U.S. patent application number 10/406301 was filed with the patent office on 2003-11-20 for urethane polymer foam composites in sized particulate form with controlled release of agents and additives.
This patent application is currently assigned to H.H. Brown Shoe Technologies, Inc. d/b/a Dicon Technologies, H.H. Brown Shoe Technologies, Inc. d/b/a Dicon Technologies. Invention is credited to Celia, Wayne, Hermann, Paul F..
Application Number | 20030216483 10/406301 |
Document ID | / |
Family ID | 28673752 |
Filed Date | 2003-11-20 |
United States Patent
Application |
20030216483 |
Kind Code |
A1 |
Hermann, Paul F. ; et
al. |
November 20, 2003 |
Urethane polymer foam composites in sized particulate form with
controlled release of agents and additives
Abstract
Granulated hydrophilic urethane polymer foam products with
controlled release or contact of agents and additives, formed from
the reaction product of an aqueous formulation comprising limited
quantities of an absorbent polymer, an agent or additive from the
group of detergents, soaps, abrasives, waxes, polishes, drugs,
cosmetics, biologicals, volatiles, chemicals, water emulsions,
water mixture with solid particles and optionally selective
additives with adequate water and a predetermined ratio of
hydrophilic urethane prepolymer to provide the polymerized solid.
The agents and additives if any, are homogenously incorporated
strands, fibers and intercellular structures of the matrix for the
formed urethane polymer foam product to materially increase mass
transfer between the agents and additives and a target in the
effluent. The hydrophilic urethane polymer will allow intimate
contact between agent/additive and effluent target.
Inventors: |
Hermann, Paul F.; (Dover,
NH) ; Celia, Wayne; (Paramus, NJ) |
Correspondence
Address: |
LERNER, DAVID, LITTENBERG,
KRUMHOLZ & MENTLIK
600 SOUTH AVENUE WEST
WESTFIELD
NJ
07090
US
|
Assignee: |
H.H. Brown Shoe Technologies, Inc.
d/b/a Dicon Technologies
3-00 Banta Place
Fair Lawn
NJ
07410
|
Family ID: |
28673752 |
Appl. No.: |
10/406301 |
Filed: |
April 3, 2003 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
10406301 |
Apr 3, 2003 |
|
|
|
10115338 |
Apr 2, 2002 |
|
|
|
Current U.S.
Class: |
521/50 ;
521/82 |
Current CPC
Class: |
C11D 17/042 20130101;
A01K 1/0152 20130101; C11D 3/3726 20130101; A01K 1/0155 20130101;
C11D 17/00 20130101 |
Class at
Publication: |
521/50 ;
521/82 |
International
Class: |
C08J 009/00; C08K
003/00 |
Claims
1. A controlled release comminutent urethane polymer foam product
comprising the reaction composition of an aqueous formulation
including, a limited quantity of absorbent polymer, at least one
agent from the group detergents, soaps, abrasives, waxes, polishes,
drugs, cosmetics, biologicals, volatiles, odor absorption or
control compositions and or other active ingredients such as
polyoxometalates, water soluble chemicals, water emulsions, water
mixtures with solid particles and adequate water with a
predetermined ratio of hydrophilic urethane prepolymer whereby the
at least one agent is generally dispersed uniformly throughout the
foam product and slowly released or contacted with a water
effluent, and the formed foam product is sized, comminutent and
particles.
2. The sized comminutent and particles of the controlled release
urethane polymer foam product in claim 1 including, optionally and
selectively, at least one additive from the group of cellulose
fibers, phase change materials, vaccines, spermicides, coloring and
dyes.
3. The sized comminutent and particulate controlled release
urethane polymer foam product as in claims 1 or 2, wherein the
detergent is from the group of anionic, cationic, nonionic, and
zwitterionic surfactants, soaps or combinations of same.
4. The sized comminutent and particulate of the controlled release
urethane polymer foam product as in claims 1 or 2, wherein the wax
is from the group of crystalline wax, paraffin wax, wax emulsions
and silicone fluids.
5. The sized comminutent and particulate of the controlled release
urethane polymer foam product as in claims 1 or 2, wherein the
polish is from the group of light mineral abrasives less than 3 on
the moh hardness scale and less than 20 micron particle size.
6. The sized comminutent and particulate of the controlled release
urethane polymer foam product as in claims 1 or 2, wherein the
drugs are from the group including animal, human, and environmental
or plant species drugs, compounds or formulations of the same
prepared to alleviate or control disease.
7. The sized comminutent and particulate of the controlled release
urethane polymer foam product as in claims 1 or 2, wherein the
cosmetics are from the group of materials made to improve or
enhance the appearance such as vitamin E, retinol, aloe vera, hair
conditioners, bath oils, suntan oils and U.V. protectants, etc.
8. The sized comminutent and particulate of the controlled release
urethane polymer foam product as in claims 1 or 2, wherein the
biologicals are from the group Monera, Protista, Fungi, Plantae or
Animalia.
9. The sized comminutent and particulate of the controlled release
urethane polymer foam product as in claims 1 or 2, wherein the
volatiles are from the group fragrances, decongestants,
insecticides and solvents, etc.
10. The sized comminutent and particulate of the controlled release
urethane polymer foam product as in claims 1 or 2, wherein the odor
absorbing and controlling compositions are from the group odor
neutralizers, enzymatic reactive, fragrances and
anti-microbials.
11. The sized comminutent and particulate of the controlled release
urethane polymer foam product of claims 1 or 2 wherein the
absorbent polymer is at least 0.05% by weight of the aqueous
formulation.
12. The sized comminutent and particulate of the controlled release
urethane polymer foam product of claims 1 or 2 wherein the at least
one agent from the selected group of agents is from about 0.5% to
about 40% by weight of the aqueous formulation.
13. The sized comminutent and particulate of the controlled release
urethane polymer foam product of claims 1 or 2 wherein the water
present is in a range from about 15% to about 85% by weight of the
aqueous formulation.
14. The sized comminutent and particulate of the controlled release
urethane polymer foam product of claims 1 or 2 wherein the
hydrophilic urethane prepolymer is about 0.25% to 80% by weight of
the aqueous formulation.
15. A controlled release urethane polymer foam product comprising
the reaction composition of an aqueous formulation including, at
least less than 0.5% by weight of a absorbent polymer, at least one
agent from the group detergents, soaps, abrasives, waxes, polishes,
drugs, cosmetics, biologicals, volatiles, odor absorbing and
control compositions, and or other active ingredients, water
soluble chemicals, water emulsions, water mixtures with solid
particles in an amount from 0.5% to about 40% by weight of the
aqueous formulation and water in an amount of 15% to 80% by weight
of the aqueous formulation with a hydrophilic urethane prepolymer
in a predetermined ratio in a range from 0.25% to 80% of the
aqueous formulation whereby the at least one agent is dispersed
throughout the matrix of the formed controlled release urethane
foam product and slowly released on contact with a water effluent
and the foam matrix is as formed by sized comminutent or
particles.
