# US 2018/0022978 A1 · Increasing the Heat Flow of Flexible Cellular Foam Through the Incorporation of Highly Thermally Conductive Solids > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 2018/0022978 A1 - Document ID: US20180022978A1 - Status: Published application - Kind: A1 - Application number: 15/581,978 - Filed: 2017-04-28 - Published: 2018-01-25 - Earliest claimed: 2012-12-27 - Assignees: Peterson Chemical Technology, Inc. - Applicants: Peterson Chemical Technology LLC - Inventors: BRUCE W. PETERSON; GUALTIERO G. GIORI; MARK L. CRAWFORD - Web page: https://patentgrep.com/patent/US20180022978A1 ## CPC - C09K 5/14: Solid materials, e.g. powdery or granular - A47C 21/046: {without active means, e.g. with openings or heat conductors} - A47C 27/15: consisting of two or more layers (A47C27/16 takes precedence) - A47G 9/10: Pillows (pillow holders A47C21/00, {A47C21/026}; specially adapted for preventing snoring A61F5/56) - A47G 2009/1018: {Foam pillows} - C09K: MATERIALS FOR MISCELLANEOUS APPLICATIONS, NOT PROVIDED FOR ELSEWHERE - A47C: CHAIRS; SOFAS; BEDS - A47G: HOUSEHOLD OR TABLE EQUIPMENT (book-ends A47B5/00; knives B26B) ## Abstract Methods and combinations of mattress support surfaces comprising one or more flexible polyurethane foam layers containing highly thermally-conductive solids, such as diamond or silicon carbide, and said layer combination is capable of transferring heat from a warm surface, such as a person sleeping on a bed, to a cooler region at a faster rate throughout the mattress than the thermal dissipation rate obtained from flexible polyurethane foam without highly thermally-conductive solids. ## Claims ### Claim 1 A method for forming a flexible cellular polyurethane foam with highly thermally-conductive solids (HTCS Foam) comprising: introducing highly thermally-conductive solid particles into a mixture of flexible cellular foam-forming components comprising a polyol and an isocyanate, where the highly thermally-conductive solid particles are selected from a group consisting of silicon carbide, synthetic diamond crystal powder, natural diamond crystal powder, type IIa diamond powder, synthetic diamond, boron nitride, carbonado, and combinations thereof, and where an average particle size of highly thermally-conductive solid particles ranges from about 50 nanometers to about 3000 microns; and polymerizing the polyol and the isocyanate thereby forming the HTCS foam. ### Claim 2 (depends on 1) The method of claim 1 where the highly-thermally conductive solids ranges from about 0.1% to about 50% by weight based on the final foam net weight after gas loss. ### Claim 3 (depends on 1) The method of claim 1 where the one or more highly thermally-conductive solids ranges from about 1% to about 35% by weight based on the final foam net weight after gas loss. ### Claim 4 (depends on 1) The method of claim 1 where the one or more highly-thermally conductive solids ranges from about 5% to about 25% by weight based on the final foam net weight after gas loss. ### Claim 5 (depends on 1) The method of claim 1 wherein the HTCS Foam comprises a structure selected from the group consisting of a solid sheet, a perforated sheet, a non-planar sheet, a planar sheet, a textured sheet, and combinations thereof. ### Claim 6 (depends on 1) The method of claim 1 further comprising adhering the HTCS Foam to a layering substrate. ### Claim 7 (depends on 6) The method of claim 6 where the layering substrate is selected from the group consisting of flexible polyurethane foam, flexible polyester polyurethane foam, latex foam, flexible melamine foam, fibers in woven form, fibers in non-woven form, and combinations thereof ### Claim 8 (depends on 1) The method of claim 1 where the HTCS foam has a thermal conductivity at 75% compression that is at least 0.008 W/(m-° K) higher than an identical flexible cellular polyurethane foam in the absence of the highly thermally-conductive solid particles. ### Claim 9 (depends on 1) The method of claim 1 where the highly thermally-conductive solid particles are selected from a group consisting of synthetic diamond crystal powder, natural diamond crystal powder, type IIa diamond powder, synthetic diamond, carbonado, and combinations thereof. ### Claim 10 A method for forming a flexible cellular polyurethane foam with highly thermally-conductive solids (HTCS Foam) comprising: introducing from about from about 0.1% to about 50% by weight based on the final foam net weight highly thermally-conductive solid particles into a mixture of flexible cellular foam-forming components comprising a polyol and an isocyanate, where the highly thermally-conductive solid particles are selected from a group consisting of silicon carbide, synthetic diamond crystal powder, natural diamond crystal powder, type IIa diamond powder, synthetic diamond, boron nitride, carbonado, and combinations thereof, and where an average particle size of highly thermally-conductive solid particles ranges from about 50 nanometers to about 3000 microns; and polymerizing the polyol and the isocyanate thereby forming the HTCS foam, where the HTCS foam has a thermal conductivity at 75% compression that is at least 0.008 W/(m-° K) higher than an identical flexible cellular polyurethane foam in the absence of the highly thermally-conductive solid particles. ### Claim 11 (depends on 10) The method of claim 10 where the one or more highly thermally-conductive solids ranges from about 1% to about 35% by weight based on the final foam net weight after gas loss. ### Claim 12 (depends on 10) The method of claim 10 where the one or more highly-thermally conductive solids ranges from about 5% to about 25% by weight based on the final foam net weight after gas loss. ### Claim 13 (depends on 10) The method of claim 10 wherein the HTCS Foam comprises a structure selected from the group consisting of a solid sheet, a perforated sheet, a non-planar sheet, a planar sheet, a textured sheet, and combinations thereof. ### Claim 14 (depends on 10) The method of claim 10 further comprising adhering the HTCS Foam to a layering substrate. ### Claim 15 (depends on 14) The method of claim 14 where the layering substrate is selected from the group consisting of flexible polyurethane foam, flexible polyester polyurethane foam, latex foam, flexible melamine foam, fibers in woven form, fibers in non-woven form, and combinations thereof ### Claim 16 (depends on 10) An article of manufacture selected from the group consisting of a cushion foam, a mattress, a mattress topper pad, and combinations thereof, where the article of manufacture comprises at least one zone selected from the group consisting of a longitudinal zone, a lateral zone, and combinations thereof, where the at least one zone comprises the HTCS foam made by the method of claim 10. ### Claim 17 (depends on 10) An article of manufacture selected from the group consisting of medical cushioning foams, mattresses, pillows, bedding products, mattress pillow toppers, quilted mattress toppers, mattress toppers, pet beds, indoor cushioning foams, outdoor cushioning foams, outdoor bedding pads, outdoor pillows, and combinations thereof, where the article of manufacture further comprises at least one layer comprising the HTCS foam made by the method of claim 10. ### Claim 18 (depends on 17) The article of manufacture of claim 17 where the article is a mattress. ### Claim 19 (depends on 18) The article of manufacture of claim 18 where the highly thermally-conductive solid particles are selected from a group consisting of synthetic diamond crystal powder, natural diamond crystal powder, type IIa diamond powder, synthetic diamond, carbonado, and combinations thereof.