阅读说明：本技术 通过添加金属材料制成的增强导热的垫子泡沫 (Cushion foam made by adding metal material for enhancing heat conduction ) 是由 B·W·彼得森 M·L·克劳福德 M·D·麦克奈特 于 2019-06-14 设计创作，主要内容包括：本发明公开了用于制造并使用一个或多个导热多孔泡沫层(1)和其他结构的方法与组合,上述导热多孔泡沫层包括柔性多孔泡沫(2、3)和金属材料颗粒,所述导热多孔泡沫层(1)可以位于在垫子泡沫和床垫(20、110、120)上、下或内部,或者位于其他分层基板(2、3)、支柱与其他结构之间,以改善复合体的整体冷却能力。导热泡沫(1)可用于床垫(20、110、120)、枕头(130、140)、铺盖产品、座垫(150)、医用垫子泡沫、宠物床、以及铺盖和舒适产品中使用的类似材料。(Methods and combinations for making and using one or more thermally conductive porous foam layers (1) comprising flexible porous foam (2, 3) and particles of metallic material and other structures are disclosed, the thermally conductive porous foam layer (1) may be located on, under or within cushion foam and mattresses (20, 110, 120) or between other layered substrates (2, 3), struts and other structures to improve the overall cooling capacity of the composite. The thermally conductive foam (1) can be used in mattresses (20, 110, 120), pillows (130, 140), bedding products, seat cushions (150), medical mattress foam, pet beds, and similar materials used in bedding and comfort products.)

1. A flexible cellular foam (TC) having improved thermal conductivity foam comprising:

a flexible cellular foam, and

a plurality of metallic material particles dispersed in the flexible porous foam in an amount ranging from about 0.01 wt% to about 70 wt% to improve the thermal conductivity of the flexible porous foam, wherein the metallic material is selected from the group consisting of beryllium, magnesium, strontium, zinc, molybdenum, cadmium, titanium, vanadium, manganese, gallium, chromium, iron, cobalt, nickel, copper, zirconium, palladium, silver, tantalum, tungsten, platinum, gold, aluminum, indium, tin, bismuth, germanium, antimony, derivatives of these metallic materials in combination with an element selected from the group consisting of oxygen, halogen, carbon, silicon, and combinations thereof, and any combination of these, and wherein the metallic material particles have an average particle size ranging from about 0.1 microns to about 2000 microns.

2. The TC foam according to claim 1, wherein said flexible cellular foam is selected from the group consisting of foams and latex foams made by a process comprising polymerizing a polyol with a polyisocyanate.

3. The TC foam according to claim 1, wherein said TC foam is produced by a process comprising:

introducing the plurality of particles of metallic material into a mixture of flexible cellular foam-forming ingredients comprising a polyol and an isocyanate; and

polymerizing a polyol and an isocyanate to form the flexible cellular foam.

4. An article comprising the TC foam of claim 1, wherein said article is selected from the group consisting of medical mattress foam, mattresses, pillows, bedding products, mattress pillow cases, quilted mattress covers, and combinations thereof.

5. The TC foam of claim 1, wherein the flexible cellular foam is an open-cell polyurethane foam, a closed-cell polyurethane foam, an open-cell polyester polyurethane foam, a closed-cell polyester polyurethane foam, and combinations thereof.

6. The TC foam according to claim 1, wherein said metallic material is selected from the group consisting of titanium, zinc, nickel, copper, tungsten, platinum, gold, silver, aluminum, tin, chromium, manganese, iron, cobalt, gallium, beryllium, magnesium, strontium, zirconium, molybdenum, derivatives of these metallic materials in combination with an element selected from the group consisting of oxygen, halogen, carbon, silicon, and combinations thereof, and any combination of these.

7. The TC foam according to claim 1, wherein said metallic material particles are in the form of flakes, powders, spheres, crystalline arrays, and combinations thereof.

8. The TC foam according to claim 1, wherein said TC foam comprises a material selected from the group consisting of solid sheets, perforated sheets, non-planar sheets, textured sheets, and combinations thereof.

9. The TC foam according to claim 1, wherein said TC foam is adhered to a layered substrate.

10. The TC foam according to claim 1, including a smooth gradient transition from said TC foam to a base foam.

11. An article selected from the group consisting of mattress foam, a mattress topper, a pillow, and combinations thereof, wherein the article comprises the TC foam of claim 1.

12. An article selected from the group consisting of mattress foam, mattress pads, mattress topper pads, and combinations thereof, wherein the article is rectangular having: an opposing long side, an opposing short side, and at least one area selected from the group consisting of a longitudinal area parallel to the opposing long side, a transverse area parallel to the opposing short side, and combinations thereof, wherein the at least one area comprises the TC foam of claim 1.

13. An article of manufacture, wherein the article of manufacture is selected from the group consisting of medical mattress foam, a mattress, a pillow, a draping product, a cushion product, a mattress pillow case, a quilted mattress cover, a mattress cover, and combinations thereof, wherein the article of manufacture further comprises the TC foam of claim 1.

14. An article of manufacture, comprising:

at least one layer comprising the TC foam according to claim 1; and

an ingredient made by a process selected from the group consisting of molding, free foaming, and combinations thereof;

wherein the article is selected from the group consisting of a seat cushion, a back support, and combinations thereof.

