Fiber-Reinforced Flexible Foams for IFD and Durability

The patent applies composite materials by incorporating fibers (such as carbon fibers, metal fibers, or plant-based fibers) into the polyurethane foam matrix. This creates a fiber-reinforced composite foam structure where the fibers act as reinforcement within the foam struts, significantly improving indentation force deflection and durability while maintaining a relatively simple manufacturing process that only requires modifying the existing foam formulation with fiber additives.

The patent applies parameter changes by modifying the physical and chemical parameters of the foam structure through fiber reinforcement. The addition of fibers changes the thermal conductivity parameter of the foam material, enabling improved heat transfer properties. This is achieved by selecting fibers with appropriate thermal conductivity characteristics and optimizing their concentration and distribution within the foam matrix, rather than fundamentally changing the foam manufacturing process.

The patent applies preliminary action by incorporating fibers into the foam formulation before the foam expansion and curing process. The fibers are pre-mixed with the polyol and isocyanate components, so that during foam formation, the fibers become integrated into the developing foam structure. This preliminary incorporation ensures that the fibers are properly distributed and bonded within the foam struts before the foam sets, resulting in improved compression set and height retention without requiring complex post-processing steps.