Abstract: A foamed isocyanate-based polymer having a cellular structure and containing a superabsorbent material, the polymer being capable of: (i) absorbing at least about 20 times its weight of an aqueous fluid maintained at a temperature of from about 20.degree. to about 25.degree. C., and (ii) retaining at least about 20 times its weight of absorbed aqueous fluid which is bound to the superabsorbent material. A process for producing a foamed isocyanate-based polymer comprising the steps of: providing a substantially uniform mixture comprising an isocyanate, an active hydrogen-containing compound and a superabsorbent material, the superabsorbent material being capable of absorbing at least about 20 times its weight of an aqueous fluid maintained at a temperature in the range of from about 20.degree. to about 25.degree. C.

Abstract: A system for producing a foamed isocyanate-based polymer includes a base line comprising a first mixing device operable in a first mode and a second mode and having an active hydrogen-containing compound input and an isocyanate input. A complementary line is provided and includes a second mixing device having a filler material input. In the first mode, the first mixing device receives a feed from the active hydrogen-containing compound input and the isocyanate input, mixes the feed to produce a first foamable polymeric composition, and dispenses the first foamable polymeric composition into a first mold. In the second mold, the first mixing device returns the feed, without mixing, from the active hydrogen-containing compound input and the isocyanate input to the second mixing device which mixes the feed with feed from the filler material input to produce a second foamable polymeric composition, and dispenses the second foamable polymeric composition in a second mold.

Abstract: A polyurethane foam essentially free of organic carbon-based blowing agent, the polyurethane foam comprising a foam core having a density of from about 5 to about 45 pounds per cubic foot and an integral skin consisting of substantially non-cellular, non-porous polyurethane. The presence of the integral skin is characterized by a compression force deflection index of at least about 1.20, the compression force deflection index being defined as the ratio of (i) the compression force deflection orthogonal to a cross-section of the foam to (ii) the compression force deflection of the foam core, the compression force deflection measured according to ASTM 3574C. In a preferred embodiment, the present polyurethane foam is further characterized by a flexural modulus index of at about 1.60. In another preferred embodiment, the present invention is characterized by a density index of at least about 1.60.

Abstract: A foamed isocyanate-based polymer having a cellular structure and containing a superabsorbent material, the polymer being capable of: (i) absorbing at least about 20 times its weight of an aqueous fluid maintained at a temperature of from about 20.degree. to about 25.degree. C., and (ii) retaining at least about 20 times its weight of absorbed aqueous fluid which is bound to the superabsorbent material. A process for producing a foamed isocyanate-based polymer comprising the steps of: providing a substantially uniform mixture comprising an isocyanate, an active hydrogen-containing compound and a superabsorbent material, the superabsorbent material being capable of absorbing at least about 20 times its weight of an aqueous fluid maintained at a temperature in the range of from about 20.degree. to about 25.degree. C.

Abstract: A foamed isocyanate-based polymer containing a filler material, the filler material being present at a level greater than 30% by weight of the polymer and having a specific gravity of less than about 2.0 with the provisio that the filler material is not melamine. A process for producing the a foamed isocyanate-based polymer is also disclosed. The process comprises the steps of: providing a first mixture comprising water, a catalyst and a substantially inert filler material, the filler material being wetted by the water and the catalyst; providing a second mixture comprising an isocyanate and an active hydrogen-containing compound; mixing the first mixture and the second mixture to provide a reaction mixture; allowing the reaction mixture to expand to produce the foamed isocyanate-based polymer.

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 process and system for mixing at least two independent streams in a mixing device having independent inputs for each of the at least two independent streams, comprising structure and steps for: (i) feeding a first stream, provided as a free-flowing solids stream, to a pressure chamber; (ii) compressing the first stream in the pressure chamber; (iii) feeding the first stream to a first input in the mixing device; (iv) feeding a second stream to a second input in the mixing device; (v) impinging the first stream and the second stream on one another in a mixing device to produce a mixture; and (vi) dispensing the mixture from the mixing device; wherein the compressing in Step (ii) is conducted to achieve a substantially linear relationship between a weight of the first stream and a period of impingement of the weight in Step (v). Preferably, the process and system are adapted to produce a filled foamed isocyanate-based polymer (e.g. filled polyurethane foam).

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.

Abstract: An energy absorbing panel comprising a resilient polyurethane foam core having a density in the range of from about 1.5 to about 24 pounds per cubic foot and an indentation force deflection at 25%, when measured pursuant to ASTM 3574-B.sub.1, less than about 4000 pounds and at least one energy absorbing surface comprised of a flexible reinforcing layer covering the resilient polyurethane foam core. The panel is useful in a variety of applications where energy management is required. Upon impact, the panel is capable of absorbing at about 70% of the input energy. Futher, upon compression of the panel at the energy absorbing surface to about 50% by volume of the uncompressed panel in a direction substantially normal to the reinforcing layer, the panel recovers to at least about 90% of the volume of the uncompressed panel in less than about 30 minutes. The panel is particularly advantageous for use in vehicular applications such as door panels, instrument panel topper pads, air bag doors and the like.

