Woodbridge Foam Corporation

G Ronald Blair

Robert N Wilson

Kasper J Van Veen

Harold R Attfield

A rebond foam comprising a plurality of isocyanate-based polymeric foam pieces bonded to one another with an isocyanate-based binder is disclosed. A superabsorbent material is comprised in one or both of the isocyanate-based polymeric foam pieces and the isocyanate-based binder. The rebond foam is capable of: (i) absorbing at least about 5 times its weight of a 0.9 wt./wt. % aqueous NaCl solution maintained at a temperature of from about 20.degree. to about 25.degree. C., and (ii) retaining at least about 5 times its weight of absorbed aqueous NaCl solution which is bound to the superabsorbent material. A process for producing a rebond foam is also disclosed. The process comprises the steps of: (i) mixing a plurality of isocyanate-based foam pieces with a binder comprising an isocyanate and an active hydrogen-containing compounds to form a mixture, a superabsorbent material being comprised in one or both of the isocyanate-based polymeric foam pieces and the isocyanate-based binder; (ii) placing the mixture in a mold; (iii) compressing the mixture in the mold; (iv) reacting the isocyanate and the active hydrogen-containing compound; (v) bonding the isocyanate-based foam pieces to one another to form the rebond foam. The rebond foam is useful as applications where fluid absorption and retention is desirable (e.g. personal hygiene devices, etc.).

Rebond foam and process for production thereof

A foamed isocyanate-based polymer having a cellular structure and comprising a superabsorbent material, the polymer being capable of: (i) absorbing at least about 10 times its weight of a 0.9 wt./wt. % aqueous NaCl solution maintained at a temperature of from about 20.degree. to about 25.degree. C., and (ii) retaining at least about 10 times its weight of absorbed aqueous NaCl solution which is bound to the superabsorbent material, the cellular structure having a cell size of at least about 30 cells/inch when measured pursuant to ASTM D3576-77. A process for producing the foamed isocyanate-based polymer is also described. The process comprises the steps of: contacting an isocyanate, an active hydrogen-containing compound, an aqueous blowing agent, a catalyst and a superabsorbent material, the superabsorbent material being capable of absorbing at least about 10 times its weight of a 0.9 wt./wt. % aqueous NaCl solution maintained at a temperature in the range of from about 20.degree. to about 25.degree. C.; and expanding the reaction mixture to produce the foamed isocyanate-based polymer. The active hydrogen-containing compound comprises from about 10% to 100% by weight of a hydrophilic active hydrogen-containing compound and from 0 to about 90% by weight a non-hydrophilic active hydrogen-containing compound. The foamed isocyanate-based polymer is ideally suitable for use in an absorption layer in a personal hygiene device.

Foamed polymer and process for production thereof

A polymer-modified polyol dispersion comprises a polyaddition product dispersed in a polyol. The polyaddition product is present in an amount of from about 25 to about 70 percent by weight based on the total weight of the polyaddition product and the polyol. The dispersion has a viscosity in the range of from about 4,000 to about 50,000 mPa.s, the viscosity remaining substantially the same after production of the dispersion. A process for producing the polymer-modified polyol dispersion is also disclosed together with a process for using the dispersion to produce a polyurethane foam.

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Richmond Hill, Canada

G Ronald Blair