US4451583A — Recycling of flexible polyurethane foam scrap

Claim 1

Independent Claim 85 words

In a process for preparing a flexible polyurethane foam from a foam forming reaction mixture comprising a polyol, an organic polyisocyanate, a foaming agent and a reaction catalyst, the improvement comprising blending in said reaction mixture a proportion of comminuted, flexible polyurethane foam scrap having a maximum particle size of less than about 600 microns to form a suspension in said reaction mixture, said proportion of scrap being from about 3 to about 40 parts, by weight, based on 100 parts of total polyol weight.

Claim 2

Dependent Claim 85 words

In a process for preparing a flexible polyurethane foam from a foam forming reaction mixture comprising a polyol, an organic polyisocyanate, a foaming agent and a reaction catalyst, the improvement comprising blending in said reaction mixture a proportion of comminuted, flexible polyurethane foam scrap having a maximum particle size of less than about 600 microns to form a suspension in said reaction mixture, said proportion of scrap being from about 3 to about 40 parts, by weight, based on 100 parts of total polyol weight.

Claim 3

Dependent Claim 12 words

The process of claim 1, wherein said polyol is a polyether polyol.

Claim 4

Dependent Claim 13 words

The process of claim 2, wherein said reaction mixture further comprises a surfactant.

Claim 5

Dependent Claim 16 words

The process of claim 3, wherein said proportion ranges from about 5 to about 32 parts.

Claim 6

Dependent Claim 16 words

The process of claim 4, wherein said proportion ranges from about 8 to about 24 parts.

Claim 7

Dependent Claim 28 words

The process of claim 3, wherein said polyether polyol is an oxyalkylated polyhydric alcohol having a molecular weight of about 1,000-6,000 and said organic polyisocyanate is toluene diisocyanate.

Claim 8

Dependent Claim 29 words

The process of claim 6, wherein said polyether polyol is oxypropylated glycerin and said reaction mixture comprises water and a catalyst mixture of an amine and a stannous salt.

Claim 9

Dependent Claim 30 words

The process of claim 3, wherein said foam scrap is flexible, compression-densified polyurethane foam having a density within the range from about 1.5 to about 15 pounds per cubic foot.

Claim 10

Dependent Claim 32 words

The process of claim 8, wherein said foam scrap is employed in a proportion ranging from about 8 to about 24 parts, by weight, based on 100 parts of total polyol weight.

Claim 11

Dependent Claim 28 words

The process of claim 9, wherein said polyether polyol is an oxyalkylated polyhydric alcohol having a molecular weight of about 1,000-6,000 and said organic polyisocyanate is toluene diisocyanate.

Claim 12

Dependent Claim 29 words

The process of claim 10, wherein said polyether polyol is oxypropylated glycerin and said reaction mixture comprises water and a catalyst mixture of an amine and a stannous salt.

Claim 13

Dependent Claim 181 words

In a process for preparing a flexible, compression-densified polyurethane foam having a density within the range from about 1.5 to about 15 pounds per cubic foot prepared by (a) placing a polyurethane foam forming reaction mixture in a reaction zone and allowing the mixture to rise freely, thereby forming a partially cured cellular material, said reaction mixture being comprised of a polyol, an organic polyisocyanate, a foaming agent and a reaction catalyst; (b) applying a compressive force to the partially cured cellular material after completion of the rise, thereby; (c) reducing the volume of the partially cured cellular material to between about 3/4 and about 1/10 of its original volume; and (d) removing the compressive force and completing the cure of the compressed cellular material; the improvement comprising blending in said reaction mixture a proportion of comminuted, flexible polyurethane foam scrap having a maximum particle size of less than about 600 microns to form a suspension in said reaction mixture, said proportion of scrap being from about 3 to 40 parts, by weight, based on 100 parts of total polyol weight.

Claim 14

Dependent Claim 181 words

In a process for preparing a flexible, compression-densified polyurethane foam having a density within the range from about 1.5 to about 15 pounds per cubic foot prepared by (a) placing a polyurethane foam forming reaction mixture in a reaction zone and allowing the mixture to rise freely, thereby forming a partially cured cellular material, said reaction mixture being comprised of a polyol, an organic polyisocyanate, a foaming agent and a reaction catalyst; (b) applying a compressive force to the partially cured cellular material after completion of the rise, thereby; (c) reducing the volume of the partially cured cellular material to between about 3/4 and about 1/10 of its original volume; and (d) removing the compressive force and completing the cure of the compressed cellular material; the improvement comprising blending in said reaction mixture a proportion of comminuted, flexible polyurethane foam scrap having a maximum particle size of less than about 600 microns to form a suspension in said reaction mixture, said proportion of scrap being from about 3 to 40 parts, by weight, based on 100 parts of total polyol weight.

Claim 15

Dependent Claim 12 words

The process of claim 12, wherein said polyol is a polyether polyol.

Claim 16

Dependent Claim 13 words

The process of claim 13, wherein said reaction mixture further comprises a surfactant.

Claim 17

Dependent Claim 32 words

The process of claim 14, wherein said foam scrap is employed in a proportion ranging from about 8 to about 24 parts, by weight, based on 100 parts of total polyol weight.

Claim 18

Dependent Claim 30 words

The process of claim 15, wherein said foam scrap is flexible, compression-densified polyurethane foam having a density within the range from about 1.5 to about 15 pounds per cubic foot.

Claim 19

Dependent Claim 28 words

The process of claim 16, wherein said polyether polyol is an oxyalkylated polyhydric alcohol having a molecular weight of about 1,000-6,000 and said organic polyisocyanate is toluene diisocyanate.

Claim 20

Dependent Claim 29 words

The process of claim 17, wherein said polyether polyol is oxypropylated glycerin and said reaction mixture comprises water and a catalyst mixture of an amine and a stannous salt.

Claim 21

Dependent Claim 12 words

A polyurethane foam product prepared according to the process of claim 1.

Claim 22

Dependent Claim 12 words

A polyurethane foam product prepared according to the process of claim 8.

Claim 23

Dependent Claim 12 words

A polyurethane foam product prepared according to the process of claim 11.

Claim 24

Dependent Claim 12 words

A polyurethane foam product prepared according to the process of claim 12.

Claim 25

Dependent Claim 12 words

A polyurethane foam product prepared according to the process of claim 18.

Annuity Stage	Window Opens	Payment Deadline	Surcharge Period Until	Estimated Fee	Status
3.5 Years (Year 4)	1987-05-29	1987-11-28	1988-05-29	$2000.00	Window Closed / Lapsed
7.5 Years (Year 8)	1991-05-29	1991-11-28	1992-05-29	$3760.00	Window Closed / Lapsed
11.5 Years (Year 12)	1995-05-29	1995-11-28	1996-05-29	$7700.00	Window Closed / Lapsed

Recycling of flexible polyurethane foam scrap

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