Rebond foam and process for production thereof

Abstract

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.).