Abstract: An article including a panel-like structure mountable in an automobile vehicle to form a part of the interior thereof and conceal a secondary restraint system, and a process for making the same are disclosed. According to this process, an outer layer is established on a first mold surface, with the exterior surface of the outer layer having an opaque visual appearance and a configuration complementary to the first mold surface. A casting composition is then rotationally casted onto an inner surface of the outer layer to create an inner layer of a predetermined thickness while restricting the gel thickness along an elongated structurally weakened tear seam. The casting composition is then fused. The outer layer and inner layer collectively define a layered composite structure, with the outer layer presenting the same opaque visual appearance to the exterior surface thereof unaffected by change in the inner layer thickness so that the structurally weakened tear seam is hidden from view.

Abstract: This invention relates to an improved method for the production of a pour-in-place composite article. These composite articles comprise an exterior covering and a flexible polyurethane foam core. This method comprises inserting a support armature into a pre-sewn exterior covering, positioning an exterior covering in a shaped mold, and applying pressurized gas to the outside surface of the exterior covering at the point directly opposite the position that the reaction mixture will be injected into the mold. The pressurized gas is either applied to the outside surface of the exterior covering either at some point prior to injection of the reaction mixture into the shaped mold, or the pressurized gas is applied simultaneously with the injection of the reaction mixture into the shaped mold. The application of pressurized gas is discontinued once the injection step is completed, allowing the reaction mixture to fully react and expand to conform the composite article to the shape of the mold.

Abstract: A lightweight shaft configured for use as a golf club shaft or a composite golf club equipped with such a shaft. The uniqueness of this shaft is that it is made of two distinct composite walls (tubes, one tube within another) with a greater density than, and separated by, an expansive middle layer of lesser density material which expands with the application of heat during the composite curing cycle. Additionally, the tip of the shaft (one to six inches in length from the tip, or longer, as required by design) is to be made of solid material (composite, metal or other material). The addition of this solid tip to the shaft as called for in this invention, provides for a stronger and solid tip that can be adjusted to fit into the hosel openings of any club head. This goes to provide a much stronger joining of the head to the shaft and adds to the clubs impact with the golf ball thus providing for greater travel distance of the ball.

Abstract: A method for forming products such as simulated leather including one or more layers from thermoplastic, thermosetting or elastomer materials all formed by slush-moulding, comprising: forming in a slush-moulding mould a first layer of compacted material representing the exposed layer of the finished product, on said first layer forming a second layer of expandable material by further slush-moulding, completing with heat the consolidation of said layers by gelling and expansion of said second layer, the free face of which has an irregular shape. To the layered material thus formed is coupled a support of rigid material without discontinuity points or regions between them by filling every possible interspace.

Abstract: A scouring pad fabrication method, which includes the step of coating a hydrophilic material on the top side wall of a first scouring pad been put in a mold, the step of pouring a sponge dope in the mold over the hydrophilic material and then placing a second scouring pad on the sponge dope, the step of heating the mold to let the hydrophilic material be dissolved in the sponge dope and foamed with the sponge dope into a sponge, the step of taking the foamed material thus obtained out of the mold and then splitting the foamed material into two equal halves each having a sponge layer and a scouring pad at one side of the sponge layer.

Abstract: The present invention is directed to a pre-inked thermoplastic foam which is utilized to form a relief image which includes open cells in the area that is designed to transfer ink and enclosed or sealed cells in the area which is designed to be impermeable to ink or other print medium. The present invention also includes the method of using and manufacturing the pre-inked foam.

Abstract: A novel tube material, and method of forming the tube, are described. The tube has an inner liner, preferably flexible, an intermediate layer of in situ molded expanding foam material, and a flexible outer liner. The tube is rigid, with the structural strength derived entirely from the intermediate layer. The preferred method of construction uses an inner core which is used to hold the inner liner in place during forming. The inner core includes a mechanism to reduce its diameter, to facilitate removal after curing of the foam.