Abstract: A new composite material of an open foam substrate and bonded micropackaged active ingredient particles is generated by foam polymerization of a prepolymer phase and an aqueous phase. The foam substrate is an open cell foam for dispensing active ingredient liquids or solids released from the particles. The particles of micropackaged active ingredient liquids or solids are formed with frangible containment walls for breaking and releasing the active ingredient in response to defined stress. The aqueous phase is a pourable and flowable slurry mixture of an aqueous liquid carrier such as water, micropackaged active ingredient particles in the range of 1%-60% by weight of the aqueous phase, and surfactant wetting agent for adjusting the surface tension of the aqueous phase to produce an open cell foam upon polymerization with the prepolymer phase. The prepolymer phase is a hydrophilic polyurethane prepolymer receptive to the aqueous phase for foam polymerization upon mixing.

Abstract: A new composite material of an open foam substrate and bonded micropackaged active ingredient particles is generated by foam polymerization of a prepolymer phase and an aqueous phase. The foam substrate is an open cell foam for dispensing active ingredient liquids or solids released from the particles. The particles of micropackaged active ingredient liquids or solids are formed with frangible containment walls for breaking and releasing the active ingredient in response to defined stress. The micropackaged active ingredient particles are approximately 400 to 5,000 microns in diameter. The aqueous phase is a pourable and flowable slurry mixture of an aqueous liquid carrier such as water, micropackaged active ingredient particles in the range of 1%-60% by weight of the aqueous phase, and surfactant wetting agent for adjusting the surface tension of the aqueous phase to produce an open cell foam upon polymerization with the prepolymer phase.

Abstract: A reticulated hydrophilic foam substrate and bonded active surface particle powder composite filter material is generated by foam polymerization of a prepolymer phase with an aqueous phase. The reticulated hydrophilic foam substrate is characterized by relatively low pressure drop and low resistance to flow through the foam substrate. The prepolymer phase is a hydrophilic polyurethane prepolymer receptive to the aqueous phase for foam polymerization upon mixing with the aqueous phase. The aqueous phase in turn is a pourable and flowable slurry mixture of water, active surface particle powder, and surfactant wetting agent. The aqueous phase includes sufficient water or other evaporable liquid to provide a protective liquid layer or coating over the active surfaces of the powder particles.