Processes for producing flexible polyurethane foam laminates and laminates produced thereby

A continuous compression molding process for producing a laminate comprising a flexible polyurethane foam, a first flexible film facing material and a second flexible film facing material, the method comprising:

• (a) feeding the first flexible film facing material along a first heated surface;
• (b) feeding the second flexible film facing material along a second heated surface, wherein the second heated surface is disposed generally parallel to the first heated surface at a preselected distance that defines a vertical space between the first flexible film facing material and the second flexible film facing material and that defines the thickness of the laminate;
• (c) depositing a polyurethane foam-forming composition onto the first flexible film facing material as it is being fed;
• and
• (d) allowing the polyurethane foam-forming composition to react in the vertical space to form the flexible polyurethane foam, thereby rising until the rise is restricted by the second flexible film facing material,
• wherein the laminate has a foam density of no more than 10 lb/ft3 (160kg/m3),
• wherein the first heated surface comprises one or more first heated metal platens and the second heated surface comprises one or more second heated metal platens, and
• wherein the polyurethane foam-forming composition comprises a mixture of an isocyanate-reactive composition and a polyisocyanate, wherein the isocyanate-reactive composition comprises:
• (i) at least 70% by weight and up to 90% by weight, based on the total weight of isocyanate-reactive components in the isocyanate-reactive composition, of a polyether polyol having a nominal functionality of at least 3 and an average OH number of 20 to 100;
• (ii) a polyether diol having a number average molecular weight of at least 1000 grams/mole, and
• (iii) a chain extender having a hydroxyl functional of 2 and a molecular weight of no more than 300 grams/mole.