Patent ID: 8535476

Claim:
A process for producing a laminate or composite structure which comprises heat bonding a substrate comprising polypropylene to a polyurethane foam, wherein the polyurethane foam is produced using (i) at least one natural oil derived polyol in an amount from at least 30 weight percent based on total weight of polyols, (ii) at least one other polyol which is not a natural oil derived polyol and is a polyether polyol of a mixture of propylene oxide and ethylene oxide having an unsaturation less than 0.1 meq/g, wherein the ratio of natural oil derived polyol to not natural oil derived polyol is 1:1, and (iii) a catalyst blend comprising 0.0015 to less than 0.2 pphp at least one amine catalyst and 0.0015 to less than 0.2 pphp of at least one stannous octoate catalyst, wherein the at least one natural oil derived polyol has a functionality of at least 3, a hydroxyl number less than 150, and at least 50 percent by weight of the polyol, based on the total weight of the polyol, derived from natural oil, and wherein the at least one natural oil derived polyol is produced by reacting a hydroxymethylated fatty acid methyl ester with at least one poly(ethylene oxide) triol; wherein the polyurethane foam has a density from 27 to 80 kg/m 3 ; wherein the heat bonding is carried out using high frequency radiation at a frequency of at least 20 MHz for 1-5 seconds, and wherein the resulting laminate or composite exhibits at least one of (1) a hydrolytic stability determined at 50 percent humidity aged compression set of at least 50, 45 or 35 percent as measured by the procedures of either ISO 1856-80 or DIN 53578, (2) volatile organic compounds or other fumes emitted as measured by the procedures of VDA 278 of at most about any of 400, 300, 250 or 200 mg; (3) fogging as measured by the procedures of DIN 75201/B-92 of at most any of 5, 4, 3, or 2 mg; or (4) bond strength as measured using the procedures of DIN 53357 of at least about any of 0.3 daN, 0.4 daN, 0.5 daN or 0.6 daN.