Abstract: A process and apparatus are disclosed for the continuous production of polyurethane foam. The invention is directed to the use of a laterally translating mold, the first portion of which has divergent side walls, including a "V"-shaped mold having divergent straight vertical side walls. A polyurethane reaction mixture is deposited at or near the apex of that mold. The deposited mixture can be a partially-expanded prefoamed fluid mixture formed, for example, by a centrifugal mixing means. Typically, the mixture is permitted to substantially complete its rise after being conveyed past the extremeties of the divergent side walls of the first mold portion. The invention contemplates use of a ratio of conveyor velocity to foam product height lower than those of the prior art. Both rectangular and circular cross sectional products can be produced.

Abstract: A process is diclosed for the production of large dimension polyester-derived polyurethane foam. A preferred embodiment of the invention is continuous production of polyurethane foam slabs having a height exceeding forty inches. Such heights are obtained through use of a slow-rise foam formulation. Slabs having a substantially rectangular or round cross section can be obtained using segmented inclined pouring boards. The slow-rise formulation is deposited on one inclined segment and moves down it and another segment more steeply inclined to effect the production of both rectangular or round slabs.

Abstract: A centrifuge and centrifugal process are disclosed for prefoaming liquid polyurethane-foam generating reactants prior to introducing the reactants into a mold. A preferred embodiment of the invention is adapted to produce continuously slabs of polyurethane foam of substantially rectangular cross section.

Abstract: A method and apparatus for forming a convolute package of flexible foam sheet material which is highly compact to facilitate shipment and storage, and which has substantially uniform layer to layer compression. Further, the material in the package is dimensionally stable upon the unwinding of the package to permit the immediate use thereof, such as die stamping components of predetermined size therefrom. The package is produced by directing an advancing web into a nip formed between a take-up roller and a supporting roller and convolutely winding the web upon the take-up roller. The web is introduced onto the periphery of the package at the nip, and the package radius at the nip is maintained so as to be less than the radius of the remaining periphery of the package. In addition, the distance between the take-up roller and supporting roller is increased by a predetermined amount upon each rotation of the package to thereby achieve a substantially uniform layer to layer compression.

Abstract: A convolute package of flexible foam sheet material which is highly compact to facilitate shipment and storage, and which has substantially uniform layer to layer compression within predetermined limits consistent with the desired compression of the overall package and without detrimental over-compression of any layers. Further, the material in the package is dimensionally stable upon the unwinding of the package to permit the immediate use thereof, such as die stamping components of predetermined size therefrom.

Abstract: Flame retardant flexible polyurethane foams having a porosity in the range between 0.5 and 10 cubic feet per minute and meeting all of the requirements of Motor Vehicle Safety Standard Docket 302 may be produced from tolylene diisocyanate (which is a mixture of the 2,4- and 2,6-isomers) and polyether polyols without downgrading the flexibility or the porosity of the foam by (a) using in the polymerization reaction a tolylene diisocyanate in which the 2,4- to 2,6-isomer ratio is such that the tolylene diisocyanate contains not more than about 76 percent by weight of the 2,4-isomer, and (b) incorporating into the reaction medium prior to polymerization from about 1 to about 8 percent by weight of dibromoneopentyl glycol in a form such that the dibromoneopentyl glycol can be polymerized with the other reactants in the foam matrix, the weight of the dibromoneopentyl glycol being based on the weight of the polyether polyol used in the polymerization reaction.