Abstract: An automotive vehicle passenger seat is described. The seat includes a frame element made from a relatively high density rigid foam, a vehicle anchorage connector and a seat body including a resilient material fixed with respect to the frame element. The vehicle anchorage connecter serves to anchor the seat to the automotive vehicle. The seat obviates the need for a metal frame thereby reducing the cost and weight of the seat, and improving the recyclability thereof. In a preferred embodiment, the seat further includes a pelvic support element which acts as an anti-submarine device.

Abstract: A process for producing a foamed isocyanate-based polymer based on an amount of water and an amount of catalyst, the process comprising the steps of: providing a first stream comprising a particulate, non-cellular filler material surrounded by a mixture comprising less than 100% by weight of the amount of water and less than 100% by weight of the amount catalyst; providing a second stream comprising an active hydrogen-containing compound and the remainder of the amount of water and the amount of catalyst; providing a thin stream comprising an isocyanate; feeding each of the first stream, the second stream and the third stream-independently of one another to a mixing device; mixing the first stream, the second stream and the third stream in the mixing device to produce a reaction mixture; and allowing the reaction mixture to expand to produce the foamed isocyanate-based polymer. A system for alternating between production of filled or untilled isocyanate-base foam is also provided.

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.

Abstract: There is disclosed a process for manufacturing a padded element. The process comprises the steps of placing a trim cover on a mandrel, the trim cover having a finished outer surface and an inner surface comprised of a thermoformable foam layer; heating the trim cover to a temperature sufficient to shape the thermoformable foam layer; shaping the trim cover to substantially the same shape as the mandrel to produce a shaped trim cover; transferring the shaped trim cover from the mandrel to a lower mold having shape substantially complimentary to the shaped trim cover; placing an upper mold over the lower mold to define a mold cavity; dispensing a liquid foamable polymeric composition in the mold cavity; and expanding the liquid foamable polymeric composition to fill substantially the mold cavity thereby forming the padded element.

Abstract: A foamed isocyanate-based polymer containing a filler material, the filler material being present at a level greater than 30% by weight of the polymer and having a specific gravity of less than about 2.0 with the provisio that the filler material is not melamine. A process for producing the a foamed isocyanate-based polymer is also disclosed. The process comprises the steps of: providing a first mixture comprising water, a catalyst and a substantially inert filler material, the filler material being wetted by the water and the catalyst; providing a second mixture comprising an isocyanate and an active hydrogen-containing compound; mixing the first mixture and the second mixture to provide a reaction mixture; allowing the reaction mixture to expand to produce the foamed isocyanate-based polymer.

Abstract: An isocyanate-based elastomer containing a filler material, the filler material being present at a level in the range of from about 30% to about 90% by weight of the elastomer and having a specific gravity of less than about 2.0. A process for producing the isocyanate-based elastomer is also disclosed. The process comprises the steps of: providing a first mixture comprising a catalyst and a filler material, the filler material being wetted by the catalyst; providing a second mixture comprising an isocyanate and an active hydrogen-containing compound; mixing the first mixture and the second mixture to provide a reaction mixture; allowing the reaction mixture to react to produce the isocyanate-based elastomer.

Abstract: A passenger seat includes a frame element molded from relatively high density foam and, optionally, one or more pelvic support elements. The frame element and pelvic support elements are molded into a seat body of relatively lower density foam to which a trim cover is applied. In one embodiment, the frame element and the pelvic support elements are integrally molded and a vehicle anchorage means in embedded into the integral element and in a second embodiment the vehicle anchorage means is embedded in the frame element which may be molded separately from the pelvic support element to which it is connected prior to molding of the foam body.

Abstract: A process for producing an energy absorbing panel having at least one energy absorbing surface in a mold comprising an upper mold and a lower mold. The process comprising placing a reinforcing layer in both of the upper mold and the lower mold. A liquid foamable polyurethane composition is then dispensed in the lower mold and allowed to expand to fill from 50-80% of the mold volume. The upper mold and lower mold are then closed to define an enclosure corresponding substantially to the energy absorbing panel and the liquid foamable polyurethane composition is expanded to fill the remainder of the enclosure to produce a resilient polyurethane foam core which adheres to the reinforcing layers thereby providing an energy absorbing surface. The reinforcing layer has a tensile strength greater than the tensile strength of the resilient polyurethane foam core.