Abstract: A method of producing a skin-covered foamed plastic article, which includes preparing a lower mold which has a cavity formed therein; putting a bag-shaped outer skin member into the cavity, the skin member having a porous inner layer; pouring a foamable material for the foamed plastic article into the bag-shaped outer skin member; and adjusting a pressure which is created in the cavity due to foaming of the foamable material.

Abstract: A mold for manufacturing a skin covered foamed plastic article incorporating a hole, with which it is possible to place the skin cover at a desired position despite of the presence of the hole, 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.

Abstract: Isotropic microporous polysulfone membranes can be prepared by using a particular combination of casting solution and precipitation solution formulations, and casting conditions. Both hollow fiber and flat membranes can be prepared in this manner. The membranes are skinless and are characterized by uniform porosity throughout the membrane.

Abstract: A mold for manufacturing a skin covered foamed plastic seat capable of effectively dealing with the variations in shape and position of the trim ends. The mold includes stopper means for fastening the trim ends attached to the edges of the skin cover, located between the upper mold and lower mold separately from a space into which a liquid foam resin is to be poured, each of the stopper means having a slit through which one trim end is inserted, and a top face portion to which both ends of the trim end are to be hooked.

Abstract: A process for preparing a polyurethane foamed article including a hard foam encapsulated by a soft foam is provided. The process provides improved encapsulation over that described in EP 68820 by frothing the hard foam formulation, with for example carbon dioxide, before it is introduced onto the rising soft foam formulation. The hard foam formulation is frothed so that is density is between 75% and 145% of the soft foam formulation.

Abstract: In manufacturing an insulating box used for a low-temperature show case having a slidable transparent windows on the top opening thereof, a recess is formed on the upper front ends of inner and outer boxes of an insulating box, said recess being provided with a frame covering the gaps between said inner and outer boxes and having a groove for receiving therein a multi-layer transparent panel. After the multi-layer transparent panel is installed in the groove and fixed with a fixation frame, an expandable insulating material is injected into the spaces between said inner and outer boxes to form said insulating box.

Abstract: A method of producing a skin-covered foamed plastic article, which includes preparing a lower mold which has a cavity formed therein; putting a bag-shaped outer skin member into the cavity, the skin member having a porous inner layer; pouring a foamable material for the foamed plastic article into the bag-shaped outer skin member; and controlling a pressure in the cavity in such a manner that the inner layer becomes saturated to a predetermined degree during curing of the material.

Abstract: A sealing gasket of foamed plastic is formed at the edge of a filter element of reticulated foam by placing the filter element on a surface adjacent to an open receptacle contoured as a mold for the desired shape of the gasket, filling the receptacle with a foam-forming liquid and avoiding contact between the liquid and the filter element until the liquid begins to froth. The liquid is then permitted to froth and overflow the receptacle on the side facing the filter element. As the froth contacts the filter element and proceeds to cure, it bonds to the edge of the elements without substantially penetrating its open pore network. The result upon curing is a gasket along the edge of a filter element fully bonded thereto without gaps or bypass, yet leaving substantially all of the surface area of the filter element exposed for use as a filter.

Abstract: A method of molding a skin-covered foamed plastic article, which employs an elastically deformable belt for assuring a positioning of a bag-shaped skin member in a mold during a molding process. The mold has in the cavity thereof at least one longitudinally curved elongate ridge for providing engagement with a stitched portion of the skin member. The belt is connected to an inner wall of the bag-shaped skin member, so that upon proper placement of the skin member in a mold, the belt is expanded thereby to press the stitched portion against the elongate ridge of the mold. With this, the skin member is tightly held in the mold during curing or foaming process of a liquid material in the mold.

Abstract: An elastic roller having a layer of foam silicone rubber formed around a roller core and having a skin layer coated with fine silicon resin powder. The elastic roller is fabricated by wrapping a masticated foaming silicone rubber stock containing a foam producing ingredient around a roller core in a foaming silicon rubber stock layer, coating the surface of the foaming silicone rubber stock layer with fine silicone resin powder, placing the roller core coated with the foaming silicone rubber stock layer in the cavity of a mold with its center axis in alignment with that of the cavity, and heating and foaming the foaming silicone rubber stock layer in the mold. The elastic roller is suitable for use on, for example, an electrophotographic apparatus, printers, facsimile terminal equipments and the like as a fixing pressure roller, photoconductive drum cleaning roller, a toner feed roller, a lubricating roller or a transfer roller.