16. A sized comminutent and particulate of the controlled release
urethane polymer foam product as in claim 15, where the aqueous
mixture includes at least one surfactant in an amount from 0.5% to
15% by weight of the aqueous mixture.
17. A controlled release urethane polymer foam product comprising:
a. the reaction composition of an aqueous formulation including, a
limited quantity of absorbent polymer, at least one agent from the
group detergents, soaps, abrasives, waxes, polishes, drugs,
cosmetics, biologicals, volatiles, odor absorbing and control
compositions and or other active ingredients, water soluble
chemicals, water emulsions water mixtures with solid particles and
adequate water with a predetermined ratio of hydrophilic urethane
prepolymer whereby the at least one agent is generally dispersed
uniformly throughout the matrix of the formed controlled release
urethane foam product and slowly released on contact with a water
effluent; and b. at least one addition from the group of abrasives
material, and c. the formed foam matrix is sized comminuting and
particles.
18. The sized comminutent and particulate of the controlled release
urethane polymer foam product in claim 17, including, optionally
and selectively, at least one additive from the group of cellulose
fibers, phase change materials, vaccines, spermicides, coloring and
dyes.
19. The sized comminutent and particulate of the controlled release
urethane polymer foam as in claims 17 or 18, where the aqueous
formulations includes at least one surfactant in an amount from
0.5% to about 15% by weight of the aqueous mixture.
20. The controlled release urethane polymer foam product
comprising: a. the reaction composition of an aqueous formulation
including, at least less than 0.5% by weight of a superabsorbent
polymer, at least one agent from the group detergents, soaps,
abrasives, waxes, polishes, drugs, cosmetics, biologicals,
volatiles, odor absorption or control compositions, and other
active ingredients, water soluble chemicals, water emulsions, water
mixtures with solid particles in an amount from 0.5% to about 40%
by weight of the aqueous formulation and water in an amount of 15%
to 80% by weight of the aqueous formulation with a hydrophilic
urethane prepolymer in a predetermined ratio in a range from 0.25%
to 80% of the aqueous formulation whereby the at least one agent is
dispersed throughout the matrix of the formed controlled release
urethane foam product and slowly released on contact with a water
effluent; and b. said formed controlled release urethane foam
product is formed from predetermined sized comminutent and
particle.
21. The controlled release comminutent urethane polymer foam
product as in claim 20, wherein the granules and particle sizes are
in a range from 0.010-0.500 inches diameter.
22. The controlled release urethane polymer foam product as in
claims 20 or 21, wherein the density of the formed controlled
release urethane foam sized comminutent and particles product is
adjusted by solid fillers in amounts by weight and in ratio to the
weight of the aqueous formulation.
23. The controlled release urethane polymer foam product as in
claim 22, wherein the density of the formed controlled release
urethane foam sized comminutent and particulate product is adjusted
in a range from 1.5 lbs/cu. ft. to about 60 lbs/cu. ft. by adding
solid fillers by weight and in ratio to the aqueous
formulation.
24. The controlled release urethane polymer foam product as in
claim 22, wherein the solid filler is selected from the group
diatomaceous earths, feldspar, wollastonite or clay for higher
densities and glass micro spheres for lower densities as a function
of the required applications and uses.
25. The controlled release comminutent urethane polymer foam
product as in claim 17 wherein the aqueous formulations contain
solid particles, the solid particles are from the group of
abrasives including natural materials.
26. The method for forming comminuted controlled release urethane
polymer foam products comprising the steps of: a. metering and
mixing an aqueous formulation having at least a limited quantity of
absorbent polymer, at least one agent from the group detergents,
soaps, abrasives, waxes, polishes, drugs, cosmetics, biologicals,
volatiles, odor absorbing and controlling compositions, water
soluble chemicals, water emulsions, water mixture with solid
particles and adequate water with a predetermined ratio of
hydrophilic urethane prepolymer to provide a polymerizing mixture
for forming the controlled release urethane foam product; b.
depositing the polymerizing mixture on releasable bottom paper
disposed on a movable carrier; c. covering the upper surface of the
polymerizing mixture with releasable top paper as the polymerizing
mixture is moved with the carrier; d. advancing the polymerizing
mixture in the top and bottom release paper by moving the carrier
and sizing the foam layer being formed to the desired thickness
until it is tack free; e. sequentially removing the top and bottom
release paper while simultaneously drying the formed foam product
to remove residual moisture; and f. passing the formed controlled
release urethane foam product to secondary operations of comminuted
the formed controlled release urethane polymer foam product into
sized granules and particles for particular applications and uses.
Description
[0001] This application is a continuation-in-part of U.S.
Application No. 10/115,338, filed Apr. 2, 2002.
BACKGROUND OF THE INVENTION
[0002] The present invention relates generally to hydrophilic
polyurethane foam composites used for various types of industrial,
commercial, residential, personal care, cleaning and other
products, and more particularly to such products formed, generated
or granulated in predetermined particle sizes of the formed
hydrophilic polyurethane foam product which contains limited
quantities of superabsorbent polymers to control the release or
contact with an agent or agents such as detergents, abrasives,
waxes, polishes, drugs, cosmetics, biologicals, volatiles, odor
control compositions, polyoxometalates (POMS) and chemicals or
optionally and selectively other additives when such foam product
composite is brought into contact with water or an aqueous effluent
during application and use of the sized particulate foam
product.
[0003] When an aqueous formulation of the present invention
including superabsorbent polymer, agents and adequate water is
mixed with a hydrophilic urethane prepolymer, as described in U.S.
Pat. No. 5,976,847, the reaction produces polymerization and forms
a hydrophilic polyurethane foam composite.
[0004] Conventional prior art urethane polymer foam is mostly
resistant and non-permeable to water. Some compositions have been
treated with a surfactant in the formula to render the resultant
urethane polymer foam products more acceptable to water. This type
of surfactant-treated urethane polymer foam products will allow
water to run along the supporting strands, fibers and intercellular
gaps of the matrix for the foamed foam but will still disallow
penetration into the strands and fibers forming the matrix of the
formed urethane polymer foam.
[0005] Conventional prior art urethane polymer foams require a
stochiometric balance of water to isocyanate below approximately
0.05% addition of water or water-bearing agent in the formulation.
This limits the amount of agent addition to the final composite. A
further limitation of agent addition is the starting viscosity of
conventional polyol components of the formula. Most additions of
agent are added to the polyol component based on the high
reactivity of the isocyanate component. The polyol component is
typically relatively high in viscosity prior to any agent addition.
