Abstract: The uneven surfaces of wood-based materials such as chipboard may be improved by applying a formable coating material, smoothing and/or modelling the coating material to achieve a smoother surface, and heating the coating material to form closed pores while maintaining the smoothed surface intact.

Abstract: The present invention relates to webs made of cellulose fibers admixed with thermobonding fibers, wherein the web surfaces are sealed to a greater or lesser extent by adding thereto a binder in modest amounts. The binder is applied without any attempt to provide deep penetration of said binder into the web material. By applying the binder in the form of a foam, a minimum of binder is required to provide bonded webs exhibiting minimal Tinting.

Abstract: Stable foam caulk, sealant and insulation compositions are disclosed. The compositions comprise solid, waxy non-ionic lipophilic surfactants having low HLB values. These surfactants, upon foamed dispensing of the composition, provide stable support for bubbles formed from drying of a latex emulsion of a film forming polymer and a volatile liquid hydrocarbon propellant. In addition to use in caulking, sealant or insulation methods, the composition can be used to form artificial terrains and other hardenable structural surfaces as backgrounds or support means for hobbies, crafts, and the like.

Abstract: The invention thus provides a method of making a foam-filled composite matrix having a cellular core, and the composite matrix of the method, e.g. for use as sacrificial energy absorbing structures particularly for the passenger compartments of vehicles, e.g. motor vehicles. Thus the structures may be used in head linings in automobiles and as linings and even seats in vehicles such as aircraft. Additionally the structures may form crash padding in crash helmets and body armour.

Abstract: A flexible, metallized, polyurethane foam has, incorporated therein, particles selected from copper and copper oxide in an amount, based on metallic copper, of at least 1% by weight of the total weight of the metallized foam. The copper can be incorporated into the foam by (a) mixing the particles with a polyol and reacting the polyol with a polyisocyanate in the presence of a foaming agent to form the flexible polyurethane foam, whereby the particles are incorporated in-situ within the foam; or (b) forming a slurry of the particles in a polymer latex medium and treating the foam with the said slurry to allow impregnation of the particles into the foam. An article for alleviation of discomfort from an ailment associated with a joint, limb or muscle contains the flexible polyurethane foam covered by a fabric.

Abstract: Method for manufacturing knockdown board material, including steps of: using a conveying device to convey a board material and immerge the board material into a resin tank to which a fireproof agent is added, after the resin fully infiltrates into the board material, the board material being compressed by rubber rollers and then dried and solidified to form a protective film; attaching printed paper to the surface of the board material by way of adhesion or thermal transfer-printing stripes on the surface of the board material; painting a layer of surface treatment agent on the surface of the board material by way of rolling or spraying; laying EVA foam material on back face of the board material and embossing stripes on the foam material; and cutting the board material into a certain shape.

Abstract: Expandable sealant and baffle compositions and methods of forming and using such compositions are provided wherein the compositions comprise a first thermoplastic resin, an epoxy resin, preferably a second thermoplastic resin different from the first thermoplastic resin, and optionally a compound selected from the group consisting of pigments, blowing agents, catalysts, curing agents, reinforcers, and mixtures thereof. The resulting compositions are formed as self-sustaining bodies which can be heat-expanded into a lightweight, high strength product for sealing hollow structural members of vehicles, substantially decreasing the noise which travels along the length of those members as well as strengthening those members with minimal increases in their weights. In a preferred embodiment, the first thermoplastic resin is an SBS block co-polymer, the epoxy resin is a bisphenol A-based liquid epoxy resin, the second thermoplastic resin is a polystyrene, and the reinforcer is hydrated amorphous silica.

Abstract: An improved foam cushion tape comprises a compressible polyurethane foam layer having a first side and an opposite second side; a composite reinforcing film comprising an anchoring layer and a reinforcing layer, wherein the second side of the polyurethane foam is disposed on the anchoring layer of the reinforcing film; a first adhesive disposed on the first side of the compressible polyurethane foam; and a second adhesive disposed on the reinforcing layer of the composite reinforcing film. The anchoring layer comprises at least one non-olefinic polymer, such as polyvinylidene chloride (PVDC), polyurethane, nylon, or the like.

