Abstract: A method comprises disposing a trim piece on a first mold portion, clamping the trim piece to the first mold portion via a clamp, closing a second mold portion, injecting foam resin into a mold cavity and onto the trim piece, the mold cavity defined at least in part by the first mold portion and the second mold portion, and curing the foam resin to form a component. The component can comprise a back panel for a seatback of a vehicle seat.

Abstract: A method of manufacturing a forming tool. The forming tool may include at least one die having a perimeter wall and a profile panel. At least a portion of the die may be manufactured using an additive manufacturing process. For instance, the profile panel may be manufactured using an additive manufacturing process or the profile panel and additional portions of the die, such as the perimeter wall, may be manufactured using an additive manufacturing process.

Abstract: A method for forming polyurethane foams for vehicle seat components in a molding apparatus is provided. The method includes a step of directing one or more polyol compositions into a mold. Each of the one or more polyol compositions includes a polyol, water, and a catalyst. The method also includes a step of directing an isocyanate composition into the mold, the isocyanate composition including one or more isocyanates. The one or more polyol compositions and the one or more isocyanates are combined into a reaction composition that forms a foamed vehicle seat component. Characteristically, the mold has a shape that defines a foamed vehicle seat component. Characteristically, either the one or more polyol compositions and/or the isocyanate composition includes a liquid antimicrobial agent that is a liquid at temperatures above 10° C.

Abstract: A catalyst composition for catalyzing a polyurethane forming reaction includes a gelling catalyst and a blowing catalyst selected such that the resulting polyurethane foam has a low level of volatile and/or malodorous material in it. The gelling catalysts are selected from tertiary aminoalkyl substituted primary or secondary amines; and the blowing catalysts are selected from bis(aminoalkyl) ethers comprising alkanol moieties, primary amine moieties, or ureido moieties derived from such primary amine moieties.

Abstract: Novel acid-blocked amine catalysts and their use in the preparation of polyurethanes. The acid-blocked amine catalysts have the general structure shown below: wherein A is the residue of an organic acid anhydride; R1 is H or C1 to C6 alkyl; R2 is H or C1 to C6 alkyl; n is an integer of 0 to 10; and B is a compound containing a protonated amine and one or more primary amine, secondary amine, or tertiary amine groups.

Abstract: Novel acid-blocked amine catalysts and their use in the preparation of polyurethanes.

Abstract: Novel acid-blocked amine catalysts and their use in the preparation of polyurethanes. The acid-blocked amine catalysts have the general structure shown below: wherein A is the residue of an organic acid anhydride; R1 is H or C1 to C6 alkyl; R2 is H or C1 to C6 alkyl; n is an integer of 0 to 10; and B is a compound containing a protonated amine and one or more primary amine, secondary amine, or tertiary amine groups.