Patent Description:
The production of flexible polyurethane foam is done in a batch molded form or continuous slabs are used as either a carrier or tunnel. These two methods are very different from each other and there are various patents related to this subject. In the patent <CIT> and <CIT>, the production of continuous slabstock flexible polyurethane foam is described in detail. In continuous slabstock polyurethane foam production, there is a tunnel, a conveyor in the tunnel, a mixing head and a line (piping) and a pump for discharging the reaction mixture from the mixing head to the conveyor. When the foam is discharged into the hopper, the conveyor in the tunnel starts to move and the material flows over the conveyor, thus it is provided to rise and cure. As the first curing is completed after about <NUM>, the blocks are cut at certain dimensions and taken aside, and the continuity of production is ensured.

<CIT> is about the production of a batch-molded flexible polyurethane. Mold release agent is applied to the inner surface of the mold before production. The mold is heated to <NUM>* C. The use of the release agent applied to the mold is to prevent the adhesion of the flexible polyurethane foam. The polyurethane foam is injected into the mold. After the hardening step, the desired molded flexible polyurethane foam is removed from the mold.

However, the present invention is about the addition of produced as a suspension of magnetite particles (<NUM>) in polyol or mixture of natural magnetite particles (<NUM>) and polyol into the continuous slabstock flexible polyurethane foam (<NUM>) during production or with the addition of natural magnetite particles (<NUM>) or mixed with magnetite particles (<NUM>) or coating (<NUM>) of the magnetite particles (<NUM>) by means of a binder (<NUM>) onto the upper surface of the slabstock flexible polyurethane foam (<NUM>) after its production.

There are some patents related to an achievement of certain features to the polyurethane foam product using a number of particles such as silver, copper, iron, nickel, calcite, activated carbon etc. addition of during the production of flexible polyurethane foam. In the patent <CIT>, polymer matrix was made by addition of nano fillers into the polymer for isolation of the sound. This polymer matrix can also be open-cell flexible polyurethane foam. In <CIT>, magnetic material is added to the thermoplastic or thermoset polymer to provide electrical permeability. <CIT> relates to an insulating polyurethane foam having a coating comprising materials such as carbon nanotube or graphene, to increase the conductivity of the polyurethane foam and to use these products for the production of antistatic products.

In <CIT>, polyurethane foam having high absorption capacity and modified toxicity level was obtained by adding copper nanoparticles to provide antibacterial property. <CIT> discloses a matrix which provides a curative effect by coating the chitosan with silver nanoparticles embedded in on the cotton fabric. <CIT> discloses the use of magnetic particles in the organic polymer by means of a binder material for using magnetic recording. Furthermore, the present invention proposes to add magnetite particles (<NUM>) into the continuous slabstock polyurethane foam (<NUM>) during the production or to coat (<NUM>) the magnetite particles (<NUM>) with a binder (<NUM>) onto the upper surface of the slabstock flexible polyurethane foam (<NUM>) after the production.

Different production techniques of magnetite particles that are using number of polymeric materials and give certain properties to the system are described in the patents. In the <CIT>, porous ferro or ferrimagnetic particles were obtained by the addition of iron oxide particles and tetraethoxysilane solution in a mixture of ammonium chloride buffer solution (pH <NUM>) and ethanol for use as the isolation molecule. In the patent <CIT>, after the reaction of iron (III) oxide, iron (II) sulphate and sodium hydroxide at <NUM> C. for <NUM> hours, black precipitate was filtered to room temperature, washed with water and dried, and after this operation <NUM>-<NUM> microns Magnetite particles were obtained. In the patent <CIT>, pH of a mixture of iron (III) chloride and iron (II) chloride was adjusted to <NUM> with the addition of sodium hydroxide until the pH was <NUM> and after the reaction at <NUM> "C and <NUM> hours system started to cool down and separation of the salts was done by decantation and after the operation <NUM> % magnetite suspension was obtained. The N-polyalkyleneepolyamine-substituted alkenylsuccinate in the hydrocarbon solvent is added to this suspension and the resulting water and hydrocarbon solvent in the emulsion are removed by under-pressurization at <NUM>° C and the N-polyalkyleneepolyamine-substituted alkenylsuccinate adsorbed magnetite particles are washed and dried and added to the oil. The magnetic liquid is obtained after the ultrasonic mixing. In <CIT>, <CIT>, <CIT> and <CIT>, iron (II) sulfate was mixed with sodium silicate and sodium hydroxide was added for pH adjustment. The air is blown into the heated mixture to provide oxidation. After the oxidation reaction was completed, magnetite particles were obtained after filtration, washing, drying and grinding. However, the present invention proposes to use natural magnetite particles (<NUM>) or magnetite particles (<NUM>) produced in polyol, in flexible polyurethane foam (<NUM>).

