ply in tension and equation (I) still applies.

[0034] Reference numeral 1000 in FIG. 15 denotes a sample after the first crack appears in the bulk solidified fill but before the second layer fractures. F (N) is the centrally applied load, L (m) is the support spacing of the sample, and x f (m) is the displacement of the central load. Here, x is the displacement of the central load so that the small angle rules apply in the following equations. f is at least ⅕ less than L and that the sample was substantially flat before testing.

[0035] Figure 15, item 1100, shows a decomposition of the forces acting on a sample at the point of the initial crack in the solidified bulk packing if a hypothetical break occurs at the center of the sample. T1(N) is the net compressive force acting on the solidified packing at its upper outermost part and T2(N) is the net tensile force acting on the solidified packing at its lower outermost part. A simple decomposition of the forces shows that: TIFF2024170406000003.tif12170

[0036] The shear stress acting in the contact area between the bulk solidified fill and the second layer is s (N / m). It is assumed that: TIFF2024170406000004.tif16170, where T r (N) is the ultimate tensile strength of the second ply measured using EN ISO 10319:2015. This relationship must hold if the assumption is made that the second ply breaks in tension before delaminating in shear.

[0037] σ f Solving for the stress in a solid rectangular beam due to bending, where (N / m) is the maximum tensile stress in the bulk solidified fill before tensile failure measured using BS EN 12390-6:2009, it can be shown that the following equation holds: TIFF2024170406000005.tif17170

[0038] Here, t b (m) is the average thickness of the solidified fill material (measured along the crack line when the material is loaded to failure in a three point bend test as described in BS EN 1849:2001).

[0039] In order for the first and / or second layers under tension not to fail when the solidified bulk fill develops the first crack, the following relationship must hold: TIFF2024170406000006.tif12170

[0040] Inserting equation V into equation VI and rearranging the equation gives: TIFF2024170406000007.tif14170

[0041] For formula (I) to hold, the layer in tension itself must be unable to withstand significant out-of-plane bending such that the reinforcing element is substantially loaded in tension rather than acting as a beam itself in bending.

[0042] Preferably, the layer in tension has an ultimate tensile strength T r According to the present invention, the stiffness of the material is in the range of 1-50 kN / m within the strain range of 5-15%.

[0043] Upon solidification, the filler material transfers bending loads to the first and / or second plies by a combination of two modes: (1) anchoring by elements trapped by the solidified filler material across the interface between the first and / or second plies and the solidified filler material, and (2) bonding of the solidified filler material to the inner surface of the first and / or second plies directly adjacent to the solidified filler material. If the first and / or second plies conform to the relationship of formula (I), failure of the composite in a three-point bending test as described in BS EN 196-1:2005 will occur gradually with the propagation of numerous small cracks in the solidified filler material before the reinforcement layers fail. This occurs because once the initial cracks form in the solidified filler material, the interface between the solidified filler and the first and / or second plies allows loads to be transferred to the first and / or second plies, which are under tension. As the strain in the ply in tension increases, it reaches a level where new cracks form in the solidified filler material. This process can be repeated multiple times until the ultimate strength of the ply in tension is reached. This allows for very large central displacements in a standard three-point bend test before catastrophic failure of the flexible composite material.

[0044] Creating a series of small cracks along the length of the composite also means that the unsolidified filler material within the body of the composite becomes exposed and can be used to impart a self-healing effect to the composite by allowing a fluid solidifying agent such as water or air or radiation to pass through the cracks and react with the unsolidified filler material trapped within the matrix of the solidified filler material, which can advantageously restore some or all of the original strength and stiffness of the solidified material.

[0045] The first layer and / or the second layer may have a tensile strength of 0.5-200 kN per meter width, preferably 1-150 kN / m, or 1-100 kN / m, based on measurements made using the EN ISO 10319:2015 standard.

[0046] At least a portion of the reinforcing elements may include a textured wedge surface (wedge element) on its inner surface to which the powder adheres upon solidification.

[0047] The first layer and / or the second layer further comprises a layer of textured wedge fabric on at least a portion of its innermost surface adjacent the powder material in the space. The textured wedge fabric can be any suitable material that allows the wedge elements to bond to the solidifiable powder when the powder is in its solidified state. The wedge elements can be a mesh, knitted or woven fabric, geogrid, nonwoven fabric, stitchbonded fabric, spunlaced nonwoven fabric, hydroentangled nonwoven fabric or a mixture thereof. Preferably, the textured wedge fabric has a thickness of 20-300 g / m 2 , more preferably 80-250g / m 2 , and even more preferably 20-150 g / m 2 It is a needle-punched nonwoven fabric having a mass of

[0048] The textured wedge fabric may comprise polyester fibers, polypropylene fibers, polyethylene terephthalate fibers, polyvinyl alcohol fibers, nylon, silnilon, vinyl, basalt fibers, carbon fibers, glass fibers, coated glass fibers, polyvinyl chloride fibers, aramid fibers, jute, cotton, viscose, fibers. Preferably, the textured wedge fabric comprises polypropylene fibers.

[0049] Preferably, when the filler material is solidified, the strength of the bond formed between the wedge element and the solidifiable powder and the strength of the bond formed between the wedge element and the reinforcing element are greater than or equal to F. r , is equal to or greater than the ultimate tensile strength of the reinforcing element (measured in Newtons per meter width of the composite (N / m)). The strength of the bond formed between the wedge element and the settable powder and the strength of the bond formed between the wedge element and the reinforcing element when the filler material is solidified can be judged based on the shear strength and / or peel strength of the bond, i.e., the extent to which the bond resists peeling. Preferably, the shear strength and / or peel strength of the bond between the wedge element and the settable powder and the bond between the wedge element and the reinforcing element when the filler material is solidified is equal to or greater than F. r Preferably, the shear strength of the bond between the wedge element and the settable powder when the filler material has set, when tested using BS EN ISO 13426-1:2005, is greater than or equal to 5-20 kN / m 2 and 5-20kN / m for the connection between the wedge element and the stiffening element. 2 Preferably, the peel resistance (peel strength) of the bond between the wedge element and the settable powder when the filler material has set is 0.5-10 kN / m and 0.5-10 kN / m for the bond between the wedge element and the reinforcing element when tested using BS EN ISO 13426-2:2005. Preferably, the peel resistance of the bond between the wedge element and the settable powder (when set) is the same or greater than the peel resistance of the bond between the wedge element and the reinforcing element, which may be of the same material.

[0050] Providing a textured wedge surface increases the surface area to which the filler material adheres and allows the filler material to solidify around individual elements that are at least partially embedded in the solidified filler material (in the space) and attached to one or both of the first and second layers, thereby forming a strong bond between the layers and the solidified filler material. Furthermore, more generally, the increased surface area of ​​the wedge surface exposed to the solidified filler material improves the bond strength between the solidified filler material and the wedge elements. A first layer that includes a nonwoven element has the same advantage in terms of increased bond strength. Thus, providing a nonwoven on the inner surface of the first and / or second layer advantageously makes the interfaces between the filler material and the second layer and the filler material and the first layer more resistant to delamination when the solidified composite is exposed to an external load.

[0051] To obtain the desired bending properties described herein, the bond between the inner nonwoven elements of the first and / or second layers (which may be penetrated by the consolidated filler material) and the reinforcing elements present must be strong enough so that the shear strength of this bond is of the same order of magnitude as the ultimate tensile strength of the reinforcing elements to prevent detachment of the wedge layer, and thus the consolidated powder, from the reinforcing elements during bending under load.

[0052] The second layer may be substantially impermeable to fluids by including a fluid impermeable element. Preferably, the hydraulic conductivity is at least 1×10 -8 ms -1 Alternatively, the hydraulic conductivity of the second layer including the fluid impermeable element may be less than 10 -3 -10 -15 ms -1 , 10 -6 -10 -14 ms -1 , or 10 -7 -10 -12 ms -1 The range may be:

[0053] The fluid impermeable element may comprise a low melting polymer, PVC, polypropylene, hot melt extrusion, HDPE, MDPE, LDPE, LLDPE, flexible polypropylene, chlorosulfonated polyethylene, polyurethane, EPDM rubber, butyl rubber, neoprene, polyurea coating, silicone, latex, natural or synthetic rubber, or a mixture thereof. Preferably, the second layer comprises a low melting polymer layer configured to be substantially fluid impermeable. Preferably, the second layer comprises an LLDPE geomembrane, which depending on its thickness can also act as a reinforcing element. Providing an LLDPE geomembrane with a thickness of 0.05-5 mm is suitable to allow the second layer to also act as a reinforcing layer.

