Abstract: A self-deploying structural element formed of a core or temperature sensitive expanding foam, a load carrying component of advanced composite material, and an outer retaining jacket. A heat generating means such as resistance heating wires is included to initiate deployment of the structure. The heating of the structure causes the foam core to expand, unrolling or unfolding the structure. The heat also cures the advanced composite material to a rigid form. The retaining jacket is preferably a heat shrink jacket which contracts around the composite material.

Abstract: A mold for molding a skin covered foamed plastic article capable of dealing with those foamed plastic articles having large curving portions without complicating the manufacturing process relating to the attachment of the skin member on the mold, without a leakage of liquid formed plastic to be poured over the mold. The mold includes a lower mold, over which a skin cover is to be placed, and on which liquid foamed plastic is to be poured onto the skin cover, the lower mold having; a fixed part on top of which the upper mold is to be placed; a movable part which makes contact with the fixed part at a lowered position at which there is a closed space between the fixed part and the movable part; and means for controlling air pressure inside the closed space between the fixed part and the movable part. A method of manufacturing a skin covered foamed plastic article using this mold is also disclosed.

Abstract: A process and resulting structure providing a utility vault with a foam-filled tube sealing the space between the vault walls and the vault cover. Preferably the tube includes an inner tube that is sufficiently porous to permit gas to flow therethrough but only a small amount of uncured foam to flow therethrough, and a plastic outer tube that prevents the foam from bonding to the vault structure.

Abstract: A method for manufacturing a foam product in which a skin material and a core material having at least one opening are set on upper molding die and lower molding die, respectively, and a foaming resin material is then poured between the skin material and the core material to integrally mold them. A recess is formed on the portion of the upper molding die that corresponds to the opening of the core material. The opening of the core material is covered by an air permeable seal member adhered to the core material. The foaming resin material is then poured in a cavity defined between the molding dies.

Abstract: A seat back or seat bottom cushion incorporates one or more inflatable/deflatable air chamber bladders. The cushions are integrally formed with the bladders by suspending the bladders in a clam shell type mold and then injecting chemicals in the mold to form a urethane foam or the like. The cushion resulting from the molds may include the outer upholstery covering as part of the molded assembly. Each bladder molded into the cushion has a port that permits passage of air into or out of the bladder.

Abstract: A mold for manufacturing a skin covered foamed plastic article, with which it is possible to place the skin cover at a desired position, without spoiling or damaging the skin cover, such that the skin covered foamed plastic article of a desired shape without any deficiencies such as wrinkles and dents can easily be manufactured. The mold includes an upper mold; and a lower mold, to be assembled with the upper mold in order to form a cavity in which a liquid foam resin undergoes foaming process to become the pad member, over which a skin cover is to be placed, the lower mold including at least one windows at which the skin cover can be pushed outward by pressure of the liquid foam resin.

Abstract: Sailboards having a tucked rail are made from a flexible, resilient mold so that the seam of the board is along its bottom edge instead of at its point of greatest breadth. A flexible mold part having the contour of the sailboard to be produced has an opening smaller than the greatest breadth of the board. The mold is first flexed so that its opening is sufficiently wide to receive the blank that forms the body of the sailboard. Secondly, the blank is inserted into the flexed mold, and thirdly, the mold is released and its resiliency returns it to its original shape. A conventional rigid mold part closes the open end, and a vacuum is applied to form the final product. The flexible mold part is flexed a second time to remove the product.

Abstract: A water heater including a water tank having a jacket surrounding the tank and providing an insulation space therebetween. A plurality of serial foam injections are introduced into the space to fill the space between the tank and the jacket.

Abstract: An improved process for producing a laminated resin foam composed of two resin foam layers of different characteristic properties wherein the layers are integrally bonded together. A first foamable resin liquid for forming flexible foam is poured into a first space in a foam processing mold on one side of a barrier projecting from the wall of the mold and pouring a second foamable resin liquid for forming a foam less flexible than the first flexible foam into a second space in said foam processing mold on the other side of said barrier. The two foamable resin liquids foam beyond the barrier into contact with each other to form the two laminated foam layers. One improvement in the process includes wetting a substantial portion of the mold cavity with the first foamable resin liquid. Various shapes of molds and barriers will produce different shapes and characteristics of the resultant foam pad, such as for a car seat.