Increasing its viscosity further by addition of agent quickly
renders the resultant viscosity too high to pump and disallows the
processing requirements of metering machinery. In addition to
limited amounts of agent capable to be added is the major objection
of conventional prior art urethane foams, that is, its water
resistance. A composite foam product made with water-resistant or
water-impermeable urethane coats or blocks the agent with its
intended contact with an aqueous effluent. This defeats the
original effort in adding the agent to the composite. The agent was
added and intended to be available to interact with moisture
bearing effluents in use.
[0006] Hydrophilic urethane polymer foams in the prior art are
described in U.S. Pat. Nos. 4,137,200; 4,339,550; 5,976,847 and
others, as well as in Polyurethane's Chemistry and Technology by
Saunders and Frisch, Volume XVI Part 2, High Polymer Systems. The
primary departure from conventional prior art non-hydrophilic
urethane foam is in the polyol component. Utilizing a hydrophilic
polyol reacted with isocyanate provides a hydrophilic urethane
prepolymer. Mixing this hydrophilic urethane prepolymer with water
results in a hydrophilic urethane polymer foam product. Adding an
agent into the water results in a formed hydrophilic urethane
polymer foam composite or product containing the agent. If the
formed hydrophilic urethane polymer foam composite including agent
is subsequently contacted with an outside aqueous-based effluent,
the agent may interact with the effluent for an intended purpose.
In this prior art hydrophilic urethane polymer foam composite
technology, the contact between the agent and the effluent, or the
expression of agent into effluent, is controlled by the inherent
hydrophilicity of the urethane polymer foam carrier. However,
hydrophilic urethane polymer foam composites in accordance with
such prior art techniques lack and do not provide any controlled
release of the agent or agents on contact with water or an
aqueous-based effluent.
[0007] It has been discovered that an improved controlled release
urethane polymer or co-polymer foam composite or product in
accordance with the present invention can be formed or obtained by
combining an aqueous formulation consisting of a limited amount of
superabsorbent polymer or copolymer, an agent or agents, optionally
and selectively additives and adequate water with a hydrophilic
urethane prepolymer. The agent or agents include, without
limitation, detergents, soaps, waxes, polishes, abrasives, solid
particles, drugs, cosmetics, biologicals, volatiles and chemicals.
This improved composition slows and materially reduces the release
of such agent or agents to a much greater extent than the known
prior art products. Further, granules or particulate compositions
formed with such compositions are adapted for cleaning, scrubbing,
abrasion, waxing, polishing, bonding, odor-controlling, catalyzing,
absorption and other chemical mass transfer applications, purposes
and uses.
SUMMARY OF THE INVENTION
[0008] Thus, in one aspect, the controlled release urethane polymer
foam product when used herein is a granulated or particulate
composition of formed hydrophilic polyurethane foam, containing a
limited quantity of superabsorbent polymer or copolymer and up to
ninety percent (90%) solid agent or agents and optionally and
selectively additives which, when exposed to an aqueous effluent,
will enable the agent or agents, and additives if any, to be
gradually released or exposed for at least one or more given
reactions or functions with the aqueous effluent.
[0009] Such controlled release urethane polymer foam products in
granular or particulate composition in accordance with the present
invention differ from the impermeable characteristic of
conventional hydrophilic urethane polymer foam products formed in
accordance with the prior art technology and are easily
identifiable because of their water absorption capability in that
they will swell up to one hundred fifty percent (150%) of their dry
volume.
[0010] It is another aspect of the present invention that the
compositions of the controlled release urethane polymer foam
products formulated and generated in accordance with the present
invention, which include a specific agent or agents or additives
such as biological or bacterial additives, can be ground or
granulated or formed in a predetermined size and, when enclosed in
a filter housing, serve as a filter, for example, of noxious waste
water.
[0011] It is another aspect of the present invention that a
granulated or sized particle form of the controlled release
urethane polymer foam product embodying a homogeneous mixture of
odor control and absorption agents, and a selected additive or
additives if any, will provide a litter composition for absorbing
animal urine and semi-solids and for controlling noxious odors in
animal litter boxes or, when placed in a suitable perforated
housing or container, will control noxious odors from garbage,
tobacco, diapers, vomit, liquor, gasoline, fish and other
odoriferous substances.
[0012] In still another aspect, the present invention covers
hydrophilic polyurethane foam products with agents such as
detergents, soaps, abrasives, waxes, polishes, drugs, cosmetics,
biologicals, volatiles, chemicals and the like and optionally and
selectively additives, formed into granules or sized particles in
which the agents, and/or additives if any, are incorporated
generally uniformly into the matrix or supporting strands, fibers
and intercellular gaps of the formed foam, and will provide a
granular or sized particulate controlled release urethane polymer
foam product from the reaction product obtained by combining an
aqueous formulation having a limited quantity of a superabsorbent
polymer or copolymer, an agent or agents and optionally and
selectively additives and adequate water with a hydrophilic
urethane prepolymer to produce a formed hydrophilic urethane
polymer foam product having unique properties such that, when
wetted, or subjected to an aqueous effluent, the formed hydrophilic
polyurethane foam product will act to slow the release of the agent
or agents, and any selected additive if any, with or into the
wetting effluent, to enable the formed product to provide extra and
additional applications or more intimate mass transfer of the
agents, and the selected additives if any, during use than those
presently obtainable from similar products now known in the prior
art.
[0013] It is another aspect of the present invention to provide a
method for formulating and forming such granular or sized
particulate controlled release urethane polymer foam products
including the steps of:
[0014] a) metering and mixing an aqueous formulation having at
least a limited quantity of superabsorbent polymer, an agent or
agents and adequate water, with a predetermined ratio of
hydrophilic urethane prepolymer to provide a polymerizing mixture
for forming the controlled release urethane foam product;
[0015] b) depositing the polymerizing mixture on releasable bottom
paper disposed on a movable carrier and covering the upper surface
of the polymerizing mixture with releasable top paper as the
polymerizing mixture is moved with the carrier;
[0016] c) advancing the polymerizing mixture in the top and bottom
release paper by moving the carrier;
[0017] d) sequentially removing the top and bottom releasable paper
while simultaneously drying the sized and formed product to remove
residual moisture; and
[0018] e) passing the sized and formed controlled release urethane
polymer foam product to secondary operations such as granulation or
particulate sizing to provide shaped and sized particulate
compositions and products for particular applications and uses.
