Abstract: A method of making a facing panel including on its visible side a portion of moquette, a portion of fabric, a portion consisting of a layer of compact polyurethane of a first color and a portion consisting of compact polyurethane of a second color, these portions being fastened to a wall or backing and the whole being made by positioning at first fragments of moquette and fabric on a die, then projecting layers of compact polyurethane and applying a lining backing.

Abstract: A composite plastic product is formed by a process which includes formation of a preform of high strength plastic having openings formed therethrough which are covered by a film barrier that is formed during molding of the preform; and wherein the preform is configured to be placed as a unit in a foam station at which material is foamed onto the insert without escape to its backside.

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 procoess by additional heat, such as an open flame.

Abstract: The present invention relates to a method of producing micropores having diameters of less than 20 nanometers in straight sides in silicon film. The silicon film produced by this process may be attached to a substrate material and used as a filter in molecular separation processes.

Abstract: A dip molding process for making an integral article having a solid inner surface and a foamed outer cover in which a hot mold is dipped into a solid plastisol which is partially fused before being dipped into a foamable plastisol which is then formed, fused and bonded to the solid plastisol to form an integral article.

Abstract: A composite plastic molding made up of a plastic foam and having a polyurethane skin is made by heating a reactive one-component system to form a polyurethane skin and then joining the polyurethane skin to the plastic foam. The one-component system is composed of a finely divided polyisocyanate in which from 0.1 to 25 equivalent percent of the isocyanate groups have been deactivated, a polyamine and/or polyol having a molecular weight of from 400 to 8000 and optionally a chain extending agent, a catalyst and known auxiliaries and additives.

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: To prevent the staining of a nitrocellulose coated shoe upper by a polyurethane shoe sole prepared from a mixture comprising a polyisocyanate, a polyol, a chain extender, a tertiary amine catalyst, a surfactant and water, an effective amount of a reactive organic halogen compound, preferably a halogenated fire retardant, is added.

Abstract: A method of molding a skin-covered foamed plastic article, which includes putting a skin member on a shaping device in a manner to cover the same thereby to prepare a first temporary unit, attaching shaping dies to the first temporary unit in a manner to cover the same thereby to prepare a second temporary unit, removing the shaping device from the second temporary unit thereby to prepare a third temporary unit, placing the third temporary unit in a mold in such a manner that a mouth portion of the third temporary unit is directed upward, pouring a liquid material of foamed plastics into the third temporary unit through the mouth portion, placing a lid member on the mold in a manner to close the mouth portion, and removing, upon sufficient curing of the material, the lid member from the mold and taking out the third temporary unit from the mold together with the cured material.

Abstract: A method of making optrodes is provided by which a pressure-sensitive volume is incorporated in the optrode by bubble transfer and/or gas entrapment in the manufacturing step sequence.

Abstract: The invention relates to a method for producing shaped articles comprising a thermoplastics show surface and a backing layer of a rigid polyurethane or polyisocyanurate foam by applying a foamable polyurethane or polyisocyanurate composition which is substantially free from appreciable amounts of halocarbon blowing agents, in a closed mould to one face of a shaped thermoplastic sheet provided to one of the matching parts constituting said mould.

Abstract: A building construction element such as insulative siding is disclosed having an outer skin with an inner surface on which a plurality of individual, spaced-apart, arcuate-shaped projections are cut or gouged from the inner surface by a cutting tool means. A low density polymetric foam material is disposed over the inner surface so as to completely surround each arcuate projection to thereby securely lock the skin to the foam material after it sets.

Abstract: A method for making a foamed article having a laminated structure comprises providing a mold having a cavity therein and a rib vertically mounted from a bottom of the cavity and having a predetermined height to establish at least two blocks on the bottom, and pouring a foamable liquid compositions into the respective blocks in amounts which permit one of the foamable liquid composition to cover the other foamable liquid composition upon foaming whereby the resulting foam has a laminated structure whose boundary between the foamed layers made of the respective foamable liquid compositions is smooth and agreeable to the touch.

Abstract: A concrete tile is disclosed having a preformed substrate member backing comprising a substantially rigid, polymeric material. The lower surface of the substrate member defines the shape of the lower surface of the tile. A concrete layer is disposed on and secured to the upper surface of the substrate member and defines the shape of the upper surface of the tile. In manufacturing the tile, a plurality of through openings in the substrate member are filled with the concrete when the concrete is applied to the substrate member. The concrete is cured on the substrate member and the hardened concrete in the openings of the substrate member forms studs securing the substrate member and concrete layer together. The use of a polymeric substrate member backing provides a tile which uses less concrete and is therefore substantially lighter in weight than other tiles of corresponding strength. The method of manufacturing the tiles utilizes the substrate member as a support for the concrete applied to its upper surface.

