Abstract: Processes for the preparation of monoisocyanates, diisocyanates or polyisocyanates of the present invention are described which comprises reacting monomeric or oligomeric primary amines or diamines, and carbon monoxide at atmospheric pressure in the presence of a catalytic amount of a compound or a complex of a divalent metal selected from palladium, nickel and platinum, and in the presence of stoichiometric or catalytic quantities of benzoquinone as an oxidant. Isocyanates are produced in high yields and purities. They can be isolated as free isocyanates or as blocked isocyanates by in situ reaction with blocking agents that contain an active hydrogen being attached to oxygen, sulfur or nitrogen. Monoisocyanates and diisocyanates serve as chemical, agricultural or pharmaceutical intermediates. Diisocyanates and polyisocyanates are used to produce polyurethanes, polyureas, polyisocyanurates and related polymers.

Abstract: A composite structure is based on a sandwich construction and a one-step molding process. The composite structure or component comprises a core layer having two outer layers on each side of the core layer. The outer layers may be composed of automotive interior trim scrap adhered with an isocyanate adhesive composition. Core layer and outer layers are thermally pressed in a single step or process to form the finished structural, multi-layer product. Decorative layers can be added as part of the one-step process. The resulting panels can be used in the manufacture of automotive, construction, furniture and other components.

Abstract: A composite structure is based on a sandwich construction and a one-step molding process. The composite structure or component comprises a core layer having two outer layers on each side of the core layer. The outer layers may be composed of automotive interior trim scrap adhered with an isocyanate adhesive composition. Core layer and outer layers are thermally pressed in a single step or process to form the finished structural, multi-layer product. Decorative layers can be added as part of the one-step process. The resulting panels can be used in the manufacture of automotive, construction, furniture and other components.

Abstract: Useful articles are produced from shredded post-industrial (scrap), including post-consumer automotive interior trim parts obtained from vehicles. Feedstock is shredded into a fluff and mixed with an isocyanate prepolymer adhesive composition. The mixture may be placed into a mold, onto a continuous web or between laminating rolls to cure the mixture under pressure. The curing step can take place at room or elevated temperatures and only requires moisture either from the atmosphere or present in the shredded scrap or fluff. The articles produced may natural wood sheets such as Luan or wood composite boards currently adhered with urea-formaldehyde or phenol-formaldehyde resins. Other applications include structural or non-structural parts such as bulk heads, roofs, floors or vertical walls used in automotive vehicles, tractor trailers, recreational vehicles or marine vessels.

Abstract: Useful articles are produced from shredded post-industrial (scrap), including post-consumer automotive interior trim parts obtained from vehicles. Feedstock is shredded into a fluff and mixed with an isocyanate prepolymer adhesive composition. The mixture may be placed into a mold, onto a continuous web or between laminating rolls to cure the mixture under pressure. The curing step can take place at room or elevated temperatures and only requires moisture either from the atmosphere or present in the shredded scrap or fluff. The articles produced may natural wood sheets such as Luan or wood composite boards currently adhered with urea-formaldehyde or phenol-formaldehyde resins. Other applications include structural or non-structural parts such as bulk heads, roofs, floors or vertical walls used in automotive vehicles, tractor trailers, recreational vehicles or marine vessels.

Abstract: A method of minimizing compression set of foam includes introducing a composition including a first component and a second component that is reactive with the first component into a cavity of a mold, curing the composition to form a foam inside the cavity, demolding the foam, and heating the foam by induction after demolding to thereby minimize compression set of the foam. A method includes introducing the composition into the cavity, heating the mold via conduction of the mold to thereby cure the composition and form the foam inside the cavity, heating the foam by induction before demolding to thereby minimize compression set of the foam, and demolding the foam. The foam includes a reaction product of the first and second components. The foam has a compression set after heat aging of ?10% at 10 minutes after the foam is demolded from the cavity of the mold.

Abstract: A method of making an acoustic insulator includes depositing thermoplastic particulate on a first surface of a base layer. The method further includes heating the particulate such that the particulate at least partially melts and penetrates the first surface of the base layer, thereby increasing density and airflow resistance of the base layer proximate the first surface such that the base layer has an areal mass in the range of 0.1 to 1.0 kg/m2 and an airflow resistance in the range of 300 to 5,000 Nsm?3 proximate the first surface.

