Abstract: An assembly for molding a composite article including a foam core and a layer is disclosed. The assembly includes a mold. The mold has an inner surface and at least partially defines a cavity, one or more gas discharge ports, and one or more retaining elements. Each of the one or more gas discharge ports has a passageway opening in fluid communication with the cavity of the mold the mold. The assembly further includes one or more sealing elements moveably engaged with the mold. Each of the one or more sealing elements includes a head and is shaped to engage the retaining element on the mold in a vented position. Further, each of the one or more sealing elements corresponds with each of the one or more gas discharge ports.

Abstract: A mold comprising a first mold element and a second mold element releasingly engagable between an open position and a closed position to define a mold cavity in the closed position and a first part line between the first mold element and second mold element. The first mold element comprises a first mold portion and a second mold portion configured to be reversible separable with respect to one another to define a second part line therebetween disposed interiorly with respect to a periphery of the first part line. At least one vent is disposed in the second part line. In one embodiment, the at least one vent comprises a passageway configured to permit mold material in the mold cavity to enter but not to exit the passageway to cause at least partial curing of the mold material in the passageway.

Abstract: There is described a foamed isocyanate-based polymer derived from a reaction mixture comprising: an isocyanate; a polyol composition comprising a first prescribed amount of polymer particles dispersed in a base polyol; a second prescribed amount of biomass-based carbonaceous particulate material; and a blowing agent. In one embodiment, the foamed isocyanate-based polymer having an Indentation Force Deflection when measured pursuant to ASTM D3574-11 which is within about 15% as that of a reference foam produced by omitting the biomass-based carbonaceous particulate material from the reaction mixture and increasing the amount of polymer particles in the polymer polyol composition to equal the sum of the first prescribed amount and the second prescribed amount.

Abstract: A composite foam article is disclosed herein. The composite foam article comprises a polyurethane foam core presenting a first surface and a second surface facing opposite the first surface. A first skin is disposed on the first surface and a second skin is disposed on the second surface. The first and second skins comprise a plurality of fibers and a polymeric binder. The composite foam article also comprises at least one supplemental layer comprising an ethylene and acrylic acid copolymer dispersed in and/or disposed between any of said aforementioned skins and core.

Abstract: A composite foam article is disclosed herein. The composite foam article comprises a surface layer and a base layer with an interface therebetween. The surface layer comprises a high-resiliency polyurethane foam having an impact resilience of greater than about 50% when tested in accordance with ASTM D3574-17, and presents a seating surface. The base layer comprises a viscoelastic polyurethane foam having an impact resilience of less than about 50% when tested in accordance with ASTM D3574-17, and presents a mounting surface opposite the seating surface. The surface layer and the base layer are present in a thickness ratio of from about 17:3 to about 2:3.

Abstract: A composite foam article is disclosed herein. The composite foam article comprises a polyurethane foam core presenting a first surface and a second surface facing opposite the first surface. A first skin is disposed on the first surface and a second skin is disposed on the second surface. The polyurethane foam core has a density of 15-80 kg/m3. The first and second skins comprise a plurality of fibers and a polymeric binder. The composite foam article has a weight per unit area of 500-1000 g/m2 and a strength of greater than 17 N at a post-compression thickness of greater than 2 mm when tested in according with SAE J949 at 23° C.

Abstract: A mold comprising a first mold element and a second mold element releasingly engagable between an open position and a closed position to define a mold cavity in the closed position and a first part line between the first mold element and second mold element. The first mold element comprises a first mold portion and a second mold portion configured to be reversible separable with respect to one another to define a second part line therebetween disposed interiorly with respect to a periphery of the first part line. At least one vent is disposed in the second part line. In one embodiment, the at least one vent comprises a passageway configured to permit mold material in the mold cavity to enter but not to exit the passageway to cause at least partial curing of the mold material in the passageway.

Abstract: A composite foam article is disclosed herein. The composite foam article comprises a surface layer and a base layer with an interface therebetween. The surface layer comprises a high-resiliency polyurethane foam having an impact resilience of greater than about 50% when tested in accordance with ASTM D3574-17, and presents a seating surface. The base layer comprises a viscoelastic polyurethane foam having an impact resilience of less than about 50% when tested in accordance with ASTM D3574-17, and presents a mounting surface opposite the seating surface. The surface layer and the base layer are present in a thickness ratio of from about 17:3 to about 2:3.

Abstract: A composite foam article is disclosed herein. The composite foam article comprises a surface layer and a base layer with an interface therebetween. The surface layer comprises a high-resiliency polyurethane foam having an impact resilience of greater than about 50% when tested in accordance with ASTM D3574-17, and presents a seating surface. The base layer comprises a viscoelastic polyurethane foam having an impact resilience of less than about 50% when tested in accordance with ASTM D3574-17, and presents a mounting surface opposite the seating surface. The surface layer and the base layer are present in a thickness ratio of from about 17:3 to about 2:3.

Abstract: An assembly for molding a composite article including a foam core and a layer is disclosed. The assembly includes a mold. The mold has an inner surface and at least partially defines a cavity, one or more gas discharge ports, and one or more retaining elements. Each of the one or more gas discharge ports has a passageway opening in fluid communication with the cavity of the mold the mold. The assembly further includes one or more sealing elements moveably engaged with the mold. Each of the one or more sealing elements includes a head and is shaped to engage the retaining element on the mold in a vented position. Further, each of the one or more sealing elements corresponds with each of the one or more gas discharge ports.