[0054] The fluid-impermeable element may be combined with the reinforcing layer described herein, thus simultaneously acting as a reinforcing layer, or may be a separate element. The fluid-impermeable element may be sandwiched between the reinforcing element and the protective or anti-slip element, or may be bonded to the underside of the second layer so that it is the outermost element. Alternatively or additionally, the fluid-impermeable element may add anti-slip properties to the flexible composite material. The fluid-impermeable element may also prevent the filler material from leaking out of the flexible composite material. Preventing liquids such as water from passing through the flexible composite material is advantageous when the surface on which the composite material is placed is very dry and will wick moisture out of the material during solidification, resulting in a partially solidified finished product, or when the product is used in applications that require impermeability, such as lining ponds or containment tanks, and preferably the fluid-impermeable layer is attached to the reinforcing layer after the connecting element is formed.

[0055] The second layer may include a nonwoven fabric on its innermost surface or at least a portion thereof (the surface adjacent to the infill material) and / or the second layer may include a nonwoven fabric on its outermost surface (the surface facing away from the infill material). The nonwoven fabric may include fibers bonded by needle punching, adhesives, heat and pressure, hydroentanglement, stitch bonding or ultrasonic welding. The second layer may alternatively include an extruded mesh, knitted or woven fabric, geogrid, membrane material, nonwoven fabric, cast polymer of mixtures thereof on its innermost surface adjacent to the infill material.

[0056] The nonwoven or other type of material on the innermost surface of the second layer (adjacent to the filler material) comprises polypropylene, polyester fibers, polyethylene terephthalate fibers, polyvinyl alcohol fibers, nylon, silnilon, vinyl, basalt fibers, carbon fibers, glass fibers, coated glass fibers, polyvinyl chloride fibers, aramid fibers, jute, cotton, viscose, or mixtures thereof. Preferably, the nonwoven comprises polypropylene.

[0057] The provision of a nonwoven layer on the outermost surface advantageously protects the composite from puncture, tearing or general damage during shipping, installation and use.

[0058] The second layer can include anti-slip elements on at least a portion of its outermost surface facing away from the filler material to improve grip between the flexible composite material and the surface on which it is placed. The anti-slip elements can be a material with high surface roughness or a material with a high coefficient of friction that can engage with the surface on which it is placed.

[0059] The anti-slip element can include, on the lower surface, polypropylene, polyester, polyurethane, rubber, PVC nonwoven, woven or knitted fabric, extruded polymer or a mixture thereof. Preferably, the anti-slip element is a nonwoven fabric that includes polypropylene. In this preferred embodiment, the anti-slip element can also function as a protective element. Alternatively, the lower outer surface can include a solidified adhesive film (as disclosed herein), which simultaneously bonds the elements of the product and functions as an anti-slip element thanks to the friction coefficient of the adhesive.

[0060] The first and second layers are joined by connecting elements that hold the layers apart at a set distance when the space between the layers is occupied by a filler material.

[0061] The connecting elements may be spaced apart in a regular or irregular arrangement along the longitudinal axis of the flexible composite material.The connecting elements may be spaced apart in a regular or irregular arrangement along the transverse axis of the flexible composite material.

[0062] The connected elements may be arranged in one of the following patterns: equilateral triangles, irregular triangles, squares, rectangles, hexagons, other polygonal shapes, substantially randomly distributed patterns, or any combination thereof.

[0063] Each connecting element includes multiple sub-elements that extend across the space in discrete columns through one or both of the layers.

[0064] The connecting elements are 0.1-100mm (1cm 2 10,000-0.01 per cm), 0.1-50 mm (1 cm 2 10,000-0.04 per cm), 1-50 mm (1 cm 2 100-0.04 per cm, preferably 1.5-30 mm (1 cm 2 44-0.1 per cm), more preferably 1-20 mm (1 cm 2100-0.25 per cm), and even more preferably 1.5-20 mm (1 cm 2 44-0.25 per cm, most preferably 2-18 mm (1 cm 2 The axially extending portions of the axially extending plates can be spaced apart from each other by a distance of 25-0.3 mm per inch.

[0065] The connecting elements can extend across the space from the first layer and / or the second layer and through the opposing layer, thereby bonding the layers together. In other words, the connecting elements can extend across the space from the first layer through the second layer, thereby bonding the layers together. Alternatively, the connecting elements can extend across the space from the first layer and the second layer, with the connecting elements extending from the first layer extending through the second layer and the connecting elements extending from the second layer extending through the first layer, thereby bonding the layers together.

[0066] The connecting elements can extend from the first layer to the second layer at an angle relative to the surfaces of those layers. When the composite is filled under pressure, the net angle of the fibers in tension will be 90 degrees relative to the mid-plane between the first and second layers. This means that as long as all fibers under tension are at 90 degrees or give a net angle of 90 degrees over a length scale of about 100 mm, some fibers under tension may be at various different angles from 0 to 90 degrees, e.g., if one of two opposing connecting elements is at 45 degrees to the mid-plane and the other is at 135 degrees, then the net angle will be 90 degrees.

[0067] The connecting elements can be positioned in the space (to form the connecting elements) by one or more of needle punching, stitch bonding, hydroentangling, and engaging with preformed hooks.

[0068] Needle punching uses axially reciprocating barbed needles supported on a needle loom to push connecting elements from one nonwoven layer across a gap toward and into the opposing layer. Alternatively, needle punching techniques can be used with external connecting elements (e.g., yarns that are not part of the first and / or second layers). The two layers are pulled through the loom, with successive piercing of the needles forming various potential patterns of connecting elements.

[0069] Stitchbonding involves the use of different types of needles to introduce an external connecting element (e.g., a thread from a spool) into a first layer and across a space to introduce it into a second layer, forming a connecting element. Alternatively, stitchbonding can introduce a connecting element without the use of an external connecting element by forming a woven loop from fibers originating from the first and / or second layers and using this loop to form a stitch. Many variations with different stitch patterns can be utilized, for example, stitchbonding can be used to provide a tricot stitch pattern (a "zigzag" stitch pattern). Tricot stitching helps to improve the flexibility of the flexible composite in the machine direction (MD) (i.e., the manufacturing direction of the flexible composite) compared to straight stitching.

[0070] Hydroentanglement uses small jets of fluid emitted at the nonwoven fibrous material to push interlocking elements out of the material (or onto it) away from a surface, where they mechanically interlock with other fibers present in the space. For this reason, this technique is carried out by fixing two surfaces at a distance, with interlocking elements from one or both surfaces of the layer mechanically interlocking in the void between them, which is then filled with a filler material.

[0071] Pre-formed hooks and eyes can be used where the hooks and / or eyes protrude from both the first and second layers (prior to filling with the filler material) allowing a connecting element (bridge) to be formed such that the connected hooks and eyes in the space communicate with each other.

[0072] When needle punching techniques are used to form the connecting fibers, the ends that protrude from the outer surface of the second layer must be fixed in place when the connecting elements extend through the first layer. This can be done in several ways: the fiber ends or "tufts" can be glued to the outer surface of the second layer using an adhesive or fused to the polymer layer; the tufts can be heat fused or melted to the outer surface of the second layer; the tufts can be mechanically intertwined; the fibers can be melted so that they shrink and melt together and cannot be easily pulled through the second layer. Alternatively, the tufts can be sufficiently sandwiched by the material of the second layer that no further attachment is required to fix them in place and prevent the connecting fibers from being pulled back through the second layer. When the tufts are adhered to the outer surface of the second layer, it may be advantageous for the tufts to be redirected to lie flat against the outer surface of the second layer so as to be substantially parallel to the first and / or second layers, or to conform to ridges formed in the first and second layers. Preferably, the average angle of the connecting elements in the space between the first and second layers is substantially perpendicular to the first and second layers.

[0073] When using needle punching techniques to make the connecting elements, the connecting elements extending through the first and / or second layers can be adapted to be fixed to the outermost side of the layers through which they extend. Preferably, the connecting elements are fixed to the outermost side of the first and / or second layers by heating or adhesive to prevent them from being pulled inwards through the respective layers. Most preferably, a low melting adhesive is used. To enable this, the protruding ends of the connecting elements can be flattened against the outer surface of the layers, and it has been found that bonding the connecting elements thus flattened substantially increases the pull-out strength of the connecting elements. The pull-out strength of this bond is aided by pinching the connecting elements by holes formed in the first and / or second layers from the time they are inserted. In embodiments where an impermeable element such as a fluid-impermeable geomembrane is provided, the connecting elements extending through the first and / or second layers do not extend through the impermeable element, as this would reduce the fluid impermeability of the impermeable element.

