IP Library › Patent Application 18456036
Patent Application
App. No. 18/456,036

COMPOSITION OF FOAM AND CUSHIONS THAT INCLUDE DIGESTERS, AND RELATED METHODS OF MANUFACTURE

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Quick Facts
Patent No.
US None
App. No.
18/456,036
Abstract

Foam compositions, cushions, and related methods of manufacture are disclosed. The foam composition or cushion include (a) polymer that includes (i) a maximum of 60% polyol that includes multiple hydroxyl groups, and (ii) less than 50% isocyanate, (b) at least 40% filler suspended in the polymer, and (c) a plurality of digesters suspended in the polymer.

Claims (31)

1 . A cushioning foam composition, comprising:

a polymer comprising:

a maximum of 60% polyol comprising multiple hydroxyl groups;

less than 50% isocyanate;

at least 40% filler suspended in the polymer; and

a plurality of digesters suspended in the polymer.

2 . The cushioning foam composition of claim 1 , wherein the polymer comprises at least one of polyurethane and polyisocyanurate.

3 . The cushioning foam composition of claim 1 , wherein the polymer comprises polyol with an amount within the range of about 2% to about 60%.

4 . The cushioning foam composition of claim 1 , wherein the polymer comprises polyol with an amount within the range of about 2% to about 8%.

5 . The cushioning foam composition of claim 4 , wherein the polyol comprises at least one of petroleum, natural oil and animal by-products.

6 . The cushioning foam composition of claim 1 , wherein the polymer comprises isocyanate with an amount within the range of about 1% to about 50%.

7 . The cushioning foam composition of claim 1 , wherein the polymer comprises isocyanate with an amount within the range of about 1% to about 5%.

8 . The cushioning foam composition of claim 7 , wherein the isocyanate comprises at least one of methylene isocyanate based liquid and toluene isocyanate based liquid.

9 . The cushioning foam composition of claim 1 , further comprising at least one of a stabilizing additive, a surfactant, a blow catalyst, a blowing agent and a gelation catalyst.

10 . The cushioning foam composition of claim 1 , wherein the filler amount is within the range of about 85%-95% of the polymer.

11 . The cushioning foam composition of claim 1 , wherein the filler amount is within the range of about 90%-95% of the polymer.

12 . The cushioning foam composition of claim 1 , wherein the filler amount is at least about 75% of the polymer.

13 . The cushioning foam composition of claim 12 , wherein the filler comprises at least one of calcium carbonate, silica, fly ash, barium sulfate, hydrocarbon gels, phase change materials, electrically conductive material, magnetizable material.

14 . The cushioning foam composition of claim 12 , wherein the filler comprises the plurality of digesters.

15 . The cushioning foam composition of claim 12 , wherein the filler consists of the plurality of digesters.

16 . The cushioning foam composition of claim 12 , wherein the plurality of digesters comprise at least one of algae, microbes and fungus.

17 . The cushioning foam composition of claim 12 , wherein the plurality of digesters are individually encapsulated.

18 . The cushioning foam composition of claim 1 , wherein a barrier encapsulates the polymer.

19 . A cushion, comprising:

a cushioning portion formed of the cushioning foam composition of claim 1 .

20 . A method of manufacturing a cushioning foam composition, comprising:

forming a polymer comprising:

a maximum of 60% polyol comprising multiple hydroxyl groups;

less than 50% isocyanate;

at least 40% filler suspended in the polymer; and

a plurality of digesters suspended in the polymer.