Abstract: A polymer-modified polyol dispersion comprises a polyaddition product dispersed in a polyol. The polyaddition product is present in an amount of from about 25 to about 70 percent by weight based on the total weight of the polyaddition product and the polyol. The dispersion has a viscosity in the range of from about 4,000 to about 50,000 mPa.s, the viscosity remaining substantially the same after production of the dispersion. A process for producing the polymer-modified polyol dispersion is also disclosed together with a process for using the dispersion to produce a polyurethane foam.

Abstract: A process for manufacturing a padded element using a mold having a mold cavity and including an upper mold having an interior surface complimentary to the upper surface of the padded element and a lower mold having an interior surface complimentary to the lower surface of the padded element. The process includes placing a trim cover on the upper mold, with the trim cover comprising an inner surface and a finished outer surface in contact with substantially the entire interior surface of the upper mold, placing a liquid foamable polymeric composition on the interior surface of the lower mold and closing the upper mold and the lower mold after the liquid foamable polymeric composition expands to fill from about 50 to about 90 volume % of the mold cavity and prior to expansion of the liquid foamable polymeric composition to a point corresponding to the interior surface of the upper mold in a closed position.

Abstract: A process for manufacturing a padded element using a mold having an upper mold and a lower mold. The process includes placing a cushion member on the lower mold. The upper surface of the cushion member includes a first portion having an open recess with a boundary extending therearound for containing a liquid foamable polymeric composition in the recess. A trim cover with a finished upper surface is placed in contact with the interior surface of the upper mold. A liquid foamable polymeric composition is dispensed in the open recess within the boundary, and the upper mold and the lower mold are closed to cover the open recess and form an enclosure containing the liquid foamable polymeric composition. The polymeric composition expands to fill substantially the enclosure and adheres to the cushion member and to the inner surface of the trim cover.

Abstract: A process for manufacturing a padded element in a mold having an upper mold and a lower mold. The process includes providing in the lower mold a cushion member with a first portion having an open recess therein, with that recess having a lower portion. The cushion member is enveloped by a trim cover having a finished upper outer surface and an inner surface. The trim cover has at least one aperture therein, and the open recess and trim cover define a cavity. The upper mold and lower mold are closed so that the upper mold is in contact with the upper outer surface of the trim cover. A liquid foamable polymeric composition is dispensed in the cavity and onto the lower surface of the open recess via the aperture in the trim cover. The polymeric composition is allowed to expand to fill substantially the cavity, and the composition comes into contact with the inner surface of the trim cover such that the first portion corresponds proportionally to the finished surface of the padded element.

Abstract: A process for producing a foamed polymer, particularly a polyurea foam, comprises reacting an isocyanate compound and at least one active hydrogen-containing compound in the presence of a heterogeneous blowing agent. The heterogeneous blowing agent is a permanent gas and is used at a temperature and a pressure thereby rendering it in the form of a liquid, solid or deep chilled gas. The exothermicity of the reaction is substantially compensated by the energy absorbing capacity of the heterogeneous blowing agent.