15. A Thermally Conductive (TC) foam, the TC foam comprising:

a flexible cellular foam made by a process comprising polymerizing a polyol with a polyisocyanate; and

a plurality of metallic material particles dispersed in the flexible porous foam in an amount in the range of about 0.01 wt% to about 25 wt% to improve the thermal conductivity of the flexible porous foam, wherein the metallic material is selected from the group consisting of titanium, zinc, nickel, copper, tungsten, platinum, gold, aluminum, tin, chromium, manganese, iron, cobalt, gallium, beryllium, magnesium, strontium, zirconium, molybdenum, derivatives of these metallic materials in combination with an element selected from the group consisting of oxygen, halogen, carbon, silicon, and combinations thereof, and any combination of these, and wherein the metallic material particles have an average particle size in the range of about 1 micron to about 1000 microns.

16. A Thermally Conductive (TC) foam, the TC foam comprising:

a flexible cellular foam generated by a process comprising polymerizing a polyol and a polyisocyanate, the flexible cellular foam selected from the group consisting of open-cell polyurethane foam, closed-cell polyurethane foam, open-cell polyester polyurethane foam, closed-cell polyester polyurethane foam, and combinations thereof; and

a plurality of metallic material particles dispersed in the flexible porous foam in an amount ranging from about 0.01 wt% to about 70 wt% to improve the thermal conductivity of the flexible porous foam, wherein the metallic material is selected from the group consisting of magnesium, titanium, vanadium, chromium, iron, cobalt, nickel, copper, zirconium, silver, platinum, gold, mercury, aluminum, tin, derivatives of these metallic materials in combination with an element selected from the group consisting of oxygen, halogen, carbon, silicon, and combinations thereof, and any combination thereof, and wherein the metallic material particles have an average particle size ranging from about 0.1 microns to about 2000 microns.

17. A Thermally Conductive (TC) latex foam comprising:

crosslinking the latex foam; and

a plurality of particles of a metallic material dispersed in the cross-linked latex foam in an amount in the range of about 0.01 wt% to about 70 wt% to improve the thermal conductivity of the cross-linked latex foam, wherein the metallic material is selected from the group consisting of beryllium, magnesium, strontium, zinc, molybdenum, cadmium, titanium, vanadium, manganese, iron, cobalt, nickel, copper, zirconium, palladium, silver, tantalum, tungsten, platinum, gold, aluminum, indium, tin, bismuth, germanium, antimony, derivatives of these metallic materials in combination with an element selected from the group consisting of oxygen, halogen, carbon, silicon, and combinations thereof, and any combination of these, wherein the particles of the metallic material have an average particle size in the range of about 0.1 microns to about 2000 microns.

Technical Field

The present application relates to methods for making and using one or more thermally conductive foam layers and other structures that include flexible porous foam and particles of metallic material, and that are located on, under, or within mattresses and draping products. The present invention more particularly relates to various types of thermally conductive foams containing particles of metallic materials, including, but not limited to, mattresses, pillows, mattress cover pads (mattress topper pads), quilted covers (quilted toppers), medical mattresses, and other draping products.

Technical Field

Flexible cellular foams, such as open-cell polyurethane flexible foams, closed-cell polyurethane flexible foams, latex foams, and melamine foams, typically have low thermal conductivities ranging from about 0.035 to about 0.060W/(m K). Low thermal conductivity materials are commonly used as thermal insulation, such as rigid polyurethane foam insulation panels or expanded polystyrene insulation panels.

Heat transfer consists of a combination of conduction, convection and radiation phenomena. In a mattress or mattress, heat transfer by radiation is not an important heat transfer mode in a mattress or mattress. In contrast, heat transfer by thermal conduction and convection is the primary route by which heat moves into and through the mattress or mattress. When a person sleeps on a mattress, the compressed foam under the body has a reduced air flow path and the primary heat transfer mode in the area under the body is conduction.

Heat is conducted from the body through the compressed foam and dissipated into the mattress or into areas of the mattress where the foam is not likewise compressed, which allows natural convection to more readily occur to remove heat from the mattress. Due to the low thermal conductivity of the foam, this mode of heat transfer is too low to cope with the generation of heat by the human or animal body, resulting in the foam warming up and thus becoming uncomfortable. This results in a wide range of hot foam around the body which makes the foam uncomfortable.

U.S. patent No. 3,255,128 discloses polyurethane foam compositions containing small particles of aluminum metal and a method of treating aluminum particles with phosphoric acid to enhance the effectiveness of aluminum metal particles in polyurethane foams. Aluminum phosphate flakes are added to an insulated polyurethane foam panel to reduce heat flow through the panel by reducing heat absorption and radiation.

U.S. patent No. 3,833,951 discloses fire resistant mattresses, pillows and sleeping bags. The metallized heat conductive layer is prepared by mixing a metal with an aqueous solution of a vinyl binder and spreading the foamed mixture over a polyurethane foam having a foam thickness of 0.1 to 1.0 inch and drying at about 280 ℃. The final dry coating thickness is 0.5 to 6 mils.

Us patent No. 6,772,825B2 discloses a support surface that is comfortable to the patient and maintains a cool skin temperature by containing a refrigerant bladder with a boiling point between 23 and 35 degrees celsius in the bladder, a flexible spacer such as polyurethane foam in the bladder, and a strip of thermally conductive aluminum or copper metal and a top metal layer located outside the bladder. Such metal strips are used to transfer heat from the refrigerated gas to the surroundings. No metal material is added to the polyurethane foam reactants prior to production of the foam substrate.

