Abstract: There is described an attachment system for attaching a plurality of elements to a resilient body, preferably for attachment of a trim cover to a foam element. The system comprising a first element having attached thereto a first attachment portion and a second element having attached thereto a second attachment portion, the first attachment portion and the second attachment portion being releasably engageable with the resilient body.

Abstract: A vehicular seat trim cover attachment device having a plurality of female attachment portions interconnected to one another by at least one connecting portion. The attachment device is preferably flexible in at least two independent planes. Each female attachment portion has a receptacle portion and a base portion. Each base portion is connected to the connecting portion. Each base portion has a lateral dimension greater than a lateral dimension of the receptacle portion. At least a portion of the connecting portion is disposed in an exoplanar relationship with respect to a pair of female attachment portions that have substantially coplanar base portions. Preferably, the connecting portion extends below the bottom surfaces of the adjacent base portions.

Abstract: A vehicular seat trim cover attachment device having a plurality of female attachment portions interconnected to one another by at least one connecting portion. The attachment device is preferably flexible in at least two independent planes. Each female attachment portion has a receptacle portion and a base portion. Each base portion is connected to the connecting portion. Each base portion has a lateral dimension greater than a lateral dimension of the receptacle portion. At least a portion of the connecting portion is disposed in an exoplanar relationship with respect to a pair of female attachment portions that have substantially coplanar base portions. Preferably, the connecting portion extends below the bottom surfaces of the adjacent base portions.

Abstract: The invention relates mold, particularly a mold for producing foam articles. In a preferred embodiment, the mold comprises a lid and a bowl releasingly engageable to define a mold cavity, the lid comprising: (i) a vent having a passageway for gas to escape from the mold cavity, and (ii) a plurality of grooves connected to the vent. The use of a plurality of grooves/slots in the mold cavity surface effectively acts as a siphon to draw gas away from the composition to be molded. The plurality of grooves/slots is connected to one or more vents which then allows for escape of the gas from the mold cavity to the exterior of the mold.

Abstract: The invention relates mold, particularly a mold for producing foam articles. In a preferred embodiment, the mold comprises a lid and a bowl releasingly engageable to define a mold cavity, the lid comprising: (i) a vent having a passageway for gas to escape from the mold cavity, and (ii) a plurality of grooves connected to the vent. The use of a plurality of grooves/slots in the mold cavity surface effectively acts as a siphon to draw gas away from the composition to be molded. The plurality of grooves/slots is connected to one or more vents which then allows for escape of the gas from the mold cavity to the exterior of the mold.

Abstract: A laminate product comprising a foam core having a pair of opposed major surfaces and a cover layer secured with respect to each major surface is described. The cover layer comprises a polymeric substrate having disposed therein a plurality of reinforcing fibrous material. It has been found that it is possible to produce a foam laminate product having improved stiffness if a lower amount of reinforcing material is used for a given amount of polymer substrate. In particular, it has been found possible to provide an improved foam laminate product having a relatively high ratio of stiffness to weight of reinforcing fibrous material. It has been further discovered that the stiffness of the resulting foam laminate product can be increased when the polymer substrate and the reinforcing fibrous material are present in a weight ratio of greater than 2.5. This is believed to be the result of improved encapsulation of the reinforcing fibrous material by the polymer substrate.

Abstract: In one of its aspects, the present invention relates to foamed isocyanate-based polymer derived from a reaction mixture comprising an isocyanate, an active hydrogen-containing compound, a dendritic macromolecule and a blowing agent; wherein at least a 15% by weight of the dendritic macromolecule may be mixed with a polyether polyol having an OH number less than about 40 mg KOH/g to form a stable liquid at 23° C. The dendritic macromolecule confers advantageous load building characteristics to the foamed isocyanate-based polymer and may be used to partially or fully displace the use of conventional copolymer polyols used. A process for production of a foam isocyanate-based polymer and a process for conferring loading building properties to a foamed isocyanate-based polymer are also described.

Abstract: A foam seat element comprising an isocyanate-based foam matrix having an A-surface for contact with an occupant and a B-surface for contact with a suspension element. An elastomeric layer is disposed on at least a portion of the B-surface for contact with the support element. This approach results in reduction in labor to produce the elastomeric layer compared with correct positioning of cloth inserts on a foam production manufacturing line. Further, since, in the preferred embodiment of the invention, the elastomeric layer is achieved by spraying a liquid elastomer-forming composition on a portion of the mold surface, the costs of achieving the elastomeric layer are significantly less than those associated with using prefabricated, pre-cut cloth inserts. Still further, the use of an elastomeric layer allows for tuning of the thickness of that layer which facilitates “tuning” the durability of the B-surface of the foam seat element based on the specific suspension system with which it will be combined.

Abstract: A vehicular seat trim cover attachment device having a plurality of female attachment portions interconnected to one another by at least one connecting portion. The attachment device is preferably flexible in at least two independent planes. Each female attachment portion has a receptacle portion and a base portion. Each base portion is connected to the connecting portion. Each base portion has a lateral dimension greater than a lateral dimension of the receptacle portion. At least a portion of the connecting portion is disposed in an exoplanar relationship with respect to a pair of female attachment portions that have substantially coplanar base portions. Preferably, the connecting portion extends below the bottom surfaces of the adjacent base portions.

