Abstract: A formed laminate (20) is made by a method and apparatus (38) by relative movement of first and second contoured mold surfaces (44,46) toward each other to compress a flexible sheet (28) and a quick reacting foamable liquid mixture (50) that has substantially completed expansion but not yet substantially cured so as to form the flexible sheet and provide a collapsed foam layer (30) bonded to the sheet. The flexible sheet (28) is preferably porous cloth, vinyl or leather. The quick reacting type foamable liquid mixture (50) which expands in about 8 to 25 seconds and most preferably in about 10 to 15 seconds.

Abstract: A process for producing an energy absorbing panel having at least one energy absorbing surface in a mold comprising an upper mold and a lower mold. The process comprising placing a reinforcing layer in both of the upper mold and the lower mold. A liquid foamable polyurethane composition is then dispensed in the lower mold and allowed to expand to fill from 50-80% of the mold volume. The upper mold and lower mold are then closed to define an enclosure corresponding substantially to the energy absorbing panel and the liquid foamable polyurethane composition is expanded to fill the remainder of the enclosure to produce a resilient polyurethane foam core which adheres to the reinforcing layers thereby providing an energy absorbing surface. The reinforcing layer has a tensile strength greater than the tensile strength of the resilient polyurethane foam core.

Abstract: A method of making an interior panel of a vehicle door having an exterior surface which is to face toward the interior of the vehicle when installed therein. The method includes the steps of heating a laminate sheet comprising (1) an outer layer of vinyl sheet and (2) a layer of relatively soft foamed material bonded thereto and vacuum forming the heated laminate sheet in a vacuum mold component oriented so that an arm rest portion of the laminate sheet is the vinyl sheet surface thereof engaged with the mold surface arm rest portion. Next, a preformed pad of foamed elastomeric material having a density in the range of 30 to 45 pounds per cubic foot is mounted on the opposite surface of the arm rest portion of the heated laminate sheet.

Abstract: A process for making helmets for cyclists which includes steps of a) pre-heating a mold; b) putting a printing ink-coated plastic film or sheet to the lower die of the mold; c) letting the plastic film or sheet be heated to deform and to closely adhered to the cavity on the lower die; d) filling a polyurethane liquid; closing the upper die of the mold; e) putting the mold in a reactor for foaming; f) shape forming; g) mold stripping; i) trimming and vent hole making; and j) packing.

Abstract: A passive insulating system can provide highly effective protection in the presence of transient high temperatures. The system comprises, for example, a porous body forming a multiplicity of fine cells with a material having low thermal conductivity, a thermally absorptive liquid, providing an endothermic reaction in the presence of a catalyst, and a finely divided catalyst for the reaction uniformly distributed in the porous body. In preferred systems, the thermally absorptive liquid is para-hydrogen, the catalyst is granulated ferric oxide, and the liquid para-hydrogen changes to gaseous para-hydrogen, and from para-hydrogen to ortho-hydrogen in the presence of the ferric oxide catalyst, absorbing heat by its heat of vaporization and endothermic catalytic reaction and reducing heat transfer through the porous body.

Abstract: A method of forming in a mould an article using a thermoplastic sandwich material, which material has a core of a thermoplastic foam and one or two, optionally fiber-reinforced, covering layers of a thermoplastic resin, the method having the steps of providing in the mould a foamable thermoplastic synthetic material and said one or two fiber-reinforced covering layers, supplying a liquid to the mould at an elevated pressure and temperature, whereby the temperature of the thermoplastic synthetic material is raised to a temperature above the temperature at which the material foams, followed by lowering the pressure of the liquid and removing the liquid from the mould with foaming of the thermoplastic synthetic material.

Abstract: Acrylic polymers having a minimum molecular weight of about 500,000, and preferably of about 1,500,000, are blended at levels of from 1 to 25% with thermoplastic resins to improve the melt rheology of the thermoplastic resins and facilitate blow molding, thermoforming, extrusion and similar processes.

Abstract: A method is disclosed for attaching a fastening tape to a molded article and also a mold is disclosed for forming a cellular plastic or foam product for use as a cushioning material for an automobile seat or backrest.The fastening tape is typically in the form of a velcro-like or surface-type fastener carrying on one side thereof a multiplicity of hooks and on the other side a plurality of anchoring members to anchor a molding materials M in the mold. A flexible sealing flange is formed on the tape for protecting the hooks against leakage therein of the molding material during the molding operation in which cooperating halves of the mold are closed with pressure-applying means engaged with and urging the tape against a flexible bottom wall of the cavity mold.

