Low density attached polyurethane foams made using a combination of frothing and blowing methods

A process for making a cushion-backed textile, comprising:

• a) forming a frothed polyurethane-forming composition having a density of about 250 to 600 grams per liter wherein the polyurethane-forming composition includes one or more polyols including at least one polyol having a hydroxyl equivalent weight of at least 400, 0.25 to 2 parts of water per 100 parts by weight polyol(s) having a hydroxyl equivalent weight of at least 400, 3 to 10 parts by weight of a physical blowing agent having a boiling temperature of −30 to 40° C. per 100 parts by weight polyol(s) having a hydroxyl equivalent weight of at least 400, 100 to 400 parts by weight of a filler per 100 parts by weight polyol(s) having a hydroxyl equivalent weight of at least 400, a foam stabilizing surfactant, at least one polyisocyanate in an amount sufficient to provide an isocyanate index of from 85 to 130 and a polyurethane catalyst in an amount such that the polyurethane-forming composition has a gel time of at least 180 seconds;
• b) forming the uncured froth into a 0.05 to 0.75 inch (0.127 to 1.9 cm) thick layer across the top surface of a textile having a width of at least 24 inches (61 cm);
• and
• c) curing the layer of the frothed composition with its top surface open to the atmosphere such that the frothed composition can freely rise to form a foamed polyurethane cushion having a density of no greater than 176 grams/liter (11 pounds/cubic foot) bonded to the textile.