Foam element having molded gas passageways and process for production thereof

Abstract

In one of its aspects, the invention relates to a foam element comprising an isocyanate-based foam matrix having surface, at least a portion of the surface comprising at least one channel having a channel surface, the channel surface being coated with a substantially fluid impermeable material. The foam element is particularly useful in a climate-control vehicular (e.g., automobile) seat.

What is claimed is:  
     
         1 . A foam element comprising an isocyanate-based foam matrix having surface, at least a portion of the surface comprising at least one channel having a channel surface, the channel surface being coated with a substantially fluid impermeable material.  
     
     
         2 . The foam element defined in  claim 1 , wherein the foam matrix comprises an isocyanate-based foam matrix.  
     
     
         3 . The foam element defined in  claim 1 , wherein the substantially fluid impermeable coating comprises an elastomeric coating.  
     
     
         4 . The foam element defined in  claim 1 , wherein the substantially fluid impermeable coating comprises a thickness of less than or equal to about 1.5 mm.  
     
     
         5 . The foam element defined in  claim 1 , wherein the substantially fluid impermeable coating comprises a thickness in the range of from about 0.01 mm to about 1.5 mm.  
     
     
         6 . The foam element defined in  claim 1 , wherein the substantially fluid impermeable coating comprises a thickness in the range of from about 0.01 mm to about 1.0 mm.  
     
     
         7 . The foam element defined in  claim 1 , further comprising a passageway in communication with the at least one channel and with another surface of the foam element.  
     
     
         8 . The foam element defined in  claim 7 , wherein the surface comprises at least two channels.  
     
     
         9 . The foam element defined in  claim 8 , wherein the two channels are interconnected by the passageway.  
     
     
         10 . The foam element defined in  claim 7 , wherein the passageway comprises a passageway surface which is coated with a substantially fluid impermeable material.  
     
     
         11 . The foam element defined in  claim 1 , wherein the substantially fluid impermeable material is substantially non-cellular.  
     
     
         12 . The foam element defined in  claim 1 , wherein the substantially fluid impermeable material is produced in situ in a mold used to produce the foam matrix.  
     
     
         13 . The foam element defined in  claim 1 , wherein the substantially fluid impermeable material is derived from an emulsion composition comprising polymer particles.  
     
     
         14 . The foam element defined in  claim 1 , wherein the foam matrix comprises a polyurethane foam.  
     
     
         15 . The foam element defined in  claim 1 , further comprising a diffuser element secured to the foam matrix and covering at least a portion of the at least one channel.  
     
     
         16 . The foam element defined in  claim 1 , further comprising a trim cover over at least the surface of the foam element.  
     
     
         17 . The foam element defined in  claim 1 , further comprising a frame element which is at least partially embedded in the foam matrix.  
     
     
         18 . A vehicular seat comprising the foam element defined in  claim 1 .  
     
     
         19 . A vehicular seat cushion comprising the foam element defined in  claim 1 .  
     
     
         20 . A vehicular seat backrest comprising the foam element defined in  claim 1 .  
     
     
         21 . A vehicular trim element comprising the foam element defined in  claim 1 .  
     
     
         22 . A vehicular headliner element comprising the foam element defined in  claim 1 .  
     
     
         23 . A construction panel comprising the foam element defined in  claim 1 .  
     
     
         24 . A mattress comprising the foam element defined in  claim 1 .  
     
     
         25 . A process for producing a foam element in a mold comprising a first mold half and a second mold, the first mold half comprising at least one ridge element, the first mold half and the second mold half being engageable to define a mold cavity, the process comprising the steps of: 
 (i) substantially completely covering the at least one ridge element with a substantially fluid impermeable material;    (ii) dispensing a liquid foamable composition in at least one of the first mold half and the second mold half;    (iii) closing the first mold half and the second mold half;    (iv) expanding the liquid foamable composition to substantially completely fill the mold cavity to produce the foam element.    
     
     
         26 . The process defined in  claim 25 , wherein the substantially fluid impermeable material comprises an elastomeric coating.  
     
     
         27 . The process defined in  claim 25 , wherein the substantially fluid impermeable material is substantially non-cellular.  
     
     
         28 . The process defined in  claim 25 , wherein Step (i) comprises applying substantially fluid impermeable material at a thickness of less than or equal to about 1.5 mm.  
     
     
         29 . The process defined in  claim 25 , wherein Step (i) comprises applying substantially fluid impermeable material at a thickness in the range of from about 0.01 mm about 1.5 mm.  
     
     
         30 . The process defined in  claim 25 , wherein Step (i) comprises applying substantially fluid impermeable material at a thickness in the range of from about 0.01 mm about 1.0 mm.  
     
     
         31 . The process defined in  claim 25 , wherein Step (i) comprises spraying a liquid material.  
     
     
         32 . The process defined in  claim 25 , wherein the liquid material comprises an emulsion composition comprising particles dispersed in a liquid material.  
     
     
         33 . The process defined in  claim 25 , wherein Step (ii) comprises dispensing the liquid foamable composition in the first mold half.  
     
     
         34 . The process defined in  claim 25 , wherein the second mold half comprises at least one post which substantially abuts with at least a portion of the at least one ridge element when the first mold half and the second mold half are engaged, and Step (i) further comprises substantially completely covering the at least one post with the substantially fluid impermeable material.  
     
     
         35 . The process defined in  claim 25 , wherein the liquid foamable composition comprises an isocyanate-based foam forming reaction mixture.  
     
     
         36 . The process defined in  claim 25 , wherein the liquid foamable composition comprises a polyurethane foam forming reaction mixture.  
     
     
         37 . The process defined in  claim 25 , comprising the further step of securing the a diffuser element to foam element to cover at least a portion of a channel formed by the at least one ridge element.  
     
     
         38 . The process defined in  claim 37 , wherein the securing step is performed during Step (iv).  
     
     
         39 . The process defined in  claim 37 , wherein the securing step is performed after Step (iv).  
     
     
         40 . The process defined in  claim 25 , comprising the further step of securing a trim cover over at least a portion of the foam element.  
     
     
         41 . The process defined in  claim 25 , comprising the further step of applying a mold release agent to one or both of the first mold half and the second mold half.  
     
     
         42 . The process defined in  claim 41 , wherein the mold release agent is applied prior to Step (i).  
     
     
         43 . The process defined in  claim 25 , wherein, prior to Step (iii), a frame element is disposed in at least one of the first mold half and the second mold half.  
     
     
         44 . A mold for producing a foam element, the mold comprising a first mold half and a second mold, the first mold half and the second mold half being engageable to define a mold cavity, the first mold half comprising at least one ridge element and the second mold half comprising at least one post, the least one ridge element and the at least one post oriented to substantially abut one another upon engagement of the first mold half and the second half.