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A method of manufacturing a polymer foam composite is described, the method comprising forming an article having a first surface and an opposite second surface from a precursor composition, the precursor composition comprising a polymer foam precursor composition, and a filler composition comprising

A method of manufacturing a polymer foam composite is described, the method comprising forming an article having a first surface and an opposite second surface from a precursor composition, the precursor composition comprising a polymer foam precursor composition, and a filler composition comprising a plurality of magnetic, electrically conductive particles; foaming the precursor composition to form a plurality of cells in precursor composition; applying a magnetic field to the foamed precursor composition, wherein the magnetic field is of a strength and applied for a time effective to align the electrically conductive, magnetic particles into mutually isolated chains between the first surface and the opposite second surface of the article; and solidifying the polymer foam precursor composition to provide a polymer foam composite having a density of about 1 to about 125 pounds per cubic foot and a volume resistivity of about 10−3 ohm-cm to about 103 ohm-cm at a pressure of 60 pounds per square inch. Polymer foam composites made by this method are also described, as well as articles formed therefrom.

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1. A method of manufacturing a polymer foam composite, the method comprising: forming an article having a first surface and an opposite second surface from a precursor composition, the precursor composition comprising a polymer foam precursor composition, anda filler composition comprising a plurali

1. A method of manufacturing a polymer foam composite, the method comprising: forming an article having a first surface and an opposite second surface from a precursor composition, the precursor composition comprising a polymer foam precursor composition, anda filler composition comprising a plurality of magnetic, electrically conductive particles;mechanically foaming the precursor composition to form a plurality of cells in precursor composition prior to forming the article;applying a magnetic field to the foamed precursor composition, wherein the magnetic field is of a strength and applied for a time effective to align the electrically conductive, magnetic particles into mutually isolated chains between the first surface and the opposite second surface of the article,wherein the foaming is substantially complete prior to applying the magnetic field; andsolidifying the polymer foam precursor composition to provide the polymer foam composite having a density of about 1 to about 125 pounds per cubic foot and a volume resistivity of about 10−3 ohm-cm to about 103 ohm-cm at a pressure of 60 pounds per square inch. 2. The method of claim 1, wherein the solidifying is after aligning the electrically conductive metal particles into the mutually isolated chains. 3. The method of claim 1, further comprising removing an amount of the first and/or second surface of the solidified foam sufficient to at least partially expose the ends of the mutually isolated chains. 4. The method of claim 1, wherein the article is a layer, and forming the article comprises casting the polymer foam precursor composition onto a first carrier, wherein the first surface is disposed on and in contact with the first carrier. 5. The method of claim 4, further comprising removing an amount of the first surface of the solidified foam sufficient to at least partially expose the ends of the mutually isolated chains. 6. The method of claim 4, further comprising disposing a second carrier onto the second surface of the layer. 7. The method of claim 6, further comprising removing an amount of the first and second surface of the solidified foam sufficient to at least partially expose the ends of the mutually isolated chains. 8. The method of claim 4, wherein the first carrier is electrically conductive. 9. The method of claim 4, wherein the first carrier is magnetic, or magnetic and electrically conductive. 10. A method of manufacturing a polymer foam composite, the method comprising: mechanically foaming a precursor composition to form a plurality of cells in the precursor composition, wherein the precursor composition comprises: a polymer foam precursor composition, anda filler composition comprising a plurality of magnetic, electrically conductive particles;forming an article having a first surface and an opposite second surface from the mechanically foamed precursor composition;applying a magnetic field of a strength and for a time effective to align the magnetic, electrically conductive particles into mutually isolated chains between the first surface and the opposite second surface of the article, wherein the foaming is substantially complete prior to applying the magnetic field; andcuring the polymer precursor composition to provide the polymer foam composite having a density of about 1 to about 125 pounds per cubic foot and a volume resistivity of about 10−3 ohm-cm to about 103 ohm-cm at a pressure of 60 pounds per square inch. 11. A method of manufacturing a polymer foam composite, the method comprising: forming an article having a first surface and an opposite second surface from a precursor composition, the precursor composition comprising a polymer foam precursor composition, anda filler composition comprising a plurality of magnetic, electrically conductive particles;mechanically foaming the precursor composition to form a plurality of cells in precursor composition prior to forming the article;applying a magnetic field to the foamed precursor composition, wherein the magnetic field is of a strength and applied for a time effective to align the electrically conductive, magnetic particles into mutually isolated chains between the first surface and the opposite second surface of the article,wherein the foaming is substantially complete prior to applying the magnetic field;solidifying the polymer foam precursor composition; andremoving an amount of the first and/or second surface of the solidified foam sufficient to at least partially expose the ends of the mutually isolated chains, to provide the polymer foam composite having a density of about 1 to about 125 pounds per cubic foot and a volume resistivity of about 10−3 ohm-cm to about 103 ohm-cm at a pressure of 60 pounds per square inch. 12. A method of manufacturing a polyurethane foam composite, comprising: mechanically foaming a precursor composition comprising a polyisocyanate component, an active hydrogen-containing component reactive with the polyisocyanate component, a surfactant, a catalyst, and a filler composition comprising a plurality of magnetic, electrically conductive particles to form cells;casting the foamed precursor composition to form a layer having a first surface and an opposite second surface;exposing the layer to a magnetic field to align the magnetic, electrically conductive particles into mutually isolated chains that essentially continuously span the layer between the first surface and the second surface, wherein the foaming is substantially complete prior to applying the magnetic field; andcuring the layer to produce the polyurethane foam composite having a volume resistivity of about 10−3 ohm-cm to about 103 ohm-cm at a pressure of 60 pounds per square inch, and wherein the distance between the first surface and the second surface is greater than 1.5 times the average diameter of the cells. 13. A method of manufacturing a silicone foam comprising: casting a mixture comprising a polysiloxane polymer having hydride substituents, a catalyst, and a filler composition comprising a plurality of magnetic, electrically conductive particles; to form a layer having a first surface and an opposite second surface;mechanically foaming the mixture;curing the mixture in an applied magnetic field to align the magnetic, electrically conductive particles into mutually isolated chains that essentially continuously span the foam between a first surface and a second opposite surface of the foam,wherein the foaming is substantially complete prior to applying the magnetic field; andremoving an amount of the first and/or second surface of the cured foam sufficient to at least partially expose the ends of the mutually isolated chains, to produce the silicone foam composite having a volume resistivity of about 10−3 ohm-cm to about 103 ohm-cm at a pressure of 60 pounds per square inch. 14. The method of claim 1, wherein the foamed precursor composition comprises about 2 to about 20 volume percent filler composition.