Abstract: To provide a decorative sheet which has a three-dimensional decorative effect and, in addition, is free from separation of a decorated area upon being exposed to abrasion or impact conditions. A decorative sheet comprising: a substrate (1) formed of a transparent resin composition; and, laminated thereon in the following order, a color layer (2), an expandable layer (3), and a pressure-sensitive adhesive layer (5).

Abstract: An improved process for permanently attaching an overlay to a wheel disc, wherein the overlay is aligned and spaced apart from the wheel disc. A mold is created by a combination of the overlay, wheel disc and localized nests that engage at predetermined times during foam filling to close the mold. The mold is adequately sealed so that there is no foam leakage as the foam expands to fill the mold and, therefore, no final trimming of excess foam is required. The improved process is capable of accommodating a wheel having turbine openings therein.

Abstract: An insulating container comprising a container body having at least one side wall and a bottom wall with the side wall including a base layer, an insulating layer on at least a portion of the base layer and a printed pattern, mineral oil application or combination thereof on at least a portion of the surface of the insulating layer is disclosed wherein a thickness of the insulating layer is controlled by the printed pattern and/or mineral oil on the selected portion of the insulating layer. Similarly, stock material incorporating the present invention includes a base layer, an insulating layer formed on at least a portion of the base layer and a printed pattern printed on and or mineral oil applied to the insulating layer is disclosed wherein the thickness of the insulating layer is again controlled by the printed pattern and/or mineral oil on the portion of the insulating layer.

Abstract: A method for foaming or foam-coating components is used for foaming hollow cavities of double-walled or multiple-walled components or foam-coating component parts with decorative surfaces so as to improve haptic properties of component parts. A material is introduced or applied in an unfoamed state to be foamed through the use of microwave energy. In order to achieve high dielectric losses and to ensure that the heat effect is evently distributed and essentially restricted to the material to be foamed, the material is adjusted in a polar manner by addition of certain substances such as conductive soot. Reflecting agents are used to improve the distribution and effect of the microwaves. The method ensures fully foamed hollow cavities and foam layers of uniform thickness. A foamable material for foaming or foam-coating components is also provided.

Abstract: A molded resin laminate in which the dimensional accuracy and the strength are excellent at a bent portion and a method for producing the same are provided. One, in which an average diameter of small cells existing in a region on a side of a resin cover to be formed into a surface layer is smaller than an average diameter of large cells existing in a region on a side of a base resin component to be formed into a base layer, is used as a foamed resin component to be formed into an intermediate layer of the molded resin laminate. After the base resin component is molded with a molding machine, the base resin component is held on a male mold of a forming machine different from the molding machine described above. A sheet-shaped laminate, which is obtained by joining the foamed resin component and the resin cover, is arranged between the base resin component and a female mold. Subsequently, the forming machine is subjected to mold clamping.

Abstract: A component, particularly for land vehicles, preferably a car body component for motor vehicles, consists of a metallic foam material with a foamed porous layer comprising a metal powder and a blowing agent and possibly at least one solid metal sheet, there being metallic bonds between the solid metal sheet and the foamed porous layer. The component has at least one stamped contour which is raised from its surface, the angles, occurring in the region of the transitions between the three-dimensionally molded contour and the surface region being of the order of 100° to 180°. To produce the component, an essentially flat, metallic foam material, which is provided with solid metal sheets as covering layers, is initially shaped into a semi-finished molded product, which is end-contoured on one side, and the semi-finished molded product, so formed, is placed into a foaming mold, one wall of which is adapted to the end-contoured side of the semi-finished molded product and foamed therein.

Abstract: Stable foam caulk, sealant and insulation compositions are disclosed. The compositions comprise solid, waxy non-ionic lipophilic surfactants having low HLB values. These surfactants, upon foamed dispensing of the composition, provide stable support for bubbles formed from drying of a latex emulsion of a film forming polymer and a volatile liquid hydrocarbon propellant. In addition to use in caulking, sealant or insulation methods, the composition can be used to form artificial terrains and other hardenable structural surfaces as backgrounds or support means for hobbies, crafts, and the like.

Abstract: A reinforced structural member has a channel-shaped laminate structure of a metal stamping, a channel-shaped foil and an intervening layer of structural foam. The reinforced structural member is formed by pressing a foil/resin preform into a channel and thermally expanding the resin to form a structural foam.

