Foamex L.p.

Foamex Innovations Operating Company

Sharon A Free

David J Kelly

Rocco P Triolo

Joseph W Lovette

Vincenzo A Bonaddio

Chiu Y Chan

Andrew M Thompson

Charles V Rose

Marc J Albero

Jagdish Patel

Robert A Volz, Deceased

Joshua D Land

William Patrick Burke, Iii

A hydrophilic ester polyurethane foam is flame laminated to a substrate using a thin sacrificial layer, preferably a sacrificial foam layer. The sacrificial layer in the resulting laminate structure has a thickness of 1.5 mm or less, and preferably is substantially burnt away. The resulting laminate exhibits good bond strength along its length and width without loss of liquid wicking and absorptive properties.

Flame laminable hydrophilic ester polyurethane foams

An ester polyurethane foam is prepared by reacting a mixture of one or more polyester polyols with one or more isocyanates and one or more silicone surfactants in the presence of a blowing agent, such as water, and other additives, such as catalysts. The cured foam is chemically treated in a caustic solution and is then felted (compressed under heat and pressure) to form a hydrophilic ester polyurethane foam having a water absorption rate of at least 30 pounds of water per square foot per minute (1.44 kPa/min). The foam also has greater water holding capacity and wet strength than cellulose.

Felted hydrophilic ester polyurethane foams

An ester polyurethane foam is prepared by reacting a mixture of one or more polyester polyols with one or more isocyanates and one or more silicone surfactants in the presence of a blowing agent, such as water, and other additives, such as catalysts. The cured foam is chemically treated in a caustic solution to form a hydrophilic ester polyurethane foam having a water absorption rate of at least 20 pounds of water per square foot per minute, preferably at least 25 pounds of water per square foot per minute. The foam also has greater water holding capacity and wet strength than cellulose.

Hydrophilic ester polyurethane foams

An ink retaining flexible polyurethane foam is prepared by reacting a polyether polyol with from 50 to 80 parts by weight, based on the weight of polyol, of a polyisocyanate component having one or a mixture of methylene diisocyanates. The foam has pore sizes above 70 pores per linear inch, preferably in the range of 70 to 90 pores per linear inch in an uncompressed state. The foam is reticulated to improve liquid holding capacity, and, depending upon cell size, compressed into a container. The foam absorbs and retains ink, and is resistant against attack from ink, producing less than 2.0% solvent extractables.

Ink retaining foam structure

An ink retaining flexible polyurethane foam is prepared by reacting a polyether polyol with from 20 to 50 parts by weight, based on the weight of polyol, of a polyisocyanate component having one or a mixture of toluene diisocyanates, such that the 2,4 isomer of toluene diisocyanate includes no more than seventy-five percent by weight of the polyisocyanate component, preferably no more than seventy two and one half percent by weight. The foam has pore sizes in the range of 70 to 88 pores per inch in an uncompressed state. The foam is reticulated to improve liquid holding capacity, and, depending upon pore size, felted to compression ratios from 1 to 2 up to from 1 to 20. The foam absorbs and retains ink, and is resistant against attack from ink, emitting less than 2.0% solvent extractables, preferably less than 1.1% solvent extractables.

Ink retaining foams

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

Hydrophilic polyurethane foams with rapid wet out properties are formed from the reaction product of an MDI-based or polymeric MDI-based isocyanate capped prepolymer with an aqueous component, such as water, and about 0.5 to 2.0 parts by weight, based on 100 parts by weight prepolymer, of a silicone glycol copolymer liquid surfactant with a polyether portion, said surfactant having a viscosity of about 175 to 350 CST at 25.degree. C., a molecular weight in the range of about 1500 to 20,000, with the polyether portion having a molecular weight in the range of about 200 to 2000 and containing about 40 to 100 percent by weight ethylene oxide. The surface of the hydrophilic foam wets out or absorbs droplets of water in less than thirty (30) seconds, preferably instantaneously (less than one second).

Hydrophilic urethane foam

The present invention relates to three-dimensional expanded polyurethane foam materials, such as flexible reticulated polyurethane foam compositions, that are electrically conductive and have antistatic properties. More specifically, the invention relates to a polyurethane foam having long-lasting and reliable electrical conductivity characteristics and a volume resistivity of approximately 10.sup.12 ohm.multidot.cm or less at ambient room temperature (about 70.degree. F.). This foam is produced by combining conventional polyurethane foam-forming reactants and an effective amount of an antistatic agent such as tetracyanoquinodimethane (TCNQ) or sodium perchlorate under foam-forming conditions. In one preferred embodiment, the conductive foam is subsequently reticulated by momentary exposure to a flame front.

Conductive polyurethane foam compositions and method for producing same

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.

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Wallingford, PA, United States of America

Sharon A Free