Abstract: In one of its aspects, the invention relates to a foamed isocyanate-based polymer having a compression force deformation of greater than about 130 kPa at 10% deflection when measured pursuant to ASTM 1621 and a flexural displacement at yield of greater than about 5 mm when measured pursuant to ASTM D790-00. The present foamed polymer has a novel combination of hardness/stiffness and a flexibility.

Abstract: In one of its aspects, the present invention relates to a foamed isocyanate-based polymer derived from a reaction mixture comprising toluene diisocyanate, wherein the foam has a compression force deformation of at least about 50 kPa at 30% deflection when measured pursuant to ASTM 3574 and a density of less than about 45 kg/m3. In another of its aspects, the present invention relates to a process for producing a foamed isocyanate-based polymer comprising the steps of: contacting an isocyanate comprising toluene diisocyanate, an active hydrogen-containing compound, a dendritic macromolecule and a blowing agent to form a reaction mixture; and expanding the reaction mixture to produce the foamed isocyanate-based polymer; 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.

Abstract: In one of its aspects, the present invention relates to an attachment device which comprises a series of attachment portions. The attachment portions are interconnected to one another by at least one connecting portion, preferably a flexible connecting portion. The attachment device is flexible in at least two independent planes. In most cases, the present attachment device will be flexible in more than two independent planes. A preferred manner by which such flexibility is conferred to the attachment device is by the provision of a trim cover attachment portion having a female attachment portion attached to a base portion. The base portion has a larger surface area than the surface area of the female attachment portion adjacent or attached thereto. The lateral dimension of the base portion is greater than the lateral dimension of the at least one connecting portion. A process of producing a resilient device (e.g.

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 mold (100) for producing foamed articles is described. The mold comprises an upper mold and a lower mold (102) releasingly engageable in a closed position to define a mold cavity (106) having a parting line about a periphery of the mold cavity. The parting line of the mold defines: (i) a first channel (108) along a first length of a periphery of the mold cavity, and (ii) a second channel (110) in communication with first channel, the second channel having a second length which is less than the first length. A method for producing a molded article use is also described. The subject mold and method are particularly well suited for the production of molded foam (e.g, polyurethane) articles.

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: An improved energy management device comprises a substrate body and at least one permeable insert sheet disposed in the substrate body. The shape and orientation of the sheet may be varied. In the various embodiments, the insert sheet has a wall substantially transverse to the energy absorbing surface of the energy management device. The substrate body and the at least one energy absorbing insert sheet are engaged with respect to one another. This may be achieved by having at least a portion of the substrate body disposed in the permeable portion of the insert sheet thereby “locking” in place the insert sheet. It has been discovered that such a combination of a substrate body and an insert sheet surprisingly and unexpected results in improved energy management properties when compared to the independent energy management properties of the substrate body and the insert sheet. The energy management device is useful, for example, in the construction of a vehicular bumper.

Abstract: An improved energy management device comprises a substrate body and at least one permeable insert sheet disposed in the substrate body. The shape and orientation of the sheet may be varied. In the various embodiments, the insert sheet has a wall substantially transverse to the energy absorbing surface of the energy management device. The substrate body and the at least one energy absorbing insert sheet are engaged with respect to one another. This may be achieved by having at least a portion of the substrate body disposed in the permeable portion of the insert sheet thereby "locking" in place the insert sheet. It has been discovered that such a combination of a substrate body and an insert sheet surprisingly and unexpected results in improved energy management properties when compared to the independent energy management properties of the substrate body and the insert sheet. The energy management device is useful, for example, in the construction of a vehicular bumper.

Abstract: A vent for a mold for producing foamed articles is described. The mold comprises an upper mold and a lower mold releaseably engageable in a closed position to define a mold cavity. The vent comprises a housing which is engageable to the mold, a passageway and an obstruction disposed in the passageway. The passageway and the obstruction are slidably movable in a first direction with respect to one another and define an opening between an interior and an exterior of the housing. The obstruction has a varying diameter in a direction parallel to the first direction. The subject mold and method are particularly well suited for the production of molded foam (e.g., polyurethane) articles.

Abstract: A foam composite material comprising a first isocyanate-based polymer foam comprising at least one uncontoured surface and a second, molded isocyanate-based polymer foam, the first isocyanate-based polymer foam and the second isocyanate-based polymer foam being: (i) of different composition, and (ii) fixed with respect to one another. A process for producing the foam composite material also disclosed. The foam composite material is useful in another of vehicular and non-vehicular applications.

Abstract: A passenger seat having trim cover attachment structure includes a frame element, vehicle anchorage structure connected to the frame element, and a seat body having a resilient material fixed with respect to the frame element. Trim cover attachment structure is provided and includes a relatively high density, rigid foam member having a groove disposed in a surface thereof. The groove is capable of receiving connection structure included in the trim cover.

