Foam sealing gasket

A sealing gasket comprising:

• a liner;
• and
• a polyurethane foam layer disposed on the liner, the polyurethane foam layer having a density of 50 kg/m3 to 220 kg/m3, a force-to-compress at 25% compression of not greater than 2.0 psi, and an 80% springback parameter in a range of 0.000 seconds to 1 seconds, the polyurethane foam having a thickness in a range of 0.3 mm to 10.0 mm, a surface of the polyurethane foam layer opposite the liner having a skin, wherein the polyurethane foam is a reaction product of reaction constituents comprising:
• a polyol;
• an isocyanate;
• and
• a delaying catalyst, wherein the delaying catalyst comprises an amine and a dicarboxylic acid and the delaying catalyst has a delay time of at least 3 minutes as measure at 115° C. at a concentration of 0.4 pphp in the presence of 0.3-0.4 pphp water.

A method of forming a gasket, the method comprising:

• forming a frothed reactive mixture including an isocyanate component, a polyol component, water, and a delaying catalyst, the delaying catalyst exhibiting a delay before blowing, wherein the catalyst comprises an amine and a dicarboxylic acid and the delaying catalyst has a delay time of at least 3 minutes as measure at 115° C. at a concentration of 0.4 pphp in the presence of 0.3-0.4 pphp water;
• dispensing the frothed reactive mixture on a moving carrier;
• and
• curing the reactive mixture to form a foam layer, the foam layer having a density of 50 kg/m3 to 250 kg/m3, a force-to-compress at 25% compression of not greater than 2.0 psi, and an 80% springback parameter in a range of 0.000 seconds to 1 seconds, the foam layer having a thickness in a range of 0.3 mm to 10.0 mm, a surface of the foam layer having a skin.