Polyurethane foam sheet and process for layered sheet with the same

A method of producing a polyurethane foam sheet, comprising the steps of introducing a liquid mixture, obtained by mixing together a heated and melted hot melt urethane prepolymer (A) with a number average molecular weight within a range from 1,000 to 10,000 and containing isocyanate groups at molecular terminals, and a diol (B) into a space between a first releasable substrate and a second releasable substrate to form a sheet-like product in a continuous manner, and water foaming said sheet-like product sandwiched between said first releasable substrate and said second releasable substrate by bringing either one surface or both surfaces of said releasable substrates into contact with water vapor, wherein

• a ratio of a weight equivalence of active hydrogen atom-containing groups within said diol (B), relative to a weight equivalence of isocyanate groups within said hot melt urethane prepolymer (A) [isocyanate group equivalence/active hydrogen atom-containing group equivalence], is within a range from 1.5 to 20.0.

A method of producing a polyurethane foam sheet, comprising the steps of introducing a liquid mixture, obtained by mixing together a heated and melted hot melt urethane prepolymer (A), with a number of average molecular weight within a range from 1,000 to 10,000 and containing isocyanate groups at molecular terminals, and a diol (B) into a space between a first releasable substrate and a second releasable substrate to form a sheet-like product in a continuous manner, removing one of said first releasable substrate and said second releasable substrate, and water foaming said sheet-like product by bringing said sheet-like product into direct contact with water vapor, wherein

• a ratio of a weight equivalence of active hydrogen atom-containing groups within said diol (B), relative to a weight equivalence of isocyanate groups within said hot melt urethane prepolymer (A) [isocyanate group equivalence/active hydrogen atom-containing group equivalence], is within a range from 1.5 to 20.0.

A method of producing a laminated sheet, comprising the steps of applying a liquid mixture, obtained by mixing together a heated and melted hot melt urethane prepolymer (A), with a number average molecular weight within a range from 1,000 to 10,000 and containing isocyanate groups at molecular terminals, and a diol (B), onto a substrate in a sheet-like manner, water foaming said liquid mixture by bringing said sheet-like liquid mixture into contact with water vapor to form a polyurethane foam sheet and bonding a third substrate onto said polyurethane foam sheet, wherein

• a ratio of a weight equivalence of active hydrogen atom-containing groups within said diol (B) relative to a weight equivalence of isocyanate groups within said hot melt urethane prepolymer (A) [isocyanate group equivalence/active hydrogen atom-containing group equivalence], is within a range from 1.5 to 20.0.

A method of producing a laminated sheet, comprising the steps of applying a liquid mixture, obtained by mixing together a heated and melted hot melt urethane prepolymer (A), with a number average molecular weight within a range from 1,000 to 10,000 and containing isocyanate groups at molecular terminals, and a diol (B), onto a substrate in a sheet-like manner, bonding a third substrate onto said sheet-like liquid mixture to form a laminate, and water foaming said liquid mixture by bringing said laminate into contact with water vapor, wherein

• a ratio of a weight equivalence of active hydrogen atom-containing groups within said diol (B), relative to a weight equivalence of isocyanate groups within said hot melt urethane prepolymer (A) [isocyanate group equivalence/active hydrogen atom-containing group equivalence], is within a range from 1.5 to 20.0.

A method of producing a laminated sheet, comprising the steps of applying a liquid mixture, obtained by mixing together a heated and melted hot melt urethane prepolymer (A), with a number average molecular weight within a range from 1,000 to 10,000 and containing isocyanate groups at molecular terminals, and a diol (B), into a space between a first resealable substrate and a second releasable substrate to form a sheet-like product in a continuous manner, removing one of said first releasable substrate and said second relaseable substrate water foaming said sheet-like product by bringing an exposed surface of said sheet-like product, and/or a remaining first or second releasable substrate, into contact with water vapor to form a polyurethane form sheet, and bonding a third substrate to said exposed surface of said polyurethane foam sheet from which said first or second releasable substrate has been removed, wherein

• a ratio of a weight equivalence of active hydrogen atom-containing groups within said diol (B), relative to a weight equivalence of isocyanate groups within said hot melt urethane prepolymer (A) [isocyanate group equivalence/active hydrogen atom-containing group equivalence], is within a range from 1.5 to 20.0.

(canceled)

(canceled)