[0019] In still another aspect of the present invention to provide
a method for formulating and forming the granulated or sized
particulate controlled release urethane polymer composition or
products, in which all the steps are the same as those above
described except that step c is modified as follows:
[0020] c) advancing the polymerizing mixture in the top and bottom
release paper by moving the carrier and sizing the foam layer being
formed to the desired thickness until it is tack free;
[0021] It is another aspect of the present invention to provide
formed shaped and sized granules or particulate of controlled
release urethane polymer foam compositions or products with
abrasive characteristics from a polymerized combination of an
aqueous mixture having, a limited quantity of a superabsorbent
polymer, agents from the group of a sized quantity of abrasive
particles and adequate water with a predetermined quantity of
hydrophilic urethane prepolymer, in which the agent or agents
including the abrasive particles are incorporated into the matrix
or supporting strands and fibers and the intercellular structure of
the formed foam to provide unique properties, applications and uses
such as animal litter, and filling devices.
[0022] It is another aspect of the present invention to provide a
method for formulating and forming such granular or sized particles
of the controlled release urethane polymer foam compositions or
products with abrasive particles homogeneously dispersed
therethrough including the steps of:
[0023] a) metering and mixing an aqueous formulation having at
least a quantity of superabsorbent polymer, an agent or agents, a
sized quantity of abrasive particles and adequate water with a
predetermined ratio of hydrophilic urethane prepolymer to provide a
polymerizing mixture for forming the controlled release urethane
foam product with abrasive characteristics;
[0024] b) depositing the polymerizing mixture on releasable bottom
paper disposed on a movable carrier and covering the upper surface
of the polymerizing mixture with releasable top paper as the
polymerizing mixture is moved with the carrier;
[0025] c) advancing the polymerizing mixture in the top and bottom
release paper by moving the carrier and sizing the foam layer being
formed to the desired thickness until it is tack free;
[0026] d) sequentially removing the top and bottom releasable paper
while simultaneously drying the sized and formed product to remove
residual moisture; and
[0027] e) passing the sized and formed controlled release urethane
polymer foam composition or product with abrasive characteristics
to secondary operations such as granulation or particle sizing, to
provide shaped and sized products for particular applications and
uses.
[0028] It is a still further aspect of the present invention to
provide a ground or granulated or sized particles of the controlled
release urethane polymer foam compositions or products in
accordance with the present invention to absorb and retain various
liquids and semi-solids and to control noxious odors from a
polymerized combination of an aqueous mixture having, a limited
quantity of superabsorbent polymer, a selected acid, neutral and
alkaline odor control agent or agents and optionally and
selectively additives and adequate water with a predetermined
quantity of hydrophilic urethane prepolymer to provide the formed
composite formulated and comminuted to the desired particle size
for the given application and use.
[0029] It is a still further aspect of the present invention to
provide a method for formulating a ground or granulated or sized
particulate controlled release urethane polymer foam composition or
product for the control of obnoxious odors and adapted to absorb
various liquids or semi-solids and for the control of noxious odors
including the steps of:
[0030] a) metering and mixing an aqueous formulation having at
least a limited quantity of superabsorbent polymer, at least one
acid, neutral and alkaline odor control agent or agents, optionally
and selectively additives and adequate water with a predetermined
quantity of hydrophilic urethane prepolymer to provide a
polymerizing mixture for forming the controlled release urethane
foam product with absorption characteristics and the control of
noxious odors;
[0031] b) depositing the polymerizing mixture on releasable bottom
paper disposed on a movable carrier and covering the upper surface
of the polymerizing mixture with releasable top paper as the
polymerizing mixture is moved with the carrier;
[0032] c) advancing the polymerizing mixture in the top and bottom
release paper by moving the carrier and sizing the foam layer being
formed to the desired thickness until it is tack free;
[0033] d) sequentially removing the top and bottom releasable paper
while simultaneously drying the sized and formed product to remove
residual moisture; and
[0034] e) passing the sized and formed controlled release urethane
polymer foam composition or product to a comminuting or sizing
device set to provide the desired particle size of the formed
composition or product for the particular applications and
uses.
[0035] These and other aspects and advantages of the present
invention will be better understood from the detailed description
which follows below when taken with the FIGURES of the
drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0036] FIG. 1 is a schematic illustration of a portion of the
strands, fibers and intercellular gaps in the matrix or supporting
structure for a formed foam granulated or sized particulate
controlled released urethane polymer foam composite or product in
accordance with the present invention having an agent or agents and
selected additives homogenously dispensed therethrough.
[0037] FIG. 2 is an enlarged cross-section taken on line 2-2 of the
strands of the supporting structure of the matrix shown in FIG. 1
of the drawings.
[0038] FIG. 3 is a schematic diagram showing the mechanical steps
for one method of formulating a sized particulate controlled
release urethane polymer composite or product in accordance with
the present work.
[0039] FIG. 4 is a further schematic illustration for selecting the
sized particulate controlled release urethane polymer foam
composition or product with means to add liquids or solids to the
sized formed particles in conjunction with the formulation, size
selection and packaging of the commercial product for marketing
purposes.
DETAILED DESCRIPTION
[0040] Controlled release urethane foam products in accordance with
the present invention take various forms because of the myriad of
agents that can be embodied into the matrix or supporting strands,
fibers and intercellular structure of the formed foam compositions
or product and the multiplicity of applications and uses to which
such products can be applied or adapted.
[0041] One basic form of the controlled release urethane foam
products in accordance with the present invention is formulated and
formed, as hereinafter more fully described, by combining an
aqueous mixture of a limited quantity of superabsorbent polymer,
one or more agents from the group, detergents, soaps, abrasives,
waxes, polishes, biologicals, volatiles and the like materials, and
additionally optionally and selectively additives if any, with a
predetermined ratio of a hydrophilic urethane prepolymer to provide
a polymerizing mixture so that during polymerization the agent or
agents and any additive, if any, will be incorporated and bound
into the matrix or supporting structure of the formed urethane foam
product.
[0042] The absorbent polymers or superabsorbent polymers or
copolymers in such formulations are preferably sodium
polyacrylate/polyalchohol polymers and co-polymer sorbents
described in U.S. Pat. Nos. 5,763,335 and 4,914,170, purchasable in
the commercial marketplace.
[0043] The detergent agents used in the formulation of the
granulated or sized particulate controlled release urethane polymer
foam compositions or products are those surfactant chemicals
commonly available and known to those skilled in the art to satisfy
hard surface cleansing, skin cleansing, rug cleansing and other
cleaning tasks such as in detergents sold as "LYSOL APC, SIMPLE
GREEN, 409, MR. CLEAN, SOFT-SCRUB, RESOLVE CARPET CLEANSER", etc.
all registered trademarks. These trademarked products illustrate a
combination of surfactants, solvents and other miscellaneous
ingredients. Any soaps or detergent formulations may thus be
considered as the agent. In some cases, more than one agent may be
utilized in the formulation of the granulated or sized particulates
controlled release urethane polymer form compositions or products
in accordance with the present invention as a function of the
application or use for the particular composition or product.
