Preparation of expanded flexible polyurethane foam micro-bits

Claim 1

The method of preparing, from pieces of flexible polyurethane foam, micro-bits of flexible polyurethane foam which show under magnification (a) broken and inter-connected strand portions from adjacent cells of said flexible foam; (b) said broken and inter-connected strand portions being tripodal particles with generally uneven length legs; (c) said strand portions having hook-like projections, indentations and flutes extending therefrom, said hook-like projections, indentations and flutes having been formed by the destruction of the cell windows of said flexible foam; and (d) said strand portions being characterized by a substantially total absence of intact cell windows, which method comprises feeding into a confined comminuting zone having a feed inlet and including a plurality of rotatable impact surfaces spaced apart from one another pieces of flexible polyurethane foam and a cooling fluid inert to the flexible polyurethane foam; repeatedly impelling the polyurethane foam pieces in the cooling fluid through a circular path by rotating said impact surfaces at from about 4700 to about 8000 revolutions per minute and thus by said impact surfaces driving said polyurethane foam pieces against corner-shaped edges of a plurality of orifices arranged in arcuate screening array in said comminuting zone, said orifices being from substantially circular ranging from about 0.102 to about 3.175 millimeters in diameter, to substantially rectangular, ranging from about 0.254 to about 3.175 millimeters in width and from about 3.81 to about 12.7 millimeters in length, thereby comminuting said pieces of flexible polyurethane foam and providing micro-bits of the flexible polyurethane foam; said cooling fluid being provided in an amount sufficient to maintain the temperature in the comminuting zone below that at which degradation of said flexible polyurethane foam would occur.

Claim 2

The method of preparing, from pieces of flexible polyurethane foam, micro-bits of flexible polyurethane foam which show under magnification (a) broken and inter-connected strand portions from adjacent cells of said flexible foam; (b) said broken and inter-connected strand portions being tripodal particles with generally uneven length legs; (c) said strand portions having hook-like projections, indentations and flutes extending therefrom, said hook-like projections, indentations and flutes having been formed by the destruction of the cell windows of said flexible foam; and (d) said strand portions being characterized by a substantially total absence of intact cell windows, which method comprises feeding into a confined comminuting zone having a feed inlet and including a plurality of rotatable impact surfaces spaced apart from one another pieces of flexible polyurethane foam and a cooling fluid inert to the flexible polyurethane foam; repeatedly impelling the polyurethane foam pieces in the cooling fluid through a circular path by rotating said impact surfaces at from about 4700 to about 8000 revolutions per minute and thus by said impact surfaces driving said polyurethane foam pieces against corner-shaped edges of a plurality of orifices arranged in arcuate screening array in said comminuting zone, said orifices being from substantially circular ranging from about 0.102 to about 3.175 millimeters in diameter, to substantially rectangular, ranging from about 0.254 to about 3.175 millimeters in width and from about 3.81 to about 12.7 millimeters in length, thereby comminuting said pieces of flexible polyurethane foam and providing micro-bits of the flexible polyurethane foam; said cooling fluid being provided in an amount sufficient to maintain the temperature in the comminuting zone below that at which degradation of said flexible polyurethane foam would occur.

Claim 4

The method as claimed in claims 1 or 2, wherein the cooling fluid or cooling water is fed at a rate and temperature to maintain the polyurethane below 149° C.