Foamex L.p.

Other

Scotfoam Corporation

Rocco P Triolo

David J Kelly

Sharon A Free

Richard A Rossow

Chiu Y Chan

Robert Mohr

Beat Niederoest

Robert A Volz, Deceased

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

Modified or filled rebond polyurethane foam structures having desired plushness and compression without adversely affected tensile strength at a given density as compared to unfilled rebond polyurethane foams are formed from an admixture of shredded or chopped polyurethane foam particles and a finely divided inorganic mineral filler, such as barium sulfate or calcium carbonate or mixtures of these and like mineral fillers, that is further mixed with a substantially non-foam forming liquid prepolymer binder that is free of surfactants in foam-stabilizing amounts. A portion of the polyurethane foam particles, from about 10 to about 60 parts by weight based upon 100 parts by weight, is replaced with filler. For each 100 parts by weight of the combined foam particles and filler, about 10 to about 30 parts by weight of prepolymer is added. After the wetted admixture is compressed to the required density, the prepolymer binder is cured with heat and/or steam. Surprisingly, the resultant filled rebond polyurethane foam structure is more plush and softer than unfilled rebond foam, and the filler is uniformly distributed throughout the cured binder and external to the foam cells of the foam particles.

Modified rebond polyurethane foam structure and method of making such

The present invention relates to very fine cell flexible polyurethane foams having at least 87 pores per linear inch (as measured by pressure drop techniques) wherein at least 65% of the isocyanate equivalents of said polyurethane are obtained from MDI. The invention also relates to processes for preparing the very fine cell polyurethane foams.

Very fine cell polyurethane foams and processes for producing the same

Modified or filled rebond polyurethane foam structures having desired plushness and compression without adversely affected tensile strength at a given density as compared to unfilled rebond polyurethane foams are formed from an admixture of shredded or chopped polyurethane foam particles and a finely divided inorganic mineral filler, such as barium sulfate or calcium carbonate or mixtures of these and like mineral fillers, that is further mixed with a substantially non-foam forming liquid prepolymer binder. A portion of the polyurethane foam particles, from about 10 to about 60 parts by weight based upon 100 parts by weight, is replaced with filler. For each 100 parts by weight of the combined foam particles and filler, about 10 to about 30 parts by weight of prepolymer is added. After the wetted admixture is compressed to the required density, the prepolymer binder is cured with heat and/or steam. Surprisingly, the resultant filled rebond polyurethane foam structure is more plush and softer than unfilled rebond foam, and the filler is uniformly distributed throughout the cured binder and external to the foam cells of the foam particles.

A breathable or air-permeable, open cell, flexible urethane polymer suitable for use in cushions is formed from a foam-forming composition containing from about 0.5 to 2.0 parts by weight of butyl oleate, based upon 100 parts by weight polyol, under controlled pressure conditions maintained at or, preferably, below atmospheric pressure. The pressure during foaming is maintained in the range of about 0.5 to 1.0 bar, preferably 0.5 to 0.9 bar. Resultant air permeability is unexpectedly significantly increased over urethane polymers of equivalent composition. Other polymer properties are enhanced.

Breathable open cell urethane polymers

A low density, open cell polymeric body is formed by coating or filling a reticulated polymeric foam with a liquid-form polymer which is resistant to high temperatures, curing the liquid form polymer in and on the foam and then removing the foam skeleton by dissolving and leaching the foam out of the solid polymeric body which remains.

Low density, high temperature resistant polymeric bodies

The present invention provides a polyurethane foam having significantly improved longevity in a microbiological process in which the foam functions as a support medium for microorganism in a water system containing nutrients for the microorganisms. Also provided is a method of making said improved foam and an improved microbiological metabolizing (e.g., digestion) process employing said improved foam. The present invention is based upon the discovery that enhanced foam life in such a watery, abrasive environment is substantially enhanced if the polyurethane foam formulation has a urea/urethane ratio of less than about 5 and preferably a urethane index of about 100.

Polyurethane foam and a microbiological metabolizing system

Heat activatable, fabric conditioning products comprising thick, absorbent substrates impregnated with fabric conditioning chemicals are suitable for use at elevated temperatures encountered in laundry dryers. Prior to being used, such products tend to be stiff and boardy because of the brittle, wax-like properties of the fabric softener chemicals at ambient temperature. The stiff-boardy properties have been substantially eliminated by temporarily compressing the thick impregnated substrate to less than 70% of its original thickness. However, substantial impregnate is lost as dust from the substrate during compression at ambient temperatures. When hot rollers are employed for compressing the impregnated substrate, the loss of chemical impregnated ingredients caused by the compression step is substantially reduced.

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Broomall, PA, United States of America

Rocco P Triolo