Abstract: A water-based embossing composition for use in chemically embossing a foamable polymeric material having a blowing agent incorporated therein comprising: (A) a film-forming resin dissolved or dispersed in said aqueous composition; (B) a modifier which is effective in modifying the activity of the blowing agent comprising particulate solids which are substantially insoluble and uniformly dispersible in the liquid medium of the embossing composition and which have an average particle size of no greater than about 100 microns, said modifier being present in the composition in an amount of at least about 3 wt. %; and (C) optionally, a colorant or a softening agent for the modifier solids or a mixture thereof.

Abstract: A sound insulating structure is provided which is made by foam-backing a carpet in a single operation and which includes a consolidated layer with few or no cells followed by a cellular soft elastic layer. To this end structured materials such as fleece and/or cut foam into which foaming takes place in order to form the consolidated layer, are provided on the back of the carpet or of a foam-proof covering thereon.

Abstract: A method for manufacturing an automobile trim component includes the step of coextruding a plastic unfoamed material and foamed material into a multilayer parison, which is thereafter blow molded to a desired form. After the layers are cured, the article is removed from the blow mold and sectioned into multilayer skin halves, and one skin is placed in an injection mold. The core resin, either thermoplastic or thermoset in nature, is then injected into the injection mold and onto the skin, and then compresses the resin against the skin to produce a shell comprising a resin core layer, intermediate foam layer, and decorative outer layer.

Abstract: An expansion molding apparatus for forming molded articles having consistently or partially thin-walls by expanding expandable thermoplastic resin beads in a cavity formed between molds with the application of heat. The apparatus has a moving device, for example, a cylinder which moles the molds in one orthogonal direction relative to a closing direction of the molds when filling the cavity with the expandable thermoplastic resin beads. After filling the resin beads in the cavity by moving at least one of the molds in at least one direction orthogonal to the closing direction so that a distance in a circumference section of the cavity becomes greater, the mold is moved back to the original position and the application of heat is performed to obtain molded articles.

Abstract: A process for the manufacture of moulded material-covered products is provided wherein material is placed over a mould and held by clamping means proximate the periphery of the mould and thereafter material is drawn into the mould to conform to the shape of the interior surface of the mould prior to the injection of foamable thermoplastics material into the mould to form the product. The process includes the step of disposing a stop at predetermined positions on the material so that when the material is drawn into the mould, the stop precludes further material from ingressing into the mould and any further movement of material into mould is by the stretching of material.

Abstract: An elastic permeable material and method of making same involves a board-like basic structure made of a foam material having therein close cells. The basic structure is provided with a plurality of recesses which are filled with an emulsified foam body having therein open cells. The basic structure is subjected to a heating and then a curing before the top and the bottom layers of the basic structure are peeled off so that the recesses become through holes. The basic structure is used as a main framework while the foam bodies embedded in the through holes form a permeable framework. The elastic permeable material is provided thereon a permeable outer covering adhered thereto. The basic structure is heated under a pressure so as to bring about a reduction in the thickness of the basic structure, thereby resulting in a formation of corrugated surface of the elastic permeable material.

Abstract: An EVA insole manufacturing process includes a step of mixing an EVA resin with a foaming agent for producing a molding through squeezing and cutting procedures, and a step of heating the molding thus obtained in a mold so that it forms into a predetermined shape. Two or more moldings which respectively contain a different concentration of foaming agent or a different pigment color may be molded together so as to produce an insole which has different hardness and color at different parts thereof.

Abstract: An air bag cover for a vehicle has a main body formed of a thermoplastic polyurethane elastomer and a skin layer applied over the main body. The skin layer is preferably of an `integral skin` reaction type polyurethane and is applied over the main body. Break lines may be formed in the main body portion of the airbag cover for permitting an inflated air bag to rip the cover for emerging into the vehicle cabin. The polyurethane elastomer of the main body preferably has a Shore A hardness rating of over 80.

Abstract: Thermoformable polyisocyanurate foams are prepared by reacting together under foam-forming conditions an organic polyisocyanate and an isocyanate-reactive compound, especially an aromatic polyester polyol, the equivalent ratio of isocyanate groups to isocyanate reactive groups being at least about 1.2:1. The foams and faced composites thereof can be thermoformed for a wide range of uses, such as in the interior of motor vehicles, aircraft, ships and other transport means, and of both residential and commercial buildings.

