Rebond polyurethane foam comprising reclaimed carpet material and methods for the manufacture of same

US9410026B1 · US · B1

Patent metadata
FieldValue
Publication numberUS-9410026-B1
Application numberUS-78604410-A
CountryUS
Kind codeB1
Filing dateMay 24, 2010
Priority dateMay 22, 2009
Publication dateAug 9, 2016
Grant dateAug 9, 2016

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  1. Title

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  2. Abstract

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  3. Assignees and inventors

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  4. Key dates

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  5. First independent claim

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  6. CPC / IPC classifications

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  7. Citations and related patents

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Abstract

Official abstract text for this publication.

Disclosed are rebond polyurethane foams comprised of a plurality of polyurethane foam particles bound together to form a matrix. Reclaimed carpet material is distributed within the matrix of foam particles as a filler material. Also disclosed are methods for the manufacture of the rebond polyurethane foams disclosed herein.

First claim

Opening claim text (preview).

What is claimed is: 1. A rebond polyurethane foam, comprising: a plurality of preformed polyurethane foam particles bonded to one another to form a matrix; and reclaimed carpet material distributed within the matrix of polyurethane foam particles, wherein the reclaimed carpet material comprises a population of thermoplastic fibers having non-uniform linear fiber densities; and wherein the reclaimed carpet material is present in an amount of at least 35 parts by weight relative to the total amount of preformed polyurethane foam particles and reclaimed carpet material present in the rebond polyurethane foam. 2. The rebond polyurethane foam of claim 1 , wherein the reclaimed carpet material is present in an amount of from 35 to 50 weight percent of the total weight of the rebond polyurethane foam. 3. The rebond polyurethane foam of claim 1 , wherein the reclaimed carpet material comprises fibers of nylon 6, nylon 6,6, polyethylene, polypropylene, polyester, or any combination thereof. 4. The rebond polyurethane foam of claim 1 , wherein the reclaimed carpet material comprises natural fibers. 5. The rebond polyurethane foam of claim 1 , wherein the reclaimed carpet material comprises post consumer carpet material. 6. The rebond polyurethane foam of claim 1 , having a volumetric density in the range of from 1 to 50 pounds per cubic foot. 7. The rebond polyurethane foam of claim 6 , having a volumetric density in the range of from 1 to 25 pounds per cubic foot. 8. The rebond polyurethane foam of claim 1 , having a volumetric density greater than 8 pounds per cubic foot. 9. The rebond polyurethane foam of claim 1 , wherein the reclaimed carpet material is present in an amount of at least 50 parts by weight relative to the total amount of preformed polyurethane foam particles and reclaimed carpet material present in the rebond polyurethane foam.

Assignees

Inventors

Classifications

  • C08J11/04Primary

    of polymers · CPC title

  • Ingredients agglomerated by treatment with a binding agent · CPC title

  • After-treatment (C08J9/22 takes precedence) · CPC title

  • Polymeric products of isocyanates or isothiocyanates · CPC title

  • flexible · CPC title

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Frequently asked questions

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What does patent US9410026B1 cover?
Disclosed are rebond polyurethane foams comprised of a plurality of polyurethane foam particles bound together to form a matrix. Reclaimed carpet material is distributed within the matrix of foam particles as a filler material. Also disclosed are methods for the manufacture of the rebond polyurethane foams disclosed herein.
Who is the assignee on this patent?
Rees John J M, Fowler Gregory, Columbia Insurance Co
What technology area does this patent fall under?
Primary CPC classification C08J11/04. Mapped technology areas include Chemistry & Metallurgy.
When was this patent published?
Publication date Tue Aug 09 2016 00:00:00 GMT+0000 (Coordinated Universal Time) (B1). Legal status and post-grant events are not shown on this page.
What related patents are in patentsdb?
We list 8 related publications on this page (citations in our corpus or others sharing the same primary CPC).