Abstract: A process for producing multi-layer game ball products includes the steps of extruding an inner layer precursor as a parison in a partial melt state, forming an outer layer, introducing the inner and outer layers into a mold and expanding the parison within the mold to form the multi-layer game ball product. The outer layer may take the form of pre-cut panels vacuum supported in the mold and an intermediate layer may be provided for dimensional stability in the product. Subsequent to expanding the parison a filler such as foam may be injected into the center space for forming a core.

Abstract: In order to manufacture compound composite bodies having at least two lay with a support material made completely or substantially from a polymer and with a porous layer firmly connected thereto, a substantially microwave-permeable polymer is utilized for the support material and a polymer having microwave absorbing properties is utilized for the porous layer. The polymer for the porous layer, treated with foaming agent, is heated with microwave energy up to the decomposition temperature of the foaming agent. The resulting polymer foam is sufficiently heated using microwave energy that the support material, at its bordering layer adjacent the foamed polymer, is sufficiently melted substantially due to heat conduction out of the foamed layer that, subsequent to cooling, a firm composite between the support material and the foamed polymer is effected.

Abstract: A wear layer is applied to a flooring material to yield a product having superior properties. The wear layer is applied to the flooring material using a coating composition comprising (i) a polyvinyl chloride (PVC) resin, (ii) an acrylic or methacrylic compound and (iii) a radiation-reactive urethane oligomer, which composition is substantially or completely free of internal or external plasticizers, heating to heat-cure the coating composition and irradiating the composition to radiation-cure the coating composition.

Abstract: In a process for the production of molded parts that have a lamination of decorative material, as well as a foam layer between the decorative material and the molded part, the decorative material is first provided with an unfoamed backside layer. The backside layer is then connected to the molded part and expanded, while connected to the molded part, under the effect of heat.

Abstract: A heat insulating paper cup with improved insulation in areas where printed matter exists. The printed matter is applied using a water-based alkyd or epoxy ink. In one embodiment the cup can include a body member having an inside surface and an outside surface, and a bottom panel member having a upper surface and a bottom surface. The body member is coated on its outside surface with a foamed synthetic resin, and on its inside surface with an unfoamed synthetic resin. The bottom panel member is optionally coated on its upper surface with a foamed or an unfoamed synthetic resin. The body member and bottom panel member are oriented and joined to form a seal at an interface between a portion of inside surface of the body member and a portion of the upper surface of the bottom panel member. The printed matter is applied prior to foaming of the synthetic resin on the outer surface of the cup.

Abstract: A process for producing an ethylene vinyl acetate insole involves weighing molding compounds for manufacturing the ethylene vinyl acetate insole. The molding compounds are mixed and rolled by means of a roller so as to form a sheet material. The sheet material is cut into a plurality of elongated strips. A predetermined amount of the strips are placed into a first mold unit, which is heated and pressurized so as to form a partially foamed insole. The partially foamed insole is placed into a second mold unit, which is heated, pressurized, and cooled so as to form a completely foamed insole. The completely foamed insole is trimmed to form a finished ethylene vinyl acetate insole.

Abstract: A method of forming fabric for making foam-in-place molded articles such as preferably seat cushions. A film is secured to a frame and tacked by adhesive to a piece of fabric, not secured to the frame, that forms the outer covering of the seat cushion for permitting the fabric to move relative to the film during forming to enable fabrics which cannot stretch a considerable amount to be used. To form the fabric, the film and fabric are placed in a female mold and the film and fabric are drawn into a cavity of the mold and against a contoured surface in the cavity forming a recess in the film and fabric. To counteract compressive stresses in the fabric during forming, the frame can have one or more fabric tensioners that selectively apply tension to the fabric during forming. To mold the cushion, a foam is poured into the recess and allowed to cure until it hardens into a foam core and bonds with the film.

Abstract: It has been discovered that improved poured-in-place sandwich panels may be made which have a planar, rigid, cellular polyisocyanurate or polyurethane foam core, an interior facer on one side of the polyisocyanurate foam core and a metal skin on the other, opposite side of the polyisocyanurate foam core. Adhesion of the metal skin to the polyisocyanurate or polyurethane foam core is improved through the use of a primer layer, such as a polyurea or a polyepoxide. Preferably, glass fibers are provided in the polyisocyanurate or polyurethane foam core as reinforcement and as fire retardant.

