Abstract: A foam seat element comprising an isocyanate-based foam matrix having an A-surface for contact with an occupant and a B-surface for contact with a suspension element. An elastomeric layer is disposed on at least a portion of the B-surface for contact with the support element. This approach results in reduction in labor to produce the elastomeric layer compared with correct positioning of cloth inserts on a foam production manufacturing line. Further, since, in the preferred embodiment of the invention, the elastomeric layer is achieved by spraying a liquid elastomer-forming composition on a portion of the mold surface, the costs of achieving the elastomeric layer are significantly less than those associated with using prefabricated, pre-cut cloth inserts. Still further, the use of an elastomeric layer allows for tuning of the thickness of that layer which facilitates “tuning” the durability of the B-surface of the foam seat element based on the specific suspension system with which it will be combined.

Abstract: An improved energy management device comprises a substrate body and at least one permeable insert sheet disposed in the substrate body. The shape and orientation of the sheet may be varied. In the various embodiments, the insert sheet has a wall substantially transverse to the energy absorbing surface of the energy management device. The substrate body and the at least one energy absorbing insert sheet are engaged with respect to one another. This may be achieved by having at least a portion of the substrate body disposed in the permeable portion of the insert sheet thereby “locking” in place the insert sheet. It has been discovered that such a combination of a substrate body and an insert sheet surprisingly and unexpected results in improved energy management properties when compared to the independent energy management properties of the substrate body and the insert sheet. The energy management device is useful, for example, in the construction of a vehicular bumper.

Abstract: An improved energy management device comprises a substrate body and at least one permeable insert sheet disposed in the substrate body. The shape and orientation of the sheet may be varied. In the various embodiments, the insert sheet has a wall substantially transverse to the energy absorbing surface of the energy management device. The substrate body and the at least one energy absorbing insert sheet are engaged with respect to one another. This may be achieved by having at least a portion of the substrate body disposed in the permeable portion of the insert sheet thereby "locking" in place the insert sheet. It has been discovered that such a combination of a substrate body and an insert sheet surprisingly and unexpected results in improved energy management properties when compared to the independent energy management properties of the substrate body and the insert sheet. The energy management device is useful, for example, in the construction of a vehicular bumper.

Abstract: A process for producing a polyurethane foam includes the steps of (a) providing a substantially uniform mixture having an isocyanate, an active hydrogen-containing compound, a blowing agent, and a catalyst to form a reaction mixture, and (b) expanding the reaction mixture to produce the polyurethane foam. The active hydrogen-containing compound has from about 50 to 100 parts-by-weight of a first active hydrogen-containing compound having an equivalent weight of from about 200 to about 800 and from 0 to about 50 parts-by-weight of a second active hydrogen-containing compound. The average equivalent weight of the active-hydrogen containing compound is in the range of from about 150 to about 700.