Abstract: Processes for producing a polyurethane foam described herein include mixing a physical blowing agent with one or more of an isocyanate-reacting mixture and an isocyanate at a sorption pressure psorp for a time tsorp, reacting the isocyanate-reacting mixture and the isocyanate at a pressure p1 for a time t1, reducing the pressure to a pressure p2, maintaining the pressure at the pressure p2 for a time t2, and reducing the pressure to atmospheric pressure patm. In various embodiments, patm<p2<psat<psorp and psat<p1, where psat is a saturation pressure for the physical blowing agent.

Abstract: Skinned composites contain a plasticized polymer skin layer adhered to a layer of a polyurethane. The polyurethane is made from a reaction mixture that contains specified amounts of a polyester polyol and an acidic material. The presence of both the polyester polyol and acid leads to significantly improved adhesion between the polyurethane and skin layer. The invention is particularly useful when the skin is highly plasticized.

Abstract: PVC-skinned composites include a substrate, a skin and an intermediate polyurethane layer. The polyurethane layer is characterized in having a low molecular weight between crosslinks, i.e., is somewhat highly crosslinked. The high level of crosslinking in the polyurethane leads to improved performance of the skin layer. The skin layer retains its original color upon aging, is less prone to shrinking and other loss of physical properties, and adheres better to the polyurethane layer.

Abstract: PVC-skinned composites include a substrate, a skin and an intermediate polyurethane layer. The polyurethane layer is characterized in having a low molecular weight between crosslinks, i.e., is somewhat highly crosslinked. The high level of crosslinking in the polyurethane leads to improved performance of the skin layer. The skin layer retains its original color upon aging, is less prone to shrinking and other loss of physical properties, and adheres better to the polyurethane layer.

Abstract: Skinned composites contain a plasticized polymer skin layer adhered to a layer of a polyurethane. The polyurethane is made from a reaction mixture that contains specified amounts of a polyester polyol and an acidic material. The presence of both the polyester polyol and acid leads to significantly improved adhesion between the polyurethane and skin layer. The invention is particularly useful when the skin is highly plasticized.