Wm. T. Burnett & Company

Michael S Buchanan

Walter V Greenhouse

Roland N Fracalossi

Gregory B Davis

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

Polyurethane foams having a particulate resin carrying a fragrance incorporated therein during formation of the foam are described. The physical characteristics of the foams are not detrimentally affected by the incorporation of the resin while providing a foam which will release fragrance over an extended time period.

Fragrance-emitting polyurethane foams

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.

Process for making foam-in-form polyurethane foam buns and apparatus

Polyurethane foam products comprising a foam filled with a foam and a large amount of combustion retardant materials are described. The foams are prepared by foaming a polyurethane foam-forming diisocyanate and polyol around pre-formed polyurethane foam chips having incorporated therein solid combustion retardant materials. The polyurethane foam-filled foams have excellent physical characteristics and, because of their combustion properties, are particularly suitable for furniture upholstery and cushioning applications including in mattresses.

Polyurethane foam-filled foam resistant to combustion and method of

Polyurethane foam products comprising a foam filled with a foam and a large amount of solid material inert to the foam products are described. The foams are prepared by foaming a polyurethane foam-forming diisocyanate and polyol around pre-formed polyurethane foam chips having incorporated therein or therewith solid materials inert to the foam. The inert material can be a fire- or combustion-retardant material; a material such as graphite or the like to render the foam conductive; or a filler material to impart various other characteristics. The polyurethane foam-filled foams can be tailored to have excellent physical characteristics and are particularly suitable for furniture upholstery, cushioning applications including in mattresses, and where special properties are required.

Polyurethane foam-filled foams and method of producing same

Rebonded polyurethane foams having incorporated into the foam urea and/or melamine are described. The rebonded foams have excellent resistance to smoldering combustion and flaming combustion. The rebonded foam is highly suitable, inter alia, for cushioning and seating structures.

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Baltimore, MD, United States of America

Michael S Buchanan