Surface Infusion of Flexible Cellular Foams With Novel Liquid Gel Mixture

Abstract

Compositions and methods for making a novel liquid gel mixture comprising at least one flexible polymer carrier, parachlorobenzotrifluoride, optional thermally-conductive materials, and optional performance-enhancing additives; using the liquid gel mixture for making surface-infused layers on layering substrates; and using combinations of surface-infused gel layer and layering substrate in cushioning foams and mattresses. Layering substrates are surface-infused with a liquid gel mixture and may be compressed to increase the penetration depth of liquid gel mixture into the substrate layer surface. This compositions may be used in mattresses, mattress topper pads, pillows, bedding products, furniture upholstery, pet beds, medical cushioning foams, seat cushions and backs, automotive foam, sports cushioning, transportation cushioning, headrests, arm rests, personal protective equipment, toys, and the like.

What is claimed is: 
     
         1 . A liquid gel mixture comprising at least one flexible polymeric carrier solvated in parachlorobenzotrifluoride (PCBTF). 
     
     
         2 . The liquid gel mixture of  claim 1  in the absence of toluene. 
     
     
         3 . The liquid gel mixture of  claim 1  further comprising PCBTF in the range of about 0.1% to about 99% by weight of the liquid gel mixture. 
     
     
         4 . The liquid gel mixture of  claim 1  further comprising PCBTF in the range of about 5% to about 75% by weight of the liquid gel mixture. 
     
     
         5 . The liquid gel mixture of  claim 1  where the at least one flexible polymeric carrier is selected from a group consisting of gelatinous A-B-A tri-block copolymer elastomers, thermoplastic polyurethane elastomers, thermoplastic polyester elastomers, latex elastomers, neoprene elastomers, and combinations thereof. 
     
     
         6 . The liquid gel mixture of  claim 5  wherein the gelatinous A-B-A tri-block copolymer elastomer comprises an A-B-A tri-block copolymer resin selected from the group consisting of styrene-ethylene-butylene-styrene (SEBS), styrene-ethylene-propylene-styrene (SEPS), styrene-ethylene-ethylene-propylene-styrene (SEEPS), styrene-butadiene-styrene (SBS), styrene-isoprene-styrene (SIS) and combinations thereof. 
     
     
         7 . The liquid gel mixture of  claim 1  further comprising a highly thermally-conductive material in the range of about 0.1% to about 95% by weight of the liquid gel mixture. 
     
     
         8 . The liquid gel mixture of  claim 1  further comprising a highly thermally-conductive material that is in solid form and has a thermal conductivity from about 100 W/(m-° K) to about 3500 W/(m-° K). 
     
     
         9 . The liquid gel mixture of  claim 1  further comprising a highly thermally-conductive material selected from the group consisting of natural flake graphite, powder graphite, graphene, synthetic graphite, graphite-based particulates, aluminum nitride, diamond, diamond crystal powder, natural diamond crystal powder, type IIa diamond powder, carbanado “Black Diamond”, silicon carbide, boron nitride, aluminum flakes or powder, copper flakes or powder, metallic flakes, and combinations thereof. 
     
     
         10 . The liquid gel mixture of  claim 7  wherein the liquid gel mixture is formed by compounding the at least one flexible polymeric carrier, the PCBTF, the at least one highly thermally-conductive material, and at least one performance-enhancing additive selected from the group consisting of plasticizers, solid fillers, phase change materials, microencapsulated phase change materials, colorants, solvents, antioxidants, anti-static agents, anti-microbial agents, liquid flame retardants, solid flame retardants, ultraviolet stabilizers, surface tension modifiers, emulsifying agents, surfactants, fragrances, blowing catalysts, gelation catalysts, and combinations thereof. 
     
     
         11 . The liquid gel mixture of  claim 1  further comprising a phase change material having a solid/liquid phase transition temperature from about 20° C. to about 35° C. and which is present in the liquid gel mixture in the range of about 5% to about 80% by weight of the liquid gel mixture after solvent loss. 
     
     
         12 . A liquid gel mixture comprising:
 at least one gelatinous A-B-A tri-block copolymer resin selected from the group consisting of styrene-ethylene-butylene-styrene (SEBS), styrene-ethylene-propylene-styrene (SEPS), styrene-ethylene-ethylene-propylene-styrene (SEEPS), styrene-butadiene-styrene (SBS), styrene-isoprene-styrene (SIS) and combinations thereof; and   parachlorobenzotrifluoride (PCBTF) in the range of about 0.1% to about 99% by weight of the liquid gel mixture.   
     
     
         13 . A liquid gel mixture comprising:
 styrene-ethylene-butylene-styrene (SEBS); and   parachlorobenzotrifluoride (PCBTF) in the range of about 0.1% to about 99% by weight of the liquid gel mixture.   
     
     
         14 . A liquid gel mixture comprising:
 styrene-ethylene-propylene-styrene (SEPS), and   parachlorobenzotrifluoride (PCBTF) in the range of about 0.1% to about 99% by weight of the liquid gel mixture.   
     
