Increasing the Heat Flow of Flexible Cellular Foam Through the Incorporation of Highly Thermally Conductive Solids

Abstract

Methods and combinations of mattress support surfaces comprising one or more flexible polyurethane foam layers containing highly thermally-conductive solids, such as diamond or silicon carbide, and said layer combination is capable of transferring heat from a warm surface, such as a person sleeping on a bed, to a cooler region at a faster rate throughout the mattress than the thermal dissipation rate obtained from flexible polyurethane foam without highly thermally-conductive solids.

What is claimed is: 
     
         1 . A flexible cellular foam with highly thermally-conductive solids (HTCS Foam) comprising:
 a flexible cellular foam, and   highly thermally-conductive solid particles dispersed in the flexible cellular foam, where the highly thermally-conductive solid particles are selected from a group consisting of silicon carbide, synthetic diamond crystal powder, natural diamond crystal powder, type lla diamond powder, synthetic diamond, boron nitride, carbonado, and combinations thereof.   
     
     
         2 . The flexible cellular foam with highly thermally-conductive solids of  claim 1  where the flexible cellular foam is produced by a process comprising polymerizing a polyol with a polyisocyanate. 
     
     
         3 . The flexible cellular foam with highly thermally-conductive solids of  claim 1  where the flexible cellular foam with highly thermally-conductive solids is produced by a method comprising:
 introducing the highly thermally-conductive solid particles into a mixture of flexible cellular foam-forming components comprising a polyol and an isocyanate; and 
 polymerizing the polyol and the isocyanate to form the flexible cellular foam. 
 
     
     
         4 . The flexible cellular foam with highly thermally-conductive solids of  claim 1  where the flexible cellular foam is selected from the group consisting of an open-celled polyurethane foam, partially open-celled polyurethane foam, open-celled polyester polyurethane foam, partially open-celled polyester polyurethane foam, and combinations thereof. 
     
     
         5 . The flexible cellular foam with highly thermally-conductive solids of  claim 1  where the one or more highly-thermally conductive solids ranges from about 0.1% to about 50% by weight based on the final foam net weight after gas loss. 
     
     
         6 . The flexible cellular foam with highly thermally-conductive solids of  claim 1  where the one or more highly thermally-conductive solids ranges from about 1% to about 35% by weight based on the final foam net weight after gas loss. 
     
     
         7 . The flexible cellular foam with highly thermally-conductive solids of  claim 1  where the one or more highly-thermally conductive solids ranges from about 5% to about 25% by weight based on the final foam net weight after gas loss. 
     
     
         8 . The flexible cellular foam with highly thermally-conductive solids of  claim 1  wherein said one or more highly thermally-conductive solids have an average particle size ranging from about 1 to about 3000 microns. 
     
     
         9 . The flexible cellular foam with highly thermally-conductive solids of  claim 1  wherein said one or more highly thermally-conductive solids have an average particle size ranging from about 50 to about 1000 nanometers. 
     
     
         10 . The flexible cellular foam with highly thermally-conductive solids of  claim 1  wherein the HTCS Foam comprises a structure selected from the group consisting of a solid sheet, a perforated sheet, a non-planar sheet, a planar sheet, a textured sheet, and combinations thereof. 
     
     
         11 . The flexible cellular foam with highly thermally-conductive solids of  claim 1  where the HTCS Foam is adhered to a layering substrate. 
     
     
         12 . A cushion foam comprising at least one layer comprised of the flexible cellular foam with highly thermally-conductive solids of  claim 1 . 
     
     
         13 . A mattress comprising at least one layer comprised of the flexible cellular foam with highly thermally-conductive solids of  claim 1 . 
     
     
         14 . A mattress topper pad comprising at least one layer comprised of the flexible cellular foam with highly thermally-conductive solids of  claim 1 . 
     
     
         15 . A pillow comprising the flexible cellular foam with highly thermally-conductive solids of  claim 1 . 
     
     
         16 . An article of manufacture selected from the group consisting of a cushion foam, a mattress, a mattress topper pad, and combinations thereof, where the article of manufacture comprises at least one zone selected from the group consisting of a longitudinal zone, a lateral zone, and combinations thereof, where the at least one zone comprises the flexible cellular foam with highly thermally-conductive solids of  claim 1 . 
     
     
         17 . An article of manufacture selected from the group consisting of medical cushioning foams, mattresses, pillows, bedding products, mattress pillow toppers, quilted mattress toppers, mattress toppers, pet beds, indoor cushioning foams, outdoor cushioning foams, outdoor bedding pads, outdoor pillows, and combinations thereof, where the article of manufacture further comprises at least one layer comprising the flexible cellular foam with highly thermally-conductive solids of  claim 1 . 
     
     
         18 . A flexible cellular latex foam with highly thermally-conductive solids comprising:
 a cross-linked latex foam, and   highly thermally-conductive solid particles dispersed in the cross-linked latex foam, where the highly thermally-conductive solid particles are selected from a group of silicon carbide, synthetic diamond crystal powder, natural diamond crystal powder, type lla diamond powder, synthetic diamond, boron nitride, carbonado, and combinations thereof.   
     
     
         19 . A flexible cellular melamine foam with highly thermally-conductive solids comprising:
 a cross-linked melamine foam, and   highly thermally-conductive solid particles dispersed in the cross-linked melamine foam, where the highly thermally-conductive solid particles are selected from a group of silicon carbide, synthetic diamond crystal powder, natural diamond crystal powder, type lla diamond powder, synthetic diamond, boron nitride, carbonado, and combinations thereof.