[0044] The abrasive agents used in the formulation of the
granulated or sized particulate controlled release urethane polymer
foam compositions or products are classified into at least two
groups. The first group would be particles that have (a) low
abrasive qualities such as diatomaceous earth, (b) medium abrasive
qualities such as feldspar, and (c) high-abrasive qualities such as
silica. The second group would be sheet stock abrasives in the form
of (a) non-woven fiber such as those commercially available as
Scotchbrite.RTM., floor cleaning pads and Buf-Puff.RTM.; (b) woven
or paper adhesively bonded sheets such as sandpaper; and (c)
naturally occurring abrasive materials such as Loofah, Apricot
Seed, crushed Walnut shell, crushed Jojoba shell and the like.
Abrasives will function to polish, abrade or remove substrate
materials over which the foam composite is rubbed.
[0045] The wax agents used in the formulations of the granulated or
sized particulate controlled release urethane polymer foam
compositions or products are materials which impart a shine on a
secondary surface with which they are brought in contact and
include crystalline waxes, paraffin waxes, wax emulsions and
silicone fluids such as:
1 POLISHING APPLICATION WAX AGENT Vinyl Furniture Metal Shoe Auto
Crystalline X X X wax Paraffin X X X wax Wax X X emulsions Silicone
X X X X X fluids
[0046] The drug agents used in the formulation of the granulated or
sized particulate of controlled release urethane polymer foam
compositions or products may be any medicament or pharmaceutical
used to alter the body response such as vitamins, analgesics,
vaccines, spermicides and the like.
2 DRUG AGENT APPLICATION Ben Gay Analgesic wrap Desitin Diaper rash
protective pad Vitamin C Skin enhancement Nonoxynol 9 Contraceptive
Iodine Germ Kill
[0047] The cosmetic agents used in the formulation of the
granulated or sized particles of controlled release urethane
polymer foam products are those chemical materials established to
alter the external appearance, feel or smell of a human or animal
body such as, by way of illustration and not limitation, skin
conditioners, hair color dyes, hair shampoos, fragrances, lip
glosses, nail polishes, aqueous dispersible body powders and liquid
emulsions, etc.
3 COSMETIC AGENT APPLICATION Sodium laurol sarcosinate maximizes
suds Sodium laureth sulphate copious suds Anionic surfactants skin
cleaning Citric acid PH modifier Isothionate skin softener
[0048] The biological agents used in the formulation of the
granular or sized particles of controlled release urethane polymer
foam compositions or products are those materials produced by or
consisting of live cells that react with aqueous effluent which
include, by way of illustration and not limitation, bacteria, plant
cells, viruses, algae and fungi.
4 BIOLOGICAL AGENT APPLICATION Azolla (plant) scrub heavy metals
Jimson weed (plant) scrub radioactivity Chlorella (green algae)
scrub heavy metals Pseudomonas (bacteria) scrub heavy metals Yeast
strain R14 (yeast) scrub heavy metals
[0049] The chemical agents used in the formulation of the
granulated or sized particles of controlled release urethane
polymer foam compositions or products not specifically embodied in
the agents as above identified include materials intended to enable
a secondary reaction when the formed foam product is contacted by
an aqueous effluent such, for example:
5 THE AGENT OR ADDITIVE APPLICATION OR USE Human Blood Absorb
oxygen from water Odor Absorbent Destroy noxious odor materials
Phase Change Agents Absorb and release BTUs Baking Soda Agents
Alkalize acid solutions Cellulose Fibers Absorption and tensile
strength
[0050] Any of the agents from the groups enumerated may first be
formed in an aqueous premix solution with a typical surfactant
material and then added to the aqueous mixture to be combined with
the hydrophilic urethane prepolymer. Surfactants may be used with
the agents in the aqueous mixture to increase the concentration of
the selected agent or agents in the aqueous mixture. The
surfactants are preferably present in amounts of about 0.5% to
about 3.5% by weight of the aqueous mixture. The surfactants may be
prepared from anionic polyoxyethylene and polyoxypropylene oxides
such as BASF surfactant, available under the trademark "PLURONIC".
Other surfactants known as anionics, cationics and or
zwitterionics, singularly or in combination, can be added to the
formulation, as known by those skilled in the art, to satisfy
specific needs.
[0051] The aqueous mixture may further consist of various
combinations of other selected additives without departing from the
scope of the present invention, including, for example, germicides,
bactericides and fungicides. Such products are provided in the
commercial marketplace by a myriad of suppliers for controlling
germs, or bacterial and fungal growth. One preferred material
available in the commercial marketplace is supplied by Lauricidin
Co. of Galena, Ill. 61036, under the trademark "LAURICIDIN".
[0052] In those applications desiring biocidal protection, the
selected agent is added into the aqueous phase at the proper rate
so as to function yet be safe to handle. Typical prior art volume
of such agent when added is less than 1% by weight of the aqueous
mixture. However, it has been discovered that up to ten percent
(10%) by weight of an active anti-bacterial may be added in the
formulations in accordance with the present invention without
adverse results. It is believed that the controlled release
characteristics of the composition and products so formulated
prevents any skin irritation or problems.
[0053] In addition, volatile agents and volatile additives may be
used in the formulation of the granulated or sized particles of
controlled release urethane polymer foam compositions or products
in accordance with the present invention. Such volatiles are
materials having a low boiling or subliming temperature at
atmospheric pressure that vaporize to produce a secondary reaction
as is the case with fragrances and solvents.
[0054] Thus, an agent or agents, when used herein, are any active
ingredients added into the aqueous formulation for composites or
products in accordance with the present invention prior to
polymerization that will provide a desired end result for the
application and use of the formed controlled release urethane
polymer foam composites or products. Accordingly, the agents as set
forth above are only by way of illustration and not limitation of
the formed granulated or sized particulate controlled release
urethane foam composites or products in accordance with the present
invention.
[0055] During polymerization, water soluble agents and the selected
additives if any, are incorporated homogenously into the matrix or
strands, fibers and intercellular supporting structure of the
granulated or sized particulates of the formed foam compositions or
products. These agents and additives, if any, remain bound in
position in the matrix until the granulated or sized particulate of
the formed foam composition or products are wetted or contacted by
sufficient moisture to activate the agents in the granules or sized
particles of such formed foam compositions or products, at which
time one or more of the agents and such additives if any, present
are slowly released from the matrix or supporting strands, fibers
or intercellular structure of the formed foam granulated or sized
particulates compositions or product and diffuse toward the
surface, where they can be put to use for cleaning, scrubbing,
waxing, polishing, controlling noxious odors, as the case may be,
for a given agent or agents and the selected additive, if any, for
a given application or use. Non-water soluble solid agents such as
abrasives incorporated in the granules or size particulates of the
formed controlled release urethane polymer foam composition or
products remain bound in situ for contact with and to effect a
change in the aqueous effluent such as binding a component of the
aqueous effluent to the agent. It is noted that in some cases, the
agent may be added to the prepolymer rather than the aqueous
mixture during formulation, particularly when the agent is
anhydrous or oil-based.