Therefore, it is useful and desirable to develop improved heat transfer in a mattress or mattress in order to provide a cooler and more comfortable sleep.

Disclosure of Invention

The present invention provides, in one non-limiting form, a method of forming a flexible cellular foam having improved thermal conductivity (referred to as "TC foam" or thermally conductive foam), the foam comprising: a flexible polyurethane foam and/or a polyester polyurethane foam and/or a latex foam, which may have open-cell properties or closed-cell properties, and a plurality of particles of a metallic material selected from a broad group of metals and metal derivatives. Phase change materials, colorants, plasticizers, and other performance modifying additives may optionally be added to the TC foam. The TC foam includes a metallic material in a range of 0.01% to 70%, or from about 0.5% to about 25% by weight on a weight basis. The average particle size of the metallic material particles ranges between about 0.1 microns to about 2000 microns.

Alternatively, the TC foam may include a plurality of metallic material particles and a latex foam that may have open-cell or closed-cell properties. In this embodiment, phase change materials, colorants, plasticizers, and other performance modifying additives may be optionally added to the TC foam. The TC foam comprises a metallic material in the range of 0.01% to 70% on a weight basis.

Alternatively, the TC foam may comprise a plurality of particles of metallic material and the melamine foam may have open-cell or closed-cell properties. In this embodiment, phase change materials, colorants, plasticizers, and other performance modifying additives may be optionally added to the TC foam. The TC foam comprises a metallic material in the range of 0.01% to 70% on a weight basis.

The metallic material used in the methods and compositions described herein may be selected from the non-limiting list of aluminum, copper, iron, steel, silver, gold, platinum, nickel, tin, chromium, vanadium, tungsten, titanium, and combinations thereof, or derivatives made from any of these materials in combination with oxygen, halogen, carbon, or silicon, and any combination thereof. In addition, these derivatives will include nitrates, carbides, carbonates, and the like. The metallic material may be flakes, powders, crystal arrangements, particles, and combinations thereof.

TC foams may be cut or molded in a number of configurations such as, but not limited to, planar layers, convoluted layers (convoluted layers), CNC cut layers, surface modification layers, 3D surface textures, molded pillows (molded pillows), smooth molded surfaces, molded surfaces with regular or irregular patterns (molded surfaces), support posts, conduits (e.g., without limitation, conduits for directing or flowing air), or desired physical structures modified in any manner such as, but not limited to, perforations, grooving (channeling), reticulation, or other methods known in the foaming art for modifying foam structures. The TC foam may be adhered in the cushion or mattress composite by an adhesive, or melting of the thermoplastic on the foam surface and re-solidifying the thermoplastic and locking the TC foam in place on the base foam. Alternatively, the TC foam may be provided as an entire cushion or mattress product without the need to attach it to any other material, such as a mattress cover (mattress topper), a full body mattress or pillow product. That is, the TC foam may be the only foam in the foam component of the product, or may be a portion of the foam component of the product, including but not limited to a layer of the product.

In non-limiting embodiments, suitable layered substrates including, but not limited to, flexible polyurethane foam, latex foam, flexible melamine foam, and other substrates such as thermoplastic or thermoset elastomers, fibers in woven or non-woven form, and combinations thereof, in combination with one or more TC foams are also provided. Articles that may be manufactured from these combinations of one or more TC foam substrates include, but are not limited to, mattresses, mattress covers, pillows, draping products, pet beds, quilted mattress covers, pillows or mattress cores (inserts), molded support foam (molded support foam) or other materials commonly used in draping environments.

Drawings

FIG. 1 is a schematic view of a possible heat transfer path in a cross section of a mattress;

FIG. 2 is a first exemplary configuration for use with a mattress and/or a mattress application;

FIG. 3 is a second exemplary configuration for use with a mattress and/or a mattress application;

FIG. 4 is a third exemplary configuration for use with a mattress and/or a mattress application;

FIG. 5 is a fourth exemplary configuration for use with a mattress and/or a mattress application;

FIG. 6 is a fifth exemplary configuration for use with a mattress and/or a mattress application;

FIG. 7 is a sixth exemplary configuration for use with a mattress and/or a mattress application;

FIG. 8 is a seventh exemplary configuration for use with a mat and/or mat application;

FIG. 9 is an eighth exemplary configuration for use with a mattress and/or a bed mattress application;

FIG. 10 is a ninth exemplary configuration for use with a cushion and/or mattress application;

FIG. 11 is an exemplary exploded view of a lateral mattress area in a mattress and/or mattress application;

FIG. 12 is an exemplary exploded view of a longitudinal mattress section in a mattress and/or mattress application;

FIG. 13 is an example of a molded pillow product in which the entire structure is molded from TC foam;

FIG. 14 is an example of a molded pillow product, where TC foam is an area or layer within the pillow;

FIG. 15 is an example of a wheelchair seat cushion using TC foam in its construction; and

fig. 16 is a photograph of TC foam from example I with thermally conductive particles added to open cell flexible polyurethane foam.

It will be appreciated that fig. 1-15 are schematic and that the various elements are not necessarily to scale or proportional and that many details have been removed or simplified for clarity and, thus, the methods and compositions are not necessarily limited to the embodiments depicted in the above-described figures.

