Polyurethane foam products with controlled release of agents and additives

The method for forming controlled release urethane foam products comprising the steps of:

• a. metering and mixing an aqueous formulation having at least a limited quantity of superabsorbent polymer, at least one agent from the group detergents, soaps, abrasives, waxes, polishes, drugs, cosmetics, biologicals, volatiles, odor absorbing and controlling compositions, water soluble chemicals, water emulsions, water mixture with solid particles and adequate water with a predetermined ratio of hydrophilic urethane prepolymer to provide a polymerizing mixture for forming the controlled release urethane foam product;
• b. depositing the polymerizing mixture on releasable bottom paper disposed on a movable carrier;
• c. covering the upper surface of the polymerizing mixture with releasable top paper as the polymerizing mixture is moved with the carrier;
• d. advancing the polymerizing mixture in the top and bottom release paper by moving the carrier and sizing the foam layer being formed to the desired thickness until it is tack free;
• e. sequentially removing the top and bottom release paper while simultaneously drying the formed foam product to remove residual moisture;
• and
• f. passing the formed controlled release urethane foam product to secondary operations such as die cutting, molding and granulation to provide shaped and sized products and sized particulate products for particular applications and uses.

The method for forming controlled release urethane foam products comprising the steps of:

• a. metering and mixing an aqueous formulation having at least a limited quantity of superabsorbent polymer, at least one agent from the group detergents, soaps, abrasives, waxes, polishes, drugs, cosmetics, biologicals, volatiles, odor absorbing and controlling compositions, water soluble chemicals, water emulsions, water mixture with solid particles and adequate water with a predetermined ratio of hydrophilic urethane prepolymer to provide a polymerizing mixture for forming the controlled release urethane foam product;
• b. dispensing a predetermined quantity of the polymerizing aqueous mixture into a shaped and sized mold;
• and
• c. placing a cover on the mold for to control the size and shape of the formed controlled release urethane foam product.

The method for forming controlled release urethane foam products having an abrasive layer formed integrally with one exterior face comprising the steps of:

• a. metering and mixing an aqueous formulation having at least a limited quantity of superabsorbent polymer, at least one agent from the group detergents, soaps, abrasives, waxes, polishes, drugs, cosmetics, biologicals, volatiles, odor absorbing and controlling compositions, water soluble chemicals, water emulsions, water mixture with solid particles and adequate water with a predetermined ratio of hydrophilic urethane prepolymer to provide a polymerizing mixture for forming the controlled release urethane foam product;
• b. dispensing a predetermined quantity of the polymerizing aqueous mixture into a shaped and sized mold;
• c. cutting a sized and shaped piece of abrasive non-woven material and fitting it into the mold for contact with the surface of the polymerizing mixture;
• d. placing a cover on the mold to control the size of the polymerizing mixture;
• and
• e. removing the formed controlled release urethane foam product with the abrasive non-woven material affixed to at least one exterior face and removing excess moisture from the formed foam product.

The method for forming controlled release urethane foam products having an abrasive layer formed on one exterior face comprising the steps of:

• a. metering and mixing an aqueous formulation having at least a limited quantity of superabsorbent polymer, at least one agent from the group detergents, soaps, abrasives, waxes, polishes, drugs, cosmetics, biologicals, volatiles, odor absorbing and controlling compositions, water soluble chemicals, water emulsions, water mixture with solid particles and adequate water with a predetermined ratio of hydrophilic urethane prepolymer to provide a polymerizing mixture for forming the controlled release urethane foam product;
• b. dispensing a predetermined quantity of the polymerizing aqueous mixture into a shaped and sized mold;
• c. placing a cover on the mold for contact with he surface of the shaped polymerizing mixture to control the size thereof and removing the sized and shaped and formed controlled release urethane foam product from the mold;
• d. removing residual moisture from the formed controlled release urethane foam product;
• e. cutting a piece of abrasive non-woven material in the shape of the mold;
• and
• f. laminating the abrasive non-woven material to the matching shaped surface of the formed controlled release urethane foam product.

The method for forming controlled release urethane foam products having an abrasive layer formed on one exterior face comprising the steps of:

• a. metering and mixing an aqueous formulation having at least a limited quantity of superabsorbent polymer, at least one agent from the group detergents, soaps, abrasives, waxes, polishes, drugs, cosmetics, biologicals, volatiles, odor absorbing and controlling compositions, water soluble chemicals, water emulsions, water mixture with solid particles and adequate water with a predetermined ratio of hydrophilic urethane prepolymer to provide a polymerizing mixture for forming the controlled release urethane foam product;
• b. dispensing a predetermined quantity of the polymerizing aqueous mixture into a shaped and sized mold;
• c. placing a cover on the mold for contact with the surface of the shaped abrasive non-woven material;
• d. cutting a piece of abrasive non-woven material in the shape of the mold;
• and
• e. adhering the abrasive non-woven material to the matching shaped surface of the molded controlled release urethane foam product.

The method for forming comminuted controlled release urethane foam products comprising the steps of:

• a. metering and mixing an aqueous formulation having at least a limited quantity of superabsorbent polymer, at least one agent from the group detergents, soaps, abrasives, waxes, polishes, drugs, cosmetics, biologicals, volatiles, odor absorbing and controlling compositions, water soluble chemicals, water emulsions, water mixture with solid particles and adequate water with a predetermined ratio of hydrophilic urethane prepolymer to provide a polymerizing mixture for forming the controlled release urethane foam product;
• b. depositing the polymerizing mixture on releasable bottom paper disposed on a movable carrier;
• c. covering the upper surface of the polymerizing mixture with releasable top paper as the polymerizing mixture is moved with the carrier;
• d. advancing the polymerizing mixture in the top and bottom release paper by moving the carrier and sizing the foam layer being formed to the desired thickness until it is tack free;
• e. sequentially removing the top and bottom release paper while simultaneously drying the formed foam product to remove residual moisture;
• and
• f. passing the formed controlled release urethane foam product to the secondary operations of comminuting the formed controlled release urethane foam product into sized particles for particular applications and uses.