Abstract: A process for producing a sealed stitched skin structure including the steps of: (a) providing a stitched skin member; (b) providing an aqueous thermoplastic polyolefin dispersion sealant coating composition; (c) applying the aqueous thermoplastic polyolefin dispersion sealant coating composition from step (a) to at least a portion of the surface of at least one side of the skin member to form a wet film or coating of the thermoplastic polyolefin dispersion sealant coating composition on the surface of the skin member; (d) drying the wet coating from step (c) on the skin member surface; and (e) heating the dried skin member from step (d) at a temperature sufficient to form a film or coating of the aqueous thermoplastic polyolefin dispersion sealant coating composition on the stitches of the seam in the skin member; wherein the film or coating seals the stitches in the skin member; a sealed stitched skin structure made by the process above; and a polyurethane foamed article.

Abstract: A composite structure including (a) a three-dimensional random loop material comprising a plurality of random loops arranged in a three-dimensional orientation formed from a polyolefin polymer; and (b) a polyurethane foam in contact with substantially all of the surfaces of the three-dimensional random loop material; wherein the polyurethane foam can be the reaction product of (a) an isocyanate component; and (b) an isocyanate-reactive component; and a method of making the above polyurethane foam and three-dimensional random loop composite structure.

Abstract: The present invention relates to method to make a spray skin from an aqueous polyolefin dispersion composition comprising a an olefin block copolymer, a dispersing agent, preferably an ethylene acrylic acid, and water, wherein said aqueous dispersion preferably has a pH less than 12 and is derived from the melt blending. The method comprises the steps of spraying the aqueous polyolefin dispersion onto a heated mold forming the skin and then allowing it to dry.

Abstract: The present invention relates to a method for producing a composite part, preferably an automotive trim composite part, comprising a textured skin and a rigid or foam substrate layer. The method comprises the steps of forming the skin by spraying or casting an aqueous thermoplastic dispersion which is derived from the melt blending of thermoplastic polymer, a dispersing agent, and water onto a textured mold and molding the rigid or form substrate onto the skin.

Abstract: The present invention relates to method to make a spray skin from an aqueous polyolefin dispersion composition comprising a an olefin block copolymer, a dispersing agent, preferably an ethylene acrylic acid, and water, wherein said aqueous dispersion preferably has a pH less than 12 and is derived from the melt blending. The method comprises the steps of spraying the aqueous polyolefin dispersion onto a heated mold forming the skin and then allowing it to dry.

Abstract: Fiber-reinforced polyurethane structures are made with a polyol composition that contains a particulate filler such as calcium carbonate, in addition to the fibers. The polyol composition and the polyisocyanate composition are selected such that the polymer formed in their reaction has a calculated molecular weight between crosslinks (Mc) of from 300 to 420. The polyisocyanate component contains a urethane-modified MDI and/or a urethane-modified polymeric MDI.

Abstract: Fiber-reinforced polyurethane structures are made with a polyol composition that contains a particulate filler such as calcium carbonate, in addition to the fibers. The polyol composition and the polyisocyanate composition are selected such that the polymer formed in their reaction has a calculated molecular weight between crosslinks (Mc) of from 300 to 420. The polyisocyanate component contains a urethane-modified MDI and/or a urethane-modified polymeric MDI.

Abstract: The present invention is a method to manufacture shaped foam composite articles comprising a foam core and one or more skin and shaped foam composite articles made therefrom. Specifically, cold formed shaped foam articles having an upper and lower surface having a skin applied to one or both of the surfaces. Preferably the foam comprises a styrenic polymer foam and the skins may independently be mono-layered or multi-layered. The shaped foam article and the skin may be made from the same or different materials. In the case where there are more than one skin, the skins may comprise the same or different materials.

Abstract: Polyurethane and/or polyurea polymers are produced in a reaction injection molding process. The high equivalent weight isocyanate-reactive materials include a high proportion of a hydroxymethylated polyester which can be prepared using annually renewable starting materials.

Abstract: There is disclosed a closure panel. The panel finds particular utility as a liftgate or endgate for automotive vehicles. Typically, the assembly includes a first panel portion opposite a second panel portion and an intermediate material therebetween. Preferably, one or more of the panel portions is formed of a polymeric material and the intermediate material is preferably a structural foam that can bond to both the first and the second panel portions.

Abstract: There is disclosed a closure panel. The panel finds particular utility as a liftgate or endgate for automotive vehicles. Typically, the assembly includes a first panel portion opposite a second panel portion and an intermediate material therebetween. Preferably, one or more of the panel portions is formed of a polymeric material and the intermediate material is preferably a structural foam that can bond to both the first and the second panel portions.