Abstract: A component, particularly for land vehicles, preferably a car body component for motor vehicles, consists of a metallic foam material with a foamed porous layer comprising a metal powder and a blowing agent and possibly at least one solid metal sheet, there being metallic bonds between the solid metal sheet and the foamed porous layer. The component has at least one stamped contour which is raised from its surface, the angles, occurring in the region of the transitions between the three-dimensionally molded contour and the surface region being of the order of 100.degree. to 180.degree.. To produce the component, an essentially flat, metallic foam material, which is provided with solid metal sheets as covering layers, is initially shaped into a semi-finished molded product, which is end-contoured on one side, and the semi-finished molded product, so formed, is placed into a foaming mold, one wall of which is adapted to the end-contoured side of the semi-finished molded product, and foamed therein.

Abstract: A process for making PU air permeable nubuck sheets includes coating a separable release substrate material such an cloth, plastics, or paper with a polyurethane (PU) resin preparation before disposing the same in an impregnation tank to allow the PU resin to congeal into a sheet of minute pores attached to the release substrate material. The release substrate material together with the sheet is soaked in a wash tank to rinse off residual dimethyformamide (DMP) A beck surface of the release substrate material is coated with a water soluble resin (which may later dissolve in water and then be rinsed off) and the release substrate material is put into an oven to dry and then removed to a grinder for processing into a nubuck sheet with the feel and visual characteristics of real nubuck. The nubuck sheet is washed in a wash tank to rinse off the water soluble resin, dried, subjected to surface finishing, and than separated from the release substrate material to obtain a PU air permeable nubuck sheet.

Abstract: An insulating container comprising a container body having at least one side wall and a bottom wall with the side wall including a base layer, an insulating layer on at least a portion of the base layer and a printed pattern, mineral oil application or combination thereof on at least a portion of the surface of the insulating layer is disclosed wherein a thickness of the insulating layer is controlled by the printed pattern and/or mineral oil on the selected portion of the insulating layer. Similarly, stock material incorporating the present invention includes a base layer, an insulating layer formed on at least a portion of the base layer and a printed pattern printed on and or mineral oil applied to the insulating layer is disclosed wherein the thickness of the insulating layer is again controlled by the printed pattern and/or mineral oil on the portion of the insulating layer.

Abstract: A multilayer article such as a door trim board is fabricated by the steps of extruding melted resin layers (13m), (12m) and (11m) respectively forming a soft skin material (13), a foamed soft intermediate layer (12) and a base member (11) in the form of a multilayer resin sheet from a die-head (40) of an extruding machine, supply the extruded multilayer resin sheet to a molding machine in such a manner that the resin layer for the skin material is placed on a lower molding die of the molding machine and molding the resin layers in the form of the multilayer article. The resin layer for the skin material consists of thermoplastic elastomer, the resin layer for the intermediate layer consists of ethylenic copolymer copolymerized with ethylene and at least radical copolymerizable acid anhydride, and the resin layer for the base member consists of olefinic resin.

Abstract: NCO-terminated prepolymers are made by reacting a polymeric diphenylmethane diisocyanate (PMDI) and a polyol having a functionality of from about 1.8 to about 4.0 and a molecular weight of from about 400 to about 2,000. The PMDI and polyol are reacted in amounts such that the equivalent ratio of isocyanate groups to hydroxyl groups is from about 15:1 to about 160:1. These prepolymers are useful in the production of polyurethane foams, particularly laminated foams.

Abstract: A method for making a surface covering is disclosed which includes providing a surface covering having a backing layer, a foamable layer, and a design layer, wherein the design layer includes a portion of a pattern printed with at least one retarder composition. A wear layer is then provided on the design layer and the wear layer is cured. The foamable layer is thereby expanded to form a foam layer, and the pattern printed with at least one retarder composition is chemically embossed. The cured product is subsequently cooled to ambient temperature and then the top surface of the wear layer is subjected to a sufficient temperature to soften the wear layer. After being softened the wear layer is mechanically embossed with a surface texture, the embossed surface texture is set in the wear layer, and a top coat may then be provided on the embossed set wear layer. A surface covering having the various features described above is also disclosed.