Abstract: A structural building module and 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 juncture 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 include 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.

Abstract: A fiber matrix burner and method of manufacture in which a shaped burner element is formed by accreting a slurry onto a foraminous support. The slurry is comprised of ceramic fibers, a binding agent, a vaporizable filler, and a powdered, normally non-flammable aluminum alloy having a melting point between 660.degree. C. and 1,000.degree. C. After the drying and firing, a porous matrix of the fibers is formed which flamelessly combusts a fuel-air mixture. During combustion, the aluminum alloy inhibits growth of alumina crystals on the fiber surface to prolong burner life and, in addition, protects the burner both from extreme temperature and flashback.

Abstract: A composite plastic product is formed by a process which includes formation of a preform of high strength plastic having openings formed therethrough which are covered by a film barrier that is formed during molding of the preform; and wherein the preform is configured to be placed as a unit in a foam station at which material is foamed onto the insert without escape to its backside.

Abstract: A composite foam seat cushion is comprised of foams of different firmnesses which are bonded to adjacent foams without adhesives or glues. The cushion has a supportive bottom of one or more firm foams, a layer of soft foam on the top of and supported by the bottom layer, a protective front foam cap for the front edge of the layer of soft foam, a protective back foam cap for the back edge of the layer of soft foam and side walls of foam(s) of suitable firmness to provide support. A method of preparing the composite foam seat cushion is disclosed.

Abstract: In a method for making a molded polyurethane article having a nonwoven material secured to the article's surface which comprises placing the nonwoven material on the internal surface of a mold, adding and foaming a polyurethane composition in the mold and recovering the molded polyurethane article with the nonwoven material attached to the surface of the article, the improvement which comprises coating the nonwoven material with a composition consisting essentially of a fully hydrolyzed polyvinyl alcohol, an organic polyisocyanate and a catalyst for the urethane reaction, and curing the coating on the nonwoven material prior to adding and foaming the polyurethane composition in the mold.

Abstract: A method for casting in situ an insole on a foot comprising the steps of preparing a mold defining an open top recess, providing a casting material in the recess, placing the foot inside the recess at a predetermined angle and position relative to the mold, engaging the casting material by the plantar surface of the foot, permitting the casting material to conform to the shape of the plantar surface of the foot, and permitting the casting material to harden.

Abstract: A flexible polyurethane foam article with regions of different hardness is made by introducing into a mould a foam formulation giving a foam of a given hardness and then introducing a foam formulation giving a foam of different hardness directly onto the first foam formulation at a time corresponding to a volume expansion in the range 100% to 2300%.

Abstract: A polyurethane RIM method has two mixheads. Reactants are brought to each mixhead and are supplied as separate streams to two spaced cavities in a mold having a pre-formed porous mat separating the two cavities. One stream contains an isocyanate, polyol, chain extender and crosslinker selected to have a very low viscosity and which reacts to produce a high modulus armature or load bearing member. The other stream contains a polyol and isocyanate with additives that have relatively high viscosity to produce a semi-rigid polyurethane foam. At each mixhead the proportions of ingredients are controlled to give a desired isocyanate index to control the flex modulus and other properties of the loading bearing member and foam molded components of the product. The low viscosity material penetrates the porous mat to reinforce it and the porosity of the mat prevents the high viscosity material from entering the armature cavity so as to reduce the load capacity of the finished product.

Abstract: A method of making a sailboard or surfboard, in which a prefabricated foam core has fibrous material wound about it and a polyurethane resin especially set with a reaction retarder is poured onto the fibrous material, whereupon the thus treated foam core is inserted in a molding tool and the mold is closed for curing the polyurethane resin. Desirably, the mold is lined with a surface layer, particularly a deep drawn thermoplastic film, before the treated foam core is inserted. In this way one can make low-weight boards of high strength with relatively low production and material costs.

Abstract: A ball batting aid consisting of a spherical ball made of an expandable elastomeric material having a finite length of braided rope secured thereto, the ball being formed so that there is no air pocket within the confines thereof. An enlargement is placed on one end of the rope located in the central portion of the ball and when the ball is formed, the elastomeric material is expanded into the space between the braids of the rope to effect a securement of the material to the rope.

