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 Polyurethane foam articles coated with a crushed foam and method of producing

Details
Inventors: Chancler, Francis X.;
Assignee: Rohm and Haas Company (Philadelphia, PA)
Primary Examiner: Lusignan; Michael R.
Assistant Examiner: Childs; S. L.
Attorney, Agent or Firm: Baker; Patrick C.

Crushed foam coated urethane foam is disclosed wherein the crushed foam coating contains a pigment or a flame retardant or both to protect the urethane foam against discoloration due to ultraviolet light or to provide protection against fires. The crushed foam may be obtained from a frothed latex applied to the polyurethane foam, dried and crushed to a final thickness of 10 mils to 250 mils.

DETAILED DESCRIPTION What is claimed is: 1.
An article of manufacture comprising a polyurethane foam coated with a crushed foam, said crushed foam resulting from application to said polyurethane foam of a foamed polymer emulsion containing a crosslinkable emulsion polymer followed by drying, crushing and curing said foamed polymer emulsion, said crushed foam having incorporated therein one or more of a pigment, a filler, and a flame retardant.
2.
The article of claim 1 wherein the pigment or filler is selected from titanium dioxide, calcium carbonate kaolin, colored lakes and toners, ochre, carbon black, graphite, aluminum powder or flakes, chrome yellow, molybdate orange, toluidine red or copper phthalocyanines.
3.
The article of claim 1 wherein the flame retardant is selected from aluminum trihydrate, zinc borate, ammonium polyphoshate, ammonium sulfamate or tris-2,3-dibromophosphate.
4.
The article of claim 1 wherein the polymer emulsion is prepared from an acrylic emulsion polymer.
5.
The article of claim 1 wherein the polymer emulsion is prepared from a vinyl chloride emulsion polymer.
6.
The article of claim 1 wherein the polymer emulsion is prepared from a vinylidene chloride emulsion polymer.
7.
The article of claim 1 wherein the foam coating is from 30 to 180 mils.
in thickness prior to crushing.
8.
The article of claim 1 wherein the emulsion polymer is prepared from at least three of the following monomers: (a) an .
alpha.
, .
beta.
-ethylenically unsaturated acid; (b) a monomer of the formula ##STR5## wherein R is hydrogen of alkyl and R.
sup.
1 is straight, branched or cyclic alkyl, alkoxyalkyl or alkylthioalkyl; (c) a monomer of the formula ##STR6## wherein R.
sup.
2 is hydrogen or methyl and R.
sup.
3 is hydrogen or hydroxy lower alkyl and (d) a monomer of the formula ##STR7## wherein R.
sup.
2 is hydrogen or methyl and R.
sup.
4 is halo, lower alkanoyloxy, cyano, formyl, phenyl, tolyl, methoxyethyl, 2,4-diamino-s-triazinyl lower alkyl or epoxy.
9.
The article of claim 1 wherein the emulsion polymer of the crushed foam has the following composition: (a) 0-3% itaconic acid; (b) 40-97% ethyl acrylate, vinyl or vinylidene chloride; (c) 0



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