Abstract: An improved cushioned carpet fabric is provided. The cushioned carpet comprises a primary carpet having a primary base and a plurality of pile-forming yarns projecting outwardly from one side. A layer of reinforcement material is bonded to the primary base on the side opposite the pile forming yarns. The reinforcement layer is adjacent to and embedded in, a cushion layer of a polymer such as a polyurethane. There is preferably no additional adhesive between the cushion layer and the layer of reinforcement material since the primary carpet fabric is mated in-situ to the polyurethane-forming composition without preheating the polyurethane-forming composition. An apparatus and process for forming the cushioned carpet fabric of the present invention are also provided.

Abstract: An improved panel structure wherein at least one face of the panel is perforated with small holes and where it is desirable to minimize the number of holes that get filled in with adhesive. For example, an improved noise reducing acoustic panel (30) (FIG. 3) constructed of a nonperforated inner skin (14), a perforated outer skin (16) having small holes (18), two sections (12, 12a) of honeycomb core material which are bonded or spliced together by a partially or fully encapsulated foaming adhesive (32e) which has been foamed and expanded, thereby forcing a supported film adhesive (34c) against the walls (24, 24a) of the honeycomb cells in the area of the gap (22) whereby the supported film adhesive (34c) bonds to the walls (24, 24a) of the honeycomb cells in the area of the gap (22). The nonperforated inner skin (14) has been adhesively bonded by a film adhesive to the honeycomb core sections (12, 12a).

Abstract: A method for manufacturing a fabric covered cushion includes the steps of coating one side of a stretchable fabric with gel/foam in order to make said fabric resistant to passage of air therethrough, disposing the coated fabric over a mold adapted for vacuum forming the cooled fabric and positioning at least one strap member in the mold with a portion of the strap member extending beyond a boundary of the mold. Thereafter, a vacuum is applied between the mold and the fabric in order to stretch the fabric and cause intimate contact between the fabric and the mold. An additional volume of foam is deposited on the fabric coating while the vacuum is being applied in order to enable bonding between the additional volume of gel/foam, the coated fabric and strap member. The additional gel/foam is allowed to set and bond with the fabric and the strap member, and a fabric covered cushion is removed from the mold having the selected contour.

Abstract: The panel material of the present invention comprises (A) two sheets of FRP molded board as upper and lower surface materials, and, as a core material, (B) a high density, rigid polyurethane foam layer which has been obtained by injecting a rigid polyurethane foam starting material between these two sheets of FRP molded board and allowing this starting material to foam, and which has a closed cell structure and a density of 0.2.about.0.5 g/cm.sup.3. In addition, the manufacturing method of the panel material of the present invention includes a process for obtaining an integrally molded sandwich panel by injecting a rigid polyurethane foam starting material into a space between two sheets of FRP molded board which have been set in a mold, and allowing it to foam; and a process in which panel material is made by cutting this sandwich panel to a desired size.

Abstract: An improved method of forming a vehicle trim part includes the initial step of securing an insert to a vinyl skin in a vacuum mold. The cloth insert is attached to the outer face of the skin, and the two are then placed into a foam mold as a single preform. In this way, if the cloth is improperly connected to the skin, the part can be identified as scrap before foam is injected to complete the part. Once the preform is moved into the foam mold, foam is injected behind the part. Since the preform is positioned within the mold as a single part, the invention more accurately positions the insert and skin relative to the mold prior to foam injection. Again, this improves the quality and appearance of the vinyl part.

Abstract: A method of reinforcing or retrofitting building roof structures against hurricane-force winds which does not require removal of part or all of the roof. The improved method includes directing a thin stream of a liquid polymer foam adhesive under pressure upwardly along the intersections of the rafters or support members and the roof panels, preferably on both sides of the support members. The foam adhesive then creams and foams, forming polymer foam adhesive gussets which firmly adhere to the adjacent surfaces of the support members and roof panels. This method increases the pull-off strength of a roof about seven fold and is able to withstand hurricane-force winds.

Abstract: Fluoropolymer is advantageously foamed by first forming a composite structure of a layer of the fluoropolymer to be foamed and a layer of different material such as a different fluoropolymer not to be foamed, followed by heating the composite structure to the foamable state for the layer of fluoropolymer to be foamed, pressurizing the heated composite structure with supercritical carbon dioxide, rapidly depressurizing the heated composite structure, whereby the foamable layer foams and the other layer foams less or not at all, and cooling the foamed composite structure.