Abstract: A method for encapsulating electronic components in high acceleration and high thermal cycling environments. A liquid uncured thermal setting polyurethane formulation is mixed with a finely ground particulate foam which serves as a nucleating agent. The mixture is in accordance with the polyurethane formulation. The resultant foam contains open air pockets which allow it to be compressed and then re-expand.

Abstract: Rigid polyisocyanurate foams are prepared by reacting together an organic polyisocyanate, a blowing agent, a trimerization catalyst, and a minor amount of a polyol, the polyol comprising a sufficient proportion of at least one polyoxyalkylene polyol having (i) terminal oxypropylene oxide blocks, (ii) a molecular weight of from about 300 to 3000, and (iii) an average hydroxyl functionality of from about 2 to 5 to form a foamed polyisocyanurate whose gel time is greater than about 70 seconds and friability is less than about 20 percent, as measured by the ASTM C-421 friability test. Laminates of such foams exhibit a high degree of fire resistance, low foam friability and good facer adhesion.

Abstract: A method for manufacturing a predetermined shape of molded plastics, comprising the steps of introducing a foamable shell forming material in molding dies, introducing a hard core forming material having a foaming agent on the shell forming material, clamping the molding dies together, and heating both the material located in the molding dies by an induction heating.

Abstract: A shock-absorbing innersole for use in footwear, which innersole comprises an innersole body composed of a substantially nondeformable elastomeric-type urethane cellular polymer, having a contoured molded heel and arch section and a substantially flat sheet containing a ball and toe section, the innersole having one or more shock-absorbing inserts in the innersole positioned in the heel, ball or both areas of the innersole, the insert composed of a solid elastomeric polymer which has greater shock-absorbing properties and greater surface tack than the elastomeric urethane of the innersole body.

Abstract: A cushion for the seating part or the back rest of the seat of a motor vehicle or the like is prepared with very comfortable seating and good resistance to compression without any spring but similar in properties to cushions which include some metallic structures such as springs. The process consists of introducing within a die, a base foam material (1) from a precut block and lateral parts (2). An external layer (4) of foamed material is formed. The external layer is separated from layers (1) and (2) by means of a sheet of non-woven material (3). The non-woven material permits a controlled compenetration of layer (4) within the layers (1) and (2).

Abstract: A hot or cold compress a layer of substituted urea/urethane hydrogel material bonded to a porous substrate. The hydrogel material is made up of a high molecular weight polyol, a toluene diisocyanate prepolymer and water. Generally, the water and polyol each comprises between about 40 to 50% by weight of the hydrogel, with the diisocyanate prepolymer making up the remaining 12-16% by weight. The hot or cold compresses of the present invention are formed by preparing the hydrogel material and then placing a porous substrate in contact with the hydrogel prior to the time that gel formation is complete. In this manner, the hydrogel becomes integrally bonded to the porous substrate. Other materials such as terrycloth can be bonded to the porous substrate prior to bonding the substrate to the hydrogel. Articles useful in therapy can then be formed by attaching the edges of the cloth/porous substrate to form the desired object.

Abstract: The present invention relates to a method for the manufacture of moulded bodies such as cornices from foam plastics material, the visible side of these bodies being heavily textured or profiled, smooth, non-porous and free from separation elements, with a unit weight of less than 200 kg/m.sup.3. In the method, a thin, elastic, heat-deformable film (3) is inserted between two heated mould portions (1, 2) in such a way that the film edges are clamped between the superimposed mould edges of the two mould portions (1, 2), a reactive, heat emitting, foaming plastics mixture is introduced through the upper mould portion (1) in such a way that it may be distributed on the film, and the hollow chamber formed between the film and the lower mould portion is evacuated during foaming, such that the film intimately conforms to the shape of the lower mould portion.

Abstract: The process for making and the structure of a panel of light-weight, cellular concrete having at least one opening, and capable of holding at least one pane of glass or sheet of ceramic in said opening without a mounting frame.

Abstract: A shoe sole of elastomeric material is formed with at least one pressurized gas cell at least one wall of which is defined by a layer in which a substantially inextensible reinforcement is embedded to prevent bulging. The cell envelope can be formed by rotational casting of a liquid material within a cavity of a wear layer to simultaneously penetrate the reinforcing layer.

