Foam compositions and articles including cyclodextrin crosslinked with polyurethane prepolymer and preparation thereof

1. A process comprising:

providing a cyclodextrin with at least one isocyanate-reactive group on at least a portion of the cyclodextrin;

providing a polyurethane prepolymer;

providing water;

combining the cyclodextrin, the water and the polyurethane prepolymer; and

reacting the polyurethane prepolymer with the water and the cyclodextrin to form a foam composition comprising the cyclodextrin crosslinked with the polyurethane prepolymer and having a foam structure, wherein the cyclodextrin crosslinked with a polyurethane prepolymer comprises a reaction product of a reactive isocyanate moiety reacted with at least one isocyanate-reactive group on at least a portion of the cyclodextrin, and the isocyanate-reactive group is an active hydrogen on a modifying group attached to the at least a portion of the cyclodextrin

wherein the content of the water in the composition is in the range from 10 wt. % to 80 wt based on the composition, prior to the crosslinking, foaming and drying steps; and

wherein the content of the cyclodextrin in the composition is from 0.5 wt % to 50 wt % based on the composition, prior to the crosslinking, foaming and drying steps.

2. The process of claim 1 wherein the cyclodextrin is an α-cyclodextrin, a β-cyclodextrin, a γ-cyclodextrin or a mixture of any two or more thereof.

3. The process of claim 1 wherein the at least one isocyanate-reactive group comprises a hydroxyalkyl group, an aminoalkyl group, a carboxyl group, a sulfhydryl group, an epoxy group, or a combination of any two or more thereof.

4. The process of claim 1 wherein the reactive isocyanate moiety comprises an aliphatic, cycloaliphatic, arylaliphatic, heterocyclic or aromatic polyisocyanate or a mixture thereof.

5. The process of claim 1 wherein the polyurethane prepolymer has an average isocyanate functionality of about 2 or greater.

6. The process of claim 1 wherein a ratio of the water to the cyclodextrin and the polyurethane prepolymer is selected to result in formation of the foam.

7. The process of claim 6 wherein the ratio is controlled to avoid formation of a hydrogel.

8. The process of claim 1 wherein the at least one isocyanate-reactive group is a primary hydroxyl group of the cyclodextrin, a secondary hydroxyl group of the cyclodextrin, an active hydrogen on a modifying group attached to the cyclodextrin, or a combination of any two or more thereof.

9. The process of claim 1 further comprising providing an alkylene glycol, a polyalkylene glycol, glycerol or a combination of any two or more thereof and combining the alkylene glycol, the polyalkylene glycol, the glycerol or the combination of any two or more thereof with one or more of the cyclodextrin, the water and the polyurethane prepolymer prior to or during the reacting.

10. The process of claim 1 wherein a portion of the cyclodextrin is not cross-linked.

11. The process of claim 10 wherein the non-crosslinked cyclodextrin comprises free modified and/or unmodified cyclodextrin, modified and/or unmodified cyclodextrin singly bonded to the polyurethane prepolymer or a mixture of any two or more thereof.

12. The process of claim 1 wherein the reacting is carried out at a temperature in the range from about 30° C. to about 120° C.

13. The process of claim 1 wherein at least a portion of the modified cyclodextrin is complexed.

14. The process of claim 1 wherein the foam has an original volume and upon absorption of water is capable of swelling to a volume at least about 20% greater than its original volume.

15. The process of claim 1 wherein the foam has an original weight and upon absorption of water is capable of increasing its weight to a weight at least about 20% greater than its original weight.

16. The process of claim 1 wherein the combining further comprises applying the cyclodextrin, the polyurethane prepolymer and the water, in any order, to a substrate.

17. A personal care product including a foam composition made by the process of claim 1 .

18. A process for preparing a foam-containing personal care product, comprising:

providing a cyclodextrin with at least one isocyanate-reactive group on at least a portion of the cyclodextrin;

providing a polyurethane prepolymer;

combining the cyclodextrin, the water and the polyurethane prepolymer;

reacting the polyurethane prepolymer with the water and the cyclodextrin to form a foam composition comprising the cyclodextrin crosslinked with the polyurethane prepolymer and having a foam structure; and

applying the cyclodextrin, the water and the polyurethane prepolymer to a substrate, wherein the cyclodextrin crosslinked with a polyurethane prepolymer comprises a reaction product of a reactive isocyanate moiety reacted with at least one isocyanate-reactive group on at least a portion of the cyclodextrin, and the isocyanate-reactive group is an active hydrogen on a modifying group attached to the at least a portion of the cyclodextrin;

wherein the content of the water in the composition is in the range from 10 wt. % to 80 wt. based on the composition, prior to the crosslinking, foaming and drying steps; and

wherein the content of the cyclodextrin in the composition is from 0.5 wt % to 50 wt % based on the composition, prior to the crosslinking, foaming and drying steps.

19. The process of claim 18 wherein the substrate comprises an element of the personal care product.

20. The process of claim 19 wherein the element comprises a backing layer on at least a portion of which the foam forms a layer.

21. The process of claim 18 wherein the personal care product comprises one or more of a bandage, a wound dressing, a wipe, a diaper, a diaper pant, a training pant, an absorbent underpant, a protective swimming undergarment, an incontinence garment, a panty shield or liner, a feminine hygiene product or a perspiration shield.