     
         15 . A liquid gel mixture comprising:
 styrene-ethylene-ethylene-propylene-styrene (SEEPS); and   parachlorobenzotrifluoride (PCBTF) in the range of about 0.1% to about 99% by weight of the liquid gel mixture.   
     
     
         16 . A surface-infused layering substrate comprising:
 at least one layering substrate having a surface, where the surface is at least partially infused with at least one cured flexible gel polymeric carrier layer.   
     
     
         17 . The surface-infused layering substrate of  claim 16  where the at least one cured flexible gel polymeric carrier layer is produced by a method comprising:
 solvating at least one flexible polymeric carrier in parachlorobenzotrifluoride (PCBTF) to give a liquid gel mixture; and 
 coating the layering substrate with the liquid gel mixture. 
 
     
     
         18 . The surface-infused gel layer of  claim 16  wherein the at least one cured flexible gel polymeric carrier layer is formed from a flexible polymeric carrier selected from the group consisting of gelatinous A-B-A tri-block copolymer elastomers, thermoplastic polyurethane elastomers, thermoplastic polyester elastomers, latex elastomers, neoprene elastomers, and combinations thereof. 
     
     
         19 . The surface-infused gel layer of  claim 18  wherein the gelatinous A-B-A tri-block copolymer elastomer comprises an A-B-A triblock copolymer resin selected from the group consisting of styrene-ethylene-butylene-styrene (SEBS), styrene-ethylene-propylene-styrene (SEPS), styrene-ethylene-ethylene-propylene-styrene (SEEPS), styrene-butadiene-styrene (SBS), styrene-isoprene-styrene (SIS) and combinations thereof. 
     
     
         20 . The surface-infused layering substrate of  claim 16  further comprising at least one highly thermally-conductive material present in the range of about 0.1% to about 95% by weight of the surface-infused layering substrate after solvent loss. 
     
     
         21 . The surface-infused layering substrate of  claim 16  wherein at least one highly thermally-conductive material is in solid form and has a thermal conductivity from about 100 W/(m-° K) to about 3500 W/(m-° K). 
     
     
         22 . The surface-infused layering substrate of  claim 16  wherein at least one highly thermally-conductive material is selected from the group consisting of natural flake graphite, powder graphite, graphene, synthetic graphite, graphite-based particulates, aluminum nitride, diamond, diamond crystal powder, natural diamond crystal powder, type IIa diamond powder, carbanado “Black Diamond”, silicon carbide, boron nitride, aluminum flakes or powder, copper flakes or powder, metallic flakes, and combinations thereof. 
     
     
         23 . The surface-infused layering substrate of  claim 16  wherein the at least one cured flexible gel polymeric carrier layer is formed by compounding together at least one flexible polymeric carrier and parachlorobenzotrifluoride (PCBTF), and at least one highly thermally-conductive material. 
     
     
         24 . The surface-infused layering substrate of  claim 16  where the compounding additionally comprises compounding at least one performance-enhancing additive selected from the group consisting of plasticizers, solid fillers, phase change materials, microencapsulated phase change materials, colorants, solvents, antioxidants, anti-static agents, anti-microbial agents, liquid flame retardants, solid flame retardants, ultraviolet stabilizers, surface tension modifiers, emulsifying agents, surfactants, fragrances, blowing catalysts, gelation catalysts, and combinations thereof. 
     
     
         25 . The surface-infused layering substrate of  claim 16  wherein the at least one cured flexible gel polymeric carrier layer is produced by a method comprising, not necessarily in this order:
 making a liquid gel mixture by solvating at least one flexible polymeric carrier in the parachlorobenzotrifluoride (PCBTF) solvent; 
 infusing at least a portion of the liquid gel mixture into at least one layering substrate to give a product having a surface-infused gel layer on the layering substrate; and 
 at least partially removing the PCBTF solvent from the product. 
 
     
     
         26 . The surface-infused layering substrate of  claim 25  where the method further comprises compressing the product of the at least one layering substrate and liquid gel mixture to produce the at least one cured flexible gel polymeric carrier layer on the layering substrate. 
     
     
         27 . The surface-infused layering substrate of  claim 25  where the method further comprises introducing at least one highly thermally-conductive material into the flexible polymeric carrier; 
     
     
         28 . The surface-infused layering substrate of  claim 16  wherein the at least one layering substrate is selected from the group consisting of open-celled polyether polyurethane foam, partially open-celled polyether polyurethane foam, reticulated polyurethane foam, high-resiliency polyether polyurethane foam, open-celled viscoelastic polyether polyurethane foam, partially open-celled viscoelastic polyether polyurethane foam, open-celled polyester polyurethane foam, partially open-celled polyester polyurethane foam, open-celled polyester foam, partially open-celled polyester foam, latex foam, melamine foam, and combinations thereof. 
     
