Abstract: Apparatus for continuously shaping a compressible or cellular polymer material, such as polyurethane foam, by cutting portions of the material from a surface of one or more slabs of material (180) includes two compression rollers (146, 146a), two moving patterned platforms (132, 132a) interposed between the compression rollers, and one or more cutting blades (76) for transversely cutting the slab or slabs just as the cellular material emerges from between the compression rollers. At least one of the moving patterned platforms, preferably an endless belt, defines a recess or pattern of recesses. When a single slab or multiple slabs of material are fed and compressed between the compression rollers, a portion of the material from one side of the slab or slabs fills the recess or recesses in one of the moving patterned belts. The blade then transversely cuts the cellular material.

Abstract: A one piece air mattress suitable for use in health care settings to aid in prevention of bed sores has air cells permanently attached to a common base sheet along a base perimeter of each cell. The air cells and base sheet are of flexible radio frequency weldable plastic material, and all the air cells can be simultaneously welded to the base sheet in a single welding step using a special welding jig. Air supply conduits are defined by strips bonded to the base sheet in overlying relationship to orifices opening the supply conduits to the air cells, thereby eliminating the need for external air hoses and connections. An alternating pressure air mattress can be made by opening different air supply conduits to alternating sets of the air cells.

Abstract: Polyurethane foams formed at elevated pressure using a graft polyol, or mixture of polyols to form a polyol system, having a low functionality and a high solids content, exhibit superior dynamic shock cushioning characteristics (energy absorption) as illustrated by the drop curves of deceleration versus static load. The foam-forming ingredients are mixed together and foamed under controlled pressures in the range of 1.2 to 1.5 bar, preferably 1.3 to 1.4 bar. The polyol preferably has a functionality in the range of about 2.0 to 2.5, a hydroxyl number in the range of about 50 to 90, a solids content above about 35%, preferably about 50 to 55%.

Abstract: An inflatable mattress for clinical bed use has a base pad including two sheets joined to define one or more narrow air conduits extending along the pad. A body supporting surface is provided by individually detachable inflatable elements covering the base pad. Each inflatable element is secured across the pad transversely to and communicates with at least one air conduit through apertured fasteners. Air permeable foam in the air conduits holds the conduits open in a gatched condition of the pad. Cushioning material contained between the sheets exteriorly to the air conduits provides body support in the event of deflation of the mattress. Constant pressure and alternating pressure modes of operation are supported with appropriate air supply systems.

Abstract: A seat cushion assembly is formed by (a) placing a foam-fabric laminate (14, 15) and an air impervious adhesive film (16) over a mold (18); (b) drawing the adhesive against the foam and urging the fabric against the mold by vacuum; (c) placing a foam pad (12) adjacent to the adhesive film; (d) heating the film and diffusing it into the foam pad and into the foam of the foam-fabric laminate; and (e) curing the film adhesive. The foam layer laminated to the fabric is formed as the reaction product of a polyether polyol or a graft polyether polyol with about 30 to 60 parts by weight of an MDI or polymeric MDI/TDI blended isocyanate with the major portion MDI or mixtures thereof, about 1.5 to 3.0 parts by weight water as a blowing agent, about 0.05 to about 0.90 parts by weight amine catalyst and about 0.5 to about 1.5 parts by weight silicone surfactant, wherein all amounts are based on 100 parts by weight polyol.

Abstract: In a method for bonding a foam-fabric composite to a molded foam core, particularly suitable for use as an automotive cushion assembly, specific advantageous polymeric MDI-based foams are used to achieve consistently excellent bond strength. In the method, a foam layer is flame laminated to a fabric layer. Then the foam-fabric laminate and an air impervious adhesive film are placed over a mold surface, and the adhesive is drawn against the foam of the foam-fabric laminate and the fabric layer is urged against the mold surface by applied vacuum. The foam core pad is placed adjacent to the adhesive film. The film is heated and diffused into the foam pad and into the foam of the foam-fabric laminate, respectively, and allowed to cure. The foam layer laminated to the fabric is formed as the reaction product of a polyether polyol or a graft polyether polyol with from about 30 to about 60 parts by weight of an MDI or a polymeric MDI/TDI blended isocyanate or mixtures thereof, from about 1.5 to 3.

Abstract: Modified or filled rebond polyurethane foam structures having desired plushness and compression without adversely affected tensile strength at a given density as compared to unfilled rebond polyurethane foams are formed from an admixture of shredded or chopped polyurethane foam particles and a finely divided inorganic mineral filler, such as barium sulfate or calcium carbonate or mixtures of these and like mineral fillers, that is further mixed with a substantially non-foam forming liquid prepolymer binder. A portion of the polyurethane foam particles, from about 10 to about 60 parts by weight based upon 100 parts by weight, is replaced with filler. For each 100 parts by weight of the combined foam particles and filler, about 10 to about 30 parts by weight of prepolymer is added. After the wetted admixture is compressed to the required density, the prepolymer binder is cured with heat and/or steam.

Abstract: The present invention relates to a method of making a laminated product, such as an insulator pad comprised of foam and stiffening layers held together with adhesive. A thin protective barrier foam sheet is placed between the surface of a compression roller and the sheets to be laminated together by passing them between compression rollers. The thin protective barrier foam sheet may or may not form the outer layer of the laminated product and prevents adhesive and foam material from contaminating the surface of the roller.