US 11,926,137 B2
Composite foam article
David M. Begg, Etobicoke (CA); Kevin Liping Dong, Woodbridge (CA); Dorota Ulman, Mississauga (CA); Scott D. Wheeler, Stoney Creek (CA); and Le-Cheng Jimmy Lin, Vaughan (CA)
Assigned to Proprietect L.P., Toronto (CA)
Appl. No. 17/278,859
Filed by Proprietect L.P., Toronto (CA)
PCT Filed Sep. 25, 2019, PCT No. PCT/IB2019/058147
§ 371(c)(1), (2) Date Mar. 23, 2021,
PCT Pub. No. WO2020/065561, PCT Pub. Date Apr. 2, 2020.
Claims priority of provisional application 62/845,477, filed on May 9, 2019.
Claims priority of provisional application 62/736,292, filed on Sep. 25, 2018.
Prior Publication US 2022/0032577 A1, Feb. 3, 2022
Int. Cl. B32B 5/24 (2006.01); B29C 43/00 (2006.01); B29C 43/20 (2006.01); B29C 51/00 (2006.01); B29C 51/16 (2006.01); B29C 51/42 (2006.01); B32B 1/02 (2006.01); B32B 5/02 (2006.01); B32B 5/18 (2006.01); B32B 9/02 (2006.01); B32B 9/04 (2006.01); B32B 27/06 (2006.01); B32B 27/08 (2006.01); B32B 27/12 (2006.01); B32B 27/16 (2006.01); B32B 27/30 (2006.01); B32B 27/32 (2006.01); B32B 37/04 (2006.01); B32B 37/06 (2006.01); B32B 37/10 (2006.01); B32B 37/18 (2006.01); B60N 2/90 (2018.01); B29K 23/00 (2006.01); B29K 75/00 (2006.01); B29K 105/04 (2006.01); B29K 309/08 (2006.01); B29L 9/00 (2006.01); B60R 13/02 (2006.01)
CPC B32B 5/245 (2013.01) [B29C 43/003 (2013.01); B29C 43/203 (2013.01); B29C 51/004 (2013.01); B29C 51/16 (2013.01); B29C 51/421 (2013.01); B32B 1/02 (2013.01); B32B 5/022 (2013.01); B32B 5/024 (2013.01); B32B 5/028 (2013.01); B32B 5/18 (2013.01); B32B 9/025 (2013.01); B32B 9/046 (2013.01); B32B 27/065 (2013.01); B32B 27/08 (2013.01); B32B 27/12 (2013.01); B32B 27/16 (2013.01); B32B 27/304 (2013.01); B32B 27/308 (2013.01); B32B 27/32 (2013.01); B32B 37/04 (2013.01); B32B 37/06 (2013.01); B32B 37/10 (2013.01); B32B 37/185 (2013.01); B60N 2/90 (2018.02); B29K 2023/08 (2013.01); B29K 2023/12 (2013.01); B29K 2075/00 (2013.01); B29K 2105/04 (2013.01); B29K 2309/08 (2013.01); B29K 2995/0077 (2013.01); B29L 2009/00 (2013.01); B32B 2260/021 (2013.01); B32B 2260/023 (2013.01); B32B 2260/046 (2013.01); B32B 2262/101 (2013.01); B32B 2264/108 (2013.01); B32B 2264/303 (2020.08); B32B 2264/307 (2020.08); B32B 2266/0278 (2013.01); B32B 2270/00 (2013.01); B32B 2305/022 (2013.01); B32B 2305/026 (2013.01); B32B 2305/076 (2013.01); B32B 2305/08 (2013.01); B32B 2305/28 (2013.01); B32B 2305/38 (2013.01); B32B 2307/10 (2013.01); B32B 2307/54 (2013.01); B32B 2307/718 (2013.01); B32B 2307/72 (2013.01); B32B 2307/724 (2013.01); B32B 2307/732 (2013.01); B32B 2309/02 (2013.01); B32B 2309/105 (2013.01); B32B 2310/0445 (2013.01); B32B 2313/04 (2013.01); B32B 2315/085 (2013.01); B32B 2323/04 (2013.01); B32B 2323/10 (2013.01); B32B 2333/08 (2013.01); B32B 2375/00 (2013.01); B32B 2439/02 (2013.01); B32B 2605/003 (2013.01); B32B 2605/08 (2013.01); B60R 13/0212 (2013.01)] 16 Claims
OG exemplary drawing
 
1. A composite foam article comprising:
a polyurethane foam core presenting a first surface and a second surface facing opposite said first surface, said polyurethane foam core having a density of from 45 to 80 kg/m3, and having a compression force deflection at 10% deflection of from 10 to 110 psi when measured in accordance with ASTM 3574-D;
a first skin which is porous and disposed on said first surface, said first skin comprising a plurality of fibers, a polymeric binder, and a polyolefin powder in addition to said polymeric binder of said first skin;
a second skin which is porous and disposed on said second surface, said second skin comprising a plurality of fibers, a polymeric binder, and a polyolefin powder in addition to said polymeric binder of said second skin;
a first additional layer comprising an ethylene and acrylic acid (“EAA”) copolymer and disposed between said first surface of said polyurethane foam core and said first skin; and
a second additional layer comprising an EAA copolymer and disposed between said second surface of said polyurethane foam core and said second skin;
wherein said composite foam article has a post-compression thickness of from 1.5 to 5 mm and a strength of greater than 17 N at a post-compression thickness of greater than 2 mm when tested in accordance with SAE J949 at 23° C.