Magnetite particles obtained as a result of the reactions of certain chemicals are also found naturally in certain parts of the world. Sand on the coast of Turkey, Ordu contain high amounts of magnetite particles. It has been known for many years that the sand on the beach is a source of healing and that it is good for diseases such as rheumatism and psoriasis and mechanical pain that occurs in the body (such as waist and back pains) and that it reduces the stress by balancing the energy in the body. When the reason of this healing power in the sand were investigated, it was found that the reasons is naturally occurring magnetite particles in it.

It is known that the Earth is also a magnet and has an average magnetic field of <NUM> gauss. In addition, many studies have been carried out on the positive effects of the magnetic field. And nowadays, magnetic field therapy is used with electromagnetic field devices, in the fields of orthopedics, rehabilitation, urogenital disorders and sports health; in the elimination of acute and chronic pain in the shoulder, back, elbow and waist regions, in the elimination of joint congestion, in accelerating the recovery time of the fractures and in the improvement of rheumatism and many other disorders.

In <CIT> patent, some recommendations are based on the elastic magnetic stripes directed to the north pole and the south pole in the same direction. These elastic magnetic strips have been used to improve metabolism, accelerate blood circulation, regulate the energy balance in the body and reduce the effect of stress. However, the present invention proposes the use of magnetite particles (<NUM>) instead of magnetic strips. In the patent <CIT>, the two magnetic elements are separated by foam rubber. Mentioned magnetic elements are in such a way that they are facing the same poles with which they meet the same polarity, thus providing magnetic push cushioning between the magnetic elements. Similarly, <CIT>, <CIT>, <CIT> and <CIT> are publications containing magnet plates. However, the present invention relates to the use of magnetite particles (<NUM>) on or within the flexible polyurethane foam (<NUM>). In the patent no. <CIT>, a certain amount of magnetite particles is added to the resin mixture and mentions the toilet health agent. However, the present invention relates to the use of magnetite powder (<NUM>) in the flexible polyurethane foam (<NUM>). The patent <CIT> relates to a magnetic polyurethane composition having magnetic properties, which provides a constant magnetic field similar to that produced by the human body and which can be used to simulate the nervous system. The product mentioned in the patent assists in blood circulation by providing nerve conduction. After obtaining a homogeneous mixture from the polyurethane with magnetite particles, the mixture was obtained by injecting the mixture into a certain temperature mold. Of course, this patent incorporating the magnetite powder composition is the most similar to the present invention proposal. However, the flexible polyurethane used in the present invention is produced by continuous slabstock instead of batch-molded operation. One block produced in <NUM>-<NUM> m3 volume <NUM>- <NUM> length is cut to desired dimensions after curing and final product is obtained. Furthermore, apart from the systematic difference between these two systems, the toluene diisocyanate (TDI) was used as an isocyanate in the present invention instead of methylene diphenyl diisocyanate (MDI).

The object of the present invention is produce material to reduce the mechanical pain and stress in the body by adding natural magnetite particles or produced magnetite particles in polyol to the continuous slabstock flexible polyurethane foam during production or by coating (<NUM>) the magnetite particles (<NUM>) with a binder (<NUM>) onto the upper surface of the slabstock flexible polyurethane foam (<NUM>) after the production. The present invention will be used in mat, pad, mattress equipment (pillow, mattress) and such materials. Previously, some textile products were produced with using ribbon magnets as a pain relief material, but to date, the use of magnetite particles has not been used in the production of continuous slabstock flexible polyurethane foam. By using magnetite particles in the continuous slabstock flexible polyurethane foam used in the mattress or bedding, the body will be able to remove the pain and decrease the stress. And these beds can be used in the treatment of pain in hospitals, rehabilitation and physical therapy centers.