Abstract: Moldless process for manufacturing foamed articles is disclosed wherein a trim cover is first prepared as having a composite structure of an outer facing material such as fabric and an inner backing material of low melting point such as a thin foam of polystyrene and having a shape substantially corresponding to a final contour of the finished article; the trim cover is heated and forced to form a pre-shaped cover conforming to the final contour of the finished article preferably by means of a restraining frame such as basket or plastic cage configured to the final contour of the finished article; highly reactive polyurethane composition foamable at low internal pressure is poured inside the pre-shaped cover and allowed to foam and expand to fill substantially an entire volume within the pre-shaped cover; and then the pre-shaped cover is externally heated to around the melting temperature of the backing material so as to significantly shrink and virtually dissipate the backing material interposed between the

Abstract: A customized spinal orthotic device is provided to enhance spinal adjustment and manipulative procedures. The embodiment of the orthotic device shown and described is a plastic head and cervical basin which is enclosed in a plastic bag. The patient is placed in a supine position with the head and cervical spine portion received within the plastic basin but exterior of the bag. Commercial flexible polyurethane foam A and B components are mixed and placed in the bag-enclosed basin. The A and B components react exothermically to expand and to apply pressure to the cervical spine portion contained within the basin. In about fifteen minutes the polyurethane hardens to form a foam mold for the posterior apophyseal joints of the cervical spine and in the process urges the joints of the spine into their normally aligned positions. The mold may then be used by the patient on a daily basis within the purview of a clinical care program to enhance the effect of the spinal adjustment and/or manipulative procedure.

Abstract: Seamless hollow-bodied objects of expanded polystyrene are made by a method in which polystyrene material in bead form is agglomerated about a solid removable core in a split mold. The mold halves are opened and the solid core is removed, leaving at least two preliminary sections in contact with the mold halves. The mold is reclosed, and an inflatable core is inserted and inflated to desired dimensions. The inflatable core is supplied with steam for its inflation and the polystyrene heating is completed. After deflation and removal of the inflatable core and opening of the mold halves, there is obtained a desired seamless hollow article having smooth surfaces inside and out.

Abstract: A method and a foamed resin molding in which a skin layer is formed by pressing an expansible film against and into conformity with cavity walls of a mold or a bag-like cover member by foaming pressure of a foamable resin and a foamed resin body molded concurrently and integrally under the skin layer, which facilitate the easy parting of the moldings from the mold without parting agent.

Abstract: Foamed products are prepared by subjecting a crosslinked polymer such as an ethylene-carbon monoxide copolymer susceptible to heating by high frequency electromagnetic radiation such as microwave or radio frequency which has been imbibed or impregnated with a suitable mechanical or physical blowing agent such as a halogenated hydrocarbon to sufficient high frequency electromagnetic radiation to cause foaming of the polymer.

Abstract: A flow molding process and associated molding apparatus for making plastic parts employing a radio-frequency heating field. In a two-piece mold, a diaphragm is supported thereacross and over a foam plastic compound that is disposed in the bottom half of the mold. A fluid is adapted to be introduced into the mold against the diaphragm. The introduction of this fluid is controlled to initially inject the fluid into the mold to cause deflection of the diaphragm to thus expel substantially all air from the mold and to thereafter extract the fluid from the mold during the heating cycle as the material expands, the extraction causing a vacuum that assists in the plastic foam compound expansion.

Abstract: A body comprising a dimensionally stable film container filled to the dimensions defined by the film with polyurethane foam, the polyurethane foam being foamed in situ in the film container thereby forming an adhesive bond with the film.

Abstract: The invention provides a method and apparatus for the high pressure injection of polyurethane foam into a hollow envelope using means of the type including a chamber for mixing the constituents of the polyurethane foam, a cylinder communicating with said chamber and open at both its ends, one of its ends opening into the orifice of the hollow envelope and the other end serving as inlet for a piston adapted for sliding in said cylinder and driving the polyurethane foam therefrom into said envelope, wherein said envelope is substantially vertical, its upper end opens into the orifice of the hollow envelope and is of a volume close to half that defined by the envelope and the movement of the piston in said cylinder is adjustable in synchronism with the cycle of the mixing head.

Abstract: An orthotic support system is embodied as cooperating seat and back cushion elements for assembly into a wheelchair frame. These cushion elements are custom-fitted to the individual patient by injecting an incipiently reacting and foaming, fluorocarbon-blown polyurethane chemical system into the space between a rigid mold box and an elastic membrane which is fitted over the open face of the mold box and which is deformably engaged by the appropriate portions of the patient's torso. The foaming mixture is injected in predetermined excess volume and expands against the physical resistance of the patient's body where contact is made with the corresponding regions of the elastic membrane; and this forcible engagement produces selective densification of the foam where a high degree of body support is required. Elsewhere, the foam expands more freely and stretchably inflates the membrane to generate graduatedly less dense regions matably contoured to fit or partially embrace the patient.

