Polymeric foam powder processing techniques, foam powders products, and foams produced containing those foam powders
AssigneeMobius Technologies, Inc.
InventorsBryan Martel, Robert Villwock, Herman Stone
Life of this patent
Estimating the term…
Abstract
This relates variously to techniques for comminuting polymeric foams, to techniques for preparing polymeric foams containing that comminuted foam, and to the resulting comminuted foam powder and polymeric foams. The procedures may be used on foams containing production contaminants such as polyolefins, paper, and foam skins and on other foams containing consumer contaminants such as wood, metal, leather, etc. The comminuted foam powder, with or without contaminants, preferably is screened or sifted to obtain a foam powder having a particle size of about 2 mm or less.
Claims159
A method of preparing foam powder from contaminated polymeric foam, the method comprising:
- a) comminuting the contaminated foam, thereby preparing a first polymeric foam powder;
- and
- b) quenching the first polymeric foam powder, thereby forming a second polymeric foam powder.
A method of screening a polymeric foam powder by means of a sifter including a screen housing, the method comprising:
- a) conveying the polymeric foam powder into a screening assembly positioned inside the housing, wherein the assembly includes:
- (1) a substantially cylindrical tube including screening material and (2) beater bars rotating within said substantially cylindrical tube;
- b) activating the beater bars to cause the polymeric foam powder to contact the screening material;
- c) forming first foam powder particles having a predetermined first particle size range, by collecting the first foam powder particles passing through the screening material;
- and
- d) forming second foam powder particles by collecting the second foam powder particles from within the screening tube.
A method of controlling a feed rate of foam pieces to a foam comminution mill having at least two rolls and wherein the mill is adapted for monitoring mill power consumption, the method comprising:
- a) monitoring the mill power consumption while comminuting the foam pieces;
- b) deriving a signal from the mill power monitoring;
- and
- c) controlling the feed rate by means of the signal.
A method of energizing the first and second rolls of a two-roll mill, the method comprising:
- a) energizing the first roll, thereby causing rotation of the first roll;
- and
- b) energizing the second roll at a rate lower than the rotation rate of the first roll by rotation of the first roll.
A method of discharging foam pieces having a predetermined maximum size from a storage facility, the method comprising:
- a) discharging the foam pieces through a mechanically activated screen;
- and
- b) receiving the foam pieces that are discharged through the screen on a moving conveying surface having protrusions.
A method of conveying polymeric foam pieces comprising depositing an active-hydrogen compound on the polymeric foam pieces.
A method of substantially removing contaminant materials selected from the group consisting of oil and grease from polymeric foam, the method comprising:
- a) comminuting the polymeric foam to prepare polymeric foam powder;
- and
- b) treating the foam powder with a solvent capable of dissolving the contaminant material.
A method of treating polymeric foam that is contaminated with one or more materials having adhesive properties, the method comprising treating the foam to remove the adhesive properties.
A comminuted polyurethane foam powder comprising at least 5% by weight of comminuted flexible polyurethane foam powder and further including one or more production contaminants selected from the group consisting of polyurethane foam skins, polymer sheeting, and paper.
A method of preparing a blend of polyurethane foam powder and liquid active-hydrogen compound comprising:
- a) adding the foam powder to the active-hydrogen compound in a CO2 atmosphere;
- and
- b) mixing the foam powder and active-hydrogen compound in a CO2 atmosphere.
A method of removing entrapped air from a blend of a polyurethane foam powder and active-hydrogen compound by centrifuging in a vacuum environment.
A method of comminuting polyurethane foam particles dispersed in active-hydrogen compound comprising subjecting the foam particles to fluid shear forces generated by one or more mechanically activated surfaces.
A polyurethane foam composition comprising:
- a) a polyurethane foam including a reaction product of a active-hydrogen compound and a polyfunctional isocyanate;
- and
- b) polyurethane foam powder including one or more contaminants selected from the group of foam powders prepared from polyurethane foam skins, polymer sheeting, and paper.
A polyurethane foam composition comprising:
- a) a polyurethane foam including a reaction product of a active-hydrogen compound and a polyfunctional isocyanate;
- and
- b) a first polyurethane foam powder prepared from polyurethane foam having one or more contaminants selected from the group consisting of polyurethane foam skins, polymer sheeting, and paper wherein the first polyurethane foam powder is prepared by a process comprising:
- (1) comminuting the contaminated foam by means of a two-roll mill, thereby preparing a second polyurethane foam powder, (2) quenching the second polyurethane foam powder, thereby forming a third polymeric foam powder, (3) screening the third polyurethane foam powder, thereby preparing a first polyurethane foam powder having a particle size of about 2 mm or less.
A method of preparing a polyurethane foam composition comprising:
- a) preparing a liquid blend of a first active-hydrogen compound and polyurethane foam powder including one or more contaminants selected from the group of foam powders prepared from polyurethane foam skins, polymer sheeting, and paper;
- b) mixing the liquid blend with polyurethane foam forming compounds comprising a polyfunctional isocyanate, a blowing agent, and a catalyst;
- and
- c) reacting the foam forming compounds to prepare a polyurethane foam by reacting the isocyanate with the first active-hydrogen compound.
A device for discharging foam pieces having a predetermined maximum size, from a storage facility including a bottom discharge, the device comprising:
- a) a screen adapted for discharging the foam piece, wherein the screen includes a predetermined aperture that exceeds the maximum size and wherein the screen is adapted for mechanical agitation;
- b) a conveying surface adapted for receiving the foam pieces that are discharged from the screen.
A device for collecting foam powder from a mill having a first roll including a first cylindrical surface and a second roll including a second cylindrical surface, the device comprising:
- a) a first side wall having a first edge, wherein the first edge is adapted for positioning proximal the first cylindrical surface and substantially parallel to the first cylindrical surface,
- b) a second side wall having a second edge, wherein the second edge is adapted for positioning proximal the second cylindrical surface and substantially parallel to the second cylindrical surface,
- c) a bottom joining the first side wall and the second side wall,
- d) a first end wall joining the bottom and the first and second side walls, wherein the first end wall includes a first end wall edge that is adapted for positioning proximal the first and second cylindrical surfaces and substantially perpendicular to the first cylindrical surface,
- e) a second end wall opposing the first end wall and joining the bottom and the first and second side walls, wherein the second end wall includes a second end wall edge that is adapted for positioning proximal the first and second cylindrical surfaces and substantially perpendicular to the first cylindrical surface,
- f) a gaseous flow inlet;
- and
- g) a gaseous flow outlet.
Dependencies are inferred from the claim text.