Foam-like materials and methods for producing same

Abstract

Described herein are foam-like materials having substantially the same physical structure of polyurethane foams but with properties that can be tailored for a particular application. Methods of forming these foam-like materials are also described.

What is claimed is: 
     
         1 . A porous material made by the steps of:
 providing a polyurethane foam base material having a porous surface;   contacting the base material with a first fluid material;   drawing the first fluid material into intimate contact with the base material to form a coat of the first fluid material on the base material;   curing the coat on the base material; and   removing the base material from the cured coat, resulting in a porous material comprising the cured first fluid material.   
     
     
         2 . The porous material of  claim 1  wherein the step of drawing the first fluid material into intimate contact with the base material includes using a vacuum. 
     
     
         3 . The porous material of  claim 2  further comprising using positive air pressure to blow away excess fluid material from the base material before the step of curing. 
     
     
         4 . The porous material of  claim 1  wherein the first fluid material is a silicone elastomer dispersion. 
     
     
         5 . The porous material of  claim 1 , wherein the base material is removed by dissolution. 
     
     
         6 . The porous material of  claim 1  wherein the step of removing the base material comprises removing all of the base material from the cured first fluid material. 
     
     
         7 . The porous material of  claim 1  wherein the step of removing the base material comprises contacting the base material with a solution, mixture, suspension, emulsion, dispersion or combination thereof capable of dissolving the base material. 
     
     
         8 . The porous material of  claim 1  wherein the step of removing the base material comprises degradation or dissolution of the base material with a base, a solvent, an enzyme, an acid, heat, oxidation, ultraviolet light, gamma irradiation, visible light, infrared light or a combination thereof. 
     
     
         9 . The porous material of  claim 1  wherein the coat has a thickness of about 10 μm to about 500 μm. 
     
     
         10 . The porous material of  claim 1  wherein the coat has a thickness of about 50 μm to about 100 μm. 
     
     
         11 . The porous material of  claim 1  further comprising repeating the contacting step to achieve a desired thickness of the coat. 
     
     
         12 . A porous material made by the steps of:
 providing an open cell polyurethane foam base material having a porous surface;   contacting the base material with a liquid silicone dispersion to form a coating on the base material;   removing a portion of the liquid silicone dispersion from the base material by using a vacuum to draw the first fluid material into intimate contact with the porous surface of the base material and using positive air pressure to blow away excess fluid material;   curing the liquid silicone dispersion remaining on the base material after the step of removing a portion, to form a cured silicone elastomer coating on the base material; and   removing the base material from the silicone elastomer coating, thereby leaving a porous material comprising silicone.   
     
     
         13 . The porous material of  claim 12  further comprising using positive air pressure or a vacuum to remove excess fluid material from the base material before the step of curing. 
     
     
         14 . The porous material of  claim 12  wherein the step of removing the base material comprises contacting the base material with a solution capable of dissolving the base material. 
     
     
         15 . The porous material of  claim 12  wherein the step of removing the base material comprises degradation or dissolution of the base material with a base, a solvent, an enzyme, an acid, heat, oxidation, ultraviolet light, gamma irradiation, visible light, infrared light or a combination thereof. 
     
     
         16 . The porous material of  claim 12  wherein the coating has a thickness of about 10 μm to about 500 μm. 
     
     
         17 . The porous material of  claim 12  wherein the coating has a thickness of about 50 μm to about 100 μm. 
     
     
         18 . The porous material of  claim 1  further comprising repeating the contacting step to achieve a desired thickness of the coating.