[0056] FIG. 1 of the drawings shows diagrammatically an enlarged
fragment of the foam matrix generally designated 10 for a granule
or sized particle of the controlled release urethane polymer foam
of a composite or product formulated in accordance with at least
one of the methods of the present invention.
[0057] Matrix 10 from the polymerizing step for formulating the
foam composition or product is a mesh of interconnected strands and
fibers 11 defining the supporting structure for the matrix, and
formed therein are intercellular air spaces or gaps 12.
[0058] FIGS. 1 and 2 also show that the agent or agents 13 and
additives 14 are generally uniformly deposited and bonded in, out,
along and through the strands and fibers 11 and the intercellular
air spaces or gaps 12 formed by and in the supporting structures
for the matrix.
[0059] The aqueous mixture is prepared by conventional batch mixing
in blending apparatus 15 where the selected agent or agents, and
optionally and selected additives are mixed in a volume to satisfy
the intended application and use. Thus the water is added first
into the blender 15, the agent is blended in or emulsified in with
a surfactant, then the superabsorbent polymers and the additives if
any, are added and the aqueous mixture is intimately mixed.
[0060] This aqueous mixture includes, the superabsorbent polymer in
a range from 0.05% to 10% by weight, and preferably about 0.6% by
weight, at least one or more of the group of agents from 0.1 to 15%
by weight and preferably 6% by weight, water in a range from 15% to
85% by weight and preferably about 30% by weight with hydrophilic
urethane prepolymer in a range from 0.25% to 80% by weight and
preferably 30% by weight.
[0061] The hydrophilic urethane prepolymer is dispensed from a
storage tank 16 through line 17 into a mixing and dispensing
apparatus 18. The blended aqueous mixture is also passed from
blending apparatus 15 through line 19 to the mixing and dispensing
apparatus 18 in the proper stoichiometric quantity to initiate
polymerization. The polymerizing mixture 20 is dispensed through
the dispensing head or outlet 21 for the mixing and dispensing
apparatus 18 onto releasable bottom paper 22 traveling on a
continuous conveyer 23 where it first passes the releasable bottom
paper 22 enter dispensing outlet 21 to secure a layer of the
polymerizing mixture thereon. Now, the polymerizing mixture and
releasable bottom paper 22 traveling with this continuous conveyer
23 are moved through a drying oven 24.
[0062] Hydrophilic urethane prepolymer available in the commercial
marketplace is a water reactive 10,000-20,000 cps liquid and must
be intimately mixed with the above described aqueous mixture of a
limited quantity of superabsorbent polymer, agent or agents, and
optionally selected additives to initiate polymerization.
[0063] Suitable hydrophilic urethane prepolymer for use in the
present invention are known and will be readily recognized by those
of ordinary skill in the art from U.S. Pat. Nos. 5,763,335;
4,209,605; 4,160,076; 4,137,200; 3,805,532; 2,999,013; as are the
general procedures for the preparation and formation of such
prepolymers which can be found in Polyurethane's Chemistry and
Technology by J. H. Saunders and K. C. Frisch published by John
Wiley & Sons, New York, N.Y., at Vol. XVI Part 2. High Polymer
Series. "Foam Systems", pages 7-26, and "Procedures for the
Preparation of Polymers", pages 26 et seq. One preferred prepolymer
for use in the present invention is sold under the trademark BIPOL
6 by Mace Adhesives and Coatings. Another prepolymer suitable for
use in the present invention is sold under the trademark HYPOL by
The Dow Chemical Company. Still another prepolymer for use in the
present invention is sold under the trademark PREPOL by Lendall
Manufacturing Incorporated. These prepolymers are suitable for the
present invention because of their strong hydrophilic
characteristic and reasonable cost.
[0064] Admixing the aqueous mixture with a predetermined ratio of
the precise amounts of the hydrophilic urethane prepolymer
initiates polymerization. The physical characteristics such as
density and tensile strength are controlled by the ratio of
prepolymer in the aqueous mixture to produce controlled release
urethane polymer foam composition or product, which composition or
product can be granulated, ground, comminuted or sized to provide
granular or sized particulate controlled release urethane foam
compositions or products in accordance with the present
invention.
[0065] The formulation of the granules or sized particles of
controlled release urethane polymer foam composite or products is
schematically illustrated in FIGS. 3 and 4 of the drawings.
[0066] Thus, referring further to FIG. 3, the releasable bottom
paper is removed from the formed controlled release urethane
polymer foam composition or product and continues to travel on the
roller type conveyer 25 where it is discharged onto a grinder or
comminuting apparatus 26 which delivers the comminuted or ground
controlled release urethane polymer foam composition or product to
one end of an auger type feed assembly 27 for passing the
comminuted or ground composition or product to the upper or inlet
end of a rotary screener 28.
[0067] Rotary screener 28 has outlets for three sizes of the
comminuted or ground composition or product, an oversized outlet at
29; an undersized outlet at 30 and an acceptable or desired sized
outlet as at 31.
[0068] FIG. 4 schematically shows the further steps for preparing
the acceptable sized granular or particulate controlled release
urethane polymer foam composition or product for packaging and
marketing into the commercial marketplace. Thus, the acceptable
sized compositions or products from the acceptable sized outlet 31,
are dispensed into one end of an auger feed and metering device 32
which passes the comminuted or ground composition or product past
liquid metering spray head 33A and 33B. Any liquid or solid
additions to the granular or sized particulates can even be applied
to the granular or sized particles after the controlled release
urethane polymer foam composite or products have been formed,
subjected to moisture removal and comminution is complete.
[0069] The weight packer 34 has filling buckets 35a, 35b, 35c and
35d which deposit a pre-determined quantity of the granular or
sized particulate controlled release urethane foam composition or
product into marketing containers as at 36a, 36b, 36c and 36d.
These marketing containers can be delivered by conveying apparatus
37 to the delivery point for transport into the commercial
marketplace.
[0070] The present invention may be formulated as a composition of
dry particles with odor control agents uniformly dispersed
therethrough so that the formed controlled release urethane foam
product in the sized and shaped particulate form can act both to
absorb and retain noxious liquids such as urine and semi-solid
waste materials such as feces and also control or modify noxious
odors.