Abstract: A method for integrally molding a preassembled door within an instrument panel to provide a cover for a safety air cushion device includes the steps of molding the plastic instrument panel about and over the door in situ of a mold cavity and thereafter the step of removing a portion of the instrument panel which overlies the door to provide an opening therein to expose the door for opening movement with respect to the instrument panel upon deployment of the air cushion device. The invention further includes the resultant structure of an integrally molded door and instrument panel assembly having an opening formed in the instrument panel assembly for both defining a ledge to support the door and to define a path for impacting an air cushion device against the door to cause the door to be lifted from its integrally molded seat relationship on the ledge for further deployment of the air cushion device into the passenger compartment of a vehicle.

Abstract: A method of making a particular type of arm rest for a chair, which arm rest is made from a foamed material. Embedded in the arm rest is a flexible tube for containing a control mechanism for the chair.

Abstract: A method for producing a simulated rock by spraying a high density polyurethane elastomer in a flexible rubber mold. The rubber may be natural rubber or synthetic rubber. A rock is produced in molded form, not limited in size. A flexible mold is prepared by applying numerous coats of liquid uncured rubber forming materials, such as latex rubber, upon the rock exterior in combination with a fabric embedded within the rubber latex layers. A supporting cradle for the rubber mold is produced by spraying a low density urethane foam composition over the mold. The mold and cradle are stripped from the rock and are sprayed with a two component structural urethane system employing an isocyanate component and a polyol component with appropriate catalysts, fillers and additives. The structural urethane elastomer is built up to substantial thickness to provide a strong rigid load bearing polyurethane molded rock simulating the original rock surface with curing taking place in a matter of seconds or minutes.

Abstract: A laminated article, for example a bath or shower-tray, is manufactured by providing a preformed shell, for example a thermoformed acrylic sheet, which shell is placed in a mould, together with, if required, a reinforcing board, for example of chipboard or plywood. The mould is then closed and materials are injected into the mould cavity which react to form a reinforcing layer on the shell. Preferably, the injected materials comprise a polyol reactant and an isocyanate reactant which form a layer of rigid polyurethane foam. A reinforcing agent, for example glass fibre, and a blowing agent may also be introduced into the mould cavity.

Abstract: A method of making a foam product including the steps of reacting an isocyanate component with a polyol component and foaming with a foaming agent to form a self-supporting intermediate foam material. The isocyanate component is present in excess of a stoichiometric quantity needed to react with the polyol component. The self-supporting intermediate foam material is then contacted with water and the self-supporting, intermediate foam material is heated to form a foam product, the water reacting with the remaining unreacted isocyanate component. The self-supporting, intermediate foam material formed by the first foaming step is rigid or semi-rigid at room temperature but it can be softened by heating to enable it to be used for deep draw molding in a successive cure molding process without cracking, splitting or being destroyed.

Abstract: A process for producing a urethane die. A heat-resistant epoxy adhesive is applied to the inner surface of a recess provided in the body of a die. A urethane primer is applied to the adhesive while the adhesive is still in a semi-hardened state. A punch is inserted into the recess to form a space between the recess and the punch and a urethane resin is injected into the space to form a resin layer on the recess having a shape corresponding to the outer surface of the punch. A reinforcing fibrous material may be incorporated into the resin layer by applying a urethane resin having a lubricant incorporated therein to the surface of the punch and adhering a fibrous material impregnated with the urethane resin to the coated surface of the punch prior to inserting the punch into the recess.

Abstract: A fastening tape (4) is attached to a molded item (2) such as a seat cushion with a face of gripping hooks (5) turned outwardly to hold a seat cover (3) having complementary fastening member thereon. The tape (4) is molded into the seat cushion (2) during the molding process. Since a liquid molding substance is used, the hooks (5) on the tape (4) are covered with a thin plastic film (17) which prevents the molding liquid from contaminating and clogging the hooks (5). In one embodiment, the film (17) has a relatively low disintegration temperature whereby the heat applied to the mold to cure the cushion (2) disintegrates the film (17) after the cushion has cured, leaving the exposed hooks (5) unclogged and ready for use. In another embodiment, film (17) has a relatively high disintegration temperature and is removed in a separate step subsequent to the molding process by additional heat, such as an open flame.

