Abstract: Disclosed is a process for making a two or more component foam composite obtained by adhesion of a polyurethane foam onto a substrate comprising the steps of frothing an aqueous polyurethane formulation; applying the froth to a substrate and drying the froth into a foam wherein the foam has a dry density of 35 kg/m3 to 160 kg/m3 (2.2-10 lbs/cft). The process allows the production of foam backed textiles without the need for a flame lamination step or the need for an adhesive layer between the textile and the foam layer and is optionally optimized for superior handling properties for covering polyurethane molded foam cushions.

Abstract: The present invention is polyurethane dispersion composition that can be mechanically frothed to yield a foam that has good resiliency. Frothed foams of the present invention can be useful in cushioned flooring applications such as attached cushion broadloom, carpet tiles, carpet underlay, or vinyl flooring. Frothed foams of the present invention can also be useful as coatings for various textiles and for diapers.