Abstract: An interior trim component, such as a door panel, having an outer skin backed by a low density molded mat foam substrate and an energy absorbing foam backing is manufactured in a single mold tool in a multiple stage foaming operation in which the outer skin and a glass reinforcement mat are positioned in the mold cavity and a mold insert corresponding to the energy absorbing foam layer is mounted to the lid of the mold tool. A polyurethane precursor mixture is poured into the open mold and the lid closed to generate the low density molded mat substrate. The mold is opened and the mold insert removed and a second urethane precursor mixture is poured onto the substrate and the mold closed to generate the energy absorbing foam backing within the space of the mold cavity previously occupied by the mold insert.

Abstract: An interior energy absorbing panel for the passenger compartment of a motor vehicle has a thermoplastic skin, a thermoplastic retainer, a thermoplastic air duct, and an energy absorbing rigid polyurethane foam core which is reaction injection molded about the air duct and to the skin and retainer without requiring any added adhesive. When the skin is of the soft type, a layer of semirigid polyurethane foam is reaction injection molded between the skin and the energy absorbing foam core to impart a soft feel to the skin and protect the energy absorbing foam core from indentation during normal use.

Abstract: A solvent flush reaction injection molding mixhead has a mixing chamber with a solvent inlet port in one end and a chemical outlet port in an opposite end. A pair of hydraulically operated chemical injectors are connected to the mixing chamber between the solvent inlet port and chemical outlet port to inject liquid reaction molding chemicals at high pressure through injector ports into the mixing chamber. The mixed chemicals are delivered through the chemical outlet port to a spray wand on the mixhead for application to a mold surface or an object requiring a foam coating.

Abstract: A cover for an inflatable air bag housing is formed of integrally molded resinous plastic material and defined therein is a hinge area and a thin fracture line forming a door which pivots to an open position upon fracture of the cover along the fracture line when an air bag is inflated. A metal reinforcing element is embedded in the resinous plastic material and includes segments diverging and below the hinge area forming an open space or void which is filled in with a low density collapsible, energy absorbing, rigid foam which exhibits minimal spring back. The filler helps prevent sagging or read-through of the cover above the void when prolonged exposure to heat and sun is experienced. Moreover, the foam filler absorbs energy during bag deployment and aids in preventing plastic resin from leaking into the void space during the initial fabrication of the cover as the metal reinforcement element is molded in place.

Abstract: A RIM molded energy absorbing polyurethane rigid foam prepared from reacting inter alia a graft polymer polyol and an organic isocyanate using water as the blowing agent.

Abstract: Disclosed are novel storage stable liquid compositions derived from heating a liquefied methylenebis(phenyl isocyanate) with a minor proportion of a cycloalkane diol.The molded polyurethanes produced using the above liquid isocyanates are characterized by excellent resistance to elevated temperatures. In fact, their heat resistance is superior to similarly constituted prior art materials.

Abstract: Molded cellular polymers are disclosed which are derived from the reaction of organic polyisocyanates with novel active hydrogen compositions comprising (A) a polyester polyol mixture derived from (i) an aromatic polycarboxylic compound containing two or more carboxylic groups; and (ii) an excess of at least one polyol having from 2 to 8 hydroxyl groups and an equivalent weight of from about 30 to about 250; and (B) from about 5 to about 30 percent by weight of a primary or secondary amine terminated polyether of greater than 1500 molecular weight and amine functionality of from about 2 to about 8.The molded products are characterized by a combination of excellent impact strength and resistance to high temperatures as well as good resistance to burning.

Abstract: Polyurethane-polyurea polymers are disclosed that are derived from the reaction injection molding of organic polyisocyanates, optional high molecular weight active hydrogen containing compounds and extender mixtures comprising (i) aromatic diamines wherein at least one of the positions ortho to each amine group is substituted by a lower alkyl group and (ii) bis(hydroxyalkyl)cycloalkanes. The improved polymers have excellent resistance to high temperature conditions.