Abstract: A foam article for use in a seat cushion includes an open cell, polyurethane foam material that includes a base polyol; a crosslinker; an isocyanate; a surfactant; and water, that are reacted together to produce a seat cushion having dynamic and static performance specifications that are better than the performance characteristics for a traditional, high resilient material seat cushion, as well as other seating materials.

Abstract: A pressure-distributing foam structure for use in a seat application may he produced from a foam mixture comprising an ethylene oxide capped diol in a range of about 37 to about 96% weight. The foam structure may have a hardness at 25% deflection that varies within +/?150% in a temperature range of ?20° C. to 50° C. The foam structure has a hysteresis loss that varies within +/?40% in the temperature range of ?20° C. to 50° C. The pressure-distributing foam structure may be used in a seat component, such as a seat back, a seat cushion, and/or a head rest. A method of making the pressure-distributing foam structure may comprise mixing the ethylene oxide capped diol with at least one of a copolymer polyol and a base polyol.

Abstract: A foam article for use in a seat cushion includes an open cell, polyurethane foam material that includes a base polyol; a crosslinker; an isocyanate; a surfactant; and water, that are reacted together to produce a seat cushion having dynamic and static performance specifications that are better than the performance characteristics for a traditional, high resilient material seat cushion, as well as other seating materials.

Abstract: A foam article for use in a seat cushion includes an open cell, polyurethane foam material that includes a base polyol; a crosslinker; an isocyanate; a surfactant; and water, that are reacted together to produce a seat cushion having dynamic and static performance specifications that are better than the performance characteristics for a traditional, high resilient material seat cushion, as well as other seating materials.

Abstract: A foam article, for use in a seat such as a seat cushion, includes an open cell, polyurethane foam material that includes a plant oil-based polyol material content greater than five percent and is produced from the reaction of a base polyol formulation blend including at least a portion of a plant oil-based polyol, a copolymer polyol including at least a portion of a plant oil-based polyol, water, a cross-linking agent, a catalyst, cell opener and a surfactant that are reacted with an isocyanate material for producing the seat cushion having performance specifications that are equivalent or better than the performance characteristics for a traditional petroleum oil-based polyol material seat cushion.

Abstract: A system and method of forming seating materials having variable density gradient for high hardness ratio of high-to-low deflection, and more specifically to forming foam materials for vehicle seats having variable density gradient that allow greater comfort across a wider range of occupant weights.

Abstract: A method of manufacturing a foam product comprising molding 10 the foam product by injecting liquid material into a mold cavity; de-molding 11 the foam product by removing the foam product from the mold cavity; post-curing 20 the foam product, after de-molding 11 and prior to crushing 40 the foam product, to reduce set damage and form a superficial layer thereon by applying auxiliary heat; and crushing 40 the foam product to obtain a predetermined reduction in thickness of the foam product by mechanically compressing the foam product. The method further comprising cooling 30 the foam product, after post-curing 20 and prior to crushing 40 the foam product, by removing the auxiliary heat applied to the foam product.

Abstract: A foam article for use in a seat cushion includes an open cell, polyurethane foam material that includes a base polyol; a crosslinker; an isocyanate; a surfactant; and water, that are reacted together to produce a seat cushion having dynamic and static performance specifications that are better than the performance characteristics for a traditional, high resilient material seat cushion, as well as other seating materials.

Abstract: A foam article, for use in a seat such as a seat cushion, includes an open cell, polyurethane foam material that includes a plant oil-based polyol material content greater than five percent and is produced from the reaction of a base polyol formulation blend including at least a portion of a plant oil-based polyol, a copolymer polyol including at least a portion of a plant oil-based polyol, water, a cross-linking agent, a catalyst, cell opener and a surfactant that are reacted with an isocyanate material for producing the seat cushion having performance specifications that are equivalent or better than the performance characteristics for a traditional petroleum oil-based polyol material seat cushion.

Abstract: A multi-section mold and method for molding a foam article. Micro-groove vents are formed in the parting line to expel gases from the mold cavity. Flashing that solidifies in the micro-groove vents takes the form of fringe-like elements. The roof of the mold cavity can be provided with similar micro-groove graining patterns to disrupt the accumulation of gas bubbles and minimize defects in the final foam surface.