Abstract: In a filament winding technique, filaments are wound around a mandrel, and the mandrel remains in the structure and becomes part, normally a structural part, of the article. The mandrel may be any suitable rigid, light-weight material, but a foamed material such as a structural foam is thought to be most suitable. Metal inserts for attaching other components to the filament wound article can be moulded into the mandrel surface, and locked in place by the filament windings. According to a preferred aspect of the invention a motor vehicle suspension wishbone is made according to such filament winding method and the mandrel on which the filaments are wound remains in the structure.

Abstract: An insulating foam and a process for producing insulating foam, wherein a foamable first component may be made of alkyl sulfate, half ester of maleic anhydride and acrylic resin in an aqueous solution is mechanically foamed with air, and to that foam is added an aqueous solution of magnesium oxide, dispersant, acrylic resin, perlite and/or precipitated calcium carbonate. To those components is added an aqueous solution of at least one of aluminum chloride, magnesium sulfate, magnesium chloride, zinc chloride, sulfamic acid, sodium silicate, zinc oxide, barium metaborate, vinyl alcohol, magnesium carbonate, calcium chloride and vinyl acetate. In another embodiment a polyvinyl alcohol and dispersant first portion is foamed with air and mixed with a second cementitious portion comprising magnesium oxide and barium metaborate.

Abstract: A taxidermy mold (10) is disclosed which includes an eye socket recess (13) into which an artificial eye (20) is inserted. Eye (20) is held in mold (10) while a hardenable liquid foam is poured into mold (10) to create a taxidermy form (30) having a molded eye therein. The eye (20) is held within the eye socket recess (13) during molding by means of an adhesive which separates from the eye (20) and remains in eye socket recess (13) when mold (10) is removed from the taxidermy form (30). It is therefore unnecessary to provide an additional step of cleaning the adhesive from the eye (20) after molding is completed.

Abstract: Expandable phenolic resin-coated composite beads comprise an aggregate having coated thereon a solid, expandable resin composition comprising a solid, phenolic resin initial condensation product, a foaming agent and, if necessary, a hardening agent. The expandable phenolic resin-coated composite beads provide composite cellular moldings in which the aggregates are uniformly dispersed in a phenolic resin-expanded layer and are firmly adhered to the expanded layer. The composite cellular moldings can be adhered to a face plate to form integral laminates.

Abstract: Methods of making low density modified polyimide/polyimide-amide foams and the resulting compositions. An N-substituted aliphatic imide is prepared by reacting a suitable aromatic dianhydride with a suitable oxime. A polyimide forming material is prepared by dissolving the N-substituted aliphatic imide in an esterifying solvent, then adding a suitable aromatic diamine. This material is dried to a powder. A suitable hydrated compound which is stable up to at least about 100.degree. C. is mixed with the powder. A foam is then produced by heating the material to reaction temperature for a period sufficient to produce a stable foam. The material melts, then spontaneously expands into a foam which becomes self supporting and cures to a resilient flexible foam. The addition of the hydrated compound is found to result in an exceptionally low density foam.

Abstract: A reticulated hydrophilic foam substrate and bonded active surface particle powder composite filter material is generated by foam polymerization of a prepolymer phase with an aqueous phase. The reticulated hydrophilic foam substrate is characterized by relatively low pressure drop and low resistance to flow through the foam substrate. The prepolymer phase is a hydrophilic polyurethane prepolymer receptive to the aqueous phase for foam polymerization upon mixing with the aqueous phase. The aqueous phase in turn is a pourable and flowable slurry mixture of water, active surface particle powder, and surfactant wetting agent. The aqueous phase includes sufficient water or other evaporable liquid to provide a protective liquid layer or coating over the active surfaces of the powder particles.

Abstract: A tennis racquet frame is fabricated of graphite and has tubing member for receiving the strings internally molded in the frame so that the strings do not penetrate the outside rim of the frame. This end result is achieved by preforming pieces of plastic tubing in an elongated mold, the mold shaping these tubing pieces into optimum radii for receiving the stringing. The mold is filled with plastic and the elongated strip thus formed removed from the mold and placed into a second mold which has a pair of wires installed there in and running along the longitudinal extent thereof. Plastic foam is then placed in the second mold to form a foam core which retains the wires along the back thereof with the ends of the wires protruding from the foam. The foam core strip is then removed from the mold and while being held at its ends by means of the wires is rotated to wind graphite fibers therearound, along the entire length of the core. The graphite wound core is then molded in conventional fashion to form the frame.