Starting from publications describing the benefits of magnetic field, the present invention is achieved from natural magnetite particles (<NUM>) on the coast of Turkey, Ordu or produced magnetite particles (<NUM>) in polyol by incorporating into continuous slabstock polyurethane foam (<NUM>) during the production or by applying as coating (<NUM>) by means of the binder (<NUM>); used in the production of mattress products (such as mattress and pillow), mat, pad and insoles. The magnetic hysteresis (VSM) curve of the natural magnetite powders and the magnetite powders produced in the polyol were drawn from the measurements and -<NUM> - +<NUM> and - <NUM> - +<NUM> Tesla results were obtained respectively, made by using the Cryogenic Limited PPMS device in the Electrical, Magnetic and Optical Properties Laboratory (EMOL) at the METU Central Laboratory R&D Training and Measurement Center. In the laboratory measurements, the magnetic field of the flexible polyurethane foam containing the magnetite particles (<NUM>) was found to be in the range of <NUM>-<NUM> gauss.

The object of the present invention is to produce flexible polyurethane foam containing magnetite particle (<NUM>) to reduce pain and stress in the body. Our product is a new product because it has not previously been used the magnetite particles in or on to the surface of the continuous slabstock flexible polyurethane foam (<NUM>) in order to reduce pain and reduce stress. The invention concerns with a method for producing continuous slabstock flexible polyurethane foam including magnetite particles according to the appended claims. The invention also concerns with a flexible polyurethane foam (<NUM>) containing magnetite particles (<NUM>) or a coating (<NUM>) containing magnetite particles (<NUM>) applied with a binder (<NUM>) onto the upper part of the flexible polyurethane foam (<NUM>), prepared according to the method according to the appended claims.

In order to obtain the material produced in two different ways, the following operations were performed respectively.

Sand with high moisture content containing magnetite particles is placed inside the front open steel cylinder rotating on its axis and dried with hot air blowing from the front. The dried magnetite particles were separated from the sand by means of magnets.

Iron (III) oxide, iron (II) sulfate heptahydrate and water solution heated to <NUM>-<NUM> ° C and pH of the solution was adjusted to <NUM> with the help of an alkaline media. The reaction was carried out for <NUM> to <NUM> hours. The filtered material was washed with water to remove salts and alkali media. Polyether polyol was added to the obtained particles and the system was heated to <NUM>-<NUM> ° C and water was removed by means of vacuum.

Polyurethane foam (<NUM>) including magnetite particles (<NUM>) is produced by two different methods. The operations are described below.

The magnetite (<NUM>) separated from the sand is mixed with the polyol before adding it to the system. The mixture of polyol and magnetite (<NUM>), water, reaction catalyst (tinned compounds), foaming catalysts (amines), foaming agent (methylene chloride), surfactant (silicon compounds) and TDI are pumped to the mixer head. Mix the mixture for <NUM>-<NUM> seconds with the high-speed mixer. The material overflowing from the hopper rises on the moving conveyor in the tunnel and the polyurethane foam (<NUM>) is formed after the gas outlet. The blocks cut to certain lengths (<NUM>-<NUM>) are kept for one day and then cut to the desired dimensions.

Magnetite particles (<NUM>) that produced in polyol, water, reaction catalyst (tinned compounds), foaming catalysts (amines), foaming agent (methylene chloride), surfactant (silicone compounds) and TDI are pumped to the mixer head. Mix the mixture for <NUM>-<NUM> seconds with the high-speed mixer. The material overflowing from the hopper rises on the moving conveyor in the tunnel and the polyurethane foam (<NUM>) is formed after the gas outlet. The blocks cut to certain lengths (<NUM>-<NUM>) are kept for one day and then cut to the desired dimensions.

Polyurethane-based binder (<NUM>), solvent and natural magnetite particles (<NUM>) separated from sand are mixed in a chamber and sprayed with a pistol to form a <NUM> thick coating (<NUM>) on a flexible polyurethane foam (<NUM>). The solvent contained in the coating (<NUM>) which has been removed on the coated flexible polyurethane foam (<NUM>) by the help of heat.

Everything described in the disclosure section of the invention is the same as the way it is applied to industry. The mentioned material that is flexible polyurethane foam (<NUM>) including the magnetite (<NUM>) described above is produced in the above-mentioned forms within the company. All applications for the production of flexible polyurethane foam (<NUM>) including magnetite (<NUM>) are made in the company and presented to the customer as the final product.

