US4265965A — Polyurethane foam articles coated with a crushed …

Claim 1

Independent Claim 61 words

An article of manufacture comprising a polyurethane foam coated with a crushed foam, said crushed foam resulting from application to said polyurethane foam of a foamed polymer emulsion containing a crosslinkable emulsion polymer followed by drying, crushing and curing said foamed polymer emulsion, said crushed foam having incorporated therein one or more of a pigment, a filler, and a flame retardant.

Claim 2

Dependent Claim 61 words

An article of manufacture comprising a polyurethane foam coated with a crushed foam, said crushed foam resulting from application to said polyurethane foam of a foamed polymer emulsion containing a crosslinkable emulsion polymer followed by drying, crushing and curing said foamed polymer emulsion, said crushed foam having incorporated therein one or more of a pigment, a filler, and a flame retardant.

Claim 3

Dependent Claim 39 words

The article of claim 1 wherein the pigment or filler is selected from titanium dioxide, calcium carbonate kaolin, colored lakes and toners, ochre, carbon black, graphite, aluminum powder or flakes, chrome yellow, molybdate orange, toluidine red or copper phthalocyanines.

Claim 4

Dependent Claim 22 words

The article of claim 1 wherein the flame retardant is selected from aluminum trihydrate, zinc borate, ammonium polyphoshate, ammonium sulfamate or tris-2,3-dibromophosphate.

Claim 5

Dependent Claim 16 words

The article of claim 1 wherein the polymer emulsion is prepared from an acrylic emulsion polymer.

Claim 6

Dependent Claim 17 words

The article of claim 1 wherein the polymer emulsion is prepared from a vinyl chloride emulsion polymer.

Claim 7

Dependent Claim 17 words

The article of claim 1 wherein the polymer emulsion is prepared from a vinylidene chloride emulsion polymer.

Claim 8

Dependent Claim 20 words

The article of claim 1 wherein the foam coating is from 30 to 180 mils. in thickness prior to crushing.

Claim 9

Dependent Claim 105 words

The article of claim 1 wherein the emulsion polymer is prepared from at least three of the following monomers: (a) an α, β-ethylenically unsaturated acid; (b) a monomer of the formula ##STR5## wherein R is hydrogen of alkyl and R 1 is straight, branched or cyclic alkyl, alkoxyalkyl or alkylthioalkyl; (c) a monomer of the formula ##STR6## wherein R 2 is hydrogen or methyl and R 3 is hydrogen or hydroxy lower alkyl and (d) a monomer of the formula ##STR7## wherein R 2 is hydrogen or methyl and R 4 is halo, lower alkanoyloxy, cyano, formyl, phenyl, tolyl, methoxyethyl, 2,4-diamino-s-triazinyl lower alkyl or epoxy.

Claim 10

Dependent Claim 44 words

The article of claim 1 wherein the emulsion polymer of the crushed foam has the following composition: (a) 0-3% itaconic acid; (b) 40-97% ethyl acrylate, vinyl or vinylidene chloride; (c) 0.5-10% of an acrylic amide; (d) 0-15% acrylonitrile and (e) 0-60% of butyl acrylate.

Claim 11

Dependent Claim 38 words

The article of claim 1 wherein the emulsion polymer of the crushed foam has the following composition: (a) 0.3-1.5% itaconic acid; (b) 40-70% ethyl acrylate; (c) 2-6% of an acrylic amide; (d) 3-7% acrylonitrile; (e) 20-50% butyl acrylate.

Claim 12

Dependent Claim 38 words

The article of claim 1 wherein the emulsion polymer of the crushed foam contains the following proportion of monomers: (a) 1.5% itaconic acid; (b) 65% ethyl acrylate; (c) 3.5% acrylamide; (d) 4.5% acrylonitrile and (e) 25.5% butyl acrylate.

Claim 13

Dependent Claim 43 words

The article of claim 9 wherein the emulsion polymer of the crushed foam has the following composition: (a) 52.8% vinylidene chloride; (b) 43.3% butyl acrylate; (c) 3.2% of a 1/1 molar ratio of acrylamide and N-methylolacrylamide; (d) 0.4% methacrylamide and (e) 0.3% N-methylolacrylamide.

Claim 14

Dependent Claim 41 words

The article of claim 9 wherein the emulsion polymer of the crushed foam has the following composition: (a) 68.5% vinyl chloride; (b) 29.5% butyl acrylate; (c) 1.5% of a 1/1 molar ratio of acrylamide and N-methylolacrylamide and (d) 0.5% itaconic acid.

Claim 15

Dependent Claim 91 words

A process for preparing an article of manufacture which comprises coating a polyurethane foam with a foamed polymer emulsion containing an emulsion polymer and one or more of a pigment, a filler and a flame retardant, drying the polymer emulsion foam at a temperature in the range of from about 180° to about 280° F. for a period of time ranging from 2 up to about 10 minutes followed by crushing, embossing, and curing the coated substrate at a pressure in the range of from about 5 to about 2500 p.s.i.

Claim 16

Dependent Claim 91 words

A process for preparing an article of manufacture which comprises coating a polyurethane foam with a foamed polymer emulsion containing an emulsion polymer and one or more of a pigment, a filler and a flame retardant, drying the polymer emulsion foam at a temperature in the range of from about 180° to about 280° F. for a period of time ranging from 2 up to about 10 minutes followed by crushing, embossing, and curing the coated substrate at a pressure in the range of from about 5 to about 2500 p.s.i.

