Abstract: A viscoelastic foam system is provided having an amine-based polyoxypropylene extended polyol to impart strength, recoverability and endurance to the foam, and an appropriately selected non-amine-based polyol to provide flexibility to the foam. The combination of amine-based propylene oxide extended polyol and non-amine-based polyol provides a viscoelastic semi-rigid foam with excellent impact and recovery properties, recovering to substantially 100% of its initial volume and shape following an impact, yet with sufficient rigidity and stiffness so that it is effective at absorbing multiple impacts. A method of making the above viscoelastic foam is also provided.

Abstract: A moisture removal system for a helmet is provided. The moisture removal system includes an absorbent region that is positioned inside the helmet and an evaporative region positioned outside the helmet, and is made of a moisture wicking material that carries moisture collected by the absorbent region to the evaporative region where it is dispersed by evaporation. The moisture removal system can withdraw moisture from other helmet components such as pads and/or the harness, and can be provided within a helmet or as a kit that is used to upgrade existing helmets.

Abstract: A process for preparing a polyurethane foam that contains particles of expandable graphite and a halogenated fire-retardant additive which surprisingly impart excellent fire-retardant properties to the foam and provide a stable isocyanate-reactive component having improved pot life for industrial scale production purposes. The polyurethane foam can be prepared by mixing a single isocyanate-reactive component containing the graphite and halogenated additives along with all of the polyols and other ingredients with an isocyanate component in a two-component mixing machine such as a high-pressure mixing device for applying the reaction mixture into a suitable container.

Abstract: A composite armor including a disrupting layer and a backing layer provides protection against blast and ballistic threats. The disrupting layer includes ceramic particles or tiles that disrupt the incoming projectile, while the backing layer prevents penetration past the armor by the disrupted projectile. The disrupting layer may include a layer of polygonal ceramic tiles with a deflecting front surface, encased by a retaining polymer, and may also include fire-retarding particles.

Abstract: A composite armor including a disrupting layer and a backing layer provides protection against blast and ballistic threats. The disrupting layer includes ceramic particles or tiles that disrupt the incoming projectile, while the backing layer prevents penetration past the armor by the disrupted projectile. The disrupting layer may include a layer of polygonal ceramic tiles with a deflecting front surface, encased by a retaining polymer, and may also include fire-retarding particles.

Abstract: A protective foam layer is provided. The protective layer has a foam substrate that is at least partially enclosed by a formed skin adjacent the outer surface of the foam substrate. The formed skin is substantially non-porous. The combination of the foam substrate with the formed skin results in a protective layer that is effective to absorb and/or dissipate impact force for both high- and low-speed impacts that can be experienced during a sporting event such as cycling. The formed skin can also be provided with a plurality of protective zones having vent holes through the formed skin to regulate the degree of energy absorption in the respective zones. In this manner, a single continuous protective foam layer can be provided having multiple protective zones having distinct energy absorption characteristics instead of providing discrete protective layers that must be joined or meet at a seam.

Abstract: A viscoelastic foam is provided having an amine-based polyol system to impart strength, recoverability and endurance to the foam, and an appropriately selected trifunctional non-amine-based polyol system to provide flexibility to the foam. The combination of amine-based and non amine-based polyols provides a viscoelastic semi-rigid foam with excellent impact and recovery properties, recovering to substantially 100% of its initial volume and shape following an impact, yet with high rigidity and stiffness so that it is effective at absorbing high as well as low-energy impacts. A method of making the above viscoelastic foam is also provided. In a preferred embodiment, the foam is made using an allophanate-modified MDI prepolymer in order to provide the isocyanate in liquid form at standard temperature and pressure in order to simplify the production of the invented viscoelastic foams.

Abstract: The present invention relates to a process for the production of a polyurethane foam backed instrument panel. This process comprises slicing a free-rise bun of polyurethane foam to form a skived polyurethane foam, bonding the skived foam to a skin material to form a laminate, optionally, rolling the foam/skin laminate, thermoforming the foam/skin laminate into an instrument panel skin, positioning the instrument panel skin into the cavity of a mold, positioning a retainer into the core of the mold, adhering the retainer to the laminate by placing an adhesive film onto the retainer, closing the mold to apply heat and pressure, and removing the resultant instrument panel from the mold. Suitable polyurethane foams for the present invention may be flexible foams or semi-rigid foams. This invention also relates to the polyurethane foam backed instrument panels produced by this process.

Abstract: The present invention relates to a process for the production of a polyurethane foam backed instrument panel. This process comprises slicing a free-rise bun of polyurethane foam to form a skived polyurethane foam, bonding the skived foam to a skin material to form a laminate, optionally, rolling the foam/skin laminate, thermoforming the foam/skin laminate into an instrument panel skin, positioning the instrument panel skin into the cavity of a mold, positioning a retainer into the core of the mold, adhering the retainer to the laminate by placing an adhesive film onto the retainer, closing the mold to apply heat and pressure, and removing the resultant instrument panel from the mold. Suitable polyurethane foams for the present invention may be flexible foams or semi-rigid foams. This invention also relates to the polyurethane foam backed instrument panels produced by this process.

