Flame laminable hydrophilic ester polyurethane foams
First Claim
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1. A laminate structure, comprising:
- a hydrophilic ester polyurethane foam sheet,a sacrificial sheet of a nonhydrophilic ester polyurethane foam with a density of 90 lb/ft3 or less, anda substrate,wherein the hydrophilic ester polyurethane foam sheet is bonded to the substrate by flame bonding,wherein said flame bonding heats and repolymerizes the sacrificial sheet of a nonhydrophilic ester polyurethane foam to join a face surface of said sacrificial sheet to a surface of the hydrophilic ester polyurethane foam sheet and to join a reverse surface of the sacrificial sheet to a surface of the substrate to thereby form the laminate structure of the hydrophilic ester polyurethane foam sheet, the repolymerized sacrificial sheet and the substrate;
such that the hydrophilic ester polyurethane foam sheet 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, a sacrificial sheet of a nonhydrophilic ester polyurethane foam with a density of 90 lb/ft3 or less, and a substrate, wherein the hydrophilic ester polyurethane foam sheet is bonded to the substrate by flame bonding, wherein said flame bonding heats and repolymerizes the sacrificial sheet of a nonhydrophilic ester polyurethane foam to join a face surface of said sacrificial sheet to a surface of the hydrophilic ester polyurethane foam sheet and to join a reverse surface of the sacrificial sheet to a surface of the substrate to thereby form the laminate structure of the hydrophilic ester polyurethane foam sheet, the repolymerized sacrificial sheet and the substrate; such that the hydrophilic ester polyurethane foam sheet 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