Abstract: A medical-surgical dressing comprising a reinforced sheet of silicone elastomer foam having a thickness not exceeding 10 millimeters, one of the surfaces of the sheet having a surface layer of open cell foam and the other surface having a substantially non-cellular surface skin. The dressing may be manufactured by a process comprising depositing a liquid foamable silicone composition on an absorbent surface, allowing the composition to foam and set to an elastomer and thereafter separating the foam sheet from the substrate.The dressings are useful e.g. for the treatment of wounds, burns and as liners for plaster casts.

Abstract: A method is disclosed for forming reinforced concrete structural panels wherein one or more preformed elongated structural ribs are inverted and placed horizontally into a form for casting a generally flat concrete structural slab. The structural ribs have joiners projecting downward into the form and the concrete slab which is cast in the form so that the joiners connect the reinforced ribs with the slab. In one embodiment of the invention a plurality of reinforced elongated ribs are disposed parallel to one another in the form and additional reinforcing members placed in the form perpendicular to the ends of the ribs to form a box-like structure. A plurality of these reinforced structural panels can be connected together by stringers run through the end members.

Abstract: A composite, rigid, structural, foam panel (11) comprising: (i) a flexible, non-structural, open cell reticulated or semi-reticulated, foam sheet (10); and (ii), an essentially closed cell resinous foam formed from a flowable, foamable material (12); and, wherein the open cell non-structural foam sheet (10) and the essentially closed cell foam are each coextensive with the volume of spaced defined by the panel (11). In a preferred embodiment of the invention, the flexible, non-structural, open cell reticulated or semi-reticulated foam sheet (10) comprises an electromagnetic wave absorber and, consequently, the essentially closed cell rigid structural panel (11) produced comprises a rigid, structural electromagnetic wave absorber.

Abstract: An open container includes an outer part formed of molded polyurethane and an inner liner of preformed plastic material, the polyurethane being placed in an open mold cavity and a center core plug having a plastic liner disposed thereabout is inserted into the open mold cavity to occupy a predetermined positional relationship therewith so that when the polyurethane is allowed to foam, rise, set and cure, the liner is securely bonded thereto to form a mechanically strong heat insulated container for displaying consumer items such as soft drinks immersed in ice water disposed within the container.

Abstract: A molded insulating insert of expanded polystyrene has a central section and hingedly connected side sections which are bendable toward each other to bring the insert to a U-shaped configuration for insertion in a building block cavity. The hinges are formed to provide resistance to full ninety degree bending of the side sections so that the insert side sections are inclined slightly outwardly in a free condition. On flexing inwardly and insertion in a block cavity the side sections tend to spring outwardly and frictionally grip the walls of the cavity. Lug-notch connection means frictionally retain the inserts in the U-shaped configuration and prevent dislodgement of sections in the event of hinge rupture. In molding the inserts, a transfer process is employed with the hinges partially formed in a hot mold and thereafter fully formed in a cold mold. The polystyrene is compressed in the hinge area to a higher density for hinge integrity. Density in the hinge area is approximately doubled.

Abstract: A method of making a sole construction for a shoe is disclosed, the sole construction being of the type having at least two independently prefabricated wooden parts which are interconnected at an area beneath the ball of the foot of a wearer by at least one flexible polyurethane intermediate part. The method includes steps of placing the wooden parts in a mold, introducing a polyurethane foaming material into the remaining free space in the mold, allowing the polyurethane foaming material to foam with the mold closed to form the intermediate parts in interconnected relation with the wooden parts, removing the wooden and intermediate parts from the mold and thereafter working the side surfaces of the sole construction and the surfaces thereof facing the foot sole by grinding or milling.

Abstract: A cushion article, such as a seat cushion or the like, for snapping in place onto an appropriate seat support without additional attaching means. The seat cushion has a foam body with a snap-ring member molded integral with a peripheral portion of the body, the snap-ring member providing means for snapping the seat cushion over the seat support. A process and a mold assembly are disclosed for molding the seat cushion, utilizing the snap-ring member as an integral part of the process and mold assembly to evacuate entrapped air from the mold cavity.