[0074] Preferably, the peel strength of the unconsolidated flexible composite between the first and second layers (i.e. the force required to separate the bond between the first and second layers of the unconsolidated flexible composite by peeling) is 0.1 kN / m-20 kN / m, preferably 0.3 kN / m-3 kN / m, as measured using BS EN 13426-2:2005. Substantially all of the peel strength of the unconsolidated flexible composite between the first and second layers is provided by the connecting element and is a function of the tensile strength of the connecting element itself and the tensile strength provided by how the connecting element bonds to the first and / or second layers. It has been found that a peel strength within the above mentioned range is necessary to provide and maintain good packing density of the filler material in the space during both manufacture and operation prior to solidification of the settable filler material.

[0075] When stitchbond techniques are used to form the connecting elements, the elements can be fixed in place to prevent the stitches from unraveling (unravelling) lengthwise when the flexible composite is cut crosswise. Unraveling of stitches can be reduced by heat laminating a polymer to one side of the flexible composite to melt the polymer around the elements, which helps prevent the connecting elements from pulling out and unravelling once cooled.

[0076] The connecting elements may be fibers. Preferably, the fibers originate from the first layer and / or the second layer. In this way, the first and / or second layer act as fiber donors.

[0077] When the first layer and / or the second layer act as a fiber provider, the connecting elements are fibers originating from one of the first layer and / or the second layer, and therefore of the same material as the first layer and / or the second layer. Preferably, the fibers originating from the first layer and / or the second layer (and therefore the first layer and / or the second layer) can comprise polypropylene fibers, polyester fibers, polyethylene terephthalate fibers, polyvinyl alcohol fibers, elastomeric fibers, nylon, silnylon, vinyl, basalt fibers, carbon fibers, alkali-resistant glass fibers, glass fibers, coated glass fibers, polyvinyl chloride fibers, aramid fibers, jute, cotton, viscose, bicomponent fibers consisting of combinations of these fibers with a heat-activated binder, or mixtures thereof. Preferably, the fibers originating from the first layer and / or the second layer comprise polypropylene fibers.

[0078] When the first layer and / or second layer do not function as a fiber provider (e.g., when stitchbonding or needlebonding with external yarns is used to place connecting elements within a space), the first layer and / or second layer are not limited to nonwoven materials, but can be woven, knitted, heat-set, extruded, spunbonded or other materials.

[0079] The elements extending substantially across the space from the first layer and / or the second layer can extend back into the space through the opposing layer. The elements extending substantially back into the space may be configured to bond with other elements located in the space. Preferably, the elements extending substantially back into the space bond with other elements by entanglement. Alternatively, the elements extending substantially back into the space are configured to bond with the layer from which the fibers originate.

[0080] Alternatively, the connecting elements are external connecting elements inserted by stitchbonding technique. The connecting elements inserted by stitchbonding can include polypropylene fibers, polyester fibers, polyethylene terephthalate fibers, polyvinyl alcohol fibers, elastomeric fibers, nylon, silnylon, vinyl, basalt fibers, carbon fibers, alkali-resistant glass fibers, glass fibers, coated glass fibers, polyvinyl chloride fibers, aramid fibers, jute, cotton, viscose, bicomponent fibers consisting of combinations of such fibers with a heat-activated binder, or mixtures thereof. Preferably, the connecting elements are external polypropylene threads.

[0081] The space between the first and second layers is occupied by a filler material. In accordance with the present disclosure, "filler material" is used to refer to a solidifiable filler material trapped between the first and second layers. Optionally, the flexible composite material may contain a second, third, fourth filler material, etc. One layer of the filler material must be solidifiable, but the second or further filler layers need not be solidifiable. As used below, "first filler material" refers to a solidifiable filler material, and "second filler material" refers to an additional filler layer that may or may not be solidifiable.

[0082] A second filler material can be disposed in the space between the first and second layers and can be solidified into a rigid or semi-rigid solid upon application of a liquid, gas or radiation, the second filler material being separated from the first filler material by a separation layer disposed in the space between the first and second layers.

[0083] The first filler material (previously described as filler material) and / or the second filler material may be selected from one or more of a powder, a paste, or a foamable composition. Optionally, the first filler material and / or the second filler material include one or more of settable filler materials such as, but not limited to, Portland cement, high alumina cement, cement and aggregate mixtures, lime and aggregate mixtures, calcium sulfate, calcium fluoride, calcium silicate, gypsum, calcium aluminate, magnesium cement, or mixtures thereof. Preferably, the settable filler material includes Portland cement or high alumina cement. The cement may be combined with additives typically found in cement or concrete compositions.

[0084] High alumina cement has the advantage that it provides a shorter setting time and a more rapid increase in early strength than other cements, and provides higher tensile and compressive strength, as well as much higher abrasion resistance and hardness. In addition, high alumina cement has excellent acid resistance and can inhibit the growth of colonies of sulfate-producing bacteria.

[0085] The liquid used to set the cement is preferably water, seawater or water that has been modified by the addition of other chemicals, including any of the additives mentioned above that are water soluble.

[0086] The filler material may be one component of a multi-part curable resin that solidifies when two or more liquid components are mixed together, such as an epoxy resin system.

[0087] The filling material and any further filling materials may include filler materials, which may include sand or fine aggregate, fly ash, glass beads, low density or recycled fillers, chopped natural or synthetic fibers, lime powder, limestone, mica insulation, surface modified silica, impact modifiers, expandable microspheres, thermally conductive particles, melakaolin, conductive particles, silica, clay, talc, colorants, superabsorbent polymers, antioxidants, antimicrobial agents, surfactants, fluoropolymers, pigments, biocides such as antifungal or antibacterial agents, and antiradiation fillers, or any mixture thereof.

[0088] One or more of the above filler materials can be used to reduce the weight and / or cost of the resulting composite material, modify the thermal properties, or impart various physical properties resulting from the physical property activity of the filler material, such as electrical, optical, liquid barrier, etc.

[0089] The filler material and / or the second filler material can include a reaction modifier. The reaction modifier of the filler material and / or the second filler material can include a lithium compound, a sodium compound, an organic compound (citric acid, tartaric acid), a sulfate source, a plasticizer, an accelerator, a retarder, a superplasticizer, a shrinkage reducer, a waterproofing agent, a pH adjuster, glass beads, a pozzolanic material, a foaming agent, a dispersible polymer powder, or a mixture thereof.

[0090] Preferably the filler material has a consolidated tensile strength of 0.1-20 MPa, or 0.1-10 MPa, or 0.5-5 MPa, when tested using BS EN 12390-6: 2009. Preferably the filler material has a consolidated compressive strength of 1-500 MPa, or 2.5-100 MPa, or 5-50 MPa, when tested using BS EN 12390-3: 2009.

[0091] The second filler material can provide fluid impermeability (in addition to the impermeability provided by the filler material), for example, by using a swellable material. Filler materials that swell with water or oil can be used to selectively prevent the passage of certain liquids or contaminants through the surface. The second filler material can include water-swellable materials such as bentonite clay, superabsorbent polymers, modified acrylic resins, oil-swellable elastomers, or mixtures thereof.

[0092] Preferably, the first filler material comprises cement and the second filler material comprises a fluid swelling substance such as bentonite, or a swelling polymer such as a superabsorbent polymer, or other non-setting secondary filler material such as blast furnace slag, carbon black powder, activated carbon powder, thermal or electrical insulation material or mixtures thereof.

[0093] The second filler material may include a fire-resistant material such as an intumescent material, gypsum, plaster or a mixture thereof. Preferably, the second filler material includes an intumescent filler.

[0094] When a second filling material is provided, the separation layer separating the first filling material from the second filling material may be one or more of paper, woven, nonwoven, nonwoven spunlace, extrusion, knit, membrane sheet or recycled fiber type fabric. Preferably, the separation layer is a nonwoven, such as a spunlace nonwoven or needle punched nonwoven. The separation element may be made of materials including wood pulp fibers, polyester fibers, polypropylene, polyethylene terephthalate fibers, polyvinyl alcohol fibers, nylon, silnilon, vinyl, basalt fibers, carbon fibers, glass fibers, coated glass fibers, polyvinyl chloride fibers, aramid fibers, jute, cotton, viscose and mixtures thereof. Preferably, the separation layer may comprise a polypropylene nonwoven, more preferably a polypropylene spunlace nonwoven.