Claim 17

Dependent Claim 106 words

The process according to claim 14 wherein the emulsion polymer is prepared from at least three of the following monomers: (a) an α, β-ethylenically unsaturated acid; (b) a monomer of the formula ##STR8## wherein R is hydrogen of alkyl and R 1 is straight, branched or cyclic alkyl, alkoxyalkyl or alkylthioalkyl; (c) a monomer of the formula ##STR9## wherein R 2 is hydrogen or methyl and R 3 is hydrogen or hydroxy lower alkyl and (d) a monomer of the formula ##STR10## wherein R 2 is hydrogen or methyl and R 4 is halo, lower alkanoyloxy, cyano, formyl, phenyl, tolyl, methoxyethyl, 2,4-diamino-s-triazinyl lower alkyl or epoxy.

Claim 18

Dependent Claim 40 words

The process of claim 15 wherein the emulsion polymer has the following composition: (a) 0-3% itaconic acid; (b) 40-97% ethyl acrylate, vinyl or vinylidene chloride; (c) 0.5-10% of an acrylic amide; (d) 0-15% acrylonitrile and (e) 0-60% of butyl acrylate.

Claim 19

Dependent Claim 34 words

The process of claim 15 wherein the emulsion polymer has the following composition: (a) 0.3-1.5% itaconic acid; (b) 40-70% ethyl acrylate; (c) 2-6% of an acrylic amide; (d) 3-7% acrylonitrile; (e) 20-50% butyl acrylate.

Claim 20

Dependent Claim 32 words

The process of claim 15 wherein the emulsion polymer has the following composition: (a) 1.5% itaconic acid; (b) 65% ethyl acrylate; (c) 3.5% acrylamide; (d) 4.5% acrylonitrile and (e) 25.5% butyl acrylate.

Claim 21

Dependent Claim 39 words

The process of claim 15 wherein the emulsion foam has the following composition: (a) 52.8% vinylidene chloride; (b) 43.3% butyl acrylate; (c) 3.2% of a 1/1 molar ratio of acrylamide and N-methylolacrylamide; (d) 0.4% methacrylamide and (e) 0.3% N-methylolacrylamide.

Claim 22

Dependent Claim 37 words

The process of claim 15 wherein the emulsion foam has the following composition: (a) 68.5% vinyl chloride; (b) 29.5% butyl acrylate; (c) 1.5% of a 1/1 molar ratio of acrylamide and N-methylolacrylamide and (d) 0.5% itaconic acid.

Claim 23

Dependent Claim 10 words

An acoustical panel formed from the article of claim 1.

Claim 24

Independent Claim 180 words

A method for producing a composite building material having a continuously textured surface, comprising: a. providing (i) a foamed emulsion of an uncured and uncrosslinked elastomeric resin composition and (ii) a self-supporting resilient urethane foam substrate; b. disposing said foamed elastomeric resin composition onto a surface of said urethane substrate to form a substantially uniform coating of predetermined thickness on the substrate, said thickness being such as to permit the irregular cell structure of the underlying urethane substrate to affect the exposed surface of the elastomeric layer in the subsequent step (d) so that after the composite structure is fully processed said textured surface is formed therein; c. drying said elastomeric resin foam coating until said elastomeric resin foam forms a layer which is only partially cured and partially crosslinked; d. crushing said composite structure so that said partially cured elastomeric layer is densified, the resultant partial compression of the elastomeric foam creating a continuous texture on the exposed surface thereof; and e. further curing said textured elastomeric layer to hold said textured surface and forming said composite building material.

Claim 25

Independent Claim 180 words

A method for producing a composite building material having a continuously textured surface, comprising: a. providing (i) a foamed emulsion of an uncured and uncrosslinked elastomeric resin composition and (ii) a self-supporting resilient urethane foam substrate; b. disposing said foamed elastomeric resin composition onto a surface of said urethane substrate to form a substantially uniform coating of predetermined thickness on the substrate, said thickness being such as to permit the irregular cell structure of the underlying urethane substrate to affect the exposed surface of the elastomeric layer in the subsequent step (d) so that after the composite structure is fully processed said textured surface is formed therein; c. drying said elastomeric resin foam coating until said elastomeric resin foam forms a layer which is only partially cured and partially crosslinked; d. crushing said composite structure so that said partially cured elastomeric layer is densified, the resultant partial compression of the elastomeric foam creating a continuous texture on the exposed surface thereof; and e. further curing said textured elastomeric layer to hold said textured surface and forming said composite building material.

Claim 26

Dependent Claim 10 words

A product produced according to the method of claim 22.

Claim 27

Dependent Claim 55 words

A composite building material having a continuously textured surface comprising: (a) a resilient urethane foam substrate; and (b) a cured elastomeric layer adjacent to and embedded in the cells of one surface of said substrate, said elastomeric layer having an exposed surface with a texture which approximates the cellular structure of the adjacent substrate surface.

Claim 28

Dependent Claim 55 words

A composite building material having a continuously textured surface comprising: (a) a resilient urethane foam substrate; and (b) a cured elastomeric layer adjacent to and embedded in the cells of one surface of said substrate, said elastomeric layer having an exposed surface with a texture which approximates the cellular structure of the adjacent substrate surface.

Annuity Stage	Window Opens	Payment Deadline	Surcharge Period Until	Estimated Fee	Status
3.5 Years (Year 4)	1984-05-04	1984-11-03	1985-05-05	$2000.00	Window Closed / Lapsed
7.5 Years (Year 8)	1988-05-04	1988-11-03	1989-05-05	$3760.00	Window Closed / Lapsed
11.5 Years (Year 12)	1992-05-04	1992-11-03	1993-05-05	$7700.00	Window Closed / Lapsed

Polyurethane foam articles coated with a crushed foam and method of producing

Abstract

Inventors

Bibliographic Details

Claims Analysis

References Cited (Backward Citations)

USPTO Annuity & Maintenance Windows

Assigned Categories & Tags

Assign Category Tag