Strut-reinforced, reduced VOC polyurethane foam

• US 20070078193A1
• Filed: 09/20/2006
• Published: 04/05/2007
• Est. Priority Date: 08/31/2005
• Status: Abandoned Application

• Current Assignee: Sleep Innovations, Inc. (FXI Holdings Incorporated)
• Original Assignee: Sleep Innovations, Inc. (FXI Holdings Incorporated)
• Inventors: Griggs, William, Gilder, Stephen
• Application Number:
  US11/524,673
• Publication Number:
  US 20070078193A1
• Time in Patent Office: Days
• US Class Current: 521/99
• CPC Class Codes: C08G 2101/00 Manufacture of cellular products
• CPC Class Codes: C08J 2375/04 Polyurethanes
• CPC Class Codes: C08J 9/0014 Use of organic additives
• CPC Class Codes: C08J 9/0066 Use of inorganic compounding ingredients
• CPC Class Codes: C08K 3/36 Silica
• CPC Class Codes: C08K 5/01 Hydrocarbons C08K5/0091 takes precedence
• CPC Class Codes: C08L 75/04 Polyurethanes

Abstract

A polyurethane foam produced from a formulation comprising a polyol, an isocyanate, a strut reinforcing agent and a VOC reducing agent. The isocyanate reacts with the polyol to produce the polyurethane foam. By including the strut reinforcing and VOC adsorption agents in the formulation during the reaction between the isocyanate and the polyol, the air permeability and firmness of the polyurethane foam are enhanced while the amount of VOCs within and the level of VOCs emitted by the polyurethane foam are reduced relative to a polyurethane foam produced by reacting the isocyanate and the polyol in the absence of the strut reinforcing or VOC reducing agents.

Claims

1. A polyurethane foam produced from a formulation comprising:

a polyol;

an isocyanate, said isocyanate reacting with said polyol to produce a polyurethane foam;

a strut reinforcing agent; and

a volatile organic compound (VOC) adsorption agent;

wherein inclusion of said strut reinforcing agent in said formulation during said reaction between said isocyanate and said polyol enhances air permeability of said polyurethane foam produced thereby relative to a polyurethane foam produced by reacting said isocyanate and said polyol in the absence of said strut reinforcing agent; and

wherein inclusion of said VOC adsorption agent in said formulation during said reaction between said isocyanate and said polyol reduces the level of VOC emissions from said polyurethane foam relative to a polyurethane foam produced by reacting said isocyanate and said polyol in the absence of said VOC adsorption agent.

2. The polyurethane foam of claim 1 wherein the VOC adsorption agent is a zeolite.

3. The polyurethane foam of claim 2, wherein the strut reinforcing agent is a mineral oil.

4. The polyurethane foam of claim 2, wherein said strut reinforcing agent is paraffin.

5. The polyurethane foam of claim 1, wherein said strut reinforcing agent is naphthalene.

6. The polyurethane foam of claim 1, wherein the VOC adsorption agent is a carbonaceous compound.

7. The polyurethane foam of claim 6, wherein the carbonaceous compound is selected from the group consisting of carbon black, charcoal, activated carbon, graphite, carbon fibers, fibrils, carbon-silica, silica-coated carbon black and metal-treated carbon black.

8. The polyurethane foam of claim 6, wherein the VOC adsorption agent is activated carbon.

9. The polyurethane foam of claim 8, wherein the strut reinforcing agent is a mineral oil.

10. The polyurethane foam of claim 8, wherein said strut reinforcing agent is paraffin.

11. The polyurethane foam of claim 8, wherein said strut reinforcing agent is naphthalene.

12. A polyurethane foam produced from a formulation comprising:

a polyol;

an isocyanate, said isocyanate reacting with said polyol to produce a polyurethane foam;

a strut reinforcing agent; and

a volatile organic compound (VOC) adsorption agent;

wherein inclusion of said strut reinforcing agent in said formulation during said reaction between said isocyanate and said polyol enhances firmness of said polyurethane foam produced thereby relative to a polyurethane foam produced by reacting said isocyanate and said polyol in the absence of said strut reinforcing agent; and

wherein inclusion of said VOC adsorption agent in said formulation during said reaction between said isocyanate and said polyol reduces the amount of VOCs within said polyurethane foam relative to a polyurethane foam produced by reacting said isocyanate and said polyol in the absence of said VOC adsorption agent.

13. The polyurethane foam of claim 12 wherein the VOC adsorption agent is a zeolite.

14. The polyurethane foam of claim 13, wherein the strut reinforcing agent is selected from the group consisting of a mineral oil, paraffin and naphthalene.

15. The polyurethane foam of claim 12, wherein the VOC adsorption agent is a carbonaceous compound.

16. The polyurethane foam of claim 15, wherein the carbonaceous compound is selected from the group consisting of carbon black, charcoal, activated carbon, graphite, carbon fibers, fibrils, carbon-silica, silica-coated carbon black and metal-treated carbon black.

17. The polyurethane foam of claim 12, wherein the VOC adsorption agent is activated carbon.

18. A polyurethane foam produced from a formulation comprising:

a polyol;

an isocyanate, said isocyanate reacting with said polyol to produce a polyurethane foam;

a strut reinforcing agent; and

a volatile organic compound (VOC) adsorption agent;

wherein inclusion of said strut reinforcing agent in said formulation during said reaction between said isocyanate and said polyol enhances both air permeability and firmness of said polyurethane foam produced thereby relative to a polyurethane foam produced by reacting said isocyanate and said polyol in the absence of said strut reinforcing agent; and

wherein inclusion of said VOC adsorption agent in said formulation during said reaction between said isocyanate and said polyol reduces both the amount of VOCs within said polyurethane foam and the level of VOCs emitted by said polyurethane foam relative to a polyurethane foam produced by reacting said isocyanate and said polyol in the absence of said VOC adsorption agent.

19. The polyurethane foam of claim 18, wherein said strut reinforcing agent is an aromatic hydrocarbon and said VOC adsorption agent is an activated carbon.

20. The polyurethane foam of claim 18, wherein said strut reinforcing agent is an organic chemical compound and said VOC adsorption agent is an activated carbon.