Abstract: A first reaction mixture, prepared from (a) aromatic 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 a closed mold with a rigid cavity. After this mixture has become resistant to permeation, but is still compressible, a second reaction mixture, prepared from (c) aliphatic and/or cycloaliphatic polyisocyanates 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 sanding tool (8) or surface finishing tool for sanding or finishing a work piece such as profiled moldings or edges of panel type work pieces has a foam material body (17), at least one surface of which has a contour corresponding to the cross-sectional shape of the surface to be sanded or finished. A sanding or finishing belt (11) is secured to the contoured surface of the foam material body. The tool is produced in a simple, economical manner by casting or molding. For this purpose a profiled body having a surface configuration corresponding to that of the work piece is inserted into a mold. A length of sanding belt or sandpaper is inserted into the mold so that the rough surface faces the profiled body. The mold is then filled with a foam material which, after curing, is intimately bonded to the sanding belt or paper with the desired contour.

Abstract: A method and system are described for manufacturing molded packings used in the shipment of articles such as computers, typewriters and the like. The system employs a plurality of mold plugs positioned on a rotating platform whereby the mold plugs are alternately moved between work stations. At one work station a separator sheet is manually placed over a mold plug. At another work station a foaming material dispensing gun is automatically operated in a predetermined pattern over a mold which encloses the mold plug. The pattern is manually adjustable to fit any particular mold plug. Control over the system is obtained with a microprocessor programmed to operate with sensors and actuators associated with the system.

Abstract: Polymeric foam, particularly polyurethane foam block, is produced in a stationary, longitudinally-extending, channel-shaped, mould (1a). A mixture of foam reactants partially expands in a vessel (40) and overflows down a fall plate (41) to the bottom of the mould. The vessel and fall plate are progressively transported from one end of the mould to the other to lay down partially expanded foam over the bottom of the mould (FIG. 1). The ends (11,12) of the mould may be opened to permit entry and exit of a foam lay-down unit (6) and transporting means (7) and to permit removal of the expanded foam strand (61) (FIGS. 6 and 7). The mould may be covered (14) after foam lay down and means (5) may be provided for removing gases emanating from the foam (FIG. 1).

Abstract: A method of manufacturing a thermally insulated building block (54a) comprises foaming a quantity of foamable plastics material in an enclosed space (56) between a building block (54) and a closure means (52), the quantity of material being sufficient to fill the enclosed space (56). The foamable material may be injected into a cavity in the block onto an outer surface of the block (54) or onto the closure means (52) prior to locating the block (54) and closure means (52) relative to each other to form the enclosed space (56) therebetween. The block (54) is transported between upper and lower parallel endless belts (55, 50) during foaming and either belt (55, 50) may provide the closure means (52). If the lower belt (50) provides the closure means (52) the upper belt (55) maintains the block (54) in contact with the closure means (52) during foaming.

Abstract: The invention relates to a process and apparatus for manufacturing adapter blocks with channels and making a mold system for producing the blocks. The adapter blocks have channels in at least one surface and connection openings running through the thickness of the blocks.For forming the connection openings the mold has anchoring pins and it is designed for producing more than one adapter block at a time. The casting material is supplied into the mold from below and along one long side thereof. Gasket plates with nipples are placed on the connection side or sides, such nipples being received in conical connection openings.

Abstract: A packaging system for encapsulating an article within a solid foam material. An article to be encapsulated is supported on a base. A wall enclosure is disposed on the base to form a mold cavity. At the top of the base and above the article to be encapsulated is a cover. Expandable plastic foam in liquid form is introduced into an orifice of the base and the expandable plastic foam advances through a passageway in the base and is discharged from an orifice in the base into the mold cavity to encapsulate the article. The foam material in liquid form solidifies into a solid plastic foam material for packaging the article.

Abstract: Cushioned automotive strap handles with spring steel base strips, cushions, and wrapped and sealed covers are made by injection molding resin cladding directly onto steel base strips before assembly with the cushion and cover. The base strips 10 are cut to length with formed end regions 11 which are mounted on a mold part 15 so that a midregion of base strip 10 spans an injection mold cavity 18. Pins 21 within mold cavity 18 locate base strip 10 in a plane spaced from the cavity walls so that the cavity surrounds the midregion of the base strip. The injection molded resin cladding 25 also surrounds the midregion of base strip 10 and provides raised resin shoulders 20 extending along longitudinal side edges of the base strip. The surrounding engagement of cladding 25 secures resin shoulders 20 against transverse movement relative to the base strip.

Abstract: An adapter block having fluid channels is made up of at least two parts bonded together. At least one of the parts is made up of an integral skin foam material, more specially polyurethane. A foam-molded core of this material is covered over by an integrally molded, unfoamed skin. At the faces that are to be bonded the skin is first machined away by a roughening tool. A mold for producing the adapter block is made up of two mold end parts with hollows to take up mold pins so that mold pins or stoppers may be put therein. The mold end part opposite to the end part with the pins is made of an elastically soft material. The mold pins may have concave end faces.

