Composite polyurethane foams and method of manufacture thereof
First Claim
Patent Images
1. A method for the manufacture of multiple layer polyurethane foams, which comprises:
- casting a first, foamed mixture comprising an organic isocyanate component, an active hydrogen-containing component reactive with the isocyanate component, a surfactant, and a catalyst onto a second, foamed mixture comprising an organic isocyanate component, an active hydrogen-containing component reactive with the isocyanate component, a surfactant, and a catalyst; and
curing the resulting multiple layers to form a multiple layer, polyurethane foam having no discernible structural interface line between the layers when viewed at 50×
magnification by SEM.
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Abstract
Integrally bonded composite polyurethane foams substantially free from coalescence and with no discernable bond or structural interface layer when viewed at 50×magnification can be formed by wet casting a second foamed polyurethane composition onto a first wet cast foamed polyurethane composition and simultaneously curing the cast foams. In a preferred embodiment, one curable polyurethane composition forms a slow recovery foam and the other curable polyurethane composition forms a resilient foam.
63 Citations
14 Claims
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1. A method for the manufacture of multiple layer polyurethane foams, which comprises:
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casting a first, foamed mixture comprising an organic isocyanate component, an active hydrogen-containing component reactive with the isocyanate component, a surfactant, and a catalyst onto a second, foamed mixture comprising an organic isocyanate component, an active hydrogen-containing component reactive with the isocyanate component, a surfactant, and a catalyst; and
curing the resulting multiple layers to form a multiple layer, polyurethane foam having no discernible structural interface line between the layers when viewed at 50×
magnification by SEM. - View Dependent Claims (2, 3, 4)
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5. A multiple layer, polyurethane foam, comprising
a first polyurethane foam layer; - and
a second polyurethane foam layer, wherein there is no discernible structural interface line between the layers when viewed at 50×
magnification by SEM. - View Dependent Claims (6, 7, 8, 10, 11, 12, 13, 14)
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9. A multiple layer, polyurethane foam, comprising
a first polyurethane foam layer; - and
a second polyurethane foam layer disposed on the first layer, wherein one or more cells span the boundary region between the layers.
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Specification