FLAME LAMINABLE HYDROPHILIC ESTER POLYURETHANE FOAMS
First Claim
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1. A laminate structure, comprising:
- a hydrophilic ester polyurethane foam sheet bonded to a substrate by flame bonding, wherein said flame bonding includes providing a sacrificial sheet of a nonhydrophilic ester polyurethane foam with a density of 90 lb/ft3 or less, said sacrificial sheet having a face surface and a reverse surface, heating at least the face surface of the sacrificial sheet, contacting the heated face surface of the sacrificial sheet with a surface of a sheet of hydrophilic ester polyurethane foam; and
contacting the reverse surface of the sacrificial sheet with a surface of the substrate;
such that the hydrophilic ester polyurethane foam is bonded uniformly to the substrate surface with a bond strength of at least about 7 oz/inch (76.6 N/m) with standard deviation of about 0.6 oz/inch (6.7 N/m).
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Abstract
A hydrophilic ester polyurethane foam is flame laminated to a substrate using a thin sacrificial layer, preferably a sacrificial foam layer. The sacrificial layer in the resulting laminate structure has a thickness of 1.5 mm or less, and preferably is substantially burnt away. The resulting laminate exhibits good bond strength along its length and width without loss of liquid wicking and absorptive properties.
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Citations
9 Claims
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1. A laminate structure, comprising:
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a hydrophilic ester polyurethane foam sheet bonded to a substrate by flame bonding, wherein said flame bonding includes providing a sacrificial sheet of a nonhydrophilic ester polyurethane foam with a density of 90 lb/ft3 or less, said sacrificial sheet having a face surface and a reverse surface, heating at least the face surface of the sacrificial sheet, contacting the heated face surface of the sacrificial sheet with a surface of a sheet of hydrophilic ester polyurethane foam; and
contacting the reverse surface of the sacrificial sheet with a surface of the substrate;such that the hydrophilic ester polyurethane foam is bonded uniformly to the substrate surface with a bond strength of at least about 7 oz/inch (76.6 N/m) with standard deviation of about 0.6 oz/inch (6.7 N/m). - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9)
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Specification