Before the methods and compositions are explained in detail, it is to be understood that the methods and compositions are not limited in their application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting.

Detailed Description

To provide a cooler and more comfortable sleep or contact, it is beneficial to create improved heat transfer in a mattress or cover by incorporating one or more TC foam layers comprising flexible porous foam and a metal material such as in particulate form, and used on, under or within mattresses, pillows, cover products, medical mattress foam and similar materials used in covering environments. TC foams exhibit improved thermal conductivity due to their enhanced thermal conductivity.

The flexible cellular foam may be an open cell polyurethane foam, a closed cell polyurethane foam, an open cell polyester polyurethane foam, a closed cell polyester polyurethane foam, a latex foam, a melamine foam, and combinations thereof.

Heat transfer consists of a combination of conduction, convection and radiation. In mattresses or covers, the heat transfer by radiation is not very great. In contrast, heat transfer by conduction and convection is the primary means of moving heat within the mattress or cover. When a person sleeps on a mattress, the compressed foam under the body has a reduced air flow path and the primary mode in the area under the body is conduction. Heat is conducted from the body through the compressed foam to areas of the mattress or the overlying foam that are not likewise compressed, which allows natural convection to occur more readily, so that the mattress removes heat. By increasing the thermal conductivity of the mattress or cover and dissipating heat from the body more quickly, a cooler and more comfortable sleep can be achieved. It should be understood that when discussing a person sleeping on a mattress, the same heat transfer principles and cool or warm sleep apply if a dog, other pet or warm-blooded animal is sleeping on or lying on a mattress or pillow.

The enhanced heat transfer reduces the amount of temperature gradient required to produce a given amount of heat flow. This means that for the same amount of body heat, a mattress or a cover with TC foam will be able to have a lower foam surface temperature when in contact with a person, while still dissipating heat. This will result in a cooler sleep.

Fig. 1 is a general schematic of the heat transfer path when a person sleeps on a mattress with TC foam 1 located under a first foam layer 2. However, fig. 1 does not show all possible combinations of TC foam and substrate foam.

TC foams comprise open or closed cell flexible polyurethane or polyester foams with one or more metallic materials (e.g., in the form of particles) dispersed throughout the foam. The term "dispersion" encompasses random dispersion, uniform dispersion, more concentrated dispersion within one region or volume of the foam as compared to an adjacent region or volume, and combinations thereof, of the particles of the metallic material in the foam. The TC foam includes a metallic material in a range of about 0.01% independently to about 70% on a weight basis. Alternatively, the TC foam comprises in the range of about 1% independently to about 55% of the metallic material, and in another non-limiting embodiment the TC foam comprises in the range of about 2.5% independently to about 40% of the metallic material, and in a different non-limiting version the TC foam comprises in the range of about 4% independently to about 25% of the metallic material. The term "independently" as used in connection with various ranges herein means that any lower threshold value can be combined with any higher ratio to form a suitable alternative range.

The thermal conductivity of metals is isotropic. The thermal conductivity in all directions in the metal is about 5-440W/(m- ° K). The thermal conductivity of the polyurethane foam is also isotropic, with a thermal conductivity of about 0.035-0.06W/(m- ° K) in all directions.

The addition of highly thermally conductive metal materials in the mattress or mattress provides a cooler and more comfortable sleep. The thermal conductivity of the particular metal of interest is in the range of 5-440W/(m- ° K). If the thermal conductivity of the metal additive is about 200W/(m- ° K), the thermal conductivity of the metal additive is about 1500 times the thermal conductivity of the foam. Typically, metallic materials are anisotropic in nature and exhibit approximately the same thermal conductivity in all directions. When the foam containing the metallic material is compressed, the metallic materials may contact or communicate with each other, or at least the metallic materials may come closer to each other, resulting in greater heat dissipation capability of the metallic materials, e.g., to conduct or remove heat from a body lying on the mattress.

In one non-limiting embodiment, the TC foam (foam plus metal material particles dispersed therein) may be at least about 0.01W/(m- ° K) higher than a flexible porous foam without metal material particles; or at least about 0.005W/(m- ° K) higher than a flexible porous foam without metal material particles; and in another non-limiting version at least about 0.002W/(m- ° K) higher than a flexible porous foam without metallic material particles.

The term "metal" is understood to mean exhibiting good thermal conductivity (k)>5W/(m- ° K)) and may, but need not, exhibit good electrical conductivity (resistivity, p)<10²Ω · m), oxides, compounds, alloys, or combinations thereof.

The metallic material may include, but is not limited to, lithium, sodium, potassium, rubidium, cesium, francium, beryllium, magnesium, calcium, strontium, barium, radium, zinc, molybdenum, cadmium, scandium, titanium, vanadium, chromium, manganese, iron, cobalt, nickel, copper, yttrium, zirconium, niobium, technetium, ruthenium, rhodium, palladium, silver, hafnium, tantalum, tungsten, rhenium, osmium, iridium, platinum, gold, mercury, therfordium, dubnium, seabororgium, bohrium, hastum, copernium, aluminum, gallium, indium, tin, thallium, lead, bismuth, polonium, lanthanum, cerium, praseodymium, neodymium, promethium, samarium, europium, gadolinium, terbium, dysprosium, holmium, thulium, ytterbium, lutetium, actinium, thorium, protactinium, uranium, plutonium, americium, curium, californium, columbium, yttrium, lutetium, yttrium, and combinations thereof.

