Patent ID: 7687139

Claim:
A laminate structure, comprising: a hydrophilic ester polyurethane foam sheet, a sacrificial sheet of a nonhydrophilic ester polyurethane foam with a density of 90 lb/ft 3 or less, and a substrate, wherein the hydrophilic ester polyurethane foam sheet is bonded to the substrate by flame bonding, wherein said flame bonding heats and repolymerizes the sacrificial sheet of a nonhydrophilic ester polyurethane foam to join a face surface of said sacrificial sheet to a surface of the hydrophilic ester polyurethane foam sheet and to join a reverse surface of the sacrificial sheet to a surface of the substrate to thereby form the laminate structure of the hydrophilic ester polyurethane foam sheet, the repolymerized sacrificial sheet and the substrate; such that the hydrophilic ester polyurethane foam sheet is bonded uniformly to the substrate surface with a bond strength of at least about 7 oz/inch (76.6 N/m) with standard deviation of about 0.6 oz/inch (6.7 N/m).