Abstract: A method of manufacturing a shoe which comprises forming a foamed outsole in a mold cavity and cementing an insole to the formed outsole during molding. The mold is made of a silicone rubber and has a deeper cavity for forming the outsole and a shallow cavity for receiving an insole. An upper with multi-colors is fabricated by cementing differently colored plastic segments and a lining cloth by high frequency sealing.

Abstract: Compositions and processes for forming inorganic resins, including articles of manufacture incorporating these resins are disclosed. the inorganic resins are characterized by their strength, nonflammability, dimensional stability, resistance to organic and inorganic chemicals, to heat and to abrasion and their adaptability to being formed into noncellular or cellular forms. The resins are formed by reacting a liquid component A containing an aluminum phosphate or a magnesium phosphate and a liquid component B containing a source of magnesium oxide, such as magnesia, and/or wollastonite and an essentially non-reactive phosphate dispersing agent. Various fillers may be incorporated and a blowing agent may be added to form a cellular resin.

Abstract: A taxidermy mold is disclosed which includes an eye socket recess (13) into which an artificial eye (20) is inserted and locked into position. Locking takes place by means of two diametrically opposed lugs (14) and (15) which mate with two diametrically opposed notches (26) and (27) in artificial eye (20). Alignment is maintained while a hardenable liquid foam is poured into the mold to create a taxidermy form (30) having molded eyes therein.

Abstract: The present invention relates to superior wear layer-coated embossed surface coverings which are prepared by depositing a cross-linking inhibitor on at least a portion of the surface of a cross-linkable foam formed on a backing and containing a cross-linking initiator. Preferably a wear layer is applied at this point and cross-linking of the affected areas is accomplished by heating the sheet. The sheet of material is either uniformly or differentially heated and then uniformly compressed to a desired embossing depth using a non-patterned press or roll. The noncross-linked regions remain depressed upon removal of the compressing force whereas the cross-linked regions return essentially to their original height. The wear layer remains in contact with all of the foam regions so that the resulting sheet of material has a wear layer which is uniformly adhered to the contour of the foam layer. The surface of the sheet has an embossed or textured finish.

Abstract: In order to facilitate the release of polyurethane from a steel or aluminium mould, the metal surface is provided with a mono-layer of an alkylmercaptan. A silver layer may be provided between the mould metal and the alkylmercaptan monolayer.The invention can be advantageously used for manufacturing a luminaire for a tubular discharge lamp.

Abstract: A first reaction mixture, prepared from (a) isocyanates with isocyanate contents of from 5 to 50% and (b) compounds with molecular weights of from 32 to 10,000 which contain at least two isocyanate-reactive hydrogen atoms, in an equivalent ratio of component "a" to component "b" of 0.8:1 to 5:1, from 0.1 to 20% of a blowing agent and, optionally, other known additives, is introduced into the rigid cavity of a closed mold. After this mixture has become resistant to permeation, but is still compressible, a second reaction mixture, either the same or different from the first reaction mixture, prepared from (c) isocyanates having isocyanate contents of from 5 to 50% and (d) compounds with molecular weights of from 32 to 10,000 which contain at least two isocyanate-reactive hydrogen atoms, in an equivalent ratio of component "c" to component "d" of from 0.

Abstract: A shoe-innersole material for use in providing cushioning and support in footwear, and a method of manufacturing the shoe-innersole material, the shoe innersole comprising a heel and an arch section composed of a molded, elastomeric polyurethane foam material of low compression set, the heel and arch sections directly bonded in the molding process to a full-sole material composed either of foam or a solid, flexible sheet material.

Abstract: A process for making molded flexible polyurethane cellular products which do not substantially shrink or change dimensionally upon cooling is provided by exposing the curing product to atmospheric pressure while in the confines of the mold. Exposure can be accomplished by unlatching the mold or opening a port at an appropriate time after the reaction mixture was introduced into the mold so as to burst the cell walls of the polyurethane product.

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: The body of a cabinet for storing temperature-sensitive articles such as magnetic discs and tapes is built by a process which involves the successive steps of (i) fabricating an internal skin; (ii) attaching so-called "phase-change" material to the skin; (iii) applying insulative polyurethane foam in-situ to the structure of step (ii); (iv) casting concrete or the like water-bearing material around the structure of step (iii); and (v) completing the outer finishing skin. Thus the conventional "double-box" structure is avoided. The door for the cabinet can be built by a similar sequence in which "phase-change" material, insulative form and water-bearing layers are applied successively to a pan forming the internal face of the door.