[0095] The layers may be adhered to one another with an adhesive, which may include pressure sensitive adhesives such as copolyamides, polyesters, copolyesters, polyurethanes, co-polyvinyl chloride, ethylene-vinyl acetate, polyolefins, polyamides, polypyrroles, polycarbonates, silicone rubbers, styrene block copolymers, thermoplastic polymers, styrene block polymers or acrylics, multi-part adhesives such as polyesters, polysulfides or polyurethanes, natural adhesives such as lignin-based adhesives, one-part adhesives such as UV-curable adhesives, and the like.

[0096] Depending on the end use of the flexible composite, the materials of the first and / or second layers can be selected to be water soluble, rottable, UV degradable, hydrophilic and / or hydrophobic. Natural fibers such as jute, cotton, coconut fibers, cellulose fibers, viscose fibers or mixtures thereof, or manmade fibers such as starch-based polymer fibers can be used to achieve one or more of such water soluble, rottable, UV degradable, hydrophilic and / or hydrophobic properties.

[0097] One or more of the materials in the first layer and / or the second layer may be a biocide or a biogrowth promoter. For example, the filler material and / or the first layer and / or the second layer may include a fungicide powder to prevent biogrowth, or the filler material and / or the first layer and / or the second layer may include a fertilizer to promote biogrowth. It has been found that providing a flexible composite material with a fibrous outer surface (e.g., by using a nonwoven fabric on the outer surface) can promote biogrowth. For example, it has been found that when a flexible composite material with a fibrous outer surface according to the present invention is placed in a waterway, organic and inorganic debris is captured on the fibrous outer surface, thereby building a soil layer that allows the germination of shallow rooted plants and mosses, with the roots attaching to the textured surface of the composite material.

[0098] The use of a biogrowth promoting material in one of the layers allows, for example, plants to grow on that layer. This can be advantageous in certain applications of the composite where the plant growth helps integrate the composite into the landscape / environment in which it is placed. It has been found that the plant growth advantageously acts as a cushion / buffer to absorb impacts from falling foreign objects or abrasion from objects carried in running water, such as rocks and debris that can damage the composite.

[0099] The first layer and / or the second layer can include conductive fibers or layers, which can allow detection of damage or strain to the flexible composite material and their location. The conductive fibers can be conductive carbon fibers or optical fibers, graphene coatings, or mixtures of these types of fibers or layers can be used.

[0100] The flexible composite may further include an insulating layer on the outermost of the first layer or the outermost of the second layer.

[0101] The insulating layer may include expanded polystyrene, expanded polyurethane, fiberglass, cellulose, rock wool, polystyrene foam, aerogel, polyurethane foam, perlite, cork, mixtures thereof, and multiple layers thereof. [Brief description of the drawings]

[0102] The invention can be implemented in various ways and some preferred embodiments of the flexible composite material according to the invention will now be described by way of example with reference to the accompanying drawings, in which: [Figure 1] FIG. 1 shows a cross-sectional view of a preferred embodiment of a flexible composite material. [Diagram 2] FIG. 2 shows a cross-sectional view of a preferred embodiment of a flexible composite material. [Diagram 3] FIG. 3 shows a cross-sectional view of a preferred embodiment of a flexible composite material. [Figure 4]FIG. 4 shows a cross-sectional view of a preferred embodiment of a flexible composite material. [Diagram 5] FIG. 5 shows a cross-sectional view of a preferred embodiment of a flexible composite material. [Figure 6] FIG. 6 shows a cross-sectional view of a preferred embodiment of a flexible composite material. [Figure 7] FIG. 7 shows a cross-sectional view of a preferred embodiment of a flexible composite material. [Figure 8] FIG. 8 shows a cross-sectional view of a preferred embodiment of a flexible composite material. [Figure 9] FIG. 9 shows a cross-sectional view of a preferred embodiment of a flexible composite material. [Figure 10] FIG. 10 shows the bending stiffness of two flexible composite materials of the present invention. [Figure 11] FIG. 11 shows the bending stiffness of two flexible composite materials of the present invention. [Figure 12] FIG. 12 illustrates the peel strength between a layer of flexible composite material of the present invention and consolidated powder material within a space in the flexible composite material. [Figure 13] FIG. 13 shows the peel strength between two elements that form the second layer of the flexible composite material of the present invention. [Figure 14] FIG. 14 shows the peel strength between a first layer and a second layer of an unconsolidated flexible composite material of the present invention. [Figure 15] FIG. 15 shows the forces acting on a flexible composite material during a three-point bending test. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0103] A first embodiment of a flexible composite material according to the present invention is generally shown at 100 in Figure 1 and the accompanying exploded view showing the layers that make up the composite material 100. The flexible composite material 100 comprises a first layer (a), a second layer (c) and a space (b) between the first and second layers. The space (b) contains a filler material 3 and a connecting element 2.

[0104] The structure of the flexible composite material 100 can be obtained by filling the filler material 3 between the first layer (a) and the second layer (c) under a positive pressure differential while positioning a connecting element 2 in the space (b) so that it extends between the layers using needle punching, as described above.

[0105] The first layer (a) is a fiber-providing layer 1 made of needle-punched polypropylene nonwoven fabric, which is, firstly, capable of accommodating a filling material 3 in the space (b) between the first and second layers, and secondly, selectively permeable to certain fluids, for example permeable to liquids and gases, but substantially impermeable to the filling material 3.

[0106] Fiber 2 is a polypropylene fiber pulled from the nonwoven fabric of the first layer 1, which extends through the space (b) at a net angle of about 90 degrees to layers (a) and (c) such that the fibers are substantially perpendicular to the longitudinal axis of those layers. The needling technique uses barbed needles to pick up fibers from the polypropylene nonwoven fabric of layer (a) and carry / extend them through the space (b) substantially to the second layer (c).

[0107] The filler material 3, when unsolidified, is provided in the space (b) under pressure such that tension is applied to the fibers. The pressure of the filler material and the lack of longitudinal elongation of the fibers under tension causes the first and second layers to bulge outwardly relative to the longitudinal length of the fibers under tension. In other words, the first and second layers extend outwardly beyond the fibers 2 in the direction of the net longitudinal axis of the fibers 2.

[0108] The amount / degree to which the first layer (a) and / or the second layer (c) swells due to the pressurized filling material depends on the fibers and material properties of the first and second layers. For example, the stiffness of the first and / or second layers can be increased to reduce the amount of swell, or can be further increased in one of the layers so that swell is prevented altogether. The material properties of the first layer (a) and the second layer (c) can be varied so that different sizes of swells can be obtained when the filling material is present in the space under pressure.

[0109] Thus, flexible composite material 100 shows a cross-section of a three-dimensional microstructure formed by filling a filler material under a positive pressure differential and deforming first and second layers with interconnected fibers that result in a minimum shape being formed.

[0110] As the fibers 2 pass through and exit the second layer (c) by needle punching, their main direction changes from being substantially perpendicular to the longitudinal axes of the first layer (a) and the second layer (c) to being substantially parallel to the longitudinal axes of the layers (a) and (c). The redirected portions of the fibers are configured to substantially conform to the raised surface of the second layer (c). After this redirection, the fibers are bonded to the second layer (c) using an adhesive layer 5, thereby providing a mechanical bond between the first layer (a) and the second layer (c).

[0111] The filling material can be any material, such as any suitable paste, powder or foamable composition, that can be solidified by the addition of a liquid into a rigid or semi-rigid solid when exposed to UV radiation or a gas such as air. Cements can be used together with fillers and other additives, such as reaction modifiers.

[0112] The second layer (c) comprises a reinforcing element 4 made of a woven polypropylene tape that is coated on its outer surface with a film of adhesive such as a hot melt polymer 5. The hot melt adhesive 5 allows for the attachment of the fibers 2 as they are forced through the second layer (c) and reoriented to generally conform to the shape of the second layer (c).

[0113] Once the holes created by the barbed needles are resealed by the adhesive layer, the woven polypropylene tape 4 becomes substantially impermeable to fluids.