Abstract: A method for manufacturing an air filter consists of building in two stages around a paper filtering element previously prepared, an edge made of flexible foam, first injecting resin into a separate space from the filtering element, and then letting it expand until it anchors to it.An apparatus to carry out such method consists of a die in which the filtering element is inserted, around which a channel is formed where a mobile frame is sinked, whose shape corresponds to the filtering element one, in such a way as to define an injection recess separated from the filtering element, and an expansion recess adjacent to the filtering element, connected by the mobile frame lift, so that the resin can expand and anchor to the filtering element.

Abstract: An EVA insole manufacturing process includes a step of making a molding by injecting molding an EVA resin and foaming agent mixture without through crushing or cutting procedure, and a step of heating the molding thus obtained in a mold so that it forms into a predetermined shape. Two or more moldings which respectively contain a different concentration of foaming agent or a different pigment color may be molded together so as to produce an insole which has different hardness and color at different parts thereof.

Abstract: A process for the production of composite bodies consisting of a polyurethane core and a polyurethane covering, with the core being positioned inside a mold so that an average distance of at least 0.5 mm exists between the surface of the core and the internal wall of the mold. The gap between the core and the internal wall of the mold is filled with a reaction mixture composed of a) a polyisocyanate component, and b) a polyol component. The polyol component b) must have a weight ratio of carbon to oxygen of at least 2.5:1.

Abstract: A process for the production of composite bodies of polyurethane foams and covering layers, which includes at least partly lining a mold with a covering layer, and filling the mold with a reaction mixture which reacts to form a polyurethane foam. The reaction mixture which forms a polyurethane foam consists of a polyisocyanate component, a component consisting of at least one organic compound having at least two isocyanate reactive groups, blowing agents, and salts with water of crystallization as additives for improving the bond between the foam and the covering layer.

Abstract: A process for preparing a composite foamed molded article according to the invention includes the steps of setting a skin material in the vicinity of an upper mold for stamping-mold kept at a temperature of 10 to 50.degree. C.; feeding a molten polypropylene resin composition for a substrate containing a foaming agent kept at a temperature of not lower than a decomposition temperature of the foaming agent and within the range of 180 to 240.degree. C. onto a surface of a lower mold for stamping-mold kept at a temperature of 30 to 80.degree. C.; closing the mold within 10 seconds after feeding of the composition to clamp the molds at a pressure of 20 to 70 kg/cm.sup.2 ; lifting the upper mold before a thickness of each of hardened layers formed on both surfaces of the composition layer reaches 1.0 mm to open the mold at a distance between the upper mold and lower mold of 1.

Abstract: A composite element which comprises an elastic, cellular top layer (A) and a rigid base layer (B) of thermoplastic polyurethanes, the polyurethane elastomer (B) of the base layer being prepared by reactingBa) 1 mol of at least one essentially linear, relatively high-molecular-weight polyesterol or polyetherol,Bb) from 6 to 15 mol of an organic diisocyanate, preferably 4,4'-diphenylmethane diisocyanate, andBc) from 5 to 14 mol of at least one alkanediol or dialkylene glycol,in the presence ofBd) from 0.05 to 0.3% by weight, based on the total weight of (Ba) to (Bc), of water, and, if desired,Be) a catalyst, andBf) assistants and/or additives, is used as a cushioned fitting for vehicles.

Abstract: A fastener of the hook and loop type intended to be incorporated into plastic articles by plastic molding processes is formed of a known separable fastener member having a base member and a plurality of engaging elements upstanding from one surface thereof. A covering which intimately surrounds the individual engaging elements protects the elements when exposed to the harsh environment of a molding process. This protecting covering is removable from the fastener after the molding process to expose the engaging elements without substantially destroying the performance thereof.

