Composite foam article
AssigneeProprietect L.P.
InventorsDavid M. Begg, Kevin Liping Dong, Dorota Ulman, Scott D. Wheeler, Le-Cheng Jimmy Lin
Life of this patent
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Abstract
A composite foam article is disclosed herein. The composite foam article comprises a polyurethane foam core presenting a first surface and a second surface facing opposite the first surface. A first skin is disposed on the first surface and a second skin is disposed on the second surface. The polyurethane foam core has a density of 15-80 kg/m3. The first and second skins comprise a plurality of fibers and a polymeric binder. The composite foam article has a weight per unit area of 500-1000 g/m2 and a strength of greater than 17 N at a post-compression thickness of greater than 2 mm when tested in according with SAE J949 at 23° C.
Claims16
A composite foam article comprising:
- a polyurethane foam core presenting a first surface and a second surface facing opposite said first surface, said polyurethane foam core having a density of from 45 to 80 kg/m3, and having a compression force deflection at 10% deflection of from 10 to 110 psi when measured in accordance with ASTM 3574-D;
- a first skin which is porous and disposed on said first surface, said first skin comprising a plurality of fibers, a polymeric binder, and a polyolefin powder in addition to said polymeric binder of said first skin;
- a second skin which is porous and disposed on said second surface, said second skin comprising a plurality of fibers, a polymeric binder, and a polyolefin powder in addition to said polymeric binder of said second skin;
- a first additional layer comprising an ethylene and acrylic acid (“EAA”) copolymer and disposed between said first surface of said polyurethane foam core and said first skin;
- and
- a second additional layer comprising an EAA copolymer and disposed between said second surface of said polyurethane foam core and said second skin;
- wherein said composite foam article has a post-compression thickness of from 1.5 to 5 mm and a strength of greater than 17 N at a post-compression thickness of greater than 2 mm when tested in accordance with SAE J949 at 23° C.
Dependencies are inferred from the claim text.