Process and apparatus for producing froth polyurethane foam and multi-layer foam product

Prepn. of polyurethane froth foam comprises (a) delivering polyurethane reactive components comprising an isocyanate component and a polyol component to a high pressure mix head; (b) delivering compressed gas to the high pressure mix head to form a frothable polyurethane reactive mixt.; (c) delivering the frothable mixt. to a froth foaming head; (d) frothing the frothable mixt. to form a frothed polyurethane reactive mixt.; and (e) recovering the froth foamed polyurethane prod.. Also claimed is the prepn. of filled polyurethane froth foam comprising (A) supplying a feed stream of isocyanate reactive polyol; (B) blending a filler with the feed stream in line to produce a polyol/filler blend; (C) injecting the polyol/filler blend together with one or more additional feed streams comprising an organo di-or poly-isocyanate or mixt. thereof, one or more urethane-promoting catalysts and opt. cross-linkers, chain extenders, auxiliaries and additives, and a frothing amt. of compressed a ir into a high pressure mix head to form a frothable polyurethane reactive mixt.; (D) delivering the frothable mixt. to a froth foam head and preparing a curable, filled polyurethane froth foam; and (E) curing the curable, filled foam to form a filled polyurethane froth foam prod.. Also claimed is an appts. suitable for the prepn. of filled polyurethane froth foam comprising (i) a high pressure mix head having 3 or more high pressure inlets and an outlet; (ii) an isocyanate component feed line connected to one of the high pressure inlets; (iii) a polyol component feed line connected to one of the high pressure inlets; (iv) an in-line blender positioned between a polyol source and the inlet of the high pressure mix head connected to the polyol feed line, the blender being supplied with powdered filler and being effective to blend the filler into a polyol of the polyol feed line; (v) a compressed gas line connected to one of the high pressure inlets; and (vi) a froth foam head having an inlet and an outlet, the inlet being connected to the outlet of the high pressure mix head.