Foamex L.p.

Beat Niederoest

Chiu Y Chan

Robert Mohr

Andrew M Thompson

David J Kelly

Rocco P Triolo

Joseph W Lovette

Daniel V Tursi, Jr

Neil Craig Silverman

Polyurethane foams formed under vacuum (below atmospheric pressure) conditions using toluene diisocyanate or a specific mixture of polyisocyanates with a specific mixture of polyether and graft polyols produces a foam with lower density and better flame retardancy than latex foam, but with equally high resiliency. The foam-forming ingredients are mixed together and foamed under controlled pressures in the range 0.6 to 0.95 bar (absolute), preferably 0.8 to 0.95 bar (absolute). The resulting foam has a ball rebound above about 65 percent.

Latex replacement polyurethane foams with improved flame retardancy

Polyurethane foams formed at above atmospheric pressure conditions using methylene diisocyanate or a specific mixture of polyisocyanate and with a major portion of methylene diisocyanate (MDI) with a specific mixture of polyether and graft polyols produces high density viscoelastic foams with improved hand touch (surface smoothness) that better retain viscoelasticity over time. The foam-forming ingredients are mixed together and foamed at controlled pressures in the range 1.05 to 1.5 bar (absolute), preferably 1.1 to 1.3 bar (absolute).

Fine cell, high density viscoelastic polyurethane foams

Polyurethane foams formed using a specific mixture of polyether and graft polyols with toluene diisocyanate have fine cell size (over 70 pores per inch) and higher durability with IFD retention over 70% after 12,000 cycles of roll-shear. The foam-forming ingredients are mixed together and foamed at controlled pressures in the range 1.0 to 1.5 (absolute), preferably 1.05 to 1.5 bar (absolute). The foams make particularly good carpet cushions.

Polyurethane foams with fine cell size

Foaming a polyurethane foam at above atmospheric pressure conditions using a mixture of polyisocyanate and a specific mixture of low molecular weight (high OH number) polyether and graft polyols produces viscoelastic foams with high firmness, low energy losses and high temperature sensitivity such that firmness is reduced by at least 25% when the foam is heated from room temperature (e.g., about 70&deg; F. (21&deg; C.)) to 100&deg; F. (38&deg; C.). The foam-forming ingredients are mixed together and foamed at controlled pressures in the range 1.05 to 1.5 bar (absolute), preferably 1.1 to 1.3 bar (absolute).

Low energy-loss, high firmness, temperature sensitive polyurethane foams

Polyurethane foams formed under vacuum (below atmospheric pressure) conditions using methylene diisocyanate or a specific mixture of polyisocyanate and with a major portion of methylene diisocyanate (MDI) with a specific mixture of polyether and graft polyols produces cushioning foams with lower density (1.4 to 1.8 pounds per cubic foot) and higher support factor (above 2.4). The foam-forming ingredients are mixed together and foamed under controlled pressures in the range 0.5 to 0.9 bar (absolute), preferably 0.6 to 0.8 bar (absolute). A major portion of the MDI is 4,4&prime; methylene diisocyanate.

Higher support, lower density cushioning foams

Polyurethane foams formed at elevated pressure using a graft polyol, or mixture of polyols to form a polyol system, having a low functionality and a high solids content, exhibit superior dynamic shock cushioning characteristics (energy absorption) as illustrated by the drop curves of deceleration versus static load. The foam-forming ingredients are mixed together and foamed under controlled pressures in the range of 1.2 to 1.5 bar, preferably 1.3 to 1.4 bar. The polyol preferably has a functionality in the range of about 2.0 to 2.5, a hydroxyl number in the range of about 50 to 90, a solids content above about 35%, preferably about 50 to 55%.

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Marlton, NJ, United States of America

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