Patent ID: 7048884

Claim:
A process for producing an article in a flexible foamed polymer material including: treating a former with a coagulant; dipping the treated former in an unfoamed latex to form an unfoamed latex layer; leaching the unfoamed latex layer thereon to remove excess coagulant and proteins; treating unfoamed latex layer with a stronger coagulant; dipping the treated former with the unfoamed latex layer in a stabilized latex foam mixture to form a foamed latex layer of the mixture on the former that includes air cells; curing to gel the unfoamed and foamed latex layers to form a cross-linked open cell structure over unfoamed latex layer; leaching the cured latex layers to remove excess coagulant and proteins; and stripping the layer from the former; whereby said stronger coagulant accelerates said gelation of said foam cured latex layers and enhances bonding between said layers.