Abstract: The invention relates to foam structures with enhanced physical properties which can be used in the areas of packaging, athletics, water sports, and construction. In general, the structures are laminated polymer foams that include a core of a low density foam and one or more skins of relatively high density foam covering the core. The skins provide improved physical properties to the foam structures by improving the flexural strength, resistance to bending, and resulting damage from bending in the laminated foam structure while modestly increasing the weight of the laminated structure, for example. Uses of the foam structures include, but are not limited to, packaging materials, gym mats, body boards, or eaves fillers.

Abstract: Hydrophilic polyurethane gel foams are obtainable from a polyurethane gel defined in the description, from a water-absorbing material and from a non-aqueous foaming agent and can be used in medicine, in particular for the management of deep wounds and wound cavities. Wound dressings are obtainable with a polyurethane sheet as backing and a polyurethane gel foam composed of a polyurethane gel defined in the description, of a water-absorbing material and of a non-aqueous foaming agent.

Abstract: A method of integrally bonding a foam seat pad or other article to a cover material includes steps of positioning a two ply cover material in a set stand of a lower mold. The set stand positions a main surface portion of the cover material in a desired alignment while a retaining member is used for provisionally maintaining the alignment. Side mold portions are moved in position to firmly surround the set stand and and the retaining member is removed. Then, foam resin is introduced into the space defined by the set stand and side mold portions and an upper mold is used to sealingly cover the molding apparatus. After the upper mold is closed pressurization of the internal space of the molding apparatus is effected for a desired time during setting of the foam resin.

Abstract: An insulating container comprising a container body having at least one side wall and a bottom wall with the side wall including a base layer, an insulating layer on at least a portion of the base layer and a printed pattern, mineral oil application or combination thereof on at least a portion of the surface of the insulating layer is disclosed wherein a thickness of the insulating layer is controlled by the printed pattern and/or mineral oil on the selected portion of the insulating layer. Similarly, stock material incorporating the present invention includes a base layer, an insulating layer formed on at least a portion of the base layer and a printed pattern printed on and or mineral oil applied to the insulating layer is disclosed wherein the thickness of the insulating layer is again controlled by the printed pattern and/or mineral oil on the portion of the insulating layer.

Abstract: A process is described for producing polyurethane moldings by the reaction of compounds of molecular weight 400 to 10,000 which contain at least 2 hydrogen atoms capable of reacting with isocyanates, and optionally chain extenders of molecular weight 32 to 399, with polyisocyanates, optionally in the presence of foaming agents, auxiliary materials and additives, in which defined carbamates are used as activators. The polyurethanes obtained by this process are particularly low in emissions, i.e. are stable in relation to diffusion and exhibit low fogging, and are thus particularly suitable for the production of composite bodies comprising a polyurethane core and at least one further plastic material as an outer layer. Also described is the use of these moldings and composite bodies which are stable in relation to diffusion and which cause low fogging, e.g. as dashboards or door trims in the construction of vehicles, furniture, machines or apparatus.

Abstract: A conductive roll including a conductive shaft, a conductive rubber foam layer formed on an outer circumferential surface of the conductive shaft, and a semi-conductive solid rubber layer formed on an outer circumferential surface of the conductive rubber foam layer. The conductive roll is produced by forming a cylindrical laminar body which gives the conductive rubber foam layer and semi-conductive solid rubber layer, and simultaneously vulcanizing and foaming the laminar body in a mold in which the conductive shaft is placed in position.

Abstract: The present invention relates to a thermosetting decorative laminate (11), primarily intended as flooring laminate, comprising two or more layers (3, 4, 5), whereby at least one layer is a decorative layer (4) comprising a decor paper (9) provided with a bar pattern comprising a plurality of parallel rows of bars (14), whereby the bars (14) in adjoining rows preferably are mutually offset in the longitudinal direction. The bar pattern allows said laminate (11) to be divided into m longitudinal units or panels each consisting of p rows of bars (14), whereby said unit or panel comprises m.times.p rows of bars (14). The pattern of each left end bar (A1-A9) matches the pattern of corresponding right end bar (B1-B9) of each unit or panel and the pattern of these bars matches the pattern of corresponding end bars (A, B) in corresponding rows of all m units or panels.