The system contains <NUM> neck Glass flask, temperature controller and mechanical mixer. <NUM> of iron (III) oxide, <NUM> of iron (II) sulfate heptahydrate and <NUM> of water are added into a <NUM>-neck glass flask. With the help of mechanical mixer, the media in the flask is heated to <NUM> ° C. Add <NUM>% ammonia solution (<NUM>- <NUM>) till pH <NUM> at <NUM> ° C. After <NUM> hours, the reaction temperature is cooled to room temperature and the particles are then filtered. After filtration, the remaining material is washed with water in order to remove the salts and alkaline media. <NUM> polyether polyol is added to the obtained ~<NUM> particles and heated to <NUM> ° C under vacuum to remove the water. The resulting material is used in the production of flexible polyurethane foam.

Polyether polyol ratios in magnetite used in foam recipes are as follows.

A suspension is obtained addition of <NUM> of polyether polyol in <NUM> of magnetite particles. The chemicals in Table <NUM>. are pumped into the mixer head. Mix the mixture for <NUM>-<NUM> seconds with the high-speed mixer. A flexible polyurethane foam with a standard or high elasticity polyurethane foam with an index of <NUM>- <NUM> and a memory foam with an index of <NUM>-<NUM> are obtained.

The chemicals in Table <NUM>. are pumped into the mixer head. Mix the mixture for <NUM>-<NUM> seconds with the highspeed mixer. A flexible polyurethane foam with a standard or high elasticity polyurethane foam with an index of <NUM>-<NUM> and a memory foam with <NUM>-<NUM> index are obtained.

The materials are mixed in a chamber and sprayed with a pistol to form a <NUM> thick coating (<NUM>) on a flexible polyurethane foam. The composite material obtained at the end of solvent vaporization consists of <NUM>-<NUM> wt% magnetite particles (<NUM>), <NUM>-<NUM> wt% continuous slabstock flexible polyurethane foam (<NUM>), <NUM>-<NUM> wt% polyurethane based binder (<NUM>).

Claim 1:
A method for producing continuous slabstock flexible polyurethane foam including magnetite particles as a stress and pain reducing material, comprising the steps of
- producing magnetite particles (<NUM>):
a) separation of natural magnetite particles (<NUM>) from sand comprising placing sand containing magnetite particles inside the front open steel cylinder rotating on its axis and drying with hot air blowing from the front, separating the dried magnetite particles from the sand by means of magnets,
or
b) magnetite (<NUM>) production in polyol comprising heating iron (III) oxide, iron (II) sulfate heptahydrate and water solution to <NUM>-<NUM> and adjusting pH of the solution to <NUM> using an alkaline media, carrying out the reaction for <NUM> to <NUM> hours, washing the filtered material with water to remove salts and alkali media, adding polyether polyol to the obtained particles and heating the system to <NUM>-<NUM> and removing water by means of vacuum;
- producing flexible polyurethane foam (<NUM>) including natural magnetite particles (<NUM>):
a) mixing the magnetite particles (<NUM>) separated from the sand and polyol, pumping the mixture of polyol and the magnetite particles (<NUM>) , water, tinned compounds as reaction catalyst, amines as foaming catalysts, methylene chloride as foaming agent, silicon compounds as surfactant and toluene diisocyanate TDI to a mixer head;
b) mixing the pumped mixture for <NUM> to <NUM> seconds with a high-speed mixer; and
c) allowing the mixed pumped mixture overflowing from a hopper to rise on a moving conveyor in a tunnel, wherein the polyurethane foam is formed after a gas outlet, keeping the blocks cut to certain lengths (<NUM>-<NUM>) for one day and then cutting them to the desired dimensions,
or
- producing flexible polyurethane foam (<NUM>) with magnetite particles (<NUM>) produced in polyol
a) pumping magnetite particles (<NUM>) that produced in polyol, water, tinned compounds as reaction catalyst, amines as foaming catalysts, methylene chloride as foaming agent, silicon compounds as surfactant and toluene diisocyanate TDI to the mixer head
b) mixing the pumped mixture for <NUM> to <NUM> seconds with a high-speed mixer; and
c) allowing the mixed pumped mixture overflowing from a hopper to rise on a moving conveyor in a tunnel, wherein the flexible polyurethane foam is formed after a gas outlet, keeping the blocks cut to certain lengths (<NUM>-<NUM>) for one day and then cutting them to the desired dimensions.