     
         29 . The surface-infused layering substrate of  claim 16  wherein the at least one cured flexible gel polymeric carrier layer is infused into a single layering substrate and is subsequently attached to the at least one additional layering substrate. 
     
     
         30 . A cushion foam comprising the surface-infused layering substrate of  claim 16 , where the surface-infused layering substrate is produced by a method comprising solvating a flexible polymeric carrier in parachlorobenzotrifluoride (PCBTF) before coating the layering substrate to give the surface-infused layering substrate. 
     
     
         31 . A mattress comprising the surface-infused layering substrate of  claim 16 , where the surface-infused layering substrate is produced by a method comprising solvating a flexible polymeric carrier in parachlorobenzotrifluoride (PCBTF) before coating the layering substrate to give the surface-infused layering substrate. 
     
     
         32 . A mattress topper pad comprising the surface-infused of  claim 16 , where the surface-infused layering substrate is produced by a method comprising solvating a flexible polymeric carrier in parachlorobenzotrifluoride (PCBTF) before coating the layering substrate to give the surface-infused layering substrate. 
     
     
         33 . A mattress topper pad comprising at least one surface-infused layering substrate comprising at least one cured flexible gel polymeric carrier, where the at least one surface-infused layering substrate is produced by a method comprising:
 solvating a flexible polymeric carrier in parachlorobenzotrifluoride (PCBTF) to give a liquid gel mixture before   at least partially coating a layering substrate with the liquid gel mixture.   
     
     
         34 . The mattress topper pad of  claim 33  further comprising at least one highly thermally-conductive material. 
     
     
         35 . The mattress topper pad of  claim 33  where the highly thermally-conductive material comprises:
 a highly thermally-conductive material in the range of about 0.1% to about 95% by weight of the at least one cured flexible gel polymeric carrier layer after solvent loss; and 
 the highly thermally-conductive material is in solid form and has a thermal conductivity from about 100 W/(m-° K) to about 3500 W/(m-° K). 
 
     
     
         36 . A mattress topper pad comprising at least one surface-infused layering substrate comprising at least one cured flexible gel polymeric carrier and at least one highly thermally-conductive material, where the at least one surface-infused layering substrate is produced by a method comprising:
 solvating at least one flexible polymeric carrier in parachlorobenzotrifluoride (PCBTF) to give a liquid gel mixture; and   coating at least one layering substrate comprising a phase change material having a solid/liquid phase transition temperature from about 20° C. to about 35° C. present in the surface-infused layering substrate in an amount ranging from about 5% to about 80% by weight of the at least one surface-infused layering substrate after solvent loss.   
     
     
         37 . An article of manufacture comprising at least one layering substrate and at least one surface-infused gel layer therein produced by a method comprising infusing a liquid gel mixture into the layering substrate, positioned in any orientation, where the article of manufacture is selected from the group consisting of pet beds, shoe inserts, medical cushioning foams, mattresses, mattress topper pads, pillows, bedding products, seat cushions, seat backs, head rests, armrests, wheelchair seats, cushioning for sports equipment, personal protective equipment, and combinations thereof. 
     
     
         38 . An article of manufacture comprising at least one layering substrate and at least one surface-infused gel layer therein produced by a method of infusing a liquid gel mixture into the layering substrate, positioned in any orientation, where the article is a mattress. 
     
     
         39 . An article of manufacture comprising at least one layering substrate and at least one surface-infused gel layer therein produced by a method of infusing a liquid gel mixture onto the layering substrate, positioned in any orientation, where the article is a pillow. 
     
     
         40 . An article of manufacture comprising at least one layering substrate and at least one surface-infused gel layer therein produced by a method comprising infusing a liquid gel mixture into the layering substrate, positioned in any orientation, where the article is a mattress topper pad. 
     
     
         41 . A method of forming a surface-infused gel layer comprising the following steps, not necessarily in this order:
 making a liquid mixture by solvating at least one flexible polymeric carrier in parachlorobenzotrifluoride (PCBTF) solvent;   introducing at least one highly thermally-conductive material in the flexible polymeric carrier;   infusing at least a portion of the liquid gel mixture into at least one layering substrate to give a product having a surface-infused gel layer on the layering substrate; and   at least partially removing the PCBTF solvent from the product.   
     
     
         42 . The method of  claim 41  further comprising compressing the product of at least one layering substrate and liquid gel mixture to produce the at least one cured flexible gel polymeric carrier layer on the layering substrate. 
     
     
         43 . A method of forming a surface-infused gel layer with a lamination system comprising:
 forming a liquid gel mixture comprising at least one flexible polymeric carrier in parachlorobenzotrifluoride (PCBTF);   driving a top roller and a bottom roller with an adjustable gap between them;   coating bottom roller with the liquid gel mixture;   coating a layering substrate with the liquid gel material;   compressing the layering substrate in the range of from about 0.1% to about 90%;   removing the layering substrate from the bottom roller coated with the liquid gel mixture;   evaporating the PCBTF from the surface-infused gel layer to cure flexible polymeric carrier; and   recovering the PCBTF for re-use.