COMPOSITION OF FOAM, CUSHIONS, AND RELATED METHODS OF MANUFACTURE
Foam compositions, cushions, and related methods of manufacture are disclosed. The foam composition or cushion includes a polymer that includes about 2% to about 10% polyol comprising multiple hydroxyl groups, about 1% to about 25% isocyanate and about 75% to about 95% filler suspended in the polymer.
1 . A cushioning foam composition, comprising:
polymer comprising:
about 2% to about 10% polyol comprising multiple hydroxyl groups;
about 1% to about 25% isocyanate; and
about 75%-95% filler suspended in the polymer.
2 . The cushioning foam composition of claim 1 , wherein the polyol is within the range of about 2% to about 8% of the polymer.
3 . The cushioning foam composition of claim 1 , wherein the polyol comprises at least one of petroleum and natural oils.
4 . The cushioning foam composition of claim 1 , wherein the polyol comprises at least one of animal by-products and vegetable oil.
5 . The cushioning foam composition of claim 1 , wherein isocyanate is within the range of about 1% to about 5% of the polymer.
6 . The cushioning foam composition of claim 1 , wherein the isocyanate comprises methylene isocyanate based liquid.
7 . The cushioning foam composition of claim 1 , wherein the isocyanate comprises toluene isocyanate based liquid.
8 . The cushioning foam composition of claim 1 , further comprising at least one of a stabilizing additive, a surfactant, a blow catalyst, a gelation catalyst and a blowing agent.
9 . The cushioning foam composition of claim 1 , wherein the filler is within the range of about 80%-95% of the polymer.
10 . The cushioning foam composition of claim 1 , wherein the filler comprises an inorganic filler.
11 . The cushioning foam composition of claim 1 , wherein the filler comprises an organic filler.
12 . The cushioning foam composition of claim 1 , wherein the filler includes at least one of electrically conductive material, magnetizable material and metallic material.
13 . The cushioning foam composition of claim 1 , wherein the filler includes one or more ferromagnetic fillers.
14 . The cushioning foam composition of claim 1 , wherein the fillers are located in designated regions of the foam.
15 . A method, comprising:
producing the cushioning foam composition of claim 1 .
16 . A cushion, comprising:
a foam comprising a polymer, the polymer comprising:
about 2% to about 8% polyol comprising multiple hydroxyl groups;
about 1% to about 5% isocyanate; and
about 75% to about 95% filler suspended in the polymer.
17 . The cushion of claim 16 , wherein the polyol comprises vegetable oil.
18 . The cushion of claim 16 , wherein the filler amount is within the range of about 80%-95% of the polymer.
19 . The cushion of claim 16 , wherein the fillers are located in designated regions of the foam.
20 . The cushion of claim 16 , wherein fillers comprising one material are located in a different location of the foam than fillers comprising another material.