Polymeric foam powder processing techniques, foam powders products, and foams produced containing those foam powders

Abstract

This relates variously to techniques for comminuting polymeric foams, to techniques for preparing polymeric foams containing that comminuted foam, and to the resulting comminuted foam powder and polymeric foams. The procedures may be used on foams containing production contaminants such as polyolefins, paper, and foam skins and on other foams containing consumer contaminants such as wood, metal, leather, etc. The comminuted foam powder, with or without contaminants, preferably is screened or sifted to obtain a foam powder having a particle size of about 2 mm or less.

1 - 95 . (canceled)  
     
     
         96 . A powder having a maximum particle size of 2 mm, comprising a contaminant powder of a contaminant and at least 5% by weight of a comminuted polyurethane foam powder, wherein the contaminant is selected from the group consisting of polymer sheeting, and paper, further wherein the comminuted polyurethane foam powder is a powder of flexible reversibly deformable foam having a majority of open cells.  
     
     
         97 . The powder of  claim 96  containing substantially no rigid polyurethane foam.  
     
     
         98 . The powder of  claim 96  containing said contaminants in the range from about 0.1% to about 75% by weight.  
     
     
         99 . The powder of  claim 96  containing said contaminants in the range from about 0.5% to about 75% by weight.  
     
     
         100 . The powder of  claim 96  wherein said comminuted polyurethane foam powder has been comminuted from polyurethane foam having cells with cell walls.  
     
     
         101 . The powder of  claim 100  wherein said comminuted polyurethane foam powder has substantially no remaining cells.  
     
     
         102 . The powder of  claim 96  having a particle size ranging from about 0.001 mm to about 2 mm.  
     
     
         103 . The powder of  claim 96  having a particle size ranging from about 0.001 mm to about 0.25 mm.  
     
     
         104 . The powder of  claim 96  having a particle size ranging from about 0.001 mm to about 0.150 mm.  
     
     
         105 . The powder of  claim 96  having a particle size ranging from about 0.001 mm to about 0.045 mm.  
     
     
         106 . The powder of  claim 96  having a particle size ranging from about 0.001 mm to about 0.020 mm.  
     
     
         107 . The powder of  claim 96  having a particle size ranging from about 0.001 mm to about 0.010 mm.  
     
     
         108 . The powder of  claim 96  wherein the contaminated polymeric foam comprises polyurethane foam that is contaminated with polyurethane foam skins.  
     
     
         109 . The powder of  claim 96  wherein the contaminated polymeric foam comprises polyurethane foam that is contaminated with polymeric sheet.  
     
     
         110 . The powder of  claim 109  wherein the polymeric sheet comprises a polymer selected from polyethylene, polypropylene, and polystyrene.  
     
     
         111 . The powder of  claim 110  wherein the polymeric sheet comprises polyethylene.  
     
     
         112 . The powder of  claim 111  wherein the polymeric sheet comprises polyethylene with a softening point less than about 135° C.  
     
     
         113 . The powder of  claim 96  wherein the contaminated polymeric foam comprises polyurethane foam that is contaminated with paper.  
     
     
         114 . The powder of  claim 96  consisting essentially of comminuted polyurethane and polyurethane foam skins having a size between 0.001 mm and about 2 mm.  
     
     
         115 . The powder of  claim 114  consisting essentially of particles having a size between 0.001 mm and about 0.25 mm.  
     
     
         116 . The powder of  claim 114  consisting essentially of particles having a size between 0.001 mm and about 0.150 mm.  
     
     
         117 . The powder of  claim 114  consisting essentially of particles having a size between 0.001 mm and about 0.045 mm.  
     
     
         118 . The powder of  claim 114  consisting essentially of particles having a size between 0.001 mm and about 0.020 mm.  
     
     
         119 . The powder of  claim 114  consisting essentially of particles having a size between 0.001 mm and about 0.010 mm.  
     
     
         120 . The powder of  claim 96  consisting essentially of comminuted polyurethane and polymeric sheeting and having a particle size between 0.001 mm and about 2 mm.  
     
     
         121 . The powder of  claim 120  consisting essentially of comminuted polyurethane and polymeric sheeting and having a particle size between 0.001 mm and about 0.25 mm.  
     
     
         122 . The powder of  claim 120  consisting essentially of comminuted polyurethane and polymeric sheeting and having a particle size between 0.001 mm and about 0.150 mm.  
     
     
         123 . The powder of  claim 120  consisting essentially of comminuted polyurethane and polymeric sheeting and having a particle size between 0.001 mm and about 0.045 mm.  
     
     
         124 . The powder of  claim 120  consisting essentially of comminuted polyurethane and polymeric sheeting and having a particle size between 0.001 mm and about 0.020 mm.  
     
     
         125 . The powder of  claim 120  consisting essentially of comminuted polyurethane and polymeric sheeting and having a particle size between 0.001 mm and about 0.010 mm.  
     
     
         126 . The powder of  claim 120  wherein the polymeric sheeting comprises a polymer selected from polyethylene and polypropylene and polystyrene.  
     
     
         127 . The powder of  claim 126  wherein the polymeric sheet comprises polyethylene.  
     
     
         128 . The powder of  claim 127  wherein the polymeric sheet comprises polyethylene with a softening point less than about 135° C.  
     
     
         129 . The powder of  claim 96  consisting essentially of comminuted polyurethane and paper and having a particle size between 0.001 mm and about 2 mm.  
     
     
         130 . The powder of  claim 96  consisting essentially of comminuted polyurethane and paper and having a particle size between 0.001 mm and about 0.25 mm.  
     
     
         131 . The powder of  claim 96  consisting essentially of comminuted polyurethane and paper and having a particle size between 0.001 mm and about 0.150 mm.  
     
     
         132 . The powder of  claim 96  consisting essentially of comminuted polyurethane and paper and having a particle size between 0.001 mm and about 0.045 mm.  
     
     
         133 . The powder of  claim 96  consisting essentially of comminuted polyurethane and paper and having a particle size between 0.001 mm and about 0.020 mm.  
     
     
         134 . The powder of  claim 96  consisting essentially of comminuted polyurethane and paper and having a particle size between 0.001 mm and about 0.010 mm.  
     
     
         135 - 196 . (canceled)  
     
     
         160 . The powder of  claim 96  further comprising a powder of a polyurethane foam skin of said flexible reversibly deformable foam.