[0114] The fibres from the donor layer 1 which protrude through the reinforcing element 4 may alternatively be caused to shrink using a heat source such as hot air or a radiant source, which has the effect of thickening the fibres on the outer surface of the reinforcing layer, thereby preventing them from being pulled back through the reinforcing layer. This may be used in addition to or instead of the adhesive layer 5, in which case the reinforcing layer 4 may be made more permeable but still function to substantially confine the powder fill material 3.

[0115] Liquids such as water can penetrate into the flexible fabric 100 through the first layer (a) and hydration of the filler material 3, e.g. cement, is facilitated by the fibers 2 that can carry water inside the flexible fabric 100. The second layer (c), together with the fibers 2, reinforces the filler material upon solidification and prevents crack propagation.

[0116] The reinforcing element 4 can optionally be provided with a further protective element 7 on its outer surface, which protects the underside of the flexible composite from damage during installation and use. Furthermore, the inner surface of the reinforcing element 4 can be provided with a wedge element 8, which provides a surface for fixing the filling material 3 against movement. Figure 2 shows a flexible composite according to the invention generally with the reference number 200, which additionally includes such a wedge element and a protective element, respectively with the reference numbers 8 and 7. The wedge element is a spunlaced needle punched or thermally bonded polypropylene nonwoven. The protective element is a needle punched polypropylene nonwoven. The wedge element and the protective element are not limited to being made from these materials, but can be any other suitable material of the type described above for the wedge element and the protective element.

[0117] The protective element 7 may further act as an anti-slip function, which will improve the retention of the flexible composite material when it is placed on a surface. Alternatively, the anti-slip element may completely replace the protective element 7 or may be applied to the outer surface of the protective element (not shown). The anti-slip element may be made of any suitable material, for example, the anti-slip element may be made of any of the materials mentioned above for the anti-slip element.

[0118] The wedge element 8 and protective element 7 adhere to low melting polymer coatings on both sides of the woven polypropylene fabric of the reinforcing element 4, shown as 5 and 9, respectively.

[0119] The first layer (a) may optionally comprise a reinforcing element 10 on the inner surface of the first layer 1 (the side of layer (1) closer to the filling material), which must be fluid-permeable, in contrast to element 4. A flexible composite with a reinforcing element 10 on the inner surface of the first layer (1) is generally designated by the reference number 300 in FIG. 3. The other layers and elements 1-9 are the same as those described with respect to the flexible composite 200 shown in FIG. 2. A preferred material for this reinforcing element 10 would be an open-weave polypropylene tape. This additional reinforcing element may comprise an adhesive layer 11, which may be a hot melt polymer of the type previously described. This increases the bending strength (after solidification) in both directions of the flexible composite compared to the unreinforced one. That is, the amount of load that the flexible composite can take from the first layer (a) side before breaking and from the second layer (c) side before breaking is greater than in the unreinforced case.

[0120] 4 shows another example of a flexible composite material generally designated 400 according to the present invention. In addition to having a single fiber-providing element 1 in a first layer (a) as in FIGS. 1-3, the flexible composite material 400 further includes a second fiber-providing element 12 in a second layer (c). The first layer (a) and space (b) of the flexible composite material 400 are substantially the same as the first layer (a) and space (b) of the flexible composite material 100,200, except that a portion of the fibers 2 in the space (b) additionally extends from the second fiber-providing element 12, as opposed to all of the fibers 2 extending from the fiber-providing element 1 of the flexible composite material 100,200.

[0121] The fibers 2 of the flexible composite 400 are polypropylene fibers extending from the providing element 1 and the providing element 12, which extend at a net angle of 90° to the layers (a) and (c) through the space (b) towards the opposite layer. The fibers 2 are obtained using a needle punching technique similar to that described above in relation to the flexible composite 100 and the flexible composite 200. The needle punching technique differs from the needling technique described above in that a barbed needle is used to take the fibers 2 from the polypropylene nonwoven of the second fiber providing element 12 (in addition to taking the fibers from the providing element 1 as described above) and carry them through the space (b) to the first layer (a). Thus, the needle penetrates downwards through layer 1 and in the opposite direction through layer 12. These penetrations may be sequential or simultaneous.

[0122] In some applications, it may be useful to have two different layers of infill material. For example, when a flexible composite material as disclosed herein is used to form a waterway or to lay on a riverbed, it may be desirable to have a flexible composite material that includes a layer of settable material that protects the settable or non-settable underlying material from wear or erosion.

[0123] The flexible composite material 500 of FIG. 5 comprises an additional second filler material 14, which is disposed in the space (b) and separated from the first filler material 3 by a separating layer 13, thereby defining a first filler material layer and a second filler material layer. The first filler material layer must be a settable filler, as previously described. In contrast, the second filler material 14 can be one of a variety of possible materials, such as those mentioned with respect to the second filler material. The second filler material can be a settable filler material similar to the first filler material, but can also be a non-settable material, for example a fluid-swellable material such as bentonite clay.

[0124] The separation element can be made of a polypropylene nonwoven fabric that is permeable to liquids, such as water, such that when a liquid (e.g., water) is applied to the composite material, the separation element can allow the water to penetrate through the first filler material layer to the second filler material layer to hydrate both filler materials, but can prevent the two filler materials from substantially intermixing when dry or wet.

[0125] The separating element is not limited to being made of polypropylene nonwoven fabric, but may alternatively be made of any other suitable material fabric capable of separating the two filling materials and allowing liquids such as water to pass through. The separating element may be any of the materials described above for the separating element. The separating element may also include a reinforcing element (not shown) as described above.

[0126] Any of the flexible composite materials described herein may include one or more conductive fibers (e.g., conductive carbon fibers, metal conductive wires or optical fibers such as steel, aluminum or copper, graphene coated fibers or sheets). Such fibers are inserted in space (b) alongside filler material 3 (or filler materials 3 and 14), as shown in flexible composite material 600 in FIG. 6. Providing a flexible composite with conductive fibers 15 in this manner allows a user to use conductive resistance measurements to determine if, when and where the flexible composite material is damaged, exposed to liquids, or subject to significant strain, thereby making repairs easier or monitoring the installation for other purposes. These fibers may alternatively be an integral part of any of the layers 1-15 shown in FIGS. 1-6.

[0127] All of the above-mentioned exemplary embodiments of flexible composites (flexible composites 100, 200, 300, 400, 500, 600) include elements of nonwoven material that act as fiber providers for the fibers 2, which are needled across the interior space (b) using the needle punching technique described above. This needling technique allows the first layer (a) to be mechanically bonded to the second layer (c). The flexible composites of the present invention are not limited to flexible composites produced by needle punching. An alternative example of a flexible composite according to the present invention is shown in FIG. 7, generally designated 700. The flexible composite 700 has fibers 2 inserted using a stitch bond technique, as described above. The fibers 2 are inserted through the first layer from an external yarn (as opposed to originating from the first and / or second layer as shown in the other exemplary embodiments) and are stitched through the second layer, whereby they are mechanically connected by stitches. The first layer (a) of the flexible composite material 700 comprises a needle-punched polypropylene nonwoven 1 of the type previously described. The first layer (a) of the flexible composite material 700 is not limited to being such a material, but can instead be any other material of the type previously described with respect to the first layer (a). Furthermore, the material of layer (a) is not limited to being capable of providing fibers, and thus may simply be a woven or knitted material or spunlaced, or thermally bonded or extruded. The second layer (c) is a woven polypropylene tape 4 of the type previously described. The second layer (c) may alternatively be a nonwoven material 18, preferably 200 g / m 2 An option to this embodiment (not shown) is to add a single additional layer that acts as both a reinforcing and containment element, such as a continuous LLDPE geomembrane that is thermally laminated to the underside of the product.

[0128] The flexible composite material according to the invention may comprise an insulating element on the outermost surface of the first layer (a) and / or the second layer (c). The insulating element may take the form of a new layer (d). An example of a flexible composite material with an insulating layer (d) is shown in the form of a flexible composite material 800 in FIG. 8. The insulating layer (d) may be made of any suitable material capable of providing an insulating effect to the flexible composite material. The insulating layer (d) may comprise any of the materials previously mentioned for the insulating element or layer. The insulating layer may consist of a solid foam cut into triangular or other polygonal blocks so that the composite material can be rolled.

