Abstract: An interior trim panel comprises a flexible polyurethane skin layer, an intermediate resilient polyurethane foam layer and a rigid polyurethane foam substrate. The flexible polyurethane skin layer and intermediate resilient polyurethane foam layer are formed as an expanded thermoplastic urethane (TPU) shell in a slush molding process. The rigid polyurethane foam substrate is then foamed in place on the shell in a substrate forming mold. This produces an environmentally friendly, long lasting interior trim panel that can be manufactured economically without any need for plasticizers or adhesive coatings.

Abstract: A solvent flush reaction injection molding mixhead has a mixing chamber with a solvent inlet port in one end and a chemical outlet port in an opposite end. A pair of hydraulically operated chemical injectors are connected to the mixing chamber between the solvent inlet port and chemical outlet port to inject liquid reaction molding chemicals at high pressure through injector ports into the mixing chamber. The mixed chemicals are delivered through the chemical outlet port to a spray wand on the mixhead for application to a mold surface or an object requiring a foam coating.

Abstract: A method and apparatus are disclosed for making preforms from a fibrous material such as glass fibers. The apparatus includes a porous mold form that, in carrying out the method, is attached over the open face of a charge box. The charge box and mold form are then rotated as a single unit to dump glass fibers or other fiberous reinforcement held in the charge box onto the mold form. Air is drawn through the porous mold form to thereby retain a layer of the glass fibers against the mold form. The mold form and charge box are rotated back to their initial position and then disconnected. A binder is sprayed onto the glass fibers if not otherwise already applied thereto. The binder is then cured, resulting in a unitary glass fibers preform.

Abstract: A polyurethane RIM system has at least two molding stations. The reactants are brought to the mixheads as three separate streams. One stream contains the isocyanate, the second stream contains some of the polyol, the chain extender and crosslinker and a third stream contains additional amounts of the polyol, along with what additives might be desired. At each mixhead the proportions of ingredients are controlled to give an isocyanate index of about 100, but the ratio of one polyol stream to the other is regulated to control the flex modulus and other properties of the molded product as may be desired. In this way, one source of supply can be used to feed several molding stations, each of wich may produce a product of different physical properties and thus of different costs.

Abstract: An improved polyurethane RIM process using a polycarboxy-functional alkyl siloxane as an internal release agent characterized by:(1) Tool break-in or preconditioning with siloxane treatment of the surfaces;(2) Supplying the siloxane to the mix head as a third stream when necessary to prevent undesired side reactions;(3) Using a minimal amount of siloxane that is inadequate for mold release in the absence of the tool preconditioning;(4) Adjustment of catalyst package to counter the inhibiting effects of the siloxane.The use of a bare minimal amount of siloxane prevents excess siloxane from appearing in the surface of the article and causing subsequent paint wet-out and like difficulties. The third stream isolating of the siloxane prevents its carboxy-functional groups from reacting with the prepolymer or with other ingredients that may be carried in the polyol blend.

Abstract: A quasi-prepolymer-type urethane foam for a reaction injection molding (RIM) system comprises, for the polyol side, a blend of a long-chain polyol with a short-chain diol and/or triol and an organometallic catalyst and, for the prepolymer side, a unique high--27 to 31% --free NCO quasi-prepolymer made by reacting an essentially pure MDI with a selected low molecular weight (240 to 1500) polyol having a functionality of about 2.7 to 3.3. The selected low molecular weight polyol is specifically a polyether polyol (i.e. a polyoxpropylene and/or ethylene polyol) initiated with TMP, hexanetriol, glycerine or other suitable polyol. The quasi-prepolymer, while having the expected high reactivity, surprisingly gives good rapid cures in less than 2 minutes. The resulting urethane foam is characterized by its excellent low temperature properties, especially -20% F cold flexibility and -20% F dart impact. The quasi-prepolymer storage stability can be greatly improved by the inclusion of a small amount of a liquid MDI.

Abstract: A highly reactive urethane foam for RIM to produce thin-sectioned automobile trim components having good high temperature sag performance is a quasi prepolymer system in which the polyol side is based on a relatively high molecular weight polyol combined with a known highly reactive unhindered aromatic polyamine chain extender/cross linker and with conventional short chain diols/triol extenders/cross linkers and catalysts.