Abstract: A multi-layer molded article which is made of a polypropylene resin body and a skin material lined with a foamed layer and has good appearance is produced by using molds between which a cavity clearance is freely set, placing a skin material lined with a foamed layer between the upper and lower molds and supplying a molten polypropylene resin containing a chemical blowing agent through a resin melt conduit in the lower mold when cavity clearance (t) is between (C+15) mm and (C+50) mm where "C" is a thickness of the skin material lined with the foamed layer, lowering the upper mold at a specific rate and pressing the molten resin at specific pressure to fill cavity ends with the molten resin to complete molding of a body of the resin, pressing the body for a certain time after completing molding to form a skin layer, lifting up the upper mold to decrease a compression pressure of the skin material lined with the foamed layer to a pressure lower than a blowing pressure of the polypropylene resin to form and sol

Abstract: A method of manufacturing an article is disclosed which includes an outer fabric material and an inner micro-cellular thermosetting foam plastics material. The method includes facing the outer fabric material, which has been treated on its inner side with a flexible thermosetting plastics material composition, in a mould, closing the mould to define a mould cavity and to deform the fabric material to a predetermined configuration, injecting a foamable flexible thermosetting plastics material composition into the mould, allowing the foamable flexible plastics material to react and completely fill the mould, the pressure of the reaction in the closed spaced of the mould causing the flexible plastics material to bond to the fabric material, allowing the resultant fabric covered micro-cellular foam plastics material to cure, and opening the mould and removing the article.

Abstract: A method for three-dimensionally shaping cover materials such as woven or knitted fabrics, vinyl, leather, and the like is performed by providing a cover material (18) and a layer of foamable liquid reaction mixture such as polyurethane which changes from liquid to a viscous state (16') at the beginning of the gas generating reaction, compressing the combined cover material and the foamed layer in a mold (21,22) having surface configurations corresponding to desired final three-dimensional shapes with the compression being performed when the foam layer has substantially completed rising, but before substantial curing thereof takes place, and then allowing the foamed layer bonded to the cover material to proceed in curing reaction. The three-dimensional cover material shaping is performed by this method without external heat or high pressure so that the cover material can retain its original appearance and high quality.

Abstract: Display tray with a display section (2) for mounting pieces of jewellery and a strengthened edging (3). A considerable weight saving and reduction of the manufacturing cost without impairment of the display function is achieved by the edging (3) having a core (7) of rigid foam material and a covering (8) of plastic sheeting.

Abstract: A multihardness foamed seat having side rolls including one or more zones of a second polyurethane foam encapsulated in a first polyurethane foam is prepared by arranging the seat mould (10) so that the side roll well (12) is inclined in a direction parallel to its length, introducing a liquid first foam formulation into the side roll well, and then introducing a liquid second foam formulation within a time interval corresponding to between 0.01t to 1.5t where t is the cream time of the first foam formulation. The process is particularly useful for the preparation of automobile seats having side rolls.

Abstract: An apparatus and method for fabricating accurate, numerically defined curved surfaces and volumes comprising a skeleton framework having a plurality of bulkheads fixed in spaced relationship with each other, each of the bulkheads having an equal number of boreholes passing through the outer perimeter thereof so as to provide a set of selected boreholes. A flexible spline having a memory is passed through each set of mating boreholes and is secured with the boreholes after the splines have reached their static states. The resultant framework is encased in a cured polymer and the polymer is trimmed and faired between the outer edges of the splines.

Abstract: Refrigeration units having internal parts containing a rigid polyurethane foam formed without the use of perhalogenated fluoro-chlorohydrocarbons are produced by applying a coating to the internal walls of the part in which back-foaming will take place, pouring a foam forming reaction mixture into the cavity of the part in which the internal walls have been coated and allowing the foam to form and set. The coating applied to the internal walls of the part in which back foaming is to be carried out is selected from one-component chemically cross-linking lacquers, two-component chemically cross-linking lacquers and lacquers based on aqueous polyurethane dispersions. The foam forming mixture generally includes a polyisocyanate, a polyisocyanate-reactive compound and a blowing agent. The blowing agent must include a partially halogenated hydrocarbon having at least one carbon-hydrogen bond and a boiling point in the range of from about -50.degree. to about 50.degree. C.

Abstract: Composite soundproofing panels for applications in the automotive sector have a plastic layer bonded to at least one porous material layer. The plastic layer has a composition which contains a first elastomeric material, a high density filler material, a plasticizer and a second elastomeric material. The plastic layer is bonded to at least one self-supporting, premoldable layer of porous material while maintaining a constant thickness within +10%.

Abstract: In a device for incorporating a separable fastener in a foamed seat cushion during formation of the cushion in a mold, includes a sheet having fastener elements constituting one half of a touch fastener. A foam wall surrounds the fastening surface, the wall having a height considerably greater than the height of the fastening elements. The fastener is held on a pedestal having a predetermined height extending into the mold volume and having a predetermined cross sectional dimension generally parallel to the interior mold surface as measured at a predetermined distance from said mold surface. The foam wall defines an opening which engages the sides of said pedestal with a force sufficiently strong to resist any removal force caused by tendency of the foaming action to lift the foam wall during creation of the cushion and bonding of the forming cushion to the foam wall.

