Wm. T. Burnett & Company

W.m. T. Burnett Ip, LLC

Gregory B Davis

Michael S Buchanan

Walter V Greenhouse

George J Tolen

A thermoformable non-woven material that meets at least one of the UL94 V-0 (2013) flammability standard and the ASTM E84-14 (2014) flammability standard. The material may include charring fiber having a denier per fiber at least about 3 and binding fiber having a denier per fiber between about 1 and about 8. The weight ratio of charring fiber to binding fiber may be between about 2:1 and about 4:1, and the denier per fiber of the charring fiber may be at least about twice the denier per fiber of the binding fiber.

Non-woven flame-retardant material

A continuous process for reusing scrap polyurethane involves the following stages: Chips of thermoset polyurethane foam are supported as a bed; the bed of chips while moving is heated; the bed of chips while moving is subjected to pressure or compression; and a web is formed. The resulting material is useful in many industrial applications, including padding, gaskets, and insulation.

Process for forming a continuous web from polyurethane foam pieces

Polyurethane foams based on reactive polyols and polyisocyanates containing a filler are modified with an organofunctional silane containing a hydrolyzable group and an ethylenically unsaturated linkage. The polyurethane foams have improved physical properties including improved stability, compression set, tear resistance, elongation, and tensile strength.

Polyurethane foams containing organofunctional silanes

Polyurethane foam-fiber composite structures comprising a flexible polyurethane foam uniformly mixed with a fibrous material and bonded with a liquid flexible resinous binding agent to provide a cured foam structure; the relative amounts of materials in the foam structure being such that for each 100 parts by weight of polyurethane foam particles about 10 to 500 parts of fibrous material and about 10 to 250 parts of binding agent is employed, the fibrous material having a fiber length of from 1/8' to 4' and preferably 1/4' to 3/4', a density of at least 0.75, and a diameter of less than 500 microns. The foam structures have an excellent sag factor with good resiliency for a select density.

Polyurethane foam-fiber composites

An improved method for manufacturing a foam-filled polyurethane foam bun from foam particles having uniformly dispersed therewith large amounts of solid material bonded together with new polyurethane foam is described. The method comprises uniformly applying a liquid flexible polyurethane foam-forming material to a dispersion of foam particles and solid material to provide a blend, distributing the blend within a mold, and foaming and curing the foam-forming material by a plurality of steaming steps wherein the mold is flipped from a first to second position between steaming steps. The foam buns have a uniform density gradient. Foam buns are disclosed having a variation in density across the foam bun. There is also disclosed an improved char-forming foam obtained as a result of using boric acid in the foam-forming formulation.

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Monkton, MD, United States of America

Gregory B Davis