Abstract: A method of producing polyurethane mold foam and polyurethane mold foam produced by the method are provided. With the method, the foam is formed by pouring a polyurethane foam material into a cavity shaped in a mold and foaming the material. A polyurethane foam material used as the foam material has an aspect ratio of 1 to 2.5 for a cell foamed in foam obtained free foaming.

Abstract: A molded article of rigid polyurethane foam is manufactured by using a mold of separable upper and lower mold sections mated to define a cavity therebetween. A film of polypropylene which is previously vacuum formed in conformity to the mold cavity is closely set within the cavity and secured to the lower mold section outside the cavity. A rigid polyurethane foam-forming raw material is introduced into the cavity and on the film and caused to foam and expand in place to mold an article of rigid polyurethane foam. Thereafter, the molded article is lifted together with the film from the mold cavity by a pneumatic pressure or ejector pin. The molded article is stripped from the film to remove only the molded article from the mold without taking the entire film out of the mold. The once lifted film is returned to the original shape by vacuum suction for replacing the film in the cavity.

Abstract: Disclosed herein is a method of manufacturing a rigid polyurethane foam molding for energy absorption, including the steps of introducing a rigid polyurethane foam raw material composed primarily of a polyhydroxy compound and a polyisocyanate compound into a cavity in a mold, and blowing and reacting the rigid polyurethane foam raw material in the cavity, wherein a pack ratio of a core portion of the molding ranges from 0.5 to less than 1.2. Accordingly, the rigid polyurethane foam molding can obtain a plateau value comparable to that of a rigid polyurethane foam slab stock foam suitable for an energy absorbent pad.