Suitable metallic materials may include, but are not limited to, aluminum, copper, iron, steel, silver, gold, platinum, nickel, tin, chromium, vanadium, tungsten, titanium, or any combination thereof in combination with oxygen, halogen, carbon, or silicon.

Metal compounds have been used as catalytic materials in foams, and common materials of this type include, but are not limited to, stannous octoate, dibutyltin dilaurate, bismuth neodecanoate, and zinc octoate. These catalytic compounds are used in small amounts, typically from 0.01% to 0.40% of the foam formulation. In addition, the incorporation of ions in the catalyst structure greatly limits its ability to act as an element for enhanced heat transfer. In some non-limiting embodiments, the metallic material particles are defined herein to exclude catalysts, pigments, and flame retardants that comprise metals. In another non-limiting embodiment, the TC foam is absent castor oil.

In non-limiting embodiments, the metallic material may be in the form of flakes, powders, spheres, crystal arrangements, or other various particulate forms. Suitable dimensions for the metallic material may be between about 0.1 microns independently to about 2000 microns, or alternatively, between about 1 micron independently to about 1000 microns, in another non-limiting embodiment, between about 80 microns independently to about 500 microns, and in a different non-limiting embodiment, from about 50 microns independently to about 1500 microns. To reduce accelerated compression fatigue, the most preferred size of the metallic material is less than 80 microns independently to about 500 microns, or from about 100 microns independently to about 250 microns.

The TC foam can also contain conventionally used additives ("performance enhancing additives") in amounts useful to not affect or substantially impair the desired properties of the TC foam, e.g., plasticized triblock copolymer gels, crosslinked gels, extruded polyurethane gels, stabilizers, antioxidants, antistatic agents, antimicrobial agents, ultraviolet light stabilizers, phase change materials, surface tension modifiers (e.g., silicone surfactants, emulsifiers, and/or other surfactants), solid flame retardants, liquid flame retardants, graft polyols, compatible hydroxyl containing chemicals that are fully saturated or unsaturated at one or more positions, solid or liquid fillers, antiblocking agents, colorants (e.g., inorganic pigments, carbon black, organic colorants or dyes, reactive organic colorants or dyes, thermally responsive colorants, UV curable polyurethane foams, UV curable compositions, and the like, Thermally responsive pigments, thermally responsive dyes, pH responsive colorants, pH responsive pigments and combinations thereof), fragrances, and viscosity modifiers (such as fumed silica and clay), other TC enhancing additives and small amounts of other polymers, and the like.

Metallized plasticized triblock copolymer gels can be prepared from high viscosity triblock copolymers and metallic materials, crosslinked gels, extruded polyurethane gels, optionally with molten diblock copolymers or mixed with plasticizers such as mineral oils, synthetic oils, and the like, and optionally mixed with additives such as colorants, polyols, and the like.

The addition of a phase change material to the TC foam causes the structural composite to store or release energy that is higher than the heat absorbed or released by the thermal capacity of the non-thermodynamically enhanced structure. Heat is stored if the solid phase change material becomes a liquid, and released when the liquid phase change material becomes a solid. The melting point temperature is typically selected in the range of 20 ℃ to 35 ℃ to match the human comfort zone. Once the solid phase change material is completely melted, all latent heat is used and the phase change material must be cooled back below its melting point to solidify and regenerate the phase change material for the next melting cycle. Suitable phase change materials have a solid/liquid phase transition temperature of about-10 ° F to about 220 ° F (about-23 ℃ to about 104 ℃). In another non-limiting version, the phase transition solid/liquid phase transition temperature is from about 68 ° F to about 95 ° F (about 20 ℃ to about 35 ℃).

TC foams may be prepared by one or more methods, including: batch casting or continuous casting (pumping) in a mold (form), mold, or bun production line, and in one non-limiting embodiment, the metallic material may be added or mixed to the polyol mixture in a batch or continuous manner in a mixing system such as a continuous stirred tank, static mixing elements, air stirrer, or in any other equipment known to those skilled in the art for mixing solids and additives with liquids.

TC foam may be cast in standard round block form on a conveyor belt, in molds with planar or non-planar surfaces, texturing, and 3D finishing, or in molds with rods to make the foam porous.

In one non-limiting embodiment, one or more TC foams may be added to any location within or on the surface of a mold or within the interior cavity of a mold used to make a molded product, such as, but not limited to, a pillow, mattress, or mattress cover, and individual substrate components may be added to the mold to react with, bond, or encapsulate the TC foams.

In another non-limiting embodiment, there may be a smooth gradient transition from TC foam to any desired type of substrate foam. By "smooth gradient" is meant that there is no distinct boundary or boundary between the TC foam and the substrate foam. As a non-limiting example, the pillow has a high TC side and a low TC side. Such gradient dispersion of TC solids in the cellular foam can be produced by moulding techniques or free foaming techniques or a combination of these techniques. A non-limiting example of a gradient transition foam uses a polyurethane reactant stream with a TC additive and a polyurethane reactant stream without a TC additive, with the streams with the TC additive being injected into a mold first, and the streams without the TC additive being injected into the mold, the mold being closed and the foam expanding in the mold cavity. The resulting molded article will have areas of high thermal conductivity on one side of the foam and areas of low thermal conductivity on the other side of the foam, with a gradient transition between the two areas. For example, during summer, one may choose the TC side as a cooler pillow; during the winter one may choose the non-TC side to reduce heat transfer from the human body. The gradient transition also provides the benefit of higher thermal conductivity while also reducing the overall cost of the foam article.