Abstract: A process for producing foam cushions having sections of different hardnesses using foam molding. The process broadly includes introducing a first reaction mixture into a mold, introducing a second reaction mixture into a mold, said second mixture already being in a creamed state, allowing the reaction mixtures to foam, and removing the resultant product from the mold. Prior to the introduction of the first mixture, a web with holes in it is clamped over a deepened section of the mold cavity. The first reaction mixture is then fed onto the web, with the first mixture being in a sufficiently liquid state so as to allow it to flow through the holes and into the space below the web. The second reaction mixture is then fed into the space remaining above and to the sides of the web. The second mixture is introduced at a time when itis sufficiently creamed up so that it cannot flow through the holes in the web.

Abstract: A process for producing paddings molded from polyurethane foam including several regions of different pliability, as well as the paddings thus produced.

Abstract: A method of molding a skin-covered foamed plastic article, which includes by steps putting a bag-shaped outer skin member into a cavity of a lower mold, the skin member including an outer layer and a porous inner layer lined on the outer layer; putting a first upper mold on said lower mold to close the cavity; fastening the lower and first upper molds together with a first fastening force; pouring a foamable plastic material into the bag-shaped outer skin member in the cavity and curing the same; removing the first upper mold from the lower mold after the material is hardened to a certain degree; putting a second upper mold on the lower mold to define a given space therebetween; fastening the lower and second upper molds together with a second fastening force which is greater than the first fastening force; and pouring the foamable plastic material into the given space and curing the same.

Abstract: A process and apparatus for marking an article made of foam material whenever during its manufacturing process some irregularity has occurred. As a consequence of having ascertained an irregularity in some operational parameter, after the introduction of the reactive mixture in the inner cavity of the lower shell of the mould and as long as the mould is still open, to a part of the inner cavity of the upper shell of the mould is applied a mark formed by a dyestuff resistant to the processing conditions, physically and chemically compatible with the formed article and capable of adhering thereto when, during its expansion, the article reaches to contact the marked part of the inner cavity of the upper shell of the mould. The marking operation can take place automatically by action of an equipment comprising an ejector arranged for spraying towards the internal cavity of the upper shell of the open mould the dyestuff intended to form the mark.

Abstract: Method for producing a gas separation membrane comprising a microporous support having provided thereon a non-porous coating layer. The method comprises melt extruding a thermoplastic crystalline polymer under particular melt-extrusion conditions to form a precursor in the form of a hollow fiber or flat film, coating the precursor as a support with a coating substance composed of a natural or synthetic substance capable of forming a polymeric layer which does not form pinholes upon subsequent drawing after solidification to form a coating layer on the surface of the support, and solidifying the coating layer. The support is annealed either before or after the cooling process, and this is followed by cold drawing and heat setting the support to form the gas separation membrane.

Abstract: A method of bonding rigid structural support members to a gypsum or fiberboard panel to form a structural building module. The method involves applying a polyurethane adhesive as a liquid by high pressure stream into a space formed at the junction of the support members and the panel. The space is established by providing a plurality of spaced feet on one planar side of the support members. The support members includes either integrally formed feet, which are placed on the panel, or non-integral feet that are inserted between the support members and the panels. The support members may include holes on the surface bonded to the panel in a face to face relationship or on vertical surfaces in close proximity to the panel through which foam may expand and form a mechanical interlock with the support members. The support members may be metal channels or wood members. The structural building module provides an increased strength bonded structure without the use of nails or other fasteners.

Abstract: A structural composite material is provided. The material comprises a thermoplastic layer, a layer of fibrous material spaced from the thermoplastic layer and a foam core disposed in the space between the layers. A resin impregnates and holds the layer of fibrous material together to form a fiber-reinforced resin structure. The foam core and the fiber-reinforced resin structure are integrally formed from a core material capable of having both a foamed character and a resinous character. A process for manufacturing the composite and a boat structure formed from the material are also provided.

Abstract: A method of producing an instrument panel of a motor vehicle or similar molding of forming resin which includes a section for fitting an electrical part. The electrical part fitting section is constituted by a coupler engageable with the electrical part and an opening which is contiguous with the interior of the coupler. The opening is surrounded in a liquid-tight configuration by a pressing member for sealing which is disposed on one of coactive parts of a metal mold. The coupler is removably mounted on the other metal mold part. When the metal mold parts are clamped, a peripheral edge portion of the coupler abuts against a portion of the pressing member which surrounds an opening of the pressing member. A flexible printed circuit to which the electrical part is electrically connectable is interposed between the coupler and the pressing member such that terminal portions of the circuit face the inside of the coupler.

Abstract: A method for making a composite foam part includes the steps of forming a retainer member, forming a foam member having an outer skin portion and an inner barrier film portion, and applying a contact curable adhesive system to the retainer member and barrier film portion of the foam member. The retainer member is clamped against the barrier film portion of the foam member capturing the adhesive therebetween.