Abstract: The invention relates to the surprising and unexpected discovery that a sub-group of phenolic resins (i.e., those which are substantially completely free of ether moieties) is particularly advantageous to confer load building properties to an isocyanate-based foam (e.g., a polyurethane foam). Indeed, its possible to utilize the sub-group of phenolic resins to partially or fully displace copolymer polyols conventionally used to confer load building characteristics to isocyanate-based polymer foams. Further, the invention relates to the surprising and unexpected discovery that a sub-group of phenolic resins (i.e., those which are substantially completely free of ether moieties) is particularly advantageous to confer energy absorption properties in an isocyanate-based foam.

Abstract: In one of its aspects, the invention relates to a foam element comprising an isocyanate-based foam matrix having surface, at least a portion of the surface comprising at least one channel having a channel surface, the channel surface being coated with a substantially fluid impermeable material. The foam element is particularly useful in a climate-control vehicular (e.g., automobile) seat.

Abstract: There is described an isocyanate-based polymer foam having improved anti-yellowing properties. The foam produced from a formulation comprising an isocyanate, a blowing agent, a first active hydrogen-containing compound and a second active hydrogen-containing compound different than the first active hydrogen-containing compound. The second active hydrogen-containing compound comprises an active hydrogen-containing phosphite compound. A process for producing such a foam is also described.

Abstract: Mold and method for manufacture of a molded element includes structure and/or process by which a fastener assembly is placed in an area of a mold element. After a liquid foamable composition is didpensed into the mold, a valve element is actuated at a prescribed pressure to remove gas from the mechanical fastener area so that the liquid foamable composition can fill substantially the mold cavity to produce the molded element.

Abstract: The present invention is a sensor element, particularly a sensor element useful in a vehicle occupant detection system. The sensor element comprises a first conductor and a second conductor disposed transversely with respect to one another to define a junction. In use, when a constant voltage is applied to the conductors, a first conductance is produced in the absence of applied weight to sensor element and a second conductance is produced in the presence of applied weight to the sensor element wherein the second conductance being greater than the first conductance. By incorporating a number of such junctions into matrix arrangement, the present sensor can be advantageously employed in a vehicle occupant detection system. This allows for the creation of a spreadsheet-like environment where interrogation of each matrix cell provides information about the acting force.

Abstract: A foam pad comprising a surface to which a trim cover can be secured, the surface comprising a channel having a width of up to about 15 mm. Disposed in the channel is one of a male portion or a female portion of a releasably engageable male-female trim cover attachment system. A trim cover having the other of the male or female portion attached thereto may be readily attached to the foam pad. A process and a mold for producing the foam pad are also described. The foam pad is particularly useful as a component of a vehicular seat system (e.g., seat bottom, seat back and the like).

Abstract: A foam article comprising: a foam element; and a trim cover comprising a finished outer layer and an inner layer in contact with the foam element, the inner layer comprising a material having a kinetic coefficient of friction with respect to the foam element of less than about 0.75 when measured pursuant to ASTM D1894-00 using the conditions set out in GM9206P. The foam article is advantageously suited for use in a vehicular application such as a car seat (seat bottom, seat back and the like). The invention allows for the production of improved quality products while mitigating and obviating the need for additional material and/or labor costs.

Abstract: A flexible isocyanate-based polymeric foam which has: (i) low resiliency; (ii) a Tg less than or equal to about 0° C.; and (iii) a change in tan &dgr; less than or equal to about 35% from a median value measured over a temperature range of from about −20° to about +60° C. The foam may be produced using a formulation comprising selected plasticizers as set in the disclosure. The subject foam is less temperature sensitive than currently known low resilience, flexible polyurethane foams. Thus, the present foam finds many applications such as for use in the interior of a vehicle where energy dissipation of the foam is important over a relatively wide temperature range—e.g., −20° to +60° C.

Abstract: An isocyanate-based polymer foam comprising an isocyanate-based polymer foam matrix having disposed therein a particulate material having an enthalpy of endothermic phase transition of at least about 50 J/g. A process for producing the foam is also described. During the process, the particulate material acts as a heat sink and will undergo an endothermic phase change by absorbing a significant portion of the heat of reaction liberated during the process. This improves the safety of the process by lowering the maximum exotherm experienced by the foam and/or improves product properties.

Abstract: In one of its aspects, the invention relates to a foam element comprising an isocyanate-based foam matrix having surface, at least a portion of the surface comprising at least one channel having a channel surface, the channel surface being coated with a substantially fluid impermeable material. The foam element is particularly useful in a climate-control vehicular (e.g., automobile) seat.

Abstract: A foam article comprising: a foam element; and a trim cover comprising a finished outer layer and an inner layer in contact with the foam element, the inner layer comprising a material having a kinetic coefficient of friction with respect to the foam element of less than about 0.75 when measured pursuant to ASTM D1894-00 using the conditions set out in GM9206P. The foam article is advantageously suited for use in a vehicular application such as a car seat (seat bottom, seat back and the like). The invention allows for the production of improved quality products while mitigating and obviating the need for additional material and/or labour costs.