Abstract: A composite foam article is disclosed herein. The composite foam article comprises a polyurethane foam core presenting a first surface and a second surface facing opposite the first surface. A first skin is disposed on the first surface and a second skin is disposed on the second surface. The first and second skins comprise a plurality of fibers and a polymeric binder. The composite foam article also comprises at least one supplemental layer comprising an ethylene and acrylic acid copolymer dispersed in and/or disposed between any of said aforementioned skins and core.

Abstract: A composite foam article is disclosed herein. The composite foam article comprises a polyurethane foam core presenting a first surface and a second surface facing opposite the first surface. A first skin is disposed on the first surface and a second skin is disposed on the second surface. The polyurethane foam core has a density of 15-80 kg/m3. The first and second skins comprise a plurality of fibers and a polymeric binder. The composite foam article has a weight per unit area of 500-1000 g/m2 and a strength of greater than 17 N at a post-compression thickness of greater than 2 mm when tested in according with SAE J949 at 23° C.

Abstract: A composite foam article comprises a foam core layer presenting a first surface and a second surface facing opposite the first surface. A first polymeric bonding layer is disposed on the first surface, one or more first reinforcing layers comprising a plurality of fibers and a polymeric binder are disposed on the first polymeric bonding layer, and a first polymeric containment layer is disposed on the one or more first reinforcing layers. A second polymeric bonding layer is disposed on the second surface, one or more second reinforcing layers comprising a plurality of fibers and a polymeric binder are disposed on the second polymeric bonding layer, and a second polymeric containment layer is disposed on the one or more second reinforcing layers. At least one catch layer comprising particles of carbon is dispersed in and/or disposed between any of the aforementioned layers.

Abstract: Disclosed is a vehicular seat element comprising a first major surface, a second major surface and a foam core element disposed therebetween. The first major surface is configured to be in contact with an occupant of the vehicle and the second major surface is configured to be in contact with a support surface of the vehicle. The first major surface comprises a rate sensitive foam element secured with respect to the foam core element. The foam core element and the rate sensitive foam element are different from one another.

Abstract: A composite foam article is disclosed herein. The composite foam article comprises a surface layer and abase layer with an interface therebetween. The surface layer comprises a high-resiliency polyurethane foam having an impact resilience of greater than about 50% when tested in accordance with ASTM D3574-17, and presents a seating surface. The base layer comprises a viscoelastic polyurethane foam having an impact resilience of less than about 50% when tested in accordance with ASTM D3574-17, and presents a mounting surface opposite the seating surface. The surface layer and the base layer are present in a thickness ratio of from about 17:3 to about 2:3.

Abstract: There is described a foam article comprising: a base foam having a textured surface; a trim cover covering at least a portion of the textured surface, the trim cover comprising: (i) a finished outer layer comprising an occupant-contact outer portion and inner portion; (ii) a compressible buffer layer secured with respect to the inner portion of the finished outer layer; and (iii) a contact layer secured with respect to the compressible layer and configured to be in contact with the textured surface of the base foam, the contact layer having a secant modulus at 5% strain of at least about 7 when measured according to modified ASTM D3574-11, Test E, Tensile Test.

Abstract: In a preferred embodiment there is disclosed a vehicular seat element comprising a foam substrate, the foam substrate comprising an A-surface for contact by an occupant and a B-surface opposed to the A-surface, a central portion of the A-surface have a first surface area and comprising a plurality of channels, the central portion of the A-surface comprising an occupant contact portion having a second surface area, wherein the first surface area is greater than the second surface area, a plurality of apertures disposed in the plurality of channels, each aperture interconnecting the A-surface and the B-surface of the foam substrate. The plurality of channels acts a distribution manifold for air to be moved laterally with respect to the A-surface of the foam pad and also through the holes in the seat pad to allow for circulation of air. In other words, the through holes in the foam provide a pass for air to flow from the B-surface of the foam pad to the A-surface of the foam pad, and vice versa.

Abstract: There is disclosed an improved seat element having a seating surface element that incorporates a plurality of peak portions and a plurality of valley portions. Preferably, the plurality of peak portions and the plurality of valley portions is incorporated in an outermost surface of the seating surface element. The term “outermost surface” is intended to include an area of the seating surface element for contact by and/or support of an occupant of the seat element and does not include, for example, grooves or trenches in which there is disposed a component for attachment of a trim cover. A process and a mold for production of such a seat element are also described.

Abstract: There is disclosed a vehicular seat element comprising a first major surface, a second major surface and a foam core element disposed therebetween. The first major surface is configured to be in contact with an occupant of the vehicle and the second major surface is configured to be in contact with a support surface of the vehicle. The first major surface comprises a rate sensitive foam element secured with respect to the foam core element. The foam core element and the rate sensitive foam element are different from one another.

Abstract: There is disclosed a padded element. In one embodiment, the padded element comprises a molded foam topper portion and a molded foam substrate portion secured with respect to the molded foam topper portion. The molded foam topper portion and the molded foam substrate portion have a different indentation force deflection at 25% thickness when measured pursuant to ASTM 3574-B1. In another embodiment, the padded element comprises a molded foam topper portion and a molded foam substrate portion secured with respect to the molded foam topper portion via an interference fit.