Abstract: A sound insulating component includes a decoupling layer disposed under a cap layer comprising a thermoplastic cellular foam. Advantageously, the cap layer has sufficient rigidity to maintain a predetermined shape and has an airflow resistance that allows a predetermined amount of airflow through the sound insulating component. In another embodiment, a hybrid sound insulating component includes a cap layer and a decoupling layer with an airflow control layer interposed thereof. A method of making the sound control components is also provided.

Abstract: The present invention relates to a composite shoddy for use in a vehicle interior. To this end, the composite shoddy of the present invention includes an organic material having a predetermined density defining a shoddy bottom layer and a scrim material having a predetermined density defining a scrim top layer. The scrim top layer is adapted to operatively engage a surface material and accommodate movement of a surface material in the shear direction. The composite shoddy further includes a bituminous mastic material having a predetermined density defining a mastic middle layer. The mastic middle layer is disposed between the organic bottom layer and the scrim top layer.

Abstract: The present invention relates to a composite shoddy for use in a vehicle interior. To this end, the composite shoddy of the present invention includes an organic material having a predetermined density defining shoddy bottom layer and a scrim material having a predetermined density defining a scrim top layer. The scrim top layer is adapted to operatively engage a surface material and accommodate movement of a surface material in the shear direction. The composite shoddy further includes a bituminous mastic material having a predetermined density defining a mastic middle layer. The mastic middle layer is disposed between the shoddy bottom layer and the scrim top layer.

Abstract: A method of making a composite part including an insert and an elastomer layer that is bonded to the insert. The insert is placed in a mold and an uncured elastomer is sprayed into the mold to form a composite part. The inherent adhesive properties of the uncured elastomer is the sole mechanism for bonding the elastomer to the insert.

Abstract: A method of making an acoustic insulator includes depositing thermoplastic particulate on a first surface of a base layer. The method further includes heating the particulate such that the particulate at least partially melts and penetrates the first surface of the base layer, thereby increasing density and airflow resistance of the base layer proximate the first surface such that the base layer has an areal mass in the range of 0.1 to 1.0 kg/m2 and an airflow resistance in the range of 300 to 5,000 Nsm?3 proximate the first surface.

Abstract: Methods for reducing surface gloss of a vehicle interior trim component, such as non-carpeted floor coverings. Gloss is reduced by treating a surface of the interior trim component with an energy beam, such as a gas plasma, a flame plasma, or a corona discharge, emitted from a treatment device. A positioning device supports the treatment device in a spaced relationship to the surface. The positioning device causes the treatment device and the interior trim component to be moved relative to each other during the course of the gloss reduction treatment.

Abstract: The present invention relates to a composite shoddy for use in a vehicle interior. To this end, the composite shoddy of the present invention includes an organic material having a predetermined density defining an organic bottom layer and a scrim material having a predetermined density defining a scrim top layer. The scrim top layer is adapted to operatively engage a surface material and accommodate movement of a surface material in the shear direction. The composite shoddy further includes a mastic material having a predetermined density defining a mastic middle layer. The mastic middle layer is disposed between the organic bottom layer and the scrim top layer.

Abstract: A method of making a porous interior trim system for a vehicle includes applying polyethylene particulate to a back side of a porous carpet layer; heating the carpet layer and the particulate; and molding the carpet layer and a porous layer to achieve a desired shape. Moreover, the polyethylene particulate forms a porous coating that is in direct contact with the porous layer.

Abstract: A non-pile carpet vehicle floor covering having a mass filled layer of variable thickness sprayed onto a polyurethane top surface. The method of making the vehicle floor covering comprises spraying a polyurethane layer over a mold release layer. A mass filled layer is then sprayed onto the polyurethane top layer before the polyurethane layer fully solidifies. A decoupler may be poured onto or adhesively attached to the mass filled layer. The mass filled layer may have thick areas and thin areas to provide varying levels of noise and vibration control as required by a particular vehicle application.

Abstract: A method of making a composite part including an insert and an elastomer layer that is bonded to the insert. The insert is placed in a mold and an uncured elastomer is sprayed into the mold to form a composite part. The inherent adhesive properties of the uncured elastomer is the sole mechanism for bonding the elastomer to the insert.