US 4,438,221 A · Polyurethane foam-filled foams and method of producing same

Abstract

Polyurethane foam products comprising a foam filled with a foam and a large amount of solid material inert to the foam products are described. The foams are prepared by foaming a polyurethane foam-forming diisocyanate and polyol around pre-formed polyurethane foam chips having incorporated therein or therewith solid materials inert to the foam. The inert material can be a fire- or combustion-retardant material; a material such as graphite or the like to render the foam conductive; or a filler material to impart various other characteristics. The polyurethane foam-filled foams can be tailored to have excellent physical characteristics and are particularly suitable for furniture upholstery, cushioning applications including in mattresses, and where special properties are required.

Claims15

Dependent claims

A foam-filled polyurethane foam structure obtained through the steps of

(a) obtaining particles of flexible polyurethane foam;
(b) admixing said particles of (a) with a solid material;
(c) uniformly applying to said admixture of (b) a liquid flexible polyurethane foam-forming material containing a reactive polyol and a polyisocyanate;
(d) foaming said foam-forming material of (c) with water to provide a flexible foam having bonded therein said polyurethane foam particles and said solid material;
the relative amounts of materials in said foam structure being such that for each 100 parts by weight of polyurethane foam particles, about 40 to 200 parts by weight of solid material and about 30 to 75 parts by weight of foam-forming material are used, said solid material being inert to said foam and foam-forming material.

2 more elements

Dependencies are inferred from the claim text.

Polyurethane foam-filled foams and method of producing same

Life of this patent

Polyurethane foam-filled foams and method of producing same

Life of this patent

Abstract

Claims15