Abstract: Composite shaped foam articles of manufacture and method for fabricating such articles is disclosed. The articles are formed by providing a section of foam material, treating a first surface of the section of foam material with adhesive, providing a second section of flexible foam having a surface to be joined with a surface of the first section, treating at least one of the surfaces to be joined with a suitable adhesive, joining the treated surfaces of foam, deforming the joined sections of foam into a selected shape, and curing the adhesives whereby the joined sections of foam remain elastically deformed rather than restoring to their original unstressed condition thus maintaining their selected shape.

Abstract: A laminated fabric having an integral raised area formed therein which simulates the appearance of a button, welt or the like, and method of making same. The laminated fabric is comprised of a layer of cloth or vinyl cover material, an intermediate layer of foam and a layer of backing material such as nylon. A form having the shape which corresponds to the desired shape of the raised area is disposed between the foam layer and the cover material. Anhydrous polyurethane foam forming materials are applied in liquid form to the form layer and cover material contact surface and the form layer and backing material contact surface. The unlaminated layers are placed over a die with each of the forms being positioned immediately above a die having protrusions which generally circumscribe the form. Moisture is introduced into the foam forming material and a heated press is applied to the backing material forcing the unlaminated layers down against the die.

Abstract: A process for the manufacture of a polyurethane prepolymer adhesive by a catalyst initiated reaction of polyol and isocyanate copolymers is performed under room temperature conditions, and in convenient quantities for application, storage, and transportation purposes. Compounding includes alternatives of catalyst and co-catalyst combinations, and additives, including a reaction inhibitor, plasticizer, delayed reaction catalyst and surfactant.

Abstract: This invention is directed to a polyurethane product produced by a one step process, in the absence of a polymerization catalyst, with reactants, and additives, if any, being initially intermingled in the ambient room temperature range and reacted with intermingling in the absence of externally added heat. The reactants are (1) aliphatic, aromatic, or cycloaliphatic having at least two isocyanate groups and (2) diol/polyol compounds having at least two sterically unhindered hydroxyl groups. The product is a liquid, homogeneous adhesive material characterized by a natural absence of polymerization catalyst residue and capable of being cured because of the presence of unreacted isocyanate groups, the isocyanate reactant being charged in excess of the stoichiometric requirement of the diol/polyol reactant.

Abstract: The invention is directed to a rigid article comprising a soft foam member, preferably open cell polyurethane, adhered to at least one surface of said soft foam member, a hard polyurethane resin member; said adhesion being obtained by way of penetration of hard resin affording material into cells of said soft foam member for a distance sufficient to provide a substantially permanent bond between said two members, after curing said hard resin-affording material; and said hard resin member is sufficiently thick to provide configurational support for said article. Normally, the article includes a cover member.