Polyurethane foam composition and method of making same

Method of thermally bonding flexible polyether polyurethane foam to a substrate which comprises:

• A. reacting and foaming a composition consisting essentially of
• a. a polyisocyanate reactant containing at least two isocyanate groups per molecule;
• b. at least one graft copolymer polyether polyol reactant having a molecular weight of at least about 2000 and containing an average of at least two hydroxyl groups per molecule, said graft copolymer polyether polyol having been produced by polymerizing one or more ethylenically unsaturated monomers dispersed in a polyether polyol in the presence of a free radical catalyst;
• c. a blowing agent;
• d. a catalyst;
• e. a surfactant;
• and
• f. about 1 to about 7% based on the weight of graft copolymer polyether polyol (b), of at least one polyol modifier selected from the class consisting of:
• 1. alkylene glycols having 2 to about 8 carbon atoms;
• 2. glycol ethers having the empirical formula;
• HO--[C.sub.n H.sub.2n O].sub.m H
• wherein n is an integer having values of 2 to 4 and m is an integer having values of 2 to 4 when n is 2, 2 to 3 when n is 3 and 2 when n is 4;
• 3. triols having the empirical formula:
• C.sub.x H.sub.2x-1 (OH).sub.3
• wherein x is an integer having values of 3 to about 10;
• 4. alkanolamines having the empirical formula:
• C.sub.y H.sub.2y N.sub.z (OH).sub.p
• wherein y is an integer having values of 2 to about 10, z is an integer having values of 1 to 2 and p is an integer having values of 2 to 4;
• and
• 5. polyhydric mononuclear phenols;
• B. heating the surface of the foamed composition of (A) above its melting or fusion point;
• C. contacting the melted or fused surface of the foamed composition of (A) with a substrate whereby a flexible polyurethane foam/substrate laminate is formed;
• and
• D. cooling the flexible polyurethane foam/substrate laminate below the melting or fusion point of the flexible polyurethane foam.