Abstract: A procedure is provided for producing a wound dressing having a crushed or uncrushed foam bonded to a woven, knit or nonwoven absorbent layer, particularly woven cotton gauze. The foam is self-bonded to the absorbent layer, i.e., no adhesive is needed to bond the foam. The foam may be applied by one of several methods. One procedure comprises applying a thin layer of foamed latex on a release medium. The dry foam, still on the release paper, is then simultaneously crushed and transfer bonded to the absorbent layer. A second method comprises applying the foam directly on the absorbent layer and crushing if desired. A third method comprises applying unfoamed material on the fabric and then causing foaming by the use of blowing agents then crushing if desired.

Abstract: A flexible, absorbent pad having a laminate structure comprising a top layer of a crushed foam of an addition polymer derived from an aqueous polymer latex, an underlying layer of liquid-absorbent material, and a bottom layer of a moisture-impervious film or a gauze. The addition polymer has a soft monomer component containing butadiene, ethylene/vinyl acetate, ethylene/vinyl chloride, propylene/vinyl acetate or propylene/vinyl chloride.

Abstract: A procedure is provided for producing a laminate having a crushed, polymeric latex foam, preferably thermoset, bonded either to a non-woven absorbent layer which is bonded to an absorbent layer or bonded directly to the absorbent layer, which in turn is bonded to a liquid-impermeable film or gauze. The crushed foam is self-bonded to the non-woven or absorbent layer, i.e., no adhesive is needed to bond the crushed foam. The foam may be applied by either of two methods. One procedure comprises applying a thin layer of foamed latex of a thermosettable polymer on a release medium and drying without causing thermosetting. The dry foam, still on the release paper, is then bonded to the absorbent layer when crushed by pressure. The thermosetting may be done simultaneously with bonding or subsequent thereto. A second method comprises applying the foam directly on the non-woven and drying, bonding and crushing as described above.

Abstract: A procedure is provided for producing a laminate having a textile backing, a crushed, thermoset plastic foam bonded thereto, and a transparent polymeric film, preferably also a thermoset, which may be printed or colored overall overlying the foam. The structure is self-bonded, i.e., no adhesive is used to bond the laminate to one another. The preferred procedure is to apply a thin layer of foamed latex of a thermosettable polymer on a textile followed by drying the foam, the thickness of the foam being between about 10 mils and 150 mils. The transparent film, preferably thermosetting, is suitably formed by casting a latex upon a release surface such as silicone release paper and drying the same without causing thermosetting (if a thermosettable polymer is utilized). The dry film, still on the release paper, is then suitably coated or printed with a decorative design. The decorated side of the film is then placed against the dried foam layer and bonded thereto by pressure.