Abstract: The aim of the invention was to find a method of producing a sorptive body, to be used especially with objectives such as the elimination of odors and air freshening. In the invented process a granular or powdered solid component consisting of a sorptive material, e.g. active carbon, or a compound containing such a material, is mixed with a binding agent, by which it is generally fixed to a carrier substance. The essence of the invention is that at least part of the finely-ground solid component is mixed with a liquid sorbate; only then it is combined with the dissolved binding agent. In a subsequent operation heat is applied to the mixture, thereby expelling the sorbate. The heat causes pores and capillaries to form within the binding agent, thus enabling air to enter into the sorptive substances deposited in the binding agent and so effecting an increase in the active area of the surface of the body.

Abstract: Disclosed is a taxidermy mannikin mold and molding method for making a mannikin which has eyes insert-molded therein in proper position and rotational orientation and which has proper eye-surrounding anatomical surface features. The mold cavity has therein eye socket recesses each of which is immediately surrounded by a correctly contoured surface having reference indicia marking.

Abstract: A matrix coating system and method of manufacture thereof is presented wherein the matrix coating contains chemical blowing agents which permit low pressure molding and also the formation of printing plates having deep relief. The method of manufacture is such that a foamed coating is produced which at molding temperatures is highly compressible at low pressures and which also expands into the relief or nonprinting regions of the pattern plate. The unusually low molding pressures necessary result in less distortion of rubber pattern plates or made from photo polymers. In addition, the combination of high compressibility in appropriate areas, and of volume expansion in relief areas allows the board coating to conform before and during cure to pattern plates of deep relief, so that in the cured state there results a rigid, durable high fidelity mold useful for molding numerous flexographic printing plates.

Abstract: Disclosed is a taxidermy mannikin mold and molding method for making a mannikin which has eyes insert-molded therein in proper position and rotational orientation and which has proper eye-surrounding anatomical surface features. The mold cavity has therein eye socket recesses each of which is immediately surrounded by a correctly contoured surface having reference indicia marking.

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 non-cellular or cellular forms. The resins are formed by reacting a liquid component A containing a mono aluminum or mono magnesium phosphate and a liquid component B containing a magnesium oxide and/or a wollastonite and a dispersing agent. Various fillers may be incorporated and a blowing agent may be added to form a cellular resin.

Abstract: Aromatic polymer materials, such as polyethersulphone, polysulphone or polycarbonates in granular or porous forms with a solvent such as acetone or butanone. The resultant mixture is thereafter compressed and compounded to significantly increase its density producing a pre-form substantially free of large irregular voids. The preform is then capable of being formed in a foamed structure under heat.

Abstract: Method for casting a base directly on an electron tube comprising a stem and stem leads sealed in and extending out from the stem includes: A. detachably coupling a mold to the leads and stem, B. producing a temporary pressure seal between the mold and the stem including applying static pressure in a direction that is substantially normal to the surface of the stem and C. injecting liquid castable material into the mold at substantial hydraulic pressure while maintaining the static pressure at the temporary seal.

Abstract: Composite materials having glass fiber substrates and attached foam backings are useful in surface covering applications especially as resilient floor coverings. The glass fiber substrates are usually coated with a plastisol of polyvinyl chloride. Conventional foam rubber backings made from high solids SBR latex have poor adhesion to such coated substrates. However this problem may be overcome by using foam rubber backings made from a blend of SBR and NBR latices, which backings have excellent adhesion to these coated substrates.

Abstract: A package forming apparatus which produces containers by means of molding thermoplastic material. A mold having a fixed cross-section but a variable length mold cavity is provided by a mold core having a bottom ring means outer shell unit in operative association with the mold core but which is movable axially of the mold core to vary the operative length of the mold and a removable top end plate is provided for the mold cavity.

Abstract: The invention relates to a factory prefabrication method for hollow panels for the on-site erection of insulated constructions.This method employs a three-dimensional framework 1 composed of thrust bars arranged in two parallel planes and of link bars linking the former. The method consists in placing said framework in a mold 13 containing a pulverulent material 16 wherein the framework is embedded by part of its thickness, in molding an insulating synthetic material 4 in the empty part of the mold so as to embed the visible parts of the framework 1, in placing above the mold a form sheet 2 so that the insulating material shall make contact with it and adhere to it during hardening, and after this hardening, in extracting the pulverulent material and in ejecting the obtained panel. The panel so manufactured can be provided after ejection with a second form sheet opposite the first.