Abstract: A continuous process for producing a microporous cellulosic membranes supported with an integral non-woven polymer web by preparing a casting lacquer comprising at least one cellulosic polymer, at least one solvent and at least one non-solvent wherein the casting lacquer is at the point of incipient gelation.

Abstract: A method for manufacturing products with bristles, composed of a bristle holder made of pourable or foamable material and plastic bristles anchored therein. The bristles are introduced through channels into a mold for the bristle holder, melted by heat at the end in the mold to form a thickening, and the thickening of each bristle is brought into a sealing fit with the opening of the channel guiding it, possibly leaving an undercut at the thickening, and the mold is then filled with bristle holder material. The bristles and bristle holders can be made from different materials by casting or foaming of the bristle holder, whereby the channels guiding the bristles are sealed off by the thickening so that the bristle holder material cannot escape to the outside and especially cannot have a disadvantageous effect on the bristle shoulder. In addition, a combined force and force-fitted anchoring of the bristles in the bristle holder is ensured.

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: An infrared burner with an extremely low pressure drop is described. The burner comprises a corrosion resistant mesh screen having a thick porous coating of ceramic fibers deposited thereon. In addition to a low pressure drop the burner has structural integrity and ability to generate radiant energy at a high rate. The burner is produced by admixing alumina and ceramic fibers with a clathrate-forming halocarbon material which is removed upon drying.

Abstract: An adapted separable fastener and method of making the same for attachment to foam objects such as seat cushions. A separable fastener member of the hook and loop-type is attached, in back-to-back relation, to a second member. The second member has upstanding elements such as loops or hooking elements which elements are ultimately surrounded and encapsulated by the foam during polymerization. The adapted fastener is thereby attached to the foam member. The elements are positioned in order to allow venting of the gaseous byproducts of polymerization. This promotes superior adhesion to the foam material and prevents delamination at the fastener-foam interface. A metal strip may be disposed within the adapted fastener so it may be magnetically held in the foam mold. A method and apparatus for adapting the fastener is also disclosed.

Abstract: In a process for producing a hollow body with a wall which partially comprises foamed thermoplastic material by an extrusion blow molding procedure, a preform which comprises at least first and second layers of which at least one comprises foamable plastics material is first extruded, the layer of foamable material is foamed, and then the preform is expanded in a blow molding mold by the application of an internal pressure. The hollow body may have a welded seam at a region of the hollow body at which an operation of squeezing off excess material has been carried out, the seam being in the form of an outwardly projecting flange web portion and the thickness thereof being such that the layer of foamable material is compressed at least to such an extent that it is not thicker than in the unfoamed condition.

Abstract: In a method of making an integrally foam-molded seat by disposing a trim cover in a molding cavity of a mold used for molding a polyurethane foam and having a seat surface pattern embossed on its inner wall of the molding cavity, injecting a polyurethane resin solution into the molding cavity of the mold and foaming the polyurethane resin to mold the polyurethane foam integrally combined with the trim cover, a material not adhesive to the polyurethane resin is applied onto an inner surface of at least a side part of the trim cover, so that at least the side part of the trim cover may not adhere to the corresponding portion of the molded polyurethane foam, and a defect such as a void present in the moded polyurethane foam can be easily repaired is such a void is found in the product.

Abstract: A method of manufacturing a portion of a seat. A cover member is shaped to a predetermined shape and placed in a foam molding tool into which is injected an expandable liquid foaming material to mold a foam pad which is integrally bonded to the cover member. In the manufacturing of seat backs, the cover member includes a tubular envelope cover positioned on a cantilever forming tool. Once the foam pad is molded, the cover member is turned inside out to enclose the foam pad with the cover member. The cover is then telescoped over a seat frame. Alternatively, the foam pad can be molded to a shaped fabric sheet, the envelope cover formed by sewing a second cover member to the fabric sheet. A seat cushion is made by shaping a cover member, placing the cover member in a foam molding tool which also holds the seat frame and injecting an expandable liquid foaming material into the mold to mold the foam cushion, bond the cushion to the cover and embed the seat frame in the foam.

Abstract: Thin film membranes of polyurea, polyureapolyurethane alloy, polyurea-polyurea/urethane alloy or polyurea/urethane are prepared by deposition of a thin film of suspension of the selected polymer on a thick permeable support layer by the technique of preparing a suspension of the selected polymer in a solvent which does not dissolve the thick permeable support layer and permitting the solvent to evaporate and/or permeate through the thick-permeable layer.

