Patent ID: 7338983

Claim:
A method for producing a cured, low density polyurethane foam, the method comprising: mechanically frothing a reactive polyurethane-forming composition comprising an isocyanate-containing component, an active hydrogen-containing component reactive with the isocyanate-containing component, a blowing agent comprising water, a surfactant, and catalyst system, wherein the catalyst system provides for a delayed curing of the foam; and in a continuous process, casting the frothed reactive polyurethane-forming composition onto a moving first carrier; placing a second carrier on a side of the cast froth opposite the first carrier; blowing the froth with the second carrier in place; and curing the blown froth so as to provide a polyurethane foam layer having a compression load deflection at 50% of about 0.003 to about 0.025 MPa, a compression load deflection at 75% of about 0.02 to about 0.40 MPa, a density of about 50 to about 400 kg/m 3 and a thickness of about 0.3 to about 13 mm.