[0129] The surface of the flexible composite material (first layer (a) and / or second layer (c)) may be bonded to one or more further layers (not shown) that include any number of coatings that act to improve the mechanical properties of the flexible composite material. For example, the first layer (a) and / or second layer (c) may include a coating that can indicate areas of wear on them, thereby helping the user of the flexible composite material to identify areas of wear on the composite material; can provide ultraviolet (UV) resistance to prevent UV damage to the composite material; can increase the coefficient of friction to allow vehicles or people to move and walk on the flexible composite material, respectively, without slipping; can provide a bio-growth promoting surface to promote plant growth on the surface of the flexible composite material, or a biocidal component to prevent the growth of algae, moss or other plants; can improve the fire resistance of the flexible composite material; can make the material hydrophobic or hydrophilic; and / or can improve the chemical resistance of the flexible composite material.

[0130] The flexible composite material according to the present invention may comprise a water-impermeable layer (waterproof layer) on the outermost surface of the second layer (c). One embodiment of a flexible composite material having a water-impermeable layer bonded on the outermost surface of the second layer (c) is generally shown in FIG. 9 with the reference number 900. The water-impermeable layer 17 may be made of any suitable material that is impermeable to water, preferably a polymeric material, most preferably polypropylene, polyester, PVC or polyurethane. The polymeric material may be liquefied and cast onto the flexible composite material using a slot extruder. The water-impermeability of layer 17 may be combined with any other outermost layer for the second layer described herein, for example, the water-impermeable layer may be combined to further have specific anti-slip or insulating properties.

[0131] An exemplary manufacturing sequence for the flexible composite materials described herein is set forth below.

[0132] Firstly, the first layer (consisting of needle punched polypropylene nonwoven) and the second layer (consisting of polypropylene woven tape, the outer surface of which is coated with a low melting point layer and the inner surface of which is bonded with needle punched polypropylene nonwoven) are fed into a needle loom. A loom capable of producing material up to 10m wide, for example. The loom has a series of long tubes running in the machine direction (MD) (i.e. the direction of production of the flexible composite material) fixed between the loom bed and the stripper plate. The tubes are positioned between the stripper plate and the loom bed so as to leave a gap on either side of the tube. The bed plate and the stripper plate are separated by a gap of 3-100mm. The first layer is drawn through between the loom tubes and the stripper plate. The second layer is drawn through between the loom tubes and the bed plate, with the tubes forming a sandwich between the two layers. The tubes have an outer diameter of 3-25mm and are aligned laterally (90 degrees transverse from the MD) at intervals of 4-50mm, the tubes can have non-circular cross-sections and / or can be stacked. The thickness of the final flexible composite depends on both the size of the gap between the bed plate and the stripper plate and the diameter of the tubes. The thickness of the flexible composite (after filling) is 3-50mm.

[0133] Secondly, the needles of the needle loom are aligned to pierce between the tubes. The stripper plate and loom bed contain holes or slits that are aligned to receive the needles and allow them to pass through during the piercing action. The piercing needles thus repeatedly push the fibers from the first layer across the gaps between the tubes and through the second layer with the ends of the fibers protruding 0.1-30 mm from the outer surface of the second layer. The longitudinal spacing of the connecting elements thus formed is 0.5-20 mm. The transverse spacing is fixed as a multiple of the spacing of the tubes, which may be evenly or irregularly spaced with even or irregular gaps between them. As the material is drawn through the needle loom, it slides over the fixed tubes at a line speed of 0.1-50 m / min. The needles can be set to pierce at any angle as long as they do not hit the tubes.

[0134] Third, at a location between the needle loom and the downstream end of the tube, a heater (hot air, conductive, radiative, radio frequency, etc.) and pressure roller act on the outer surface of the second layer to activate the low melting point layer and bond the ends of the connecting fibers protruding from the outer surface of the second layer. Alternatively or additionally, the above heating methods can be used to shrink or bond the protruding fiber ends to prevent pull-out.

[0135] Fourth, a protective element (consisting of a needle-punched polypropylene nonwoven) can be added to the outer surface of the second layer. It is preferable to introduce this at the same location of the heater and the line so that the same low melting adhesive that bonds the tufts of connecting fibers also bonds the protective layer. Other layers described herein with respect to the various exemplary flexible composites, such as anti-slip or fluid-impermeable layers, can be introduced in a similar manner to the first and / or second layers. For example, as disclosed herein, if a water-impermeable layer 17 is added to the flexible fabric, it may be bonded to the second layer on the outside of the reinforcing element (or protective element) in the form of a continuous film after needling. Optionally, the protective layer can be pre-glued onto the outer surface of the water-impermeable layer (not shown in FIG. 11).

[0136] Fifth, tubes extend longitudinally from the needle loom for a distance of 0.1 m-20 m. These tubes are connected at their upstream end to a pressure vessel that contains pressurized settable powder fluidized with compressed air, the particle size of which is small enough to pass through the tube. This settable powder is blown into the tube and exits into the gap between the first and second layers. The settable powder is under a positive pressure differential of 0.1-50 bar when it leaves the pressure vessel, and is compressed when it enters the gap between the first and second layers. One of these layers acts as a filter to allow air to leave the material. Stacked tubes (with a separating element introduced between them) can be used to introduce a second layer of non-settable powder as previously described.

[0137] Optionally, the edges of the flexible composite are sealed to prevent the filling material from leaking. The edges of the flexible composite can be sealed before or after the introduction of the filling material, preferably before the introduction of the filling material. The edges of the flexible composite may be sealed by elastic threads, stitches, ultrasonic bonds, heat bonds, needle punches or adhesives.

[0138] Finally, the filled flexible composite material is optionally wound behind the end of the tube.

[0139] Optionally, if a reinforcing mesh is added to the flexible composite during production, it may be necessary to determine the spacing of the needles and the speed at which the mesh is introduced into the loom from the spacing of the mesh to ensure that the needles penetrate the holes in the mesh and not the mesh itself, which could damage the needles and / or mesh.

[0140] The two main layers (first layer (a) and second layer (c)) of the flexible composite produced by the above-mentioned manufacturing method are connected by fibers originating from one of the main layers using a needle punch machine (needle loom). However, as mentioned herein, those connecting fibers may originate from elsewhere, such as threads introduced into a stitch bond machine. The above-mentioned manufacturing sequence would be the same in the latter scenario, except that the first and second layers would be pulled into a stitch bond machine rather than a needling machine. The width, thickness, line speed, connecting fiber spacing, etc. of the flexible composite fabric would remain unchanged. The main difference is that the reciprocating needle brings threads between the two layers from an external reel to connect them, rather than the barbed needle taking fibers from one layer to create the connecting fibers. Alternatively, the material may be filled by passing the needle through a bulk powder under hydrostatic pressure. EXAMPLES

[0141] Bending stiffness Figures 10 and 11 show plots of three-point bending tests carried out on two sets of flexible composite materials A and B according to the invention, based on the standard test set out in BS EN 196-1:2005. Figures 10 and 11 show flexural strength in MPa versus central displacement in mm. Plot 17 is for a set of samples of the flexible composite material 200 shown in Figure 2 above.

[0142] The tested samples used a needle punch process to place connecting elements consisting of donor fibers from the top surface. The samples had a length of 140 mm in the machine direction (MD) and a width of 40 mm in the transverse direction (TD). The thickness of the solidified fill of composites A and B was 12 and 14 mm, respectively, at the minimum point and 13.5 and 15 mm, respectively, at the maximum point (ridge point).

[0143] Supports for three-point bending were on 100 mm centers and the loading bar was applied centrally. Samples were tested with the long dimension in the MD and the first crack propagated in the TD.

[0144] The composition of composite A was: Fiber donor / wear surface: 340 g / m2 with 17 decitex staple fiber 2 PP needle punched nonwoven fabric with wedge element: 120 g / m2 with 7 decitex staple fibre 2 PP needle punched nonwoven fabric, reinforcement element: PP woven tape, 80g / m 2 , 20kN / m UTS and protection element: 120g / m with 7 decitex staple fibre 2 and interlocking fibers arranged in a regular pattern of 1.5 mm (MD) x 12 mm (TD) squares produced by needle punching the fiber-presenting surface with a 32 gauge needle; and settable filler: high alumina cement filled at a differential pressure of 4 bar; samples were set in excess water and left at standard temperature and pressure (STP) for 24 hours and tested 24 hours after the first addition of water.