Abstract: A method of forming fabric for making foam-in-place molded articles such as preferably seat cushions. A film is secured to a frame and tacked by adhesive to a piece of fabric, not secured to the frame, that forms the outer covering of the seat cushion for permitting the fabric to move relative to the film during forming to enable fabrics which cannot stretch a considerable amount to be used. To form the fabric, the film and fabric are placed in a female mold and the film and fabric are drawn into a cavity of the mold and against a contoured surface in the cavity forming a recess in the film and fabric. To counteract compressive stresses in the fabric during forming, the frame can have one or more fabric tensioners that selectively apply tension to the fabric during forming. To mold the cushion, a foam is poured into the recess and allowed to cure until it hardens into a foam core and bonds with the film.

Abstract: A process for preparing multi-level, selectively expanded, resinous sheeting comprising:(A) providing a composite comprising a backing material and adhered thereto a layer of a foamable resin which contains a blowing agent;(B) forming a partially printed composite by applying to a portion of the surface of the layer a composition containing an accelerator which functions to lower the temperature at which the blowing agent decomposes and by applying to some, but not all, of the other portions of the surface of the layer a composition containing an inhibitor which functions to decrease the activity of the blowing agent; and(C) forming the multi-level, selectively expanded, resinous sheeting by raising the temperature of the printed composite to a level such that the blowing agent decomposes and the resin fuses, the decomposition of the blowing agent evolving gas which causes expansion of the foamable resin in the portion where the surface is not printed and expansion of the foamable resin in the portion where t

Abstract: A method of making integrally a composite material comprises a first fiber cloth, which is impregnated with a foaming agent before being joined with a second fiber cloth. The combination of the first fiber cloth and the second fiber cloth is treated in a heating device in which the composite material is formed integrally of the first fiber cloth, the second fiber cloth and foam layers formed by the foaming agent of the first fiber cloth and some of the foaming agent that have permeated into the second fiber cloth from the first fiber cloth. The composite material is provided with an excellent air permeability and a heat insulating capability.

Abstract: A composite legal type bicycle frame is disclosed which contains a front frame portion and a rear frame portion. The front frame portion contains a central main and a plurality of legs for connecting the central main with various components of the bicycle, and the rear frame portion contains a rear fork, which consists of a left rear branch and a right rear branch. The left and right rear branches are first cured and glued together at respective abutting surfaces thereof to form an integral rear fork before they are adjoined with the front frame portion, via prepregs and using a cocuring procedure. The left and right rear branches are formed to contain cross-shaped matching protrusion and recess, respectively, on the abutting surfaces thereof, so as to enhance the integrity of the integral rear fork. As a result, a great flexibility of design options can be obtained. For example, the rear fork can be connected to one of the legs but not to the central main.

Abstract: An orientable in situ expandable layer comprisinga) a blend of incompatible, in situ-expandable thermoplastic particles and a thermosettable matrix resin for the in situ-expandable thermoplastic particles which blend has the capacity of expansion in height, width and length directions andb) other insoluble and matrix-resin incompatible solid particles uniformly incorporating throughout the resin matrix, which other insoluble and matrix-resin incompatible solid particles have (i) an aspect ratio of length/width greater than 1, that defines a longitudinal axis (length) of the particles which longitudinal axis is not greater than about one inch (2.54 cm.), and (ii) thermal stability at the temperature of expansion of the resin and insolubility in the resin, and (iii) an orientation in the thermosettable resin of their length in one or two directions.Moldable compositions and methods of making the compositions and molded article from the compositions are disclosed.

Abstract: The present invention relates to an arrangement for panels in vehicles, comprising an outer cover layer (1), an inner carrier (2) and an intermediate layer (3) of a highly heat-reflecting material. The heat-reflecting layer (3) extends continuously, on the one hand with a part in close connection to an area of the cover layer which at least during certain time periods is exposed to heat radiation and accordingly is given an increased temperature, and on the other hand with at least one additional part over an area which has a lower temperature. In this manner, the increased temperature is limited through reflection and through dissipation of heat from the area with the increased temperature.