Abstract: A continuous process for the preparation of a polymer-based foam sheet at ambient temperatures wherein the foam is produced from a reaction product capable of curing at ambient temperatures formed by the reaction of a reactant composition comprising a prepolymer, such as an isocyanate-capped polyether, and water, comprising:(a) providing a continuous substrate;(b) depositing said reaction product onto said substrate;(c) compressing said reaction subjecting said product to at least one compression of a predetermined degree after said reaction product has creamed but prior to the time said reaction product has finally cured; and(d) finally curing said reaction product.

Abstract: A method and a device for forming a molded portion at an end of an extruded weather strip. The method includes the steps of placing the end of the extruded weather strip made of foamed elastic material in a cavity defined by a movable upper mold member and a fixed lower mold member which composes a mold, closing the mold with the end of the extruded weather strip clamped by a predetermined clamping force, injecting a foamable molding material into the cavity, moving the upper mold member up by an force not more than the clamping amount in the process of foaming of the foamable molding material to reduce clamping of the upper mold member and to enlarge the cavity, continuing molding with the upper mold member moved up until the foamable molding material fills the enlarged cavity, and opening the mold when molding of the molded portion is completed.

Abstract: A grip sleeve is manufactured by sleeving a tubular nylon fabric lining on a cylindrical mandrel of appropriate length. The mandrel is then provided on a lower mold half which is formed as an elongated shell that is semi-circular in cross-section. The lower mold half has an inner surface which is formed with a pair of spaced and curved radial projections that support the mandrel. An upper mold half is provided on top of the lower mold half and matches with the lower mold half. The upper and lower mold halves cooperate with the mandrel to define an enclosed annular receiving space. One of the upper and lower mold halves is formed with an inlet to access the receiving space. A molding composition of elastomeric foam is introduced into the receiving space via the inlet so as to fill the receiving space. The molding composition solidifies to form an elastic and perspiration holding layer on the fabric lining, thereby producing the grip sleeve.

Abstract: A method of making a seat back which includes the steps of sewing a front panel and a back panel together along sewing seams which are exterior with respect to the interior surfaces of the panels so as to form a bag-like structure in a condition wherein the exterior surfaces of the front and rear panels are generally facing one another, sliding the bag-like structure onto a tongue-like mold while the bag-like structure is in the condition in which the panels thereof were sewn together and without inverting the same in any way so as to bring the exterior surface of the front panel into face-to-face relation with a mold surface of the tongue-like mold, contacting the exterior surface of the front panel with the mold surface of the tongue-like mold, forming a body of foam material on the interior surface of the front panel while the exterior surface thereof is in contact with the mold surface, inverting the bag-like structure with the body of foam material adhered to the front panel thereof, and mounting the inv

Abstract: Improved process for producing a complex elastic molded structure of the sandwich type, consisting of a core of polyurethane foam (10) surrounded by a skin, of which at least a part is reinforced with a reinforcing textile sheet (5, 6) impregnated with a thermosetting resin adhering to said foam, which process consists in:firstly depositing on one of the faces (4) of a mold intended to be closed by a cover (2) an assembly comprising a stiffening element (12) and a semirigid reinforcing textile sheet (6), preimpregnated with a solventless, non-tacky epoxy resin,then closing the cover (2) of the mold (1) so as to define, together with said assembly, a volume corresponding to the volume of the core which is to be formed;then injecting into the volume thus defined the reactional mixture forming the polyurethane foam,and finally allowing the product to cool and opening the mold (1) to withdraw the resulting elastic complex molded structure.

Abstract: An electrically insulated conductor including an electrically conductive element surrounded by ultramicrocellular foamed polymer insulation having a void volume greater than about 75%, wherein the transmission speed of the insulated conductor is greater than 90% of the speed of light. Such insulated conductors are useful in computer and telecommunications applications.

Abstract: A method of protecting acoustic and damping tiles from fire damage by placing a fire barrier silicone foam sheet on the inner surface of a mold, mounting the mold at a selected distance from the surface of a hull of a vessel with the fiberglass cloth side of the silicone foam sheet facing the hull and spaced therefrom, injecting a polyurethane foam into the space between the hull surface and the silicone foam sheet, curing the polyurethane foam, and removing the mold. The porosity of the polyurethane foam is imparted by incorporation of 5-50% by volume of Saran.RTM. microspheres.

