Abstract: A method for making antimicrobial rebonded carpet pad includes mixing zinc pyrithione with a polyol to form an antimicrobial polyol mixture concentrate, blending the antimicrobial polyol mixture concentrate with a binder stream, mixing the binder with foam particles and curing the binder. The percentage of zinc pyrithione mixed with the polyol and the addition ratio of the antimicrobial polyol mixture concentrate with the binder stream are selected to provide an overall concentration of zinc pyrithione in the binder of at least about 7500 ppm. The particles and binder are cured into a block and sliced to form carpet pad.

Abstract: A method for making antimicrobial rebonded carpet pad includes mixing zinc pyrithione with a polyol to form an antimicrobial polyol mixture concentrate, blending the antimicrobial polyol mixture concentrate with a binder stream, mixing the binder with foam particles and curing the binder. The percentage of zinc pyrithione mixed with the polyol and the addition ratio of the antimicrobial polyol mixture concentrate with the binder stream are selected to provide an overall concentration of zinc pyrithione in the binder of at least about 7500 ppm. The particles and binder are cured into a block and sliced to form carpet pad.

Abstract: A polyurethane foam produced from a formulation comprising a polyol, an isocyanate, a strut reinforcing agent and a VOC reducing agent. The isocyanate reacts with the polyol to produce the polyurethane foam. By including the strut reinforcing and VOC adsorption agents in the formulation during the reaction between the isocyanate and the polyol, the air permeability and firmness of the polyurethane foam are enhanced while the amount of VOCs within and the level of VOCs emitted by the polyurethane foam are reduced relative to a polyurethane foam produced by reacting the isocyanate and the polyol in the absence of the strut reinforcing or VOC reducing agents.

Abstract: A polyurethane produced from a formulation comprising a polyol, an isocyanate and a strut reinforcing agent. The isocyanate reacts with the polyol to produce the polyurethane foam. By including the strut reinforcing agent in the formulation during the reaction between the isocyanate and the polyol enhances the air permeability and firmness of the polyurethane foam relative to a polyurethane foam produced by reacting the isocyanate and the polyol in the absence of the strut reinforcing agent.

Abstract: A bonded foam product manufactured with a vegetable oil polyol is herein disclosed. The pre-polymer for use as a binder in the manufacture of a bonded foam product comprises an isocyanate and a vegetable oil polyol, wherein the pre-polymer is substantially free of any petrochemical polyol. In another aspect, the invention is method for making a bonded foam product, the method comprising coating a plurality of foam pieces with a pre-polymer, the pre-polymer comprising an isocyanate and a vegetable oil polyol, wherein the pre-polymer is substantially free of any petrochemical polyol, compressing the foam pieces into a foam log of a desired density, and steaming the foam log to cure the pre-polymer. If desired, a process oil may be added to the pre-polymer to modify the viscosity of the pre-polymer.

Abstract: A pre-polymer comprising: isocyanate, polyol, oil, and an amine catalyst and an associated method for producing a polyurethane bonded foam product. The method comprises: coating a plurality of foam pieces with the pre-polymer; compressing the foam pieces into a foam log of a desired density; and steaming the foam log to cure the pre-polymer. Preferably, the amine catalyst is dimorpholinodiethylether (DMDEE) and the isocyanate, the polyol, and the oil are present in the pre-polymer in about equal amounts.

Abstract: Foam bedding products including viscoelastic foam having a high airflow value that do not feel hot to the person sleeping on the products. One product is a pillow having a contoured core having sufficient firmness to provide effective support for a user and a hyper soft viscoelastic foam shell surrounding the core having sufficient firmness to maintain the appearance of a conventional pillow when supporting only a pillowcase or other bed coverings. The core may be made of higher density viscoelastic foam or of a resilient foam. Another product may be a mattress topper with or without foam cores for body support carried within slabs of high airflow viscoelastic foam.

Abstract: Disclosed is a polyurethane foam comprising less than about 10 weight percent melamine and less than about 10 weight percent of one or more additional flame retardant compounds, both based on the total weight of the foam. In an embodiment, the weight ratio of melamine to the additional flame retardant compounds is in the range of from about 0.5 to about 2.0. The foam is a reaction product of one or more polyols, one or more isocyanates, one or more blowing agents, and one or more catalysts. In an embodiment, the foam has a density of within the range of from about 0.9 to about 4.25 lb/ft3, a 25% IFD in the range of from about 7 to about 150 lb/50 in2, and an air flow in the range of about 2.0 to about 5.5 ft3/minute. In an embodiment, the melamine is ground melamine.

Abstract: A carpet underlay including an effective amount of an antimicrobial compound. A rebonded carpet pad may include foam particles bonded together by a binder including zinc pyrithione. The underlay may include a laminating film on one or both sides of the pad. The laminating film may include zinc pyrithione as an effective antimicrobial.