Flame laminable hydrophilic ester polyurethane foams

• US 7,687,139 B2
• Filed: 02/26/2008
• Issued: 03/30/2010
• Est. Priority Date: 07/06/2004
• Status: Active Grant

• Current Assignee: FXI, Inc. (FXI Holdings Incorporated)
• Original Assignee: Foamex Innovations Operating Company
• Inventors: Free, Sharon A., Burke, William Patrick III, Albero, Marc J., Land, Joshua D., Patel, Jagdish, Chan, Chiu Y.
• Primary Examiner(s): TORRES VELAZQUEZ, NORCA LIZ
• Application Number:
  US12/037,196
• Publication Number:
  US 20080213566A1
• Time in Patent Office: 763 Days
• Field of Search: 428/316.6
• US Class Current: 428/316.6
• CPC Class Codes: B32B 5/24 one layer being a fibrous or filamentary layer
• CPC Class Codes: B32B 5/32 at least two layers being foamed and next to each other
• CPC Class Codes: C08G 18/42 Polycondensates having carboxylic or carbonic ester groups in the main chain
• CPC Class Codes: C08G 2110/0008 flexible
• CPC Class Codes: C08G 2110/005 < 50kg/m3
• CPC Class Codes: C08G 2110/0083 prepared using water as the sole blowing agent
• CPC Class Codes: C08J 2375/06 from polyesters
• CPC Class Codes: C08J 5/121 by heating
• CPC Class Codes: Y10T 428/249953 Composite having voids in a component [e.g., porous, cellular, etc.]
• CPC Class Codes: Y10T 428/249981 Plural void-containing components
• CPC Class Codes: Y10T 428/249991 Synthetic resin or natural rubbers

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.

Claims

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, 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).

2. The laminate structure of claim 1, wherein the sacrificial sheet has a starting thickness of no more than about one millimeter.

3. The laminate structure of claim 2, wherein the sacrificial sheet has a starting thickness of from about 0.5 to about 1 mm.

4. The laminate structure of claim 1, wherein the sacrificial sheet is substantially consumed by the flame bonding.

5. The laminate structure of claim 1, wherein the sacrificial sheet is substantially melted or burned away.

6. The laminate structure of claim 1, wherein the sacrificial sheet has a pore size from 70 ppi to 200 ppi.

7. The laminate structure of claim 1, wherein the substrate comprises a material selected from the group consisting of:

a melamine or melamine-formaldehyde foam, a polyether polyurethane foam, a polyester polyurethane foam, a polymeric nonwoven, a textile fabric, an ethylene vinyl acetate (EVA) sheet or film, a polyolefin sheet or film, an acrylic sheet or film, a polyvinylchloride (PVC) sheet or film, a reticulated foam, a fleece, a cellulose sheet, a metallic sheet, a wood, pulp or pulp and fiber composite, a combination of polymers, and a polyester/polyamide/rayon fabric.

8. The laminate structure of claim 1, wherein the hydrophilic ester polyurethane foam sheet is bonded to the substrate without auxiliary adhesives.

9. An absorbent article comprising the laminate structure of claim 1.