Abstract: Molded, soft composite articles such as seat cushions are made by (a) applying a composition which forms a soft elastomer to all interior walls of an open mold, (b) introducing a composition which will react to form a low density, high resiliency, flexible foam under molding conditions into the mold in a manner such that the foam-forming composition will be substantially completely within the elastomer-forming composition; (c) closing the mold (i) prior to introduction of the foam-forming composition or (ii) at some point during or subsequent to introduction of the foam-forming mixture but before foam formation is completed and (d) allowing the foam-forming mixture to form a foam. The composite articles produced by this simple one-step process are characterized by good cushioning characteristics, good abrasion resistance and good mold reproducibility. This molding process generates less waste and requires less labor and equipment than current commercial processes.

Abstract: The present invention is directed to a novel isocyanate mixture and the use thereof in producing a flexible polyurethane foam. The polyisocyanate mixture comprises(a) for 73 to 77% by weight of methylene bis(phenylisocyanate), said methylene bis(phenylisocyanate) having an isomer content as follows:(i) from about 30 to about 34% by weight of the 2,4' isomer,(ii) from about 60 to about 66% by weight of the 4,4'- isomer, and(iii) from about 3 to about 7% by weight, the 2,2' isomer, the percent of said isomers totaling 100%(b) from 23 to 27% by weight of higher functional methylene-bridged polyphenyl polyisocyanates, the percents of components (a) and (b) totaling 100%, and wherein said polyisocyanate mixture has an isocyanate group content of from about 30 to about 33.5 percent by weight.

Abstract: The present invention is directed to a novel isocyanate mixture and the use thereof in producing a flexible polyurethane foam. The polyisocyanate mixture comprises(a) from 73 to 77% by weight of methylene bis(phenylisocyanate), said methylene bis(phenylisocyanate) having an isomer content as follows:(i) from about 30 to about 34% by weight of the 2,4' isomer,(ii) from about 60 to about 66% by weight of the 4,4'-isomer, and(iii) from about 3 to about 7% by weight, the 2,2' isomer, the percent of said isomers totaling 100%,(b) from 23 to 27% by weight of higher functional methylene-bridged polyphenyl polyisocyanates, the percents of components (a) and (b) totaling 100%, and wherein said polyisocyanate mixture has an isocyanate group content of from about 30 to about 33.5 percent by weight.