[0145] The composition of composite B was: Fiber donor / wear surface: 200 g / m2 with 6 decitex staple fiber 2 PP needle punched nonwoven fabric, UTS ~12kN / m, wedge element: 200g / m with 6 decitex staple fibre 2 PP needle punched nonwoven fabric and reinforcement / impermeable elements: 1mm LLDPE geomembrane, 900g / m 2, 15 kN / m UTS, interlocking fibres arranged in a regular pattern of 4.5 mm (MD) x 12 mm (TD) squares produced by needle punching the fibre presenting surface with a 30 gauge needle, and settable fill: 100% CEM 1 / 52.5N ordinary Portland cement filled at a differential pressure of 3 bar. Samples were set in excess water and left at standard temperature and pressure (STP) for 7 days and tested 7 days after water was first added.

[0146] The Composite A sample developed a first central crack in the cement at approximately 0.5 mm central displacement of the loading bar. Subsequent cracks, approximately 5-20 mm from the center of the sample, appeared at approximately 2.5, 4, 6, 8, and 16 mm central displacements. The woven tape reinforcement element began to fail in the center of the sample due to snapping of the component tapes at approximately 23 mm central displacement. No further cracks developed in the cement after this point. The tapes gradually failed until the sample could no longer support the central load at approximately 30 mm central displacement (off scale in Figure 9).

[0147] The composite B sample developed a first central crack in the cement at approximately 0.5 mm central displacement of the loading bar with a flexural strength of 4.8 MPa. Subsequent cracks of approximately 5-20 mm from the center of the sample appeared at central displacements of approximately 2, 2.8, 4.5, 6.5, 8, 9, 12.3, and 22 m. The second layer, reinforced with a 1 mm LLDPE geomembrane, began to fail in the center of the sample at a central displacement of approximately 25 mm. No further cracks developed in the cement after this point. The geomembrane underwent significant elongation before ultimate failure at a central displacement of approximately 35 mm (off scale in Figure 10).

[0148] The initial cracking of the solidified filler is followed by a progressive series of cracks of the solidified filler at bending loads greater than the initial cracking, and finally failure of the reinforcing elements of the second layer, indicative of the failure mode of the solidified flexible composite materials described herein.

[0149] Figures 12, 13 and 14 show three peel strength tests of Composite B described herein.

[0150] Figure 12 shows the peel strength between the second layer of Composite B in the set state and the cement infill. The data was obtained using the method described in BS EN 13426-2:2005.

[0151] The results shown in Figure 12 show an initial period of loading the sample with a displacement of 0-20 mm, followed by an elongation of 180 mm at a load of 2.5-4.3 kN per metre width. Such a range of peel strength is more than sufficient to produce the flexural properties detailed in Figure 11 without delamination.

[0152] Figure 13 shows a 1 mm LLDPE geomembrane (which acts as both a reinforcing and containment layer) and a 200 g / m 2 The peel strength data is given using the method described in BS EN 13426-2:2005. Tests were performed on unset material.

[0153] The results, shown in Figure 13, show an initial period of loading the sample with a displacement of 0-35 mm, followed by an elongation of 165 mm at a load of 1.9-2.7 kN per metre width. Such a range of peel strength is more than sufficient to produce the flexural properties detailed in Figure 11 without delamination.

[0154] Figure 14 shows the peel strength between the first and second plies of Composite B in the unconsolidated state. Peel strength data was obtained using the method described in BS EN 13426-2:2005.

[0155] The results shown in Figure 14 show an initial period of loading the sample with a displacement of 0-30 mm, followed by an elongation of 170 mm at a load of 0.42-0.65 kN per meter of width. This peel strength shows the tensile strength of the connecting fibers and how well they are attached to the first and second layers. Such a range of peel strength is more than sufficient to prevent delamination of the first and second layers in the unconsolidated state during handling and installation, and such a range has also been found to be sufficient to contain the powdered filler during its pressurized delivery in the manufacture of flexible composites.

Claims

1. 1. A flexible composite material capable of being set to become rigid or semi-rigid, comprising: A first layer; and a second layer opposite the first layer, the second layer being separated from the first layer by a space; a filler material disposed in the space between the first layer and the second layer, the filler material being capable of solidifying into a rigid or semi-rigid solid upon application of a liquid, gas, or radiation; a plurality of elements extending substantially into the space from the first layer and / or the second layer and connected to the first layer and / or the second layer, the plurality of elements being capable of passing through the first layer and / or the second layer and being capable of connecting to one another, thereby forming connecting elements that bond the layers together; A flexible composite material, characterized in that one or more of the connecting elements are placed under tension and unset filler material is provided within the spaces at a pressure such as to bulge the first layer and / or the second layer outward between adjacent connecting elements that are under tension.

2. 2. The flexible composite material of claim 1, The flexible composite material, wherein the first layer comprises a nonwoven fabric.

3. 3. The flexible composite material of claim 2, A flexible composite material, characterized in that the nonwoven fabric comprises fibers bonded by needle punching, adhesives, heat, hydroentanglement, stitch bonding or ultrasonic welding.

4. A flexible composite material according to claim 2 or 3, A flexible composite material, characterized in that the nonwoven fabric comprises polypropylene fibers.

5. A flexible composite material according to any one of claims 2 to 4, A flexible composite material characterized in that the nonwoven fabric comprises fibers having an average linear density of 0.1-100 dtex, 0.2-100 dtex, 0.5-100 dtex, 1-100 dtex, 2-50 dtex, 3-30 dtex, or a blend of fibers of different weights.

6. A flexible composite material according to any one of claims 2 to 5, A flexible composite material, characterized in that the nonwoven fabric comprises staple fibres having a length of 10-200 mm, preferably 30-150 mm, or 40-100 mm.

7. A flexible composite material according to any one of claims 1 to 6, A flexible composite material, wherein the first layer is permeable to gases and liquids, but is substantially impermeable to the filler material.

8. A flexible composite material according to any one of claims 1 to 7, The flexible composite material, characterized in that the first layer and / or the second layer further comprise a reinforcing element, the reinforcing element comprising a woven fabric, a nonwoven fabric, a continuous membrane, or a knitted fabric configured to improve the tensile strength and / or increase the stiffness of the first layer and / or the second layer.

9. 9. The flexible composite material of claim 8, 10. A flexible composite material, characterized in that the reinforcing elements comprise polyester or polypropylene.

10. A flexible composite material according to any one of claims 1 to 9, The ultimate tensile strength of the first layer and / or the second layer is determined by the following formula: where: σ ｆ is the ultimate tensile stress of the filling material when solidified (N / m ２ ) and t ｆ is the average thickness (m) of the solidified fill material; T ｒ is the ultimate tensile strength (N / m) of a layer subjected to a tensile load per meter of width.

11. A flexible composite material according to any one of claims 8 to 10, A flexible composite material, characterized in that the first layer and / or the second layer have a tensile strength per metre width of 0.5-200 kN, preferably 1-150 kN / m, or 1-100 kN / m.

12. A flexible composite material according to any one of claims 1 to 11, a wedge fabric element having a contoured surface adjacent to the powder material in the space and configured to adhere to the powder upon solidification;

13. 13. The flexible composite material of claim 12, A flexible composite material, characterized in that the textured wedge fabric comprises polypropylene fibers.

14. A flexible composite material according to claim 12 or 13, 13. A flexible composite material, characterized in that a wedge fabric element adjacent to the powder material is configured to provide a bond between the wedge fabric and the powder material upon solidification of the powder material having a peel resistance of 0.5-10 kN / m.

15. A flexible composite material according to any one of claims 12 to 14, which relies on any one of claims 8 to 11, A flexible composite material characterized in that a wedge fabric element is bonded to a reinforcing layer, and the bond between the wedge fabric and the reinforcing layer has a peel resistance of 0.5-10 kN / m.

16. A flexible composite material according to any one of claims 1 to 15, A flexible composite material, wherein the second layer is substantially impermeable to fluids.

17. 17. The flexible composite material of claim 16, The second layer has a hydraulic conductivity of 10 －３ -10 －１５ ms －１ , or 10 －６ -10 －１４ ms －１ , or 10 －７ -10 －１２ ms －１ A flexible composite material, characterized in that the elasticity of the composite material is within the range of

18. 18. A flexible composite material according to claim 16 or 17, The flexible composite material, wherein the second layer comprises a separate continuous membrane configured to be substantially impermeable to fluids, the continuous membrane comprising polypropylene, high and medium and low density polyethylene, PVC, rubber or polyurethane.

