Silicone-Impregnated Reticulated Polyurethane Foam for Skin Compatibility
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Solution Overview
Problem
Silicone polymers are not readily susceptible to being formed into open-cell resilient structures, limiting their application in products that come into contact with the human body, such as healthcare and furniture items, where open-cell structures are desirable for cushioning and other purposes.
Innovation Solution
A method involving the impregnation of reticulated polyurethane foam substrates with curable silicone polymers, using a reverse roll applicator, followed by curing, to create a foam product with enhanced mechanical and physical properties, including mildew resistance and UV protection, suitable for various industries.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If silicone polymers are used to create open-cell resilient structures, then products with improved skin compatibility and chemical inertness can be produced, but silicone polymers cannot be readily formed into open-cell resilient structures
Solution Approach 1:
The patent creates a composite material system where silicone polymer is impregnated into a polyurethane foam substrate. The polyurethane provides the open-cell resilient structure that is difficult to form with silicone alone, while the silicone impregnant provides skin compatibility and chemical inertness. This composite approach allows both materials to contribute their advantageous properties without requiring silicone to be formed into the open-cell structure directly.
Solution Approach 2:
The polyurethane foam substrate acts as an intermediary carrier that enables the silicone polymer to achieve the open-cell resilient structure indirectly. Instead of attempting to form silicone directly into open-cell structures, the silicone is impregnated into the pre-formed polyurethane foam, allowing the substrate to mediate the structural formation while the impregnant provides the desired chemical properties.
2Ease of manufacture
If reticulated polyurethane foam is used as substrate, then open-cell resilient structure with high void volume can be achieved, but the product lacks the chemical inertness and skin compatibility of silicone
Solution Approach 1:
The patent utilizes the porous nature of reticulated polyurethane foam with high void volume (up to 98%) as the substrate. This porous structure provides the desired open-cell resilient characteristics and is easily manufactured. The porosity allows subsequent impregnation with silicone polymer, combining the structural advantages of the foam with the chemical advantages of silicone.
Solution Approach 2:
By impregnating silicone polymer into the polyurethane foam substrate, the patent creates a composite material that combines the open-cell resilient structure of the foam with the skin-compatible, chemically inert properties of silicone. The composite structure allows both functional requirements to be met simultaneously.
3Strength
If silicone polymer is impregnated into foam substrate, then products with enhanced mechanical and physical properties can be produced, but the manufacturing process becomes more complex
Solution Approach 1:
The patent employs preliminary action by first forming the polyurethane foam substrate with the desired open-cell structure before impregnating it with silicone polymer. This sequence allows the structural framework to be established first, then enhanced with the silicone impregnant, simplifying the overall process compared to attempting to create the final composite structure in a single step.
Solution Approach 2:
The impregnation process acts as an intermediary step that enhances the mechanical and physical properties of the foam substrate without requiring complete re-manufacturing. The silicone polymer is introduced into the pre-formed foam structure, providing property enhancement through a relatively simple additional process step rather than complex integrated manufacturing.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The resulting silicone-impregnated foam products exhibit improved resilience, mildew resistance, and UV protection, making them suitable for diverse applications, including healthcare, aerospace, and furniture industries, with controlled resiliency and density for specific uses.
Implementation Method 1
impregnating a substrate of reticulated or non-reticulated open-cell, resilient foam material with a curable silicone polymer, curing the silicone polymer
Data Source
AI summary
The present invention relates to products having a foam carrier or substrate, and particularly to such products employing a reticulated polyurethane foam carrier impregnated with silicone polymer. The present invention also relates to a method of producing these silicone-impregnated foam products.