Abstract: This invention relates to flexible foams and flexible molded foams prepared from an isocyanate component comprising an allophanate-modified diphenylmethane diisocyanate. The present invention also relates to processes for the production of these flexible foams and flexible molded foams.

Abstract: A novel isocyanate reactive mixture is described which allows for the preparation of energy absorbing foams which meet Chrysler specification DC-640. The reactive mixture contains a) a filled polyol, b) a propylene oxide adduct of a mono-, di-, or trialkanolamine and c) a polyoxyalkylene polyamine. Foams prepared from the reactive mixture are also described.

Abstract: The present invention is directed to an isocyanate reactive mixture of specified amounts of a) a polyether polyol having a hydroxyl functionality of from 4 to 8 and having a hydroxyl number of from about 300 to about 450, b) a polyether polyol having a hydroxyl functionality of from 4 to 8 and having a hydroxyl number of from about 50 to about 200, and wherein at least 75% of the hydroxyl groups are primary hydroxyl groups, c) an adduct of a mono-, di-, or trialkanolamine and propylene oxide, said adduct having a hydroxyl number of from about 100 to about 800, and d) a polyoxyalkylene polyamine having a molecular weight of from about 2000 to about 5000, and containing from 2 to 3 primary amino groups. The invention is also directed to water-blown, energy absorbing foams made from the isocyanate reactive mixture.

Abstract: The present invention is directed to an isocyanate reactive mixture of specified amounts of a) a polyether polyol having a hydroxyl functionality of from 4 to 8 and having a hydroxyl number of from about 300 to about 450, b) a polyether polyol having a hydroxyl functionality of from 4 to 8 and having a hydroxyl number of from about 50 to about 200, and wherein at least 75% of the hydroxyl groups are primary hydroxyl groups, c) an adduct of a mono-, di-, or trialkanolamine and propylene oxide, said adduct having a hydroxyl number of from about 100 to about 800, and d) a polyoxyalkylene polyamine having a molecular weight of from about 2000 to about 5000, and containing from 2 to 3 primary amino groups. The invention is also directed to water-blown, energy absorbing foams made from the isocyanate reactive mixture.

Abstract: A novel isocyanate reactive mixture is described which allows for the preparation of energy absorbing foams which meet Chrysler specification DC-640. The reactive mixture contains a) a filled polyol, b) a propylene oxide adduct of a mono-, di-, or trialkanolamine and c) a polyoxyalkylene polyamine. Foams prepared from the reactive mixture are also described.

Abstract: The present invention is directed to an isocyanate reactive mixture and the flexible polyurethane foam produced therefrom. The reactive mixture contains specific filled polyols, water, a catalyst for the reaction between an isocyanate group and a hydroxyl group, and a specific N-hydroxyalkyl quaternary ammonium salt. The isocyanate used is toluene diisocyanate.

Abstract: The present invention is directed to an isocyanate reactive mixture and the flexible polyurethane foam produced therefrom. The reactive mixture contains specific filled polyols, water, a catalyst for the reaction between an isocyanate group and a hydroxyl group, and a specific N-hydroxyalkyl quaternary ammonium salt. The isocyanate used is toluene diisocyanate.

Abstract: The present invention is directed to a reactive mixture for use in preparing a flexible polyurethane foam and to the foams produced therefrom. The reactive mixture broadly comprises an isocyanate reactive composition comprising:A) from more than 0 up to 3 parts by weight per 100 parts by weight of components B) and C) of an amine of the formula:H.sub.2 N--R--NH.sub.2where R is a C.sub.3 to C.sub.10 straight or branched alkylene group or a C.sub.4 to C.sub.15 alicyclic group,B) from more than 0 up to 40% by weight of a relatively high molecular weight compound containing at least two aromatically bound primary amine groups, andC) from 60 to less than 100% by weight of one or more polyether polyhydroxyl compounds having hydroxyl functionalities of from 2 to 3 and molecular weights of from about 1000 to about 10,000, the percents by weight of component B) and component C) totalling 100%.

Abstract: The present invention is directed to a reactive mixture for use in preparing a flexible polyurethane foam and to the foams produced therefrom. The reactive mixture broadly comprises(A) from more than 0 up to 3 parts by weight per 100 parts by weight of components (B) and (C) of an amine of the formula:H.sub.2 N--R--NH.sub.2where R is a C.sub.4 to C.sub.10 straight or branched alkylene group, or a C.sub.4 to C.sub.15 alicyclic group,(B) from 0 to 30% by weight of a polyoxyalkylene polyamine having a molecular weight of from about 400 to about 5000 and containing from 2 to 3 primary amino groups, and(C) from 700 to 100% by weight of one or more polyether polyhydroxyl compounds having hydroxyl functionalities from about 2 to 3 and molecular weights of from about 1000 to about 10,000, the percents of components (B) and (C) totalling 100%.