Abstract: A method for forming a laminate which is composed of a decorative layer and a carrier panel comprising applying a crosslinking plastic foam onto a decorative carrier web, subjecting the thus coated web to heat treatment to dry and partially crosslink the foam and then marrying the unfoamed side of the web to a carrier panel with the application of heat and pressure so as to further crosslink the foam. Laminates in accordance with the invention are described. Such laminates possess stability against delamination as well as relative freedom from gaseous inclusions.

Abstract: A railroad tank car includes a tank body and means for applying generally uniform heat to the lower portion of the body. There are a plurality of spaced generally semicircular rings attached to the body with each pair of adjacent rings defining a heat chamber which extends laterally about the lower portion of the tank body. There are longitudinal channels having ports which open into each of the heat chambers. There is a cover for the tank which includes a longitudinally extending generally semicircular metal jacket. A layer of insulation is positioned about the jacket and a layer of plastic foam overlies and adheres to the insulation. The structure is completed by a plastic exterior coat, preferably fiberglass, which overlies and adheres to the plastic foam.

Abstract: The method of making a foam plastic cushion or structural part with a plurality of fastening assemblies thereon comprising the steps of applying a moisture proof barrier sheet of plastic to a strip of porous backing material; applying a coating of pressure sensitive adhesive to the barrier sheet; applying a strip of hook or loop material having a backing to the adhesive coating extending laterally outward of the strip of backing material, barrier sheet and adhesive coating extending laterally outward of the strip of hook or loop material; bonding the backing of the strip of hook or loop material to the barrier sheet upon the strip of backing material; successively mounting upon a mold surface of a pair of mold bodies defining a mold cavity a plurality of spaced bonded backing and hook or loop assemblies, with the hook or loop material facing the mold surface; adhering peripheral portions of the strip of backing material and adhesive coating to the mold surface for sealing the fastening assemblies thereon; and

Abstract: Hot runner injection molding apparatus for coinjecting two thermoplastic materials sequentially through separate channels to form at least a two-layer sandwich material is provided. There is a valve means for instantaneously switching the flow of thermoplastic material from one channel to the other channel, the valve means preferably comprising a shuttle ball member.

Abstract: Process for obtaining cellular materials, based on unsaturated polyester in optionally containing reinforcing and/or inert fillers, having a density between 0.2 and 1.0 kg/l by moulding under pressure a liquid foam of said resins, characterized by the fact that the liquid foam based on unsaturated polyester resins containing conventional additives, optionally containing an inert and/or reinforcing charge of mineral or organic fibers having a length which is less than 5 mm, preferably less than 3 mm and more preferably less than 1.5 mm, obtained by mechanical introduction of a gas and/or by means of a chemical and/or physical foaming agent, is firstly introduced into an open half-mould optionally containing a further fiber reinforcement, by casting an amount higher than the free volume of the mould, and subsequently said foam is cross-linked.

Abstract: A method of manufacturing a protective and decorative molding for an automobile, comprising the steps of: adding a foaming agent to a starting resinous material comprising a vinyl chloride polymer or copolymer or a blend thereof; kneading the foaming agent and the starting resinous material; successively forming the kneaded mixture into an elongated rod or sheet blank by means of extruder or calender rolls; shearing the rod or blank into pieces having a predetermined shape; and molding the piece in a mold having high-frequency heating electrodes to apply a high-frequency voltage to the piece so that the foaming agent contained in the piece decomposes and foams to provide a product having a predetermined shape.

Abstract: Preparation of supported reverse osmosis membranes on a woven, unsized, porous support using dimethylacetamide solvent and a lithium nitrate or chloride or magnesium chloride salt.

Abstract: After arranging on dual pans two thick strips of a deformable fiber-reinforced spongeous material and covering them with a liner made of an elastic cloth, a fluid polymer is poured into said pans which reacts to set and foam in a conveniently short time. During the setting time, the user keeps his/her feet fixedly inside the pans, to thus leave an impression which accurately reproduces the shape thereof. After setting, the deformable strips is bonded to the liner and retains the exact impression left by the foot.Successive trimming operations provide an insole taylored to fit the user's feet.

