Abstract: A spray gun includes a main piston chamber having an actuatable piston and a gun block. The gun block includes a mixing chamber that has a pair of impingement holes that each tangentially intersects with an exit hole of the mixing chamber at opposing tangential points. The gun block also includes a tip that is coupled to an end of the mixing chamber and has a pattern channel that is substantially axially aligned with the exit hole of the mixing chamber. The length of the pattern channel is less than the length of the exit hole of the mixing chamber. In some versions, the ratio of the pattern channel to the combined length of the pattern channel and exit hole can be between 31%, inclusive, and 5%, inclusive. A selectively coupleable handle may be provided such that users can utilize different handles with the spray gun.

Abstract: A method for the preparation of a flexible, open-celled, urethane foam which comprises reacting at least one isocyanate and at least one polyol in the presence of at least one catalyst and an epoxidized soybean oil, wherein each polyol is a saturated polyether polyol. A further aspect of the present invention provides a pre-formation method for the preparation of a flexible, open-celled, urethane foam, the method comprising reacting at least one isocyanate and at least one polyol in the presence of at least one catalyst and about 7 phR to about 25 phR of an epoxidized soybean oil, wherein each polyol is a saturated polyester polydol. Flexible, open-celled urethane foams prepared in accordance with the methods set forth previously are also included in the present invention.

Abstract: Methods for reducing the quantity of emissions emanating from a foam-forming composition during the preparation of a fully-cured foam comprising contacting emissions emanating from the foam-forming composition during preparation of the fully-cured foam with vegetable oil. A further aspect provides a method for reducing the quantity of emissions emanating from a fully-formed foam during hot processing of the foam comprising contacting emissions emanating from the foam during such hot processing with vegetable oil.

Abstract: A method and apparatus for the continuous production of flexible open cell polyurethane foam, where a process air stream is drawn through the interior of the foam material after it has completed its rise to thereby accelerate the cooling of the foam material. The process air stream contains vaporized constituents which are removed by the steps of:(a) collecting the air stream from the foam material;(b) passing the air stream into an adsorption expansion chamber having a cross-sectional area adapted to reduce the flow rate of the air stream;(c) passing the air stream into an adsorption chamber;(d) passing the air stream through at least one activated carbon char filter bed located in the chamber at a flow rate that is adapted to provide sufficient residence time for the removal of the vaporized constituents drawn from the foam material; and(e) discharging the treated air stream into the atmosphere.

Abstract: A pneumatic spray gun (10) having a mixing assembly (14) including a resin valve (18) and a catalyst valve (20) formed by valve passages (44,46) formed in a valve rotor (36). A pneumatic trigger assembly (24) and slide assembly (28) control rotation of the valve rotor to open the resin valve momentarily before the catalyst valve. A distribution plate (174) distributes the catalyst within the resin before the mixture flows into a mixer (22).

Abstract: An improved process for rapidly cooling hot freshly polymerized foam is provided by passage of a fluid coolant stream having a water vapor content which initially is in the range from slightly below to above the dew point. In preferred embodiments the cooling fluid stream is recirculated, and auxiliary blowing agents and gaseous reaction products are removed and recovered.

Abstract: This invention relates to a process and apparatus for removing fine particulate matter and vapors from a process exhaust air stream, and particularly those emitted during post-production curing or post-treatment of foamed plastics, such as polyurethane foam, in which the exhaust air stream is passed through a transfer duct into which is introduced a water spray in the form of a mist of fine droplets in an amount which exceeds the saturation point; thereafter the exhaust air stream is introduced into a filter chamber having a cross-sectional area that is substantially greater than that of the transfer duct, and the exhaust air stream passes through at least one, and preferably a plurality of high surface are a filters, whereby a portion of the water is removed from the exhaust air stream and collected in the filter chamber prior to the discharge of the exhaust air stream into the environment.

Abstract: Improved ignition resistant, flexible, open-celled polyurethane foams are described. The foams are formed in situ from the reaction, in the presence of a catalyst, of an isocyanate, one or more blowing agents including water, a foam stabilizer, a polyether polyol, melamine, and a standard flame retardant additive. Preferred standard flame retardants are halogenated phosphorus esters and a blend of about 80 to 85% pentabromodiphenyl oxide in an aromatic phosphate plasticizer. The melamine is present in the foam formulations in an amount of from 30 to 40 parts by weight per 100 parts by weight of polyol. The standard flame retardant is present in an amount of from 15 to 25 parts by weight per 100 parts by weight of polyol. The compositions of the invention are particularly suitable for use in furniture, bedding, and carpet padding.