Abstract: A surface-reinforced lightweight article is described, which includes a honeycomb structure whose sidewalls are reinforced by an expanded foam. The article can be manufactured by laying a fibrous third layer, such as several layers of dry tissue paper backed by a layer of dry fiberglass cloth, on the walls of a mold, laying a second layer of multi-cell honeycomb-like material against the third layer, and laying a finely porous first layer such as tissue paper over the second layer. Foamable plastic is poured in the mold over the three layers and the mold is closed. As the plastic foams and expands, it forces the three layers into a tight sandwich and permeates the layers to reinforce them. Specifically, expanded foam in the cells of multi-cell honeycomb-type material braces the honeycomb sidewalls against collapse, to greatly increase the strength and rigidness of the article.

Abstract: A method of manufacturing a cosmetic puff for liquid foundation includes forming a latex film coating on one side of a crimp pattern plate by applying a latex film compound thereon. The latex film coated plates are set in a manufacturing framework. The foamed latex foam compound is injected into the manufacturing framework while adding a coagulant and an activator therein to hereby produce a gelled latex foam covered with latex films on both sides. The latex foam and the latex films are simultaneously vulcanized to thereby bond the latex films onto the latex foam. A manufacturing framework for a cosmetic puff is also disclosed.

Abstract: For the production of articles comprising at least one layer of leather or simulated leather material and one layer of a synthetic resin connected to the first-mentioned layer in a shape-mating fashion, a mold cavity is filled with at least one layer of leather or a simulated leather material which later is in contact with at least one of the mold walls, and thereafter a synthetic resin, in the fluid condition or in a condition wherein it is rendered fluid, is introduced into the mold cavity. Finally, the synthetic resin is allowed to penetrate at least partially into the layer of leather or simulated leather material for the purpose of attaining an at least shape-mating bond therewith, and the peripheral edges of the layer of leather or simulated leather material are allowed to be covered by the synthetic resin.

Abstract: A method for producing simulated rocks by spraying a high density polyurethane elastomer in a flexible mold. The method includes reproducing a rock in molded form, not limited in size. A flexible mold is prepared by applying numerous coats of latex rubber upon the rock exterior in combination with a fabric embedded within the rubber latex layers. A supporting cradle for the latex mold is produced by spraying a low density urethane foam composition over the latex mold. The mold and cradle are stripped from the rock and are sprayed with a two component structural urethane system employing an isocyanate component and a polyol component with appropriate catalysts fillers and additives. The structural urethane elastomer is built up to substantial thickness to provide a strong load bearing polyurethane molded rock simulating the original rock surface with curing taking place in a matter of seconds or minutes.

Abstract: A vehicle spoiler includes a first rigid body part having an external surface contour, a second resiliently deformable foam body part having an external surface contour complementary to the first surface contour, and means for integrally securing the first and second body parts together. Preferably, the deformable foam body part is molded in situ on the rigid body part. A finishing groove extending between adjacent edges of the first external surface contour and the second external surface contour prevents recognition of differences between the materials and processes used to form the first and second body parts and prevents inconsistent transition between the body parts. A method for forming the spoiler includes fabrication of injection molded body shell parts bonded together by a foam material to form a rigid first body section. The rigid body section is then positioned within a molding cavity while foam material is introduced into the cavity and against engagement surfaces on the rigid body part.

Abstract: A coated abrasive back up pad is disclosed that may be attached to different types of drive motor assemblies by a simple rearrangement of an adapter included in the back up pad. The back up pad may have passageways with offset portions in a foam layer of the pad positioned to communicate between openings in an abrasive disk attached to the back up pad and vacuum systems in various drive motor assemblies to which it may be attached. A novel method is disclosed for molding the back up pad to form such passageways which includes molding dies into the pad that can later be removed by compressing the foam layer so that the dies cut outlet openings through which they are then removed.

Abstract: A method of producing embossed decorative thermoplastic sheets by forming a laminate including a printable composition, having a relatively low viscosity and containing an effective amount of a blowing agent, between thermoplastic resin sheets. The printable composition is applied in a design pattern to a gelled thermoplastic resin on a support surface. A second layer of thermoplastic resin having a melt viscosity which differs from that of the first layer is applied to the printed first layer to form a composite structure. This structure is heated to decompose the blowing agent and effect foaming in selected portions of the resin layer having are established by the printed design pattern containing the blowing agent.