19. 20. The flexible composite material of claim 18, A flexible composite material, characterized in that the second layer includes a nonwoven element on its outermost surface facing away from the filling material to form a protective element.

20. 20. The flexible composite material of claim 19, A flexible composite material, wherein the nonwoven element comprises fibers bonded by needle punching, adhesives, heat and pressure, hydroentanglement, stitch bonding or ultrasonic welding.

21. 21. The flexible composite material according to claim 19 or 20, 10. A flexible composite material, characterized in that the nonwoven element comprises polyester and / or polypropylene.

22. 22. A flexible composite material according to any one of claims 1 to 21, A flexible composite material, characterized in that the second layer includes, on at least a portion of its outermost surface facing away from the filling material, anti-slip elements that improve the grip between the flexible composite material and the surface on which it is placed.

23. 23. The flexible composite material of claim 22, A flexible composite material, characterized in that the anti-slip elements comprise natural rubber, synthetic rubber, polypropylene, polyester, PVC, LDPE, LLDPE or HDPE, and / or a texture.

24. 24. A flexible composite material according to any one of claims 1 to 23, The connecting elements extend between and join the first and second layers and are spaced in a regular or irregular arrangement along the longitudinal and / or transverse axes of the flexible composite material.

25. 25. A flexible composite material according to any one of claims 1 to 24, A flexible composite material, wherein the connecting elements are arranged in one of the following patterns: equilateral triangles, irregular triangles, squares, rectangles, hexagons, other polygons, tricots, a substantially random distribution, or any combination thereof.

26. 26. A flexible composite material according to any one of claims 1 to 25, A flexible composite material, wherein each connecting element includes a plurality of sub-elements, said sub-elements extending across said space in separate columns through one or both of the layers, and capable of supporting a tensile load.

27. 27. A flexible composite material according to any one of claims 24 to 26, A flexible composite material characterised in that said connecting elements are spaced apart from each other by a distance of 0.1-100mm, 0.1-50mm, preferably 0.5-30mm, more preferably 1-20mm, or most preferably 1-12mm.

28. 28. A flexible composite material according to any one of claims 24 to 27, 1. A flexible composite material, characterized in that the connecting elements extend between the first layer and / or the second layer at a net angle substantially perpendicular to an intermediate plane between the first layer and the second layer.

29. 29. A flexible composite material according to any one of claims 1 to 28, The flexible composite material, wherein the connecting elements are disposed within the spaces by one or more of needle punching, stitch bonding, hydroentangling, and engagement with preformed hooks.

30. 30. A flexible composite material according to any one of claims 1 to 29, A flexible composite material, characterized in that the connecting elements extending across the space from the first layer and / or the second layer pass through an opposing layer, thereby bonding the layers together.

31. 31. The flexible composite material of claim 30, A flexible composite material, characterized in that the connecting element extending through the first layer and / or second layer is adapted to be secured to an outermost of the layer through which it extends.

32. A flexible composite material according to claim 31, which is based on any one of claims 18 to 21, A flexible composite material, wherein the connecting elements do not penetrate the continuous membrane.

33. 33. A flexible composite material according to claim 31 or 32, A flexible composite material, wherein the connecting elements are secured by one or more of mechanical entanglement, adhesives, heat fusion, or bonding to the polymer layer by chemical or mechanical means.

34. 34. A flexible composite material according to any one of claims 1 to 33, A flexible composite material, characterized in that the peel strength between the first layer and the second layer of the unconsolidated flexible composite material is 0.1 kN / m-20 kN / m, preferably 0.3 kN / m-3 kN / m.

35. 35. A flexible composite material according to any one of claims 24 to 34, A flexible composite material, characterized in that the connecting elements change orientation to be substantially parallel to the first layer and / or second layer as they extend through the first layer and / or second layer.

36. 36. A flexible composite material according to any one of claims 1 to 35, A flexible composite material, characterized in that the connecting elements are fibers.

37. 37. A flexible composite material according to any one of claims 1 to 36, A flexible composite material, characterized in that said connecting elements originate from said first layer and / or said second layer.

38. 38. A flexible composite material according to any one of claims 29 to 37, comprising: A flexible composite material, characterized in that connecting elements extending from the first layer and / or second layer substantially across the space extend back into the space through an opposing layer.

39. 39. The flexible composite material of claim 38, A flexible composite material, comprising: a connecting element extending substantially back into said space, said connecting element being configured to connect with another element located within said space.

40. 40. The flexible composite material of claim 39, A flexible composite material, comprising connecting elements extending substantially back into said space, said connecting elements being configured to couple with other elements by intertwining.

41. 39. The flexible composite material of claim 38, A flexible composite material, characterized in that a connecting element extending substantially back into the space is configured to bond with the fiber origin layer.

42. 42. A flexible composite material according to any one of claims 1 to 41, 10. A flexible composite material, wherein the filler material is selected from one or more of a powder, a paste, or a foamable composition.

43. 43. A flexible composite material according to any one of claims 1 to 42, The flexible composite material, wherein the filler material comprises one or more of a cement-aggregate mixture, a high alumina cement, a lime-aggregate mixture, and Portland cement.

44. 44. A flexible composite material according to any one of claims 1 to 43, The flexible composite material, wherein the filling material comprises a filler material.

45. 45. A flexible composite material according to any one of claims 1 to 44, A flexible composite material, wherein the filler material comprises a reaction modifier.

46. 46. ​​A flexible composite material according to any one of claims 1 to 45, A flexible composite material, characterized in that said filler material has a tensile strength when solidified of 0.1-20 MPa, preferably 0.1-10 MPa, more preferably 0.5-5 MPa.

47. 47. A flexible composite material according to any one of claims 1 to 46, A flexible composite material, characterized in that said filler material has a compressive strength when consolidated of 1-500 MPa, preferably 5-200 MPa, more preferably 15-100 MPa.

48. 48. A flexible composite material according to any one of the preceding claims, A flexible composite material further comprising a second filler material located in the space between the first layer and the second layer, the second filler material being separated from the first filler material by a separation layer located in the space between the first layer and the second layer.

49. 49. The flexible composite material of claim 48, 11. A flexible composite material, wherein the second filler material is selected from one or more of a powder, a paste, or a foamable composition.

50. 50. A flexible composite material according to claim 48 or 49, The flexible composite material, wherein the second filler material comprises bentonite clay or a superabsorbent polymer.

51. 51. A flexible composite material according to any one of claims 48 to 50, comprising: A flexible composite material, characterized in that the separating layer is a paper or a woven, nonwoven, knitted or extruded layer.

52. 52. A flexible composite material according to any one of claims 48 to 51, 10. A flexible composite material, wherein the separating layer comprises a nonwoven polypropylene fabric.

53. 53. A flexible composite material according to any one of the preceding claims, A flexible composite material, characterised in that the layers of said flexible composite material are bonded together with an adhesive, preferably said adhesive being a hot melt adhesive.

54. 54. The flexible composite material of claim 53, A flexible composite material, characterized in that the adhesive comprises a polypropylene copolymer adhered to or as part of the reinforcing layer.

55. 55. A flexible composite material according to claim 53 or 54, A flexible composite material, wherein the adhesive provides an interlaminar shear strength substantially similar to an ultimate tensile strength of the first and / or second layers.

56. 56. A flexible composite material according to any one of the preceding claims, A flexible composite material, characterized in that one or more materials in said first layer and / or second layer are water soluble, rottable, UV degradable, hydrophilic and hydrophobic.

57. 57. A flexible composite material according to any one of the preceding claims, 10. A flexible composite material, wherein one or more materials in said first layer and / or second layer are biocides or biogrowth promoters.

58. 58. A flexible composite material according to any one of the preceding claims, A flexible composite material, characterized in that either the filling material, the first layer or the second layer contains conductive fibers, thereby enabling detection of damage or deformation to the flexible composite material and its location.

59. 59. A flexible composite material according to any one of the preceding claims, A flexible composite material further comprising an insulating layer on the outermost side of the first layer or the outermost side of the second layer, wherein additional layers can be applied outside the insulating layer.

60. 60. A flexible composite material according to any one of claims 1 to 59, A flexible composite material, further comprising a ductile layer having sufficient out-of-plane stiffness to allow the material to be bent (plastically deformed) to form the unsolidified flexible composite material into a three-dimensional shape capable of supporting its own weight before the material solidifies.

61. 20. A flexible composite material as herein described with reference to the accompanying drawings.

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