Foam composite

Abstract

A foam composite made up of a scaffold of an open cell hydrophobic material having plurality of surfaces defining a plurality of pores, and a coating of a substantially hydrophilic foam material disposed upon the surfaces of the hydrophobic foam. The resulting foam composite exhibits structural characteristics of the hydrophobic foam and absorbency characteristics of the hydrophilic foam.

Description

[0001] This application is a continuation-in-part of U.S. Application Ser. No. 09 / 540,009 filed Mar. 31, 2000.[0002] The present invention relates to the field of polymer chemistry and, in particular, to the field of foam composites having properties of both conventional hydrophobic and hydrophilic polyurethane foams.[0003] Conventional polyurethanes have taken a prominent position in the world as an inexpensive material for use in such diverse applications as foam insulation, adhesives, structural foams, shoe sole and others. The properties of conventional polyurethanes that make these uses possible are its physical strength, low cost, ability to make very low density foam, chemical resistance, and thermal stability.[0004] One of the variations of the product family is the manufacture of what are called reticulated foams. These foams are constructed such that the "windows" that separate the individual cells making up the foam structure are open and the material in the windows colla...

AI Technical Summary

Benefits of technology

[0013] In another embodiment of the invention the composite foams are provided by contacting the hydrophobic polyurethane foam with a liquid phase of a hydrophilic polyurethane prepolymer at temperatures sufficient to lower the viscosity and thereby control the coating weight of the hydrophilic prepolymer.

[0167] Referring now to FIG. 28, another embodiment of the invention is shown in which the foam composite 10 is utilized as a respirator for use in low temperature applications. The hydrophilic foam 14 in this embodiment contains a phase change material that melts and freezes at just below the temperature of the human body (98.6.degree. F. / 37.degree. C.). The latent heat of fusion of the phase change material is used as a reservoir for storing the heat of exhaled air and subsequently releasing that heat to increase the temperature of inhaled air. Thus, in a respirator having two separate chambers and through which a person inhales through one chamber and exhales through the other, cold air enters the inhale side and is heated by the freezing phase change material. Air at body temperature is exhaled through the other chamber and melts the phase change material. This continues until the inhaled air freezes all of the phase change material. At that time, a valve is turned that reverses the inhale side to the exhale side and visa versa. The net effect is that the heat energy in the exhaled air is trapped and subsequently used to heat incoming air. The net effect is the breathed air temperature is tempered thus avoiding the body heat lost in very cold weather.

Problems solved by technology

While this hydrophilic nature gives hydrophilic polyurethane its unique applications, it also leads to certain deficiencies.

Among these are low physical strength, poor cell size control, relatively high densities causing a relatively high cost per unit volume, and the fact that foam swells considerably upon absorption.

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