[0071] While the particulate form of the controlled release
urethane foam product with odor control agent is particularly
adapted for use as an animal litter for the absorption and
retention of animal urine and feces and for controlling or
modifying the noxious odors associated therewith, it also can be
applied for the absorption, adsorption, retention, control and
modification of pleasant odors or for noxious odors emanating from
garbage, tobacco, kitchens, bathrooms, bedding and other sources,
for example, by the use in filters or perforated containers
containing quantities of the granular materials or when possible by
direct sprinkling or contact.
[0072] Prior art animal litters composed of clays, shredded paper,
wood chips and inorganic fiber have claimed the ability to remove
odor and agglomerate urine. Control of odor in prior art is
attempted by masking or absorbing. Masking is defined as
overpowering the objectionable odor with an acceptable odor.
Absorbing is defined as trapping the odor in a porous shell. It has
been discovered that both solutions represent problems:
[0073] Masking Agent Problems
[0074] 1. hard to distribute uniformly in each particle
[0075] 2. ceases to function after evaporation
[0076] 3. high volume required to make up for evaporation
[0077] 4. known to create animal aversion to using litter
[0078] Absorbent Agent Problems
[0079] 1. differential density and particle size causing
separation
[0080] 2. odor releases with stress or temperature
[0081] Also, prior art litter suffers from maintaining its
structural integrity wherein urine excretions in the form of a
liquid stream dissolve particles, leaving a puddle of urine on the
floor of the litter box. The puddle is then prevented from contact
with any means of odor control in prior art litter. This
uncontrollable odor generation can necessitate a change of the
entire box of animal litter. Clumping agents, such as
superabsorbent polymers, gums, borax and alginates, have been added
to prior art animal litter to minimize this problem by increasing
the integral strength and clumping ability of the prior art
materials. However, such clumping agents, due to differences in
their specific gravity and particle size, tend to separate from the
prior art animal litter materials. As a result, the prior art
litter materials with such additives create a non-homogenous end
product, which does not make uniform contact with the urine and
thus fails to overcome the offensive or noxious odor.
[0082] In addition to the above, another major problem encountered
by the prior art animal litter materials is their potential for
--dusting--. Inappropriate handling, during shipment or the action
of the animals using the animal litter, creates frictional rubbing
forces between the particles, which reduce particle size and
generate dust. This dust can be picked up and tracked by the
animal's paws and transferred to other surfaces throughout the
house, such as floors and furniture. Further, handling such
dust-laden animal litter exposes the environment and the user to
objectionable and potentially harmful contaminants.
[0083] It has been conveniently discovered that the preferred
method of the present invention animal litter for controlling or
modifying odors from the deposited urine and fecal matter is by
neutralization of the noxious odors. Neutralization is the
permanent chemical conversion of the noxious odor into a non-toxic
stable compound. The key to chemical conversion is contact of the
neutralizer with the offensive odor.
[0084] The particulate form of the controlled release urethane foam
product with odor control agents meets and overcomes prior art
problems, particularly odors that produce objectionable olfactory
sense reactions. The objectionable odors are overcome by providing
agents, which react with the odors and convert them into harmless
non-toxic stable chemical compounds in accordance with the
following formulae:
6 ACID ODOR CONTROL NEUTRALIZERS H2S + R--COONa = Na2S + NaHS
Hydrogen Salt in Odor Sodium Sodium Sulfide Control Agent Sulfide
Hydrosulfide
[0085]
7 ALKALINE ODOR CONTROL NEUTRALIZERS NH3 + R--COOH = R--COONH4
Ammonia Acid in Odor Organic Salt Control Agent
[0086] The preferred odor control agent is a proprietary amphoteric
formulation using naturally occurring materials, which react with
odor-causing gases of organic and inorganic materials, and converts
them into odorless, stable and non-toxic compounds. It is sold in
the commercial marketplace under the brand name APPTECSORB. Other
odor control agents, which may operate in a different manner, such
as the products sold in the commercial marketplace under the brand
names ODOR-X, FEBREZE, or dio-esters from Robertet, may also be
used without departing from the scope of the present invention.
[0087] The most important aspect of any odor-controlling agent is
that it must be homogenously incorporated to insure contact and
maximum mass transfer with the noxious odor. In addition, the
litter must contain means to spread urine or other waste materials
radially through the litter to prevent puddling and to insure that
each formed homogenous particle will have sufficient integral
strength, wet or dry, to insure that it remains dust-free during
normal use.
[0088] The comminuted or sized particulate controlled release
urethane polymer foam composition or product with odor-controlling
agents obtained from a polymerized combination of an aqueous
formulation having a limited quantity of superabsorbent polymer, at
least one odor control agent from the group of acidic and alkaline
odor control neutralizers, optionally and selectively at least one
additive and adequate water with a predetermined ratio of
hydrophilic urethane prepolymer, provides a product in which the
odor control agent or agents, and additives if any, are uniformly
and homogeneously disposed throughout the matrix or supporting
structure of the dried and formed foam product so this product can
be ground or comminuted to reduce the product to dry particles
having a predetermined size in which the odor-controlling agents,
if any, are uniformly and homogeneously disposed. The dry particles
of this formed foam product can be packaged and sold and applied in
this form for various applications and uses.
[0089] The superabsorbent polymer or copolymers in the aqueous
formulation will be the same ones as above described for the
earlier forms of the granular or sized particulate forms of the
controlled release urethane polymer foam compositions and products
and therefore requires no additional comments.
[0090] Dependent on the particular application and use, the
preferred odor control agent to react with acidic, neutral or
alkaline gaseous odors can be selected from a plurality of products
available from APPTECSORB. Because these commercially available
products are water soluble and the hydrophilic urethane prepolymer
is water activated to establish the formed foam product, variable
loading of the odor control agent selected is easily obtained by
changing the ratio of the selected odor control agent in the
aqueous formulation mixed with the hydrophilic prepolymer to
establish polymerization. Thus, active loadings in a range from
0.5% to over 90% by weight of the selected odor control agent can
be obtained.
[0091] The hydrophilic urethane prepolymers are also the same as
those above described for the earlier form of the controlled
release urethane foam products and therefor require no further
description for this comminuted form of the formed foam product in
accordance with the present invention.
[0092] After the solid homogeneous controlled release urethane foam
product with the odor control agents, and optionally and
selectively additives, has been formed and dried, it can be
comminuted to a size to satisfy the particular application or use.
Particle sizes generally can be in a range from 60 mesh to 4 mesh
and, preferably for animal litter, about 50 mesh. However, those
skilled in the art will recognize the mesh size of the particles
can be smaller or larger depending on the application or use for
the dry homogeneous controlled release urethane foam product.