Abstract: A space structure which is formed in space. The structure is comprised of an expandable, flexible, generally non-elastic, impervious mold which is arranged in a collapsed state in a container which separates in space to expose the mold to the space environment. The mold is formed to a predetermined configuration by the injection of chemically hardenable filler materials. The vacuum properties of space permit very low injection perssues for the injection process, and the non-gravitational properties of space permit the mold to remain substantially sag-free during hardening of the filler materials.

Abstract: Methods of manufacturing a modular, monolithic, integrated, multi-layered, mold building structure including the steps of constructing a dismantleable mold having an outer rigid matrix and an inner inflatable plug, wherein the inside dimensions of the matrix correspond to the outside dimensions of the structure and the outside dimensions of the plug correspond to the inside dimensions of the structure, placing high strength fibers between the plug and the matrix, injecting hardenable material between the matrix and the plug, curing the hardenable material into a hard shell, removing the matrix, deflating the plug, and installing walls, doors or windows. The structures may be joined together on-site in various combinations and configurations to create different types and styles of buildings.

Abstract: An implement handle is made for use by a crippled person, utilizing a cap adapted to receive an end of the implement and an initially flexible bag attached to the cap. Material in the plastic state is inserted into the bag, the material becoming rigid with the passage of time, and the bag is placed into the hand of the crippled person while the material is becoming rigid. The crippled person maintain a substantially constant grip on the bag during this process, whereupon the rigidified handle conforms itself to his particular grip.

Abstract: The present invention is directed to a process for the production of matte, non-blocking, thin-walled molded articles, films or tubes from polyurethane elastomers prepared from high molecular weight polyols which contain dispersed polyadducts based on polyisocyanate polyaddition products. The use of these high molecular weight polyols contained dispersed polyadducts allows for the preparation of thin-walled, molded articles which have reduced surface tackiness. The present invention is additionally directed to the molded articles produced by this process and to their use for forming polyurethane foam composites.

Abstract: A method of manufacturing a foam insulated water heater of the type having an inner tank, a layer of insulating foam material surrounding the inner tank and an outer protective shell includes, in one embodiment, the steps of (1) forming a flexible, expandable bag in a configuration which may be placed between the tank and shell, (2) attaching the flexible bag between the tank and shell, (3) filling the bag with a foam material which expands, and (4) continuing to fill the bag so that foam material expands through relief openings in the bag to fill the remainder of the space between the tank and the shell.

Abstract: The base (11) of a template forming device (10) has a planar, upper surface (12) onto which a plurality of orthogonal grooves (14 and 15) are recessed. A foam mixture is introduced into a container means (20) received on the base (11), and a plurality of restraining means in the form of slats (18) are insertably received within selected grooves (14 and 15) to confine the foaming action within the container means (20) and to direct it against a selected portion of the anatomy so that when the foam is fully risen and cured a template (40) is provided which can be repeatedly used accurately to reposition and support that portion of the patient's anatomy.

Abstract: Apparatus and methods for filling foamable insulating material into a cavity or cavities within the interior of a hollow building panel, by first positioning the panel within a chamber in a press, inflating a flexible bladder within the press at the outside of the panel, filling the foamable insulating material into the cavity or cavities in the panel, and restraining at least one wall of the panel by the force of said bladder against deflection by the foamable insulating material.

Abstract: A thin walled, light-weight, relatively flexible, molded plastic package has first and second re-entrant recesses respectively at opposite sides of the package, the package stiffened against crushing. The package includes:(a) the first re-entrant recess at one side of the package containing sufficient of a predetermined quantity of an expanded synthetic resin as to substantially fill said recess, and(b) the expanded resin cured to form a hardened re-inforcing core in said first re-entrant recess and integrally with the package to stiffen same against crushing, whereby an article or articles placed in the second re-entrant recess at the opposite side of the package are protected against crushing.

Abstract: A system for forming structures, such as buildings, including the forming of a foundation slab, attaching flexible wall panels to the periphery of the foundation in a serial overlap configuration, installing prefabricated windows and doors, draping and attaching a membrane over the top of the wall panels, inflating the membrane upwardly to form a surface upon which to spray a foam substance, and spraying the foam to either the interior or exterior surfaces of the structure, including the roof membrane, so that an economical and energy efficient building can be provided at a low cost.