The combination of using both the molding process and the free foaming process includes, but is not limited to, producing the TC layer by a free foaming method, cutting it, placing it in a mold, and molding it into a vehicle seat. Alternatively, the mold may be partially filled with TC foam first, and then the ingredients may be converted to a formulation that forms a non-TC foam during the same mold casting process.

In another non-limiting example, rotational molding techniques may be used. In a non-limiting embodiment, the mold may be coated with TC foam and then the substrate inserted or formed within the foam mold.

It should be understood that the methods described herein are not limited to these examples, as there are many possible combinations of making TC foams using open or closed cell polyurethane or polyester foams that may be used in cushion foams or mattresses. Further description of the preparation of foams, including gel foams, the foams so produced, and gel foam compositions can be found in U.S. patent nos. 8,933,139B 2,8,933,140B 2, 9,080,051B 2, and U.S. patent application publication No. 2013/0296449 a1, all of which are incorporated herein by reference in their entirety.

Use of TC foams

TC foam may be manufactured and combined with substrate foam for use in a variety of bedding, comfort and/or cushion applications, including but not limited to mattresses, pillows, pillow cases, mattress covers, quilted covers, body support foam, other common bedding materials, furniture foam, wheelchair cushions, and the like, where cooler foam is desired.

Layered substrates in combination with one or more TC foams and optionally performance enhancing materials as described herein have a very wide range of applications. Suitable layered substrates include, but are not limited to, flexible polyurethane foam, flexible polyester polyurethane foam, latex foam, flexible melamine foam, and other substrates (e.g., fibers in woven or non-woven forms), and combinations thereof. More specifically, in other non-limiting embodiments, the combination of TC foam and substrate would be suitable as a pillow or pillow component, including, but not limited to, pillow cases (pillow wrap) or pillow shells (shell), pillow cores, pillow covers, comfort pads for producing medical products, medical mattresses and similar comfort and support products, as well as residential/guest room mattresses (consumer mattresses), mattress covers and similar comfort and support products, typically made of common flexible polyurethane foam or fibers. All of these uses and applications are defined herein as "draping products".

Alternatively, articles such as vehicle seat cushions, back supports, and combinations thereof may be produced that include a TC foam layer, a flexible cellular foam produced by molding techniques or free-foaming techniques, or combinations thereof, and a temperature regulating system. Such a temperature regulation system is selected from the group including, but not limited to, heating by electrical resistance, cooling by a refrigerant, and combinations thereof.

Fig. 1 shows a source of heat 10, in one non-limiting embodiment a body weight, that introduces thermal energy into a standard, open-cell viscoelastic foam layer 2 by conduction. This figure mimics a human or other warm-blooded living being lying on the mattress 20. The TC foam 1 absorbs heat and uses improved thermal conductivity to move heat laterally through the mattress. Heat transfer and convection then proceeds through the open air holes, up through the layer 2 to the top of the mattress. At this point, natural convection acts to draw heat out of the system. In this example, a viscoelastic foam layer 2 and TC foam 1 are constructed on another viscoelastic foam layer 2 and a base foam 3 as a base.

Fig. 2 is a first example of a configuration using a mattress and/or mattress application. The substrate portion may be a bottom foam layer 3 or other type of substrate including, but not limited to, springs, pocketed coils, latex cores, and the like. On top of this is a 2 inch (5 cm) standard, open viscoelastic foam (adhesive) layer 2. The top layer 1 is a 2 inch (5 cm) layer of TC foam. It is to be understood that the dimensions given in the examples and descriptions of the various figures are illustrative only and are not intended to be limiting. Throughout the drawings, the same or similar reference numbers will be used for the same or similar structures.

Fig. 3 is a second exemplary configuration for use with a mattress and/or a mattress application. The substrate part is a bottom foam layer 3 or other substrate layer type as described earlier. On top of this was a 2 inch (5 cm) layer of TC foam 1 followed by a 2 inch (5 cm) layer of standard, open cell viscoelastic foam 2.

Fig. 4 is a third exemplary configuration for use with a mattress and/or a mattress application. The base part is a bottom foam layer 3. On top of this was a 2 inch (5 cm) layer of TC foam 1 followed by a 0.75 inch (1.9 cm) layer of bottom foam 3. The top layer was a second 2 inch (5 cm) layer of TC foam 1.

Fig. 5 is a fourth exemplary configuration for use with a mattress and/or a mattress application. The base part is a bottom foam layer 3. On top of this was a 2 inch (5 cm) layer of TC foam 1 followed by a 2 inch (5 cm) layer of standard, open cell viscoelastic foam 2. The top layer was a second 2 inch (5 cm) layer of TC foam 1.

Fig. 6 is a fifth exemplary configuration for use with a mattress and/or a mattress application. The base part is a bottom foam layer 3. On top of this is a 3 inch layer of TC foam 1.

It will be understood that TC foam may include all or a portion of other structures not explicitly shown in the figures, including but not limited to a unitary mattress or mattress cover, a mattress including two or more layers of TC foam in contact with each other, which may be composed of the same or different TC foam materials, and the like. TC foam may be used in conjunction with a pocket coil or spring seat. They may be incorporated into structures that use elastomeric layers in combination with TC foam layers. CNC cut layers (non-planar or lath-like textures) may also be added as TC foam layers.

