Reduced density foam articles and process for making

Abstract

The invention discloses reduced density foams and methods of making the foams by applying or creating a nonfoaming barrier layer on a foamable layer, which barrier layer inhibits the escape of fugitive gases during the foaming process.

We claim:  
     
         1 . A foam article comprising a foam layer having at least one major surface and a barrier layer on said at least one major surface wherein the foam layer of the article has a density at least 20% lower than would be the density of a foam layer of a similar foam article made without a barrier layer.  
     
     
         2 . A foam article comprising a foam layer having at least one major surface and a barrier layer on said at least one major surface wherein the foam article has a density at least 20% lower than would be the density of a similar foam article made without a barrier layer.  
     
     
         3 . The foam article of  claim 2  comprising at least four layers wherein at least one foam layer is between two unfoamed layers.  
     
     
         4 . The foam article of  claim 2  wherein said article is a pressure sensitive adhesive article.  
     
     
         5 . The pressure sensitive adhesive article of  claim 4  comprising a multilayer article wherein at least one interior layer comprises a nonfoaming barrier layer.