Abstract: In the manufacture of cells, e.g. of the system Li-Al/LiCl-KCl/FeS.sub.x, the finely divided raw materials for the electrodes and for an included ceramic separator are respectively mixed individually with the electrolyte salt, as well as with a synthetic plastic which is decomposable without residue under heat. The mixtures are rolled into plates, and the plates are heated above the decomposition temperature of the plastic after assembly. The plastic is preferably a polyhydrocarbon such as polyisobutylene and is preferably introduced by means of a solvent. It makes the powder mixtures plastifiable and suitable for rolling. This makes it possible to produce ceramic separators, which are fundamentally composed only of loose particle accumulations, in the form of plates of uniform structure and strength and to handle these in the same way as electrode plates during cell assembly.

Abstract: Molding apparatus 10 or 11 supports a tough, resin ball core 15 in the center of a spherical mold cavity having upper and lower mold parts 12 and 13. Core 15 is about half the diameter of the mold cavity allowing room for foamed resin exterior 16 to form over and around core 15 filling the mold cavity and completing the spherical ball. A pin support 20 formed as a single pin 21 or a pair of identical pins 31 holds core 15 in the center of the mold cavity and is withdrawn after the ball is molded. The pin support is arranged at the mold parting plane and extends through the parts to the mold exterior thus providing full support and accurate location of the core within the mold cavity. A coupling element on pin support 20 is formed as a hook 28 or other engageable element outside the mold and is used for placing the core in the mold and also for supporting the ball for curing after molding.

Abstract: Disclosed is a taxidermy mannikin mold and molding method for making a mannikin which has eyes insert-molded therein in proper position and rotational orientation and which has proper eye-surrounding anatomical surface features. The mold cavity has therein eye socket recesses each of which is immediately surrounded by a correctly contoured surface having reference indicia marking.

Abstract: A high temperature and flame resistant closed cell polyimide foam material and methods of making the foam. An aromatic tetracarboxylic acid dianhydride is reacted with an oxomine to produce an N-substituted imide, which is then esterified with a suitable alcohol. The resulting liquid is dried and the dry residue is reduced to a uniform powder having particles with diameters generally in the 0.5 to 10 mm. range. The powder is preferably further dried, either before or after final size reduction, in a moderate vacuum at moderate temperature to remove any excess residual alcohol. The powder spontaneously expands to form a closed cell foam when heated to a temperature in the range of about 90.degree. to 150.degree. C. for a suitable period. When the powder is expanded in a closed mold, a well consolidated, uniform, closed cell foam product results. When expanded in an unrestricted manner, closed cell "macroballoons" having average diameters between about 0.4 to 15 mm. result.

Abstract: A method of manufacturing paneling and the like in which the thickness or weight of coatings applied to substrate materials is measured by infrared absorption providing a digital representation, accurate to 0.01 mil, of the coating's thickness or weight to 0.01 gram/sq. ft. The rate of application of the coating is adjusted in accordance with the measurement to maintain the coating weight or thickness within optimum limits.

Abstract: Process for producing foam moldings with an insert executed in a mold for foam molding consisting of a core block and a cavity block. The process comprises steps of: (a) having a film adhering to and covering the insert on one side thereof where a foam layer is formed; (b) letting the skirt portion of the film to be pinched or sandwiched by the uniting portion of the two blocks while the foaming process is executed on a foamable material; and (c) forming integrally the foam layer on that side of the insert, with the film being retained between the insert and the foam layer to be obtained.

Abstract: A method for manufacturing a heat-insulating member, such as e.g. a door or housing of a refrigerator, including a shell and a foamed heat-insulating material filled in the shell and a jig used therefor. The jig is intended to hold the shell lest the shell of the heat-insulating member to be manufactured should be deformed when a foamable liquid composition is foamed in the shell. In the jig of this invention, a jig body is formed of a heat-insulating material. The method of this invention comprises the steps of holding the shell in a hollow state by means of two jigs, injecting the foamable liquid composition into the shell to foam the same in the shell. Since the jig body of the jig of this invention is made of a heat-insulating material, the necessity of external heating, which is essential to the conventional method, is substantially obviated.

Abstract: Particulate absorbents of a water-insoluble water-swellable polymer having a gel capacity of at least 10 are immobilized with a composition comprising the absorbent in a liquid polyhydroxy organic compound. The composition may be employed by applying to an appropriate surface and subjecting the liquid film to solidifying conditions. The solidified film product has high absorptive capacity and is free of undesirable movement when positioned in absorbent articles. A foam product having both absorptive and cushioning properties is prepared from a solid, particulate, water-insoluble, water-swellable polymer having a gel capacity of at least 10, a solid, particulate blowing agent, and a liquid polyhydroxy organic compound.

