FOAM COMPOSITE AND METHODS OF MAKING THE SAME

1 . A foam composite comprising:

a matrix including viscoelastic foam;

a plurality of fibers embedded in the matrix;

wherein the fibers include at least one of natural fibers and synthetic fibers;

wherein the fibers include polyethylene and wherein the polyethylene includes at least one of low melt polyethylene, ultra-high molecular weight polyethylene, and E380F fibrillated high density polyethylene.

2 . (canceled)

3 . (canceled)

4 . (canceled)

5 . A foam composite comprising:

a matrix including viscoelastic foam;

a plurality of fibers embedded in the matrix; and

wherein the fibers include at least one of chemically interactive fibers and chemically inert fibers.

6 . The foam composite of claim 5 , wherein the chemically interactive fibers include at least one of rayon fibers, nylon fibers, and polyester fibers.

7 . The foam composite of claim 5 , wherein the chemically inert fibers include at least one of polyethylene fibers and polypropylene fibers.

8 . The foam composite of claim 7 , wherein the polyethylene fibers include at least one of low melt polyethylene fibers, ultra-high molecular weight polyethylene fibers, and E380F fibrillated high density polyethylene fibers.

9 . (canceled)

10 . (canceled)

11 . (canceled)

12 . (canceled)

13 . (canceled)

14 . (canceled)

15 . (canceled)

16 . (canceled)

17 . The foam composite of claim 1 , wherein the fibers chemically interact with the viscoelastic foam in the matrix.

18 . The foam composite of claim 1 , wherein the fibers are inert and do not chemically interact with the viscoelastic foam in the matrix.

19 . (canceled)

20 . (canceled)

21 . The foam composite of claim 1 , wherein a dynamic fatigue hardness loss of the foam composite is less than a dynamic fatigue hardness loss of the matrix alone.

22 . The foam composite of claim 21 , wherein the dynamic fatigue hardness loss of the foam composite is less than about 50% of the dynamic fatigue hardness loss of the matrix alone.

23 . (canceled)

24 . (canceled)

25 . (canceled)

26 . (canceled)

27 . The foam composite of claim 1 , wherein the foam composite has a tensile strength of about 10% to about 60% greater than a tensile strength of the matrix alone.

28 . The foam composite of claim 27 , wherein the tensile strength is a vertical tensile strength.

29 . (canceled)

30 . The foam composite of claim 27 , wherein the tensile strength is a horizontal tensile strength.

31 . The foam composite of claim 30 , wherein the horizontal tensile strength of the foam composite is about 37% greater than a horizontal tensile strength of the matrix alone.

32 . The foam composite of claim 1 , wherein the foam composite has an air permeation of at least about 3 times greater than an air permeation of the matrix alone.

33 . The foam composite of claim 1 , wherein the fibers extend in generally the same direction within the matrix.

34 . The foam composite of claim 1 , wherein the fibers are randomly oriented within the matrix.

35 . (canceled)

36 . (canceled)

37 . (canceled)

38 . (canceled)

39 . A method of manufacturing a foam composite, the method comprising:

providing fibers, a polyol, and an isocyanate;

mixing the fibers and one of the polyol and the isocyanate to form a first mixture;

adding the other of the polyol and the isocyanate to the first mixture to form a second mixture; and

expanding the second mixture into the foam composite.

40 . The method of claim 39 , wherein mixing occurs at a speed of at least about 1000 rpm.

41 . (canceled)

42 . (canceled)

43 . (canceled)

44 . The method of claim 39 , wherein expanding the second mixture occurs along an axis.

45 . The method of claim 39 , wherein expanding the second mixture causes the fibers to align in a direction that is generally parallel with the axis of expansion.

46 . The method of claim 45 , wherein expanding the second mixture causes the fibers to align in a direction that is generally perpendicular with the axis of expansion.

47 . (canceled)

48 . (canceled)