Abstract: A method of manufacturing rigid frame building elements filled with hard foam plastic, said method comprising the use of prefabricated, rigid, dimensionally stable, hollow skeleton frames, the hollow interior spaces of said skeleton frames are foamed and filled with closed cell hard foam plastic serving as heat insulation, and the elements are subjected in a press to compression pressure which overrules the foaming pressured exerted on the frame of an element from inside. For continuous-action manufacture, the used press is a (known as such on the basis of size presses) continuous-action press machine whose lower frame is equipped with lower conveyor means (4) and upper frame with upper conveyor means (5), said conveyor means confining between themselves a conveying gap, in which the passing elements are maintained subjected to compression pressure by means of pressure members (7) carried by said conveyor means.

Abstract: A method for insulating a water heater with foamed insulation comprises inflating a tube in the cavity between the shell and the tank to define a boundary for the cavity into which the insulating material is injected. The device is deflated after the foamed insulation has set in the cavity. Apparatus for carrying out such method is provided.

Abstract: A water heater including a tank, a cylindrical jacket, surrounding the tank to provide an insulating space therebetween and a cover member mounted on top of the jacket to close off the top of the insulating space. An insulating wall is provided in the insulating space between the tank and the jacket. The insulating wall is comprised of a plastic envelope member and a wall of insulating material which has been foamed-in-place inside the envelope member.

Abstract: The invention describes a method of constructing a building involving the assembly of a rigid skeletal framework of struts defining the contours of the desired building which is for example domed, or part-barrel shaped. A membrane or envelope of plastics material is inflated within the framework to lift the struts from a state of compression under their own weight into a state of tension. The membrane is then coated on at least one side with settable material such as concrete or other glass fibre reinforced material and the membrane deflated when the material has set. In an example of the invention, support zones at the junctions of the struts support the set material.

Abstract: A smooth, plastic-lined corrugated pipe having an intermediate layer of plastic foam. The pipe is made by internally coating a corrugated pipe with a foaming mixture and pressing an expandable cylinder of plastic sheet liner against the foaming mixture until the foam solidifies. An expandable mandrel apparatus presses the plastic sheet liner into position.

Abstract: A hole, particularly an accidental perforation, is closed by manoeuvering a bladder (g) into the hole employing a hollow rod (f) on which the bladder is mounted at one end. An operator operating from the other end of the rod actuates a device such as a triggered valve to cause the components of a settable foamed plastics material to pass (via tubes b and rod f) from their sources (in a) to fill the bladder (g) so that it closes the hole. The settable foamed plastics material is preferably polyurethane foam. The bladder may be of natural or synthetic rubber and may be protected against tearing by a textile envelope. The sources of foamed plastics material may be either in a portable kit (a) or rupturable containers within the bladder (g) or rod (f).

Abstract: A method of producing lightweight building blocks, in which an expandable or foamable ceramic material is charged into a mold, compacted and then fired with subsequent cooling.

Abstract: A tire press bag well is insulated with at least one envelope. The envelope extends substantially around the bag well within the bag well housing and can be inflated. The envelope, in addition to its insulating properties, can have insulation thereon and the ends of the envelope can be fastened to itself. The configuration of the envelope, once installed, desirably conforms to the shape of the bag well housing. Since heat is applied to a tire press via the bag well, insulation thereof considerably reduces heat loss as well as reduces cure time.

Abstract: A system for plugging holes in vessels which comprises the combination of a storage and delivery system for a foam-forming material, and a hole-plugging assembly. The hole-plugging assembly includes a flexible nonelastic bag member which is inserted in a folded position into the hole to be plugged and properly positioned with an associated locating means. Thereafter, a unitary foamable material is injected into the bag member to expand it and seal the hole. The locating means further assists in maintaining the inflated bag member in proper orientation and sealing engagement while the foam is curing.

Abstract: A building structure and method of making the same are disclosed wherein an inflatable form is inflated and an insulation layer of urethane foam is applied to the undersurface of the form. Hanger members are secured to the foam layer by adhesively affixing planar base portions of the hangers to the foam layer whereafter additional foam is applied to embed the hanger bases. Reinforcing mesh is secured to and supported by the hangers followed by the application of one or more layers of a cementitious material which is allowed to cure. Air pressure beneath the form is progressively increased to maintain a substantially constant uplift force on the foam. The inflatable form may be removed after curing and a protective coating applied to the outer exposed surface of urethane foam to protect it from ultraviolet degradation.

Abstract: A solar water tank for use in solar heating systems includes an insulated tank with flow systems comprised of a plurality of inlet and outlet tubes, heat exchangers, level switch and supplemental heating element, all assembled together with the manway cover for the tank in a unitary embodiment. The tank also includes a layer of polyurethane foam insulation on its interior surface. Forming apparatus for placing the insulation layer in the tank includes a flexible synthetic membrane in the form of an enclosed bag adapted for positioning in the interior of the tank.