Abstract: Improved mold structure and method of molding for mechanically frothed urethane foams is presented. The mold is filled from the bottom via an annular runner which communicates with the mold cavity. The connection between the annular runner and the mold cavity is restricted to create a back pressure in the circumferential runner.

Abstract: Cellular foams, particularly polyisocyanurate foams, are prepared by reacting together an organic polyisocyanate, a blowing agent, a trimerization catalyst, and a minor amount of a polyol mixture prepared by the transesterification with a glycol of a by-product fraction from the manufacture of dimethyl terephthalate, the major portion of said fraction comprising about 15 to 70 weight percent of dimethyl terephthalate, and about 85 to 30 weight percent of a mixture of monomethyl terephthalate, bi-ring esters and polymeric materials. Laminates of such foams exhibit a high degree of fire resistance, low smoke evolution on combustion, low foam friability and high compressive strength.

Abstract: A pull strap handle meeting all the standards of the automotive industry is formed economically with molding operations. The handle is formed with a strip 15 of strong resilient material with high tensile strength that serves as a support element. Support element 15 is enclosed within a molded cover having a firm outer side 17 and a soft inner side 18. Soft side 18 is molded of foamed resin material directly onto support element 15 to form a secure bond. Firm side 17 can be molded in a single operation with soft side 18 or can be molded separately, attached to support element 15, and located in a cavity mold that forms soft side 18. The cover can also be molded to support element 15 within a cavity mold that forms both cover sides 17 and 18 or the cover can be extruded onto support element 15 in a continuous operation.

Abstract: A high temperature and flame resistant closed cell polyimide foam material and methods of making the foam. An aromatic tetracarboxylic acid dianhydride is reacted with an oxomine to produce an N-substituted imide, which is then esterfied with a suitable alcohol. The resulting liquid is dried and the dry residue is reduced to a uniform powder having particles with diameters generally in the 0.5 to 10 mm. range. The powder is preferably further dried, either before or after final size reduction, in a moderate vacuum at moderate temperature to remove any excess residual alcohol. The powder spontaneously expands to form a closed cell foam when heated to a temperature in the range of about 90.degree. to 150.degree. C. for a suitable period. When the powder is expanded in a closed mold, a well consolidated, uniform, closed cell foam product results. When expanded in an unrestricted manner, closed cell "macroballoons" having average diameters between about 0.4 and 15 mm. result.

Abstract: A foam article suitable for use as a seat cushion includes a supportive bottom layer of firm high density foam, a comfortable top layer of soft low density foam and a border or side wall of foam of intermediate density. The foam article has a sag factor of about 4.5 to about 6.5, and the foam layers and the side wall are bonded together without employing adhesives. A method of preparing the foam article also is disclosed.

Abstract: A three-dimensional work piece, such as an interior part for a car, is manufactured by keeping the blank, such as a sheet of plastic on or in the same primary mold 24 for the initial shaping step, for the foaming step, for the curing step and for the final trimming step. The primary mold 24 shuttles back and forth in a given direction for sequential cooperation with two secondary molds 75 and 31 or 48 and 31 arranged for reciprocation in a direction extending perpendicularly to said given direction. Preferably, two primary mold members 66, 67 are arranged for horizontal back and forth shuttling in unison so that each primary mold member may cooperate with two out of three vertically reciprocable secondary molds. The efficiency is substantially doubled when each of two primary mold members 66, 67 cooperates with two out of three secondary molds.

Abstract: Chemically embossed foamed plastic sheet, and method of producing it, which sheet is formed of a base layer of fused resin particles, such as PVC, randomly intermixed with particles of a foaming inhibitor, especially benzotriazole; and an upper layer of foamed plastic, such as PVC, having irregularly shaped, lump-like elevated areas interspersed with irregularly shaped, trough-like depressions. The depressions result from the inhibiting action of foaming inhibitor particles in the base layer upon the blowing agent used for expanding the foamed layer. In the Example, the foamed layer is pigmented PVC with a gloss surface, lying in rectangular patches upon the base layer; and the base layer is fused pigmented PVC intermixed with particles of benzotriazole giving it a grainy texture.

Abstract: A method by which a previously molded hollow plastic retainer having an open end portion necessitated by the need to withdraw a mold core therefrom may be embedded in a molded trim article with the open end beneath the surface and yet the molding material is prevented from flowing through the open end portion and filling the hollow of the retainer.