Abstract: A foamed isocyanate-based polymer having a cellular structure and comprising a non-surface cross-linked superabsorbent polymer, the foamed polymer being capable of: (i) absorbing at least about 10 times its weight of a 0.9 wt./wt. % aqueous NaCl solution maintained at a temperature of from about 20.degree. to about 25.degree. C., and (ii) retaining at least about 10 times its weight of absorbed aqueous NaCl solution which is bound to the superabsorbent polymer. A process for producing the foamed isocyanate-based polymer is also described. The process comprises the steps of: contacting an isocyanate, an active hydrogen-containing compound, an aqueous blowing agent, a catalyst and a non-surface cross-linked superabsorbent polymer, the superabsorbent polymer being capable of absorbing at least about 10 times its weight of a 0.9 wt./wt. % aqueous NaCl solution maintained at a temperature in the range of from about 20.degree. to about 25.degree. C.

Abstract: A passenger seat comprising: a frame element, vehicle anchorage means connected to the frame element, a seat body comprising a resilient material fixed with respect to the frame element and trim cover attachment means, the trim cover attachment means comprising a relatively high density, rigid foam member having a groove disposed in a surface thereof, the groove capable of receiving connection means comprised in a trim cover. A process, system and mold for producing a passenger seat are also described.

Abstract: A passenger seat comprising: a frame element, vehicle anchorage means connected to the frame element, a seat body comprising a resilient material fixed with respect to the frame element and trim cover attachment means, the trim cover attachment means comprising a relatively high density, rigid foam member having a groove disposed in a surface thereof, the groove capable of receiving connection means comprised in a trim cover. A process, system and mold for producing a passenger seat are also described.

Abstract: A rebond foam comprising a plurality of isocyanate-based polymeric foam pieces bonded to one another with an isocyanate-based binder is disclosed. A superabsorbent material is comprised in one or both of the isocyanate-based polymeric foam pieces and the isocyanate-based binder. The rebond foam is capable of: (i) absorbing at least about 5 times its weight of a 0.9 wt./wt. % aqueous NaCl solution maintained at a temperature of from about 20.degree. to about 25.degree. C., and (ii) retaining at least about 5 times its weight of absorbed aqueous NaCl solution which is bound to the superabsorbent material. A process for producing a rebond foam is also disclosed.

Abstract: A fastener assembly capable of being molded into a cushion, the fastener assembly comprising: (i) a backing layer and (ii) a fastening layer opposed to one another, the backing layer comprising anchor means to secure the fastener assembly to the cushion, the fastening layer comprising a touch fastening surface spaced inwardly from the marginal edges of the fastening layer to define a peripheral margin around the fastening layer, and (iii) a foam seal disposed on the peripheral margin, the foam seal having an Indentation Force Deflection, when measured pursuant to ASTM D3574-95, in the range of from about 10 to about 1000 pounds.force. A process for producing the fastener assembly and a cushion describing the fastener assembly are also disclosed.

Abstract: A hydrophilic polyol having a molecular weight of less than about 4500 and comprising ethylene oxide units and alkylene oxide units selected from propylene oxide, butylene oxide and mixtures thereof in a weight ratio of ethylene oxide units to alkylene oxide units in the range of from about 95:5 to about 60:40, the polyol having a secondary hydroxyl content of at least about 80% based on the total hydroxyl content of the polyol. A process for producing the hydrophilic polyol is also described.

Abstract: A foamed isocyanate-based polymer having a cellular structure and comprising a superabsorbent material, the polymer being capable of: (i) absorbing at least about 10 times its weight of a 0.9 wt./wt. % aqueous NaCl solution maintained at a temperature of from about 20.degree. to about 25.degree. C., and (ii) retaining at least about 10 times its weight of absorbed aqueous NaCl solution which is bound to the superabsorbent material, the cellular structure having a cell size of at least about 30 cells/inch when measured pursuant to ASTM D3576-77. A process for producing the foamed isocyanate-based polymer is also described. The process comprises the steps of: contacting an isocyanate, an active hydrogen-containing compound, an aqueous blowing agent, a catalyst and a superabsorbent material, the superabsorbent material being capable of absorbing at least about 10 times its weight of a 0.9 wt./wt. % aqueous NaCl solution maintained at a temperature in the range of from about 20.degree. to about 25.degree. C.

Abstract: A novel method of molding an article includes providing a mold with a vent of a pre-determined size such that, due to the difference in viscosities, gases to be vented from the mold may easily pass through the vent while the material to be molded cannot quickly pass through the vent. In fact, the vent is designed such that the material to be molded which enters the vent, does not exit the end of the vent. In the most preferred embodiment, the vent is in the form of a thin ribbon-like groove so that the material to be molded which does enter the vent forms a thin ribbon of extruded material which need not be removed prior to a finish cover being applied to the molded article.

Abstract: A mold for producing foamed articles includes an upper mold and a lower mold which define a mold cavity. A vent is provided in communication with the mold cavity and has a vent passageway with an entrance and an exit. Structure is also provided for sealingly engaging the upper mold with the lower mold to cause, in cooperation with the predetermined size and shape of the vent passageway, liquid foam polymeric composition expanding inside the mold cavity to enter the vent entrance but to not exit from the vent exit to cause at least partial curing of the foam composition within the vent passageway. Preferably, the vent may be ribbon-shaped so that a ribbon of foamed composition adheres to the foamed article and may be folded flat against the article thus avoiding the labor step of trimming the flash from the product. Additionally, .[.or alternatively,.].