Abstract: The present invention relates to mattress or furniture insulator pads that are placed between the coil springs and the cushioning material in mattresses or furniture, such as chair seats. Such insulator pads prevent the springs from piercing the furniture cushion and provide a bridge across the springs to more evenly distribute weight over the springs. The insulator pads according to the invention have three layers formed by sandwiching polyurethane foam between stiffening layers, preferably formed from polypropylene openmesh netting. Most preferably, a five layer insulator pad has the polyurethane foam sandwiched between stiffening layers and also has outer layers of polyurethane foam, applied adjacent to the stiffening layers, forming the top and bottom surfaces of the pad. Such outer layer foam sheets provide friction characteristics that retard relative movement between the cushion and the springs.

Abstract: A hinged flexible polyurethane foam protective packaging element is formed from a flexible polyurethane foam laminated to a polyethylene, polypropylene or urethane film. The flexible polyurethane foam has a density in the range of 0.7 lbs/ft3 to 2.8 lbs/ft3 and IFD25 in the range of 25 lbs to 270 lbs. The film has a thickness from 2 mil to 125 mil. The foam is cut through all or substantially all of its thickness without cutting through a portion of the film. The uncut portion of the film creates a repeatably bendable hinge.

Abstract: A hinged flexible polyurethane foam protective packaging element is formed from a flexible polyurethane foam laminated to a polyethylene, polypropylene or urethane film. The flexible polyurethane foam has a density in the range of 0.7 lbs/ft3 to 2.8 lbs/ft3 and IFD25 in the range of 25 lbs to 270 lbs. The film has a thickness from 2 mil to 125 mil. The foam is cut through all or substantially all of its thickness without cutting through a portion of the film. The uncut portion of the film creates a repeatably bendable hinge.

Abstract: The present invention relates to a method of making a laminated product, such as an insulator pad comprised of foam and stiffening layers held together with adhesive. A thin protective barrier foam sheet is placed between the surface of a compression roller and the sheets to be laminated together by passing them between compression rollers. The thin protective barrier foam sheet may or may not form the outer layer of the laminated product and prevents adhesive and foam material from contaminating the surface of the roller.

Abstract: The present invention relates to sound transmission barrier and/or sound absorption media systems that are especially useful in motor vehicles and boats. These systems are based on the concept of replacing the traditional intermediate high-mass layer ("massback") with two or more high-mass layers that are separated by a strong yet light material, such as polyurethane foam.

Abstract: Polyurethane foams having improved physical properties are produced by placing a polymerizable polyurethane reaction mixture into a pressurizable chamber, then polymerizing the reaction mixture at an elevated pressure sufficient to prevent the resulting polymer from completely filling the chamber.