Rebond polyurethane foam comprising reclaimed carpet material and methods for the manufacture of same

摘要

Disclosed are rebond polyurethane foams comprised of a plurality of polyurethane foam particles bound together to form a matrix. Reclaimed carpet material is distributed within the matrix of foam particles as a filler material. Also disclosed are methods for the manufacture of the rebond polyurethane foams disclosed herein.

主权项

1. A rebond polyurethane foam, comprising:
a plurality of preformed polyurethane foam particles bonded to one another to form a matrix; and reclaimed carpet material distributed within the matrix of polyurethane foam particles, wherein the reclaimed carpet material comprises a population of thermoplastic fibers having non-uniform linear fiber densities; and wherein the reclaimed carpet material is present in an amount of at least 35 parts by weight relative to the total amount of preformed polyurethane foam particles and reclaimed carpet material present in the rebond polyurethane foam.