W. R. Grace Co.

Norman J Hayes

Irving E Isgur

Andrew B Holmstrem

Disclosed herein is a composite, self-supporting, polyurethane foam sheet prepared by forming an aqueous dispersion of hydrophilic polyurethane foam particles with fibers to serve as a binder therefor, wet-layering the dispersion onto a supporting screen to form a sheet, and removing water from the sheet. If desired, a porous web, woven or non-woven, e.g. paper, cloth, etc., can be positioned on the screen with the dispersion being layered out onto the web to form a laminar composite structure. Whether in sheet form or as a laminar structure the product of the invention is formed rapidly and possesses a desirable soft or cushioning feel.

Polyurethane foam sheet and method

The invention disclosed is for a foam sheet fabric prepared using a hydrophilic crosslinked polyurethane component prepared by reacting an isocyanate capped polyoxyethylene polyol reactant with large amounts of an aqueous reactant. The resultant fabrics may be characterized with a broad spectrum of improved properties including improved comfort, moisture control, ease of processing and may contain selective additives such as fibers, fire retardants or the like.

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Bedford, MA, United States of America

Norman J Hayes