Abstract: A rollout apparatus for rolling trapped air from a resin impregnated fiber mat has two carriage assemblies mounted for reciprocated movement in opposite direction. Each of the carriage assemblies carries depending rollers that engage an impregnated fiberglass mat laid on a mold. The carriage assemblies oscillate simultaneously in opposite directions so that the turning forces generated by the receiprocation cancel each other, thus providing a smooth vibration-free mechanism.

Abstract: An improved carpet padding comprises a layer of rebonded flexible polyurethane foam, a relatively thin intermediate layer of flexible prime polyurethane foam, and a top layer of polymer film. The layers are laminated together by either a flame or liquid adhesive method. In a preferred embodiment, the bottom layer of rebonded foam is from two to eight times as thick as the intermediate layer of prime foam, and the top layer of polymer film is a metallized polyester embossed with a uniform pattern.

Abstract: Improved, flexible, open-celled polyurethane foams of reduced density, but with stability and firmness characteristics comparable to those of standard foams, are described. The foams are formed in situ from the reaction, in the presence of a catalyst, of an isocyanate, one or more blowing agents including water, a foam stabilizer, a polyether polyol, and a liquid salt produced from the reaction of CO.sub.2 with a water-soluble amine or amino alcohol. Preferred amines or amino alcohols for the CO.sub.2 salt include primary amines and polyols which contain primary amino end groups, secondary amines which contain primary hydroxyl groups, and a variety of low molecular weight aminohydroxy compounds. The liquid salt is present in the foam formulations in an amount of at least 2 parts by weight per 100 parts by weight of polyol.

Abstract: Improved, flexible, open-celled polyurethane foams of reduced firmness, but with densities comparable to those of standard foams, are described. The foams are formed in situ from the reaction of isocyanate, one or more blowing agents including water, a foam stabilizer, polyether polyols or polyester polyols or a mixture of these polyols, and monofunctional materials chemically analogous to the polyols, in the presence of a catalyst. The monofunctional materials can be alcohols, polyesters, or polyethers. Useful monofunctional alcohols have carbon chain lengths of at least 3, and preferably from 8 to 20. Useful monofunctional polyesters have molecular weights from 300 to 2000, and preferably from 300 to 800. Useful monofunctional polyethers, which are derived from the reaction of a monofunctional alcohol with propylene oxide and/or ethylene oxide, have molecular weights from 100 to 3000, and preferably from 200 to 1800.

Abstract: Improved methods are provided for incorporating carbon dioxide and carbon dioxide generating compounds into polyurethane foam forming compositions as blowing agents to eliminate or reduce the amount of low boiling liquid auxiliary blowing agents, such as methylene chloride and chlorofluorocarbons conventionally used in the manufacture of urethane foams.

Abstract: Apparatus for lining an irrigation canal with a sheet of fiber-reinforced plastic includes structure for depositing a layer of resin and fiber on a web of flexible carrier material, partially curing the resin prior to laying the sheet in the canal, and then laying the sheet in the canal while the resin is flexible enough to conform to the shape of the canal. The final curing of the resin takes place after the sheet is placed in the canal. A predetermined-shape wrinkle is induced in the carrier web before it is laid into the canal to assist in conforming the sheet to the canal shape without causing randomly placed wrinkles so that the sheet is smooth in the canal. The apparatus forms the sheet and is propelled so that it travels along the length of the canal, fabricating a continuous sheet as it travels. In one embodiment the carrier is a flexible but nonelastic material like kraft paper, coated on one side with wax or other film to prevent saturation by the resin.

Abstract: Improved, flexible, open celled polyurethane foams are described. The foams are formed in situ from the reaction of a polyisocyanate, a conventional polyester polyol, a polyether polyol, a high hydroxyl polyester polyol and a blowing agent in the presence of a catalyst. A polyether foam stabilizer is normally also included. A small amount of a destabilizing silicone ingredient can also be included. Useful high hydroxyl number polyester polyols have hydroxyl numbers in the range 300-600, and preferably 400-450. The average equivalent weight of the useful high hydroxyl number polyester polyol is normally in the range 100-200. The compositions of the invention are useful as filter media and are especially suitable for outdoor seating applications.