Abstract: A pour mold includes two parts one of which forms a mold cavity and the other of which forms the lid for the mold cavity; the lid includes a retractable pilot pin and vacuum cups for positioning a mold insert within the mold cavity automatically upon lid closure. The pilot pin loosely pilots the insert in the mold as it closes and as the vacuum cups pull the insert toward the lid during such closure. The vacuum cups hold the insert against the lid continuously during foam injection, foam reaction and cure and as the lid is separated from the mold cavity part so as to automatically remove the finished part from the mold when the lid is separated therefrom.

Abstract: A method of producing a bow holding handle by providing a first mold cavity in the same shape as said bow holding handle but in smaller size; placing required parts of said bow holding handle in corresponding positions of said first mold cavity; sealing said first mold cavity; injecting liquid foam plastic into said first mold cavity; activating said plastic foam to cause expansion thereof and form a core of said bow holding handle as the same shape of said first mold cavity; removing said core away from said first mold cavity; wrapping said core with a plurality of layers of fiber reinforced plastics; providing a second mold cavity shaped in the form of said bow holding handle; inserting said wrapped core into said second mold cavity; sealing said second mold cavity; heating said second mold to cure said layers of fiber reinforced plastic and to cause re-expansion of said core for generating pressure within said second mold cavity pressing said core against said layers of fiber reinforced plastic and thereby

Abstract: Seat material having a covering member integrally provided on a foamed material and a patterned portion of the covering member formed by recessing the covering member in a stripe pattern and a method for producing such seat material comprising the steps of preparing a foaming mould having a patterning protrusion for recessing the covering member in a stripe pattern and clamping the covering member onto the patterning protrusion by a clipping member which is buried by the foamed material.

Abstract: A mold assembly for producing a skin-covered foamed plastic article is disclosed, which includes a lower mold having a cavity formed therein, the lower mold having a first flange portion which extends around a mouth of the lower mold; an upper mold which is to be put on the lower mold to close the cavity, the upper mold having a second flange portion which is mated with the first flange portion of the lower mold when the two molds are properly coupled; a recess at an inside part of the first flange portion which is defined by a horizontal wall and a vertical wall; a press plate which is pivotally connected to the horizontal wall of the recess; a spring for biasing the press plate in a direction to achieve an abutment with the horizontal wall; and a press structure provided on the second flange portion of the upper mold, the press structure abutting on the press plate to press the same toward the horizontal wall when the upper mold is properly mounted on the lower mold.

Abstract: A mold assembly for producing a skin-covered foamed plastic article is disclosed, which includes a lower mold having a cavity formed therein, the lower mold having a first skirt portion which extends around a mouth of the lower mold; an upper mold which is to be put on the lower mold to close the cavity, the upper mold having a second skirt portion which is mated with the first skirt portion of the lower mold when these two molds are properly coupled; and a pair of holding plates which are detachably connected through fasteners to spaced portions of the lower mold, each holding plate including a first portion which is detachably connected to the first skirt portion and a second portion which extends over a given wall portion of the cavity of the lower mold, whereby when a bag-shaped outer skin member is properly set in the cavity, the holding plates press given portions of the outer skin member against the inner wall of the cavity.

Abstract: An improvement for a process wherein a strip of fastener material is formed into the surface of urethane foam or the like during molding in a mold. The fastener material includes a backing strip having an outer surface adapted to mate with the foam material during molding and a fastener strip having an outer surface comprising one-half of a fastening system such as hook and loop fastening material. The backing strip and the fastener strip are attached to one another with their respective inner surfaces in face-to-face relationship with their outer surfaces facing outward. The fastener material fits within a longitudinal groove in the mold and the backing material overlaps the groove.

Abstract: A method for forming a composite door to custom fit a predetermined door opening. A template is formed by spraying a quick hardening foam on a door jam of the door opening. The template is moved a base member of the tool and the base member adjusted to conform to the shape of the template. A mold is formed using the template and base member. Composite material placed inside the mold and on top of the base member forms a door to custom fit the door opening.

Abstract: A method for producing a foamed innerspring unit using a foamable reaction mixture that will provide a flexible foam using diphenylmethane diisocyanate and at least one polyol is provided. The process comprises the steps of preparing the foamable reaction mixture, spraying the foamable reaction mixture into a tray, loading an innerspring unit into the foamable reaction mixture containing tray and permitting the foamable reaction mixture to rise to form a foam that is at least partially adhered to the unit. The process is especially well suited to be carried out on a continuous conveyor. A novel foamed innerspring unit is also provided.