[0093] The density of the dry formed foam product created by
admixing the aqueous formulation with the hydrophilic urethane
prepolymer is approximately 3 lbs./cu. ft. This density can be
increased by the addition of any solid fillers which aid the
particular application or use. For example, clays, feldspar, sand,
ground fibers etc. may be added to the odor control agent and water
of the aqueous mixture to effect higher densities. Densities
approaching 50 lbs./cu. ft. have been achieved. In order to lower
densities for an application where the product wants to float on
water, for example, a solids filler such as hollow micro spheres
such as 3M's K1 hollow glass beads may be added. Densities are
selected based on the particular application or use. For example, a
product used in a cat litter box may be designed to be lighter than
conventional litter but not so light as to pick up on paws or
tracked out of the animal litter box. Applications which do not
require weight, such as those for controlling odor from vents in
septic systems, are prepared with no filler additions. Solid filler
additions are incorporated into the formed foam particles and will
not wash out of the particles when they are saturated. To enhance
this binding, a coupling agent such as silane A1120 from OSI may be
utilized as an optional additive in the makeup of the aqueous
formulation. If silane is used, it is added to the aqueous
formulation at approximately one percent (1%) by weight of the
solids filler.
[0094] The following examples will aid in demonstrating controlled
release urethane foam granulated or sized particulate products in
accordance with the present invention.
EXAMPLE 1
[0095] A controlled release granulated urethane foam product for
use as a garbage disposal cleaner was prepared by combining a
aqueous mixture containing the following ingredients by weight:
8 Ingredients Percent by Weight Water 46.55 Superabsorbent HS-80
.45 Stockhausen Wollastonite 325 mesh 25.00 abrasive Nyco, N.Y
Silane A1120 OSA .195 Pluronic F-88, BASF 2.00 Color .05 Lauricidin
Med-Chem Labs MI .75 EDTA Akzo Nobel .0075 With Hydrophilic
urethane 25.00 Prepolymer
[0096] The mixed aqueous and prepolymer was deposited directly onto
release paper and advanced downstream till cured. Excess residual
moisture was driven off in an oven at approximately 250.degree. F.,
the release paper was removed and the sheet was granulated into
particles of 6-14 mesh in a Cumberland grinder. The lot of foam
particles was split into two halves and continued processing
included:
[0097] First Lot
[0098] To the weight of foam particles was intimately blended 1% by
weight of N 300A odor control Agent AppTec N.J. To this was added
3% by weight of citric acid powder.
[0099] Second Lot
[0100] To the weight of foam particles was intimately blended 1% by
weight of N 300S odor control AppTec, and 10% by weight of sodium
bicarbonate, Arm Hammer RTM Baking Soda.
[0101] Lots 1 and 2 were blended to provide a dry granulated
particulate which, when placed into a running in-sink garbage
disposal with water, would clean and disinfect the unit.
EXAMPLE 2
[0102] A controlled release urethane foam product for use as a
litter material was prepared by combining a formulation containing
the following ingredients by weight:
9 Ingredients Percent by Weight Water 30.91 F88 Pluronic surfactant
.28 BASF Feldspar filler Feldspar 46.68 Corp. Silane coupling agent
A1120 .49 OSI Color pigment Vivitone 1.67 Germaben II bacteriacide
.83 Germall Guar gum 2.00 Superabsorbant HS80 .48 Stockhausen
Prepolymer 16.66
[0103] The foam sheet was processed as in EXAMPLE 1, dried,
granulated and separated by weight into two batches. To each batch
was then added a 0.5% by weight of Apptec "S" or Apptec "A", odor
control agent. The difference being in the control of acidic or
basic odors. The two batches were then blended together to produce
a litter material to control odor, agglomerate or clump liquids,
maintain wet integrity, remain dust free, be homogenous, and absorb
more liquid than prior art litter. The function of the
superabsorbent aids in agglomeration of liquids or semi-solids for
removal.
EXAMPLE 3
[0104] A controlled release urethane foam product for use as a
litter material was prepared by combining a formulation containing
the following ingredients by weight:
10 INGREDIENTS PERCENT BY WEIGHT Water 54.36 F88 Pluronic
surfactant .48 BASF Feldspar filler Feldspar 20.00 Corp. Silane
coupling agent A1120 .20 OSI V-Gum Regular thickener 1.6 Vanderbilt
Color pigment Vivitone 1.88 Germaben II bacteriacide 1.00 Germall
Superabsorbent HS80 .48 Stockhausen with Hydrophilic Urethane 20.00
Prepolymer
[0105] The foam sheet was processed as in EXAMPLE 1 dried,
granulated and separated into two batches. To each batch was then
added a 0.5% by weight of Apptec "S" or Apptec "A", odor control
agent. The difference being in the control of acidic or basic
odors. The two batches were then blended together to produce a
litter material to control odor, maintain wet integrity, remain
dust-free, be homogenous, and absorb more liquid than prior art
litter. The function of the superabsorbent is to agglomerate
liquids or semi-solids for removal.
EXAMPLE 4
[0106] A controlled granulated urethane foam product for use as a
mass transfer complexing material to complex with and absorb
toluene in a gas stream was prepared by combining an aqueous
mixture containing the following ingredients by weight:
11 Ingredients Percent by Weight 1% F88 solution BASF 15.4 Ultra I
Ultra One Corp. 15.4 Feldspar NC 4 Feldspar 38.5 Corp. Hydrophilic
Urethane 30.7 Prepolymer
[0107] Foam was processed by combining the first three components
listed, described as the aqueous phase. The aqueous phase was then
metered in a ratio simultaneously into a mix head. The mix was
dispensed onto a releasable paper traversing on a movable conveyer.
After foam rise and cure excess moisture was driven off in an oven
at 250.degree. degrees F. The paper was stripped off and the foam
sheet was continuously fed to a Cumberland Grinder for granulation.
The granulated foam was then sized through vibratory screens to
separate the granules into proper mesh particles.
[0108] In use the particles were suspended onto a screen in a
filter housing. An effluent gas stream laden with toluene was run
through the particles and tested for breakthrough toluene at the
output side of column. Test results showed that the granules of the
present invention were superior to a similar volume of activated
carbon.
[0109] The embodiments described in the Examples above should
provide adequate details of the invention. However, it should be
noted by those skilled in the art that the disclosures herein are
exemplary only and that various other alternative adaptations and
modification may be made within the scope of the present invention.
Accordingly, the present invention in not limited by the specific
embodiments of the Examples as illustrated. It is therefore to be
understood that numerous modifications may be made to the
illustrated embodiments of the Examples and that other arrangements
may be devised without departing from the spirit and scope of the
present invention as defined by the appended claims.
* * * * *