Abstract: A foam contouring machine has first and second rollers mounted to a machine frame for rotation about mutually parallel axes. The first and second rollers have different diameters and define between them a nip. A cutting edge is mounted for cutting foam material drawn through the nip by rotation of the rollers. Each roller has a drive motor, and a controller is connected to each drive motor for independently controlling the speed of rotation of the rollers, the controller equalizing the speed of surface rotation of the rollers for rollers of different diameters. The first roller may be a pattern roller and the second roller may be a backup or compression roller. The machine also has a drive coupling assembly, which has selectable first and second modes of operation for converting operation of the machine between a foam surfacing and a foam profiling operation. The first mode independently couples each of the motors to a corresponding one of the rollers.

Abstract: The invention provides a pillow to support a user's head and neck and a portion of his upper body during sleep or resting. The pillow has a generally planar lower support surface and an upper support surface. A rear lobe and a front lobe are separated by a trough on the support surface. A wedge portion depends downwardly from the front lobe toward the front edge of the pillow. The wedge portion and front lobe together function to support the neck and a portion of the user's upper body when his head is held within and is supported by the trough.

Abstract: A thermal and acoustic barrier for automotive floor pan carpeting is made by cutting synthetic foam sheet in a continuous process to create a foam surface complementary to the three dimensional shape of the floor pan surface. The cut foam sheet is bonded to the underside of the carpeting and installed with the complementary foam surface facing the floor pan.

Abstract: An inflatable overlay for a bed mattress has a base sheet with a top and sides sized to retentively fit over the mattress, and inflatable elements secured to the sheet defining a body support surface. Impermeable sheet material is layered on the base sheet to form air conduits connected for supplying the inflatable elements. The overlay is pliable and can be folded or rolled for transport and storage.

Abstract: Synthetic foam compressed between a pattern roller and a smooth compression roller is driven against a cutting edge closely adjacent and tangent to the pattern surface but spaced from the compression roller to reproduce a three dimensional pattern roller surface on the foam sheet. Three dimensional patterns of arbitrary geometries including sharp edged, flat surfaced geometric solids can be reproduced on a foam surface.

Abstract: A breathable or air-permeable, open cell, flexible urethane polymer suitable for use in cushions is formed from a foam-forming composition containing from about 0.5 to 2.0 parts by weight of butyl oleate, based upon 100 parts by weight polyol, under controlled pressure conditions maintained at or, preferably, below atmospheric pressure. The pressure during foaming is maintained in the range of about 0.5 to 1.0 bar, preferably 0.5 to 0.9 bar. Resultant air permeability is unexpectedly significantly increased over urethane polymers of equivalent composition. Other polymer properties are enhanced.

Abstract: The present invention relates to slip-resistant machine washable floor mats particularly suitable for use in motor vehicles. The floor mats have an upper carpet fabric layer attached with adhesive or by flame lamination to a lower layer of coarse-celled reticulated polyurethane foam having pore sizes within the range of 3 to 80 pores per linear inch (about 0.19 to about 0.02 inch cell diameter). The floor mat has an air permeability greater than about 5 (ft.sup.3 /min.)/ft.sup.2 at 0.5 inch of water pressure drop, which enhances the washing and drying ability of the entire mat.

Abstract: Hydrophilic polyurethane foams with rapid wet out properties are formed from the reaction product of an MDI-based or polymeric MDI-based isocyanate capped prepolymer with an aqueous component, such as water, and about 0.5 to 2.0 parts by weight, based on 100 parts by weight prepolymer, of a silicone glycol copolymer liquid surfactant with a polyether portion, said surfactant having a viscosity of about 175 to 350 CST at 25.degree. C., a molecular weight in the range of about 1500 to 20,000, with the polyether portion having a molecular weight in the range of about 200 to 2000 and containing about 40 to 100 percent by weight ethylene oxide. The surface of the hydrophilic foam wets out or absorbs droplets of water in less than thirty (30) seconds, preferably instantaneously (less than one second).

Abstract: An air support unit for use in a modular air support bed has a common base pad of pliable material and inflatable elements releaseably fastened to one side of the base pad to define a body support surface. The air support unit constitutes a lightweight, foldable module easily and quickly interchangeable in a given bed with other modules having different patient support characteristics. The air support unit may be contained in a coverlet having a detachable top for easy access to the air support unit. An interior frame of resilient foam may be provided around the air support unit inside the coverlet for enhanced edge support.