Fig. 7 is a sixth exemplary configuration for use with a mattress and/or a mattress application. The base portion is a bottom foam layer (prime foam layer) 3. The upper portion is a 3 inch (7.6 cm) layer of TC foam 1. The interface 4 between the two layers exhibits a non-planar curl which may be achieved by rolling the surface of one or both interface layers.

FIG. 8 is a seventh exemplary configuration for use with a mat and/or mat application. The base part is a bottom foam layer 3. On top of this was a 2 inch (5 cm) layer of TC bubbles 1. The interface 4 between the two layers exhibits a non-planar curl which may be achieved by rolling the surface of one or both interface layers. The top of this example is a 2 inch (5 cm) standard, open cell viscoelastic foam layer 2.

FIG. 9 is an eighth exemplary configuration for use with a mat and/or mat application. The base part is a bottom foam layer 3. Above which is a 2 inch (5 cm) layer 2 of standard, open cell viscoelastic foam. The upper portion is a 2 inch (5 cm) layer of TC foam 1. The interface 4 between the two layers exhibits a non-planar curl which may be achieved by rolling the surface of one or both interface layers.

Fig. 10 is a ninth exemplary configuration for use with a mattress and/or a mattress application. The base part is a bottom foam layer 3. Above it is a 2 inch (5 cm) layer of TC foam 1. On top of this is another 2 inch (5 cm) layer of TC foam 1. The interface 4 between the two layers exhibits a non-planar curl which may be achieved by rolling the surface of one or both interface layers.

Fig. 11 is an exemplary exploded view of a lateral mattress area or section in mattress 110. These areas include: a lower body region or portion 112, a torso/"belly band" region or portion 114, and head and shoulder regions or portions 116. These regions or portions may or may not include TC foam, exemplary structures, other mattress layer structures, or any variation thereof. Furthermore, the regions shown are not limiting, but serve as examples to illustrate the possibility of utilizing an enhanced heat dissipation layer in specific regions of the cushion and/or mattress.

Fig. 12 is an exemplary exploded view of longitudinal mattress sections 122 and 124 in mattress 120. These regions include a left portion 122 and a right portion 124. These regions or portions 122 and 124 may or may not include TC foam, exemplary structures, other mattress layer structures, or any variation thereof. Furthermore, the regions shown are not limiting, but serve as examples to illustrate the possibility of utilizing an enhanced heat dissipation layer in specific regions of the cushion and/or mattress.

Fig. 11 and 12 are intended to illustrate the use of TC foam in different areas of the mattress to enhance thermal conductivity in specific areas. They should not be construed as limiting design drawings. The exact configuration of these zoned TC foams will depend on the purpose of the mattress structure.

Fig. 13 and 14 are schematic views of a molded pillow system. Fig. 13 is a pillow 130 molded entirely from TC foam 1, while fig. 14 shows a pillow 140 that uses TC foam 1 as a region within the overall pillow structure 2.

Fig. 15 depicts TC foam used in a wheelchair seat cushion 150.

The invention will now be further described with respect to specific formulations, methods and compositions herein to further illustrate the invention, but these examples are not intended to limit the methods and compositions herein in any way.

Example I

Two-component systems are available from Peterson Chemical Technology, Peterson Chemical Technology. The system consists of a "B" side component (PCT-M142B) containing polyol, surfactant, blowing and gelling catalyst and water, and an "A" side component (PCT-M142A) consisting of isocyanate compounds. A premix was made by combining 103.5 parts of the "B" side ingredients with 10 parts of aluminum metal additive particles LCF-1 (average particle size of about 200 microns) obtained from petersen chemical technology in a 32 ounce (0.95L) mixing cup. These ingredients were mixed for about 45 seconds, then 43.21 parts of "a" side ingredient was added, mixed for another 10 seconds, poured into a 9 "× 9" (23 cm × 23 cm) pastry box (cake box), foamed and cured at room temperature. Aluminum metal material was randomly dispersed throughout the foam structure to produce a flexible polyurethane foam. Physical properties such as density, IFD, and air flow are measured. Further, by following the ASTM E1225 standard for measurement, a measurement value of the static thermal conductivity was obtained.

The control foam was produced by the same procedure, but 10 parts of LCF-1 aluminum metal material was omitted. This foam was tested by the same procedure and used as a comparative control for TC foams.

Example II

Two-component systems are available from petersen chemical technology. The system consists of a "B" side component (PCT-MCFB) containing polyol, surfactant, blowing and gelling catalyst and water, and an "A" side component (PCT-MCFA) consisting of isocyanate compounds. A premix was made by combining 100 parts of the "B" side ingredients with 10 parts of copper wire available from peterson chemical technology in a 32 ounce (0.95L) mixing cup. These ingredients were mixed for about 45 seconds, then 46.08 parts of the "a" side ingredient was added, mixed for another 10 seconds, and poured into a 9 "x 9" (23 cm x 23 cm) pastry box, allowed to foam and cure in a room temperature environment. The copper wires were randomly dispersed throughout the foam structure to produce a flexible polyurethane foam. Physical properties such as density, IFD, and air flow are measured. Further, by following the ASTM E1225 standard for measurement, a measurement value of static thermal conductivity was also obtained.

