Foamed polymer and process for production thereof
AssigneeWoodbridge Foam Corporation
InventorPaul V. Farkas
Life of this patent
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Abstract
A foamed isocyanate-based polymer containing a filler material, the filler material being present at a level greater than 30% by weight of the polymer and having a specific gravity of less than about 2.0 with the provisio that the filler material is not melamine. A process for producing the a foamed isocyanate-based polymer is also disclosed. The process comprises the steps of: providing a first mixture comprising water, a catalyst and a substantially inert filler material, the filler material being wetted by the water and the catalyst; providing a second mixture comprising an isocyanate and an active hydrogen-containing compound; mixing the first mixture and the second mixture to provide a reaction mixture; allowing the reaction mixture to expand to produce the foamed isocyanate-based polymer.
Claims24
A polyurethane foam consisting essentially of a cellular matrix having a plurality of Plateau borders, the foam containing a non-cellular polymeric filler material at the Plateau borders, the filler material located at the Plateau borders being present at a level greater than 30% by weight of the foam and having a specific gravity of less than about 1.5.
A polyurethane foam consisting essentially of a cellular matrix having a plurality of Plateau borders, the foam containing a non-cellular polymeric filler material, the filler material being present at a level greater than 30% by weight of the foam and having a specific gravity of less than about 1.5;
- wherein:
- (i) the polymeric filler material is in particulate form and the source thereof is selected from the group consisting of plastic, foam, tire and mixtures thereof, and (ii) essentially all of the polymeric filler material is located at the Plateau borders of the cellular matrix.
A polyurethane foam consisting essentially of a cellular matrix having a plurality of Plateau borders, the foam containing a non-cellular polymeric filler material, the filler material being present at a level in the range of from about 30% to about 70% by weight of the polymer and having a specific gravity of less than about 1.5;
- wherein:
- (i) the polymeric filler material is in particulate form and the source thereof is selected from the group consisting of plastic, polymer, foam, tire and mixtures thereof, and (ii) essentially all of the polymeric filler materia is located at the Plateau borders of the cellular matrix.
Dependencies are inferred from the claim text.