Abstract: A method for the fabrication of high density smooth walled composite members laminated of resin impregnated fibers, and characterized by hydraulic pressure applied by a smooth surfaced core member comprised of noninterconnected cells subjected to heat and expanded thereby in opposition to a complementary mold with a lay-up therebetween simultaneously cured to establish a wall or skin of the product part formed thereby.

Abstract: A process and arrangement for introducing a material such as a foam into automobile body cavities for at least one of noise insulation or increased rigidity. The cavities may be provided with open spaces or be adapted to only be partially filled with the foam. A bag is initially introduced into the cavity with the bag being provided with a filler opening. The volume capacity of the bag corresponds approximately to the volume of the automobile body cavity or a portion of the body cavity which is to be filled with the foam. A mixture of expandable components is introduced into the bag and, following an expansion reaction or a setting, the foam fully fills the bag.

Abstract: A method for connecting a lateral sewer line to a main sewer line which is relined with a plastic pipe liner, comprises plugging a lateral sewer line upstream of the main sewer line to seal off the lateral sewer line, spraying a grout material downstream of the location of the plug until the space between the main sewer line and the plastic pipe liner is filled, allowing the group material to set, removing the plug from the lateral sewer line and providing an opening through the grout material and the plastic pipe liner so that the lateral sewer line is connected to and in communication with the plastic pipe liner. An apparatus which is used to plug the lateral sewer line and dispense the grout material comprises a spray gun positioned within a tubular inflatable bladder where the nozzle for the spray gun is in front of the bladder. The apparatus also includes means for conveying compressed air to and for conveying compressed air from the inflatable bladder.

Abstract: A building structure and method of making the same are disclosed wherein an inflatable form is inflated and an insulation layer of urethane form is applied to the undersurface of the foam. Hanger members are secured to the foam layer by adhesively affixing planar base portions of the hangers to the foam layer whereafter additional foam is applied to embed the hanger bases. Reinforcing mesh is secured to and supported by the hangers followed by the application of one or more layers of a cementitious material which is allowed to cure. Air pressure beneath the form is progressively increased to maintain a substantially constant uplift force on the foam. The inflatable form may be removed after curing and a protective coating applied to the outer exposed surface of urethane foam to protect it from ultraviolet degradation.

Abstract: A commodity to be packaged in a carton, box or another type of container is foamed in place while being held by distancing elements which extend into the interior of the container. The distancing elements are retracted upon completion of the foaming step, either through the open top or through openings in the top, bottom and/or side walls of the container.

Abstract: Housing construction by assemblying together extruded wall boards of a width equal to the desired wall height and cut to the appropriate length for each wall. The ceiling structure is then assembled to form a box-like assembly and the doors, windows, etc. are then cut out. The wall panel comprises plastic foam between gypsum boards and is formed with suitable conduits for electrical wire, etc.

Abstract: A plastic foam rigid swimming pool cover is fabricated by forming an amorphous plastic foam material into a shape conforming generally to the periphery of the pool and into a shape for covering the swimming pool. The cover is also shaped for lifting as an integral unit from a covering position to an uncovered position above the pool via the intermediary of a plurality of lifts such as electric or hydraulic jacks coupled to the pool cover at a plurality of points spaced around the periphery thereof. The amorphous plastic foam material is formed to the desired shape by either casting or spraying the material into or onto a form of proper shape. In some embodiments, the reinforcing members are embedded in the foam to provide added strength and rigidity. The foam cover may include soil and plant receptacles for landscaping. The cover may be formed in situ or at a remote location to a template and segmented for transport to the pool and reassembled in situ.

Abstract: Typically, injection molded expandable thermoplastics exhibit imperfect surfaces in the form of mottled areas, visible flow lines, and pin holes; these imperfections are caused by the quick chilling of the surface of the expanded thermoplastic as it contacts the mold surface. This invention is a method of injection molding expanded thermoplastics free of these defects by injecting a short-shot of the expandable thermoplastic into an elastic membrane positioned within a cooled mold cavity, containing the short-shot within the membrane until a skin forms on the thermoplastic in contact with the membrane, and then permitting expansion of the thermoplastic in the cavity to form a smooth skin or surface on a substantial portion of the article.

Abstract: A method for making a panel of plastic foam includes first coating a flexible ribbon on one side with foam and immediately thereafter while the foam is soft and flowable, laying the ribbon on a form with the foam coated side against the form. Length after length of the foam coated ribbon is laid on the form side by side in courses sufficiently close in order that the foam coating flow and cohere together on the form and thereafter the foam cures providing a panel of foam having the shape of the form.