The control foam was produced by the same procedure, but 10 parts of the copper wire were omitted. This foam was tested by the same procedure and used as a comparative control for TC foams.

Discussion of results

Table 1 shows the formulations and test results for two foams produced according to the procedure of example I. The results show a 27.2% increase in thermal conductivity (static TC) from 0.0478W/(m- ° K) to 0.0608W/(m- ° K) for the control foam. Fig. 16 is a black and white photograph of the TC foam produced in example I, with aluminum metal particles added to the open-cell flexible polyurethane foam. In contrast to the relatively light background foam color, the color of the aluminum metal particles appears black.

Table 2 shows the formulations and test results for two foams produced by following the procedure of example II. The results showed a 41.1% increase in thermal conductivity (static TC) from 0.0511W/(m- ° K) to 0.0721W/(m- ° K) for the control foam.

TABLE 1 comparison of formulations and Properties of TC foam and control foam in example I

Material	Measurement Unit	Control	Example I
				Component on the "B" side	Parts by weight	103.5	103.5
"A" side component	Parts by weight	43.21	43.21
				LCF-1	Parts by weight	0	10
				Density of	lbs/ft3(kg/m3)	3.45(55.3kg/m3)	3.62(58.0kg/m3)
IFD	lbf/50in2(N)	9.1(41N)	8.7(39N)
				Air flow rate	SCFM	4.94	4.30
Static TC	W/(m-°K)	0.0478	0.0608

TABLE 2 comparison of formulations and Properties of TC foam and control foam in example II

Material	Measurement Unit	Control	Example II
				Component on the "B" side	Parts by weight	100	100
"A" side component	Parts by weight	46.08	46.08
				Copper wire	Parts by weight	0	10
				Density of	lbs/ft3(kg/m3)	3.13(50.1)	3.45(55.3)
IFD	lbf/50in2(N)	10.1(45N)	12.4(55N)
				Air flow rate	SCFM	4.14	3.93
Static TC	W/(m-°K)	0.0511	0.0721

Various modifications may be made in the method and implementation of the invention without departing from the spirit and scope defined only in the appended claims. For example, it is contemplated that various combinations of phase change materials or phase change additives, gels, polyols, isocyanates, catalysts, metallic materials (including the size and shape of the metallic material particles) and other additives other than those specifically mentioned herein, as well as processing pressures and processing conditions, are useful.

The words "include" and "comprise" as used throughout the claims are to be interpreted as "including, but not limited to". The invention can suitably comprise, consist of, or consist essentially of the disclosed ingredients, and can be practiced in the absence of an ingredient not disclosed. In a non-limiting example, a flexible cellular foam having an improved Thermal Conductivity (TC) foam can be provided that consists essentially of or consists of a flexible cellular foam produced by a process that includes or consists essentially of the polymerization of a polyol with a polyisocyanate, and a plurality of metallic material particles dispersed in the flexible cellular foam in an amount effective to improve the thermal conductivity of the flexible cellular foam, and in a non-limiting embodiment in an amount of from about 0.01% to about 25% by weight, wherein the metallic material is any of the group of metallic materials claimed herein, having an average particle size in a range of from about 0.1 microns to about 2000 microns.

Alternatively, a Thermally Conductive (TC) latex foam may consist essentially of or consist of a crosslinked latex foam and a plurality of metallic material particles dispersed in the crosslinked latex foam in an amount effective to improve the thermal conductivity of the crosslinked latex foam, such TC latex foam having an improved thermal conductivity as compared to an otherwise identical latex foam absent the metallic material particles, wherein the improved thermal conductivity is at least 0.002W/(m- ° K) higher as compared to the crosslinked latex foam absent the metallic material particles. It is contemplated that the proportions, sizes and types of metallic material particles discussed above are equally applicable to latex foams.

It is also possible to provide a Thermally Conductive (TC) melamine foam consisting essentially of or consisting of a cross-linked melamine foam and a plurality of particles of a metallic material dispersed in the cross-linked melamine foam in an amount effective to improve the thermal conductivity of the cross-linked melamine foam, wherein the TC melamine foam has an improved thermal conductivity compared to an otherwise identical melamine foam having no particles of the metallic material, wherein the improved thermal conductivity is at least 0.002W/(m- ° K) higher than that of the cross-linked melamine without the particles of the metallic material. It is contemplated that the proportions, sizes and types of metal material particles discussed above are equally applicable to melamine foam.

As used herein, the terms "comprising," "including," "containing," "characterized by," and grammatically synonymous terms are inclusive or open-ended terms that do not exclude additional, unrecited elements or method acts, but also include the more restrictive terms "consisting of …" and "consisting essentially of …" and grammatically synonymous terms. As used herein, the term "may" in reference to a material, structure, feature, or method action means that the material, structure, feature, or method action described above is intended to be used in the practice of an embodiment of the disclosure and that the term takes precedence over the more restrictive term "is" to avoid that any implication of other compatible materials, structures, features, and methods that may be used in combination therewith should be or must be excluded.

As used herein, the singular forms "a", "an" and "the" are intended to include the plural forms as well, unless the context clearly indicates otherwise.

As used herein, the term "and/or" includes any and all combinations of one or more of the associated listed items. As used herein, the term "about" with respect to a given parameter encompasses the numerical value described and has the meaning indicated above and below (e.g., includes the degree of error associated with measurement of the given parameter).