Abstract: The present invention relates to a process for the production of a polyurethane foam backed instrument panel. This process comprises slicing a free-rise bun of polyurethane foam to form a skived polyurethane foam, bonding the skived foam to a skin material to form a laminate, optionally, rolling the foam/skin laminate, thermoforming the foam/skin laminate into an instrument panel skin, positioning the instrument panel skin into the cavity of a mold, positioning a retainer into the core of the mold, adhering the retainer to the laminate by placing an adhesive film onto the retainer, closing the mold to apply heat and pressure, and removing the resultant instrument panel from the mold. Suitable polyurethane foams for the present invention may be flexible foams or semi-rigid foams. This invention also relates to the polyurethane foam backed instrument panels produced by this process.

Abstract: The present invention relates to a process for the production of a polyurethane foam backed instrument panel. This process comprises slicing a free-rise bun of polyurethane foam to form a skived polyurethane foam, bonding the skived foam to a skin material to form a laminate, optionally, rolling the foam/skin laminate, thermoforming the foam/skin laminate into an instrument panel skin, positioning the instrument panel skin into the cavity of a mold, positioning a retainer into the core of the mold, adhering the retainer to the laminate by placing an adhesive film onto the retainer, closing the mold to apply heat and pressure, and removing the resultant instrument panel from the mold. Suitable polyurethane foams for the present invention may be flexible foams or semi-rigid foams. This invention also relates to the polyurethane foam backed instrument panels produced by this process.

Abstract: The invention is directed to a process for preparing a Class-A surface, fiber reinforced molded article. The process broadly requires the use of two separate fiber surfacing veils with a fiber reinforcement sandwiched therebetween. A polyurethane reaction system is injected into the mold. The system requires the presence of specified hindered amines.

Abstract: The present invention is directed to the production of molded polyurethane products having high flexural moduli (i.e. 1,000,000 psi or more) and high elongation wherein a reaction mixture is reacted in a closed mold. The reaction mixture comprises reacting a liquid, room temperature stable, isocyanate prepolymer with at least two hydroxy-functional polyethers having average hydroxyl functionalities of from 1.5 to 8 and number average molecular weights of from 350 to 1800, at least one hydroxyl functional organic material containing from 2 to 8 hydroxyl groups and having a number average molecular weight below 350 and at least two hydroxyl functional organic materials having average hydroxy functionalities of from 1.5 to 3 and having number average molecular weights of 4000 or more. The products are prepared from these processes using such specified isocyanate prepolymers and polyol blends.

Abstract: The invention is directed to a process for preparing SRIM molded article. The process broadly requires the use of a fiber reinforcement mat which is placed inside the mold cavity, and then a polyurethane reaction system is injected into the mold. The system comprising a polyisocyanate and a blend of active hydrogen containing compounds requires aldimines as part of the blend of active hydrogen containing compounds.

Abstract: The present invention is directed to an improved internal mold release system for the production of high density molded SRIM parts, i.e. molded parts having a density of from 1.3 to 2.0 g/cc. In particular, the process involves reacting a reaction mixture comprising an organic polyisocyanate and at least one organic compound containing isocyanate-reactive hydrogens in the presence of a catalyst and an internal mold release agent in a closed mold. The internal mold release agent is a compound corresponding to the formula: ##STR1## wherein R.sup.2 represents hydrogen, the group R.sup.5 --NH--CO--, or a C.sub.1 to C.sub.24 alkyl or substituted alkyl group, a C.sub.3 to C.sub.24 cycloalkyl or substituted cycloalkyl group, a C.sub.2 to C.sub.24 alkenyl or substituted alkenyl group, or a C.sub.6 to C.sub.24 aryl or substituted aryl group, andwherein R.sup.1, R.sup.3, R.sup.4 and R.sup.5 may be the same or different and represent a C.sub.1 to C.sub.24 alkyl or substituted alkyl group, a C.sub.3 to C.sub.

Abstract: The present invention is directed to an improved internal mold release system for the production of high density molded SRIM parts, i.e. molded parts having a density of from 1.3 to 2.0 g/cc. In particular, the process includes reacting a reaction mixture including an organic polyisocyanate and at least one organic compound containing isocyanate-reactive hydrogens in the presence of a catalyst and an internal mold release agent in a closed mold. The internal mold release agent includes:a) mixed esters including the reaction product of i) aliphatic dicarboxylic acids, ii) aliphatic polyols, and iii) monocarboxylic acids with 12 to 30 carbon atoms in the molecule.The reaction mixture may additionally include a fatty acid such as, for example, oleic acid.

Abstract: The invention is directed to a process for preparing a Class-A surface, fiber reinforced molded article. The process broadly requires the use of a polished mold and two separate fiber surfacing veils with a fiber reinforcement sandwiched therebetween. A polyurethane reaction system is injected into the mold.

Abstract: Microwave frequencies in the range of 0.5 GHz to 10 GHz are used to weld thermoplastic substrates by interposing a carrier strip. The strip is formed of a polymer carrier which is miscible in the substrates. Electrically conductive submicron carbon black susceptor particles are chosen with specified properties such that they generate enough heat within a specified time to produce a weld in which the heat generated is confined to the weld zone. The resulting weld is such that the welded assembly has essentially the same dimensions as the clamped assembly. Glass fiber reinforced substrates are welded without breaking glass fibers in the weld zone. Lap strength of welded substrates is greater than that of substrates joined by prior art methods, whether by welding or adhesive bonding. Articles microwave welded in accordance with the invention are useful for manufacturing and repairing vehicle components such as automobile bumpers and dashboards and other structural parts of automobiles, aircraft, and spacecraft.