Abstract: A lid (1) is injection-molded of polyethylene, for a widemouthed barrel of a synthetic resin, and includes an outer rim (4) encompassing the barrel neck (3) and an inner rim (5) dipping into the barrel neck. The outer lid rim (4) and inner lid rim (5) form an annular space (7), an annular web (8) projecting axially from the base of this space. For producing the lid gasket (13), the annular space (7) is exposed to an open flame for activating the annular space surface. Subsequently the sealing material, preferably polyurethane, is injected from a foaming machine into the base of the annular space (7), and thereafter the lid (1) is vibrated in order to degasify the gasket (13). The sealing material, preferably consisting of foamed polyurethane, contains a parting compound having a long-term effect.

Abstract: A method of manufacturing rotors having helical lands and intermediate grooves wherein a multi-layer rotor body (2) is moulded or otherwise formed on a shaft (1) to only a small degree of accuracy, whereafter an outer layer (3) of polymer-based material is moulded on the rotor body to a high degree of accuracy. For the purpose of eliminating shrinkage-induced distortion of the lands of the rotor body (2) subsequent to applying the outer layer, the rotor body is produced in a multiple of layers (21, 22), by casting or like moulding processes, with each of the body layers having a thickness which is greater than that of the high accuracy outer layer (3).

Abstract: A shaped multilayer polymeric article, and a method for manufacturing said article, comprising a top layer comprised of thermoset polyester resin, a supporting layer underneath said top layer comprised of high density polyurethane foam, said supporting layer having a density and thickness at least effective to provide support to said top layer; an intermediate layer underneath at least a portion of said supporting layer comprised of low density polyurethane foam; and a bottom layer underneath at least said intermediate layer comprised of high density polyurethane foam.

Abstract: A method for producing a foam base material product composed of a composite sheet having a surface layer and a foam base layer with a securing device fixed on the form base layer. The method includes the steps of preparing an insert part with the securing device integrally fixed thereto, the insert part being made of a beads foam derived from a resin, placing the insert part within a mold, placing the foam base material layer of the hot molten composite sheet on the mold so that it faces the insert part, and closing the mold whereby the composite sheet is formed and the composite sheet is integrally heat fused with the insert part. This method produces a foam base material product that is more durable and easier to assemble with an auto body than is the prior art.

Abstract: The present invention relates to a process and a device for uniform distribution of a free-flowing reaction mixture onto a continuously transported substrate over the desired width during production of foam webs. The distribution takes place towards the sides from a feed point by means of air.

Abstract: A process for the production of a foam-backed cushion portion with a cover covering same on all sides includes turning the cover inside out and applying the cover over a first mold portion of blade-like configuration with its outward surface over the first mold portion, arranged two second mold portions at respective sides of the first mold portion at a spacing therefrom, thereby forming at least one mold cavity between the first mold portion and the second mold portions. A reaction mixture is then introduced into the mold cavity to fill same with foam forming foam backing portions on the cover. The mold is then opened and the foam-backed cover is removed from the first mold portion and turned inside out to provide a foam-backed cushion portion, the cover which was disposed on the inward side of the foam material coming to lie on the outward side of the foam-backed cushion portion.

Abstract: A soft foam article (20) and a method for making the article including a permeable cover (24) of a cloth type sheet construction having an interior (26) and an exterior (28) as well as including an open cell soft polyurethane foam (30) molded in situ within the cover in direct engagement with the cover interior without permeating the cover. The soft foam article (20) includes a soft toy (22) and seating components embodied by a seat cushion (52), a seat back (54), a headrest (56), and an armrest (58). The in situ molding of the soft polyurethane foam is achieved by the use of an aqueous gel coating (34) on the cover interior (26) so as to prevent a liquid foam mixture from permeating the cover while still permitting escape of any air within the cover and of gas generated during the foaming.

Abstract: A method of manufacturing composite moldings by executing the following steps (a) to (f) by using an injection molding machine provided with a fixed die having a gate which is opened to a cavity forming surface and a movable die which can come into contact with and out of contact with the fixed die:(a) step of setting a desired skin material to a predetermined position of the movable die in a state in which the movable die is sufficiently removed from the fixed die;(b) a first die clamping step in which the movable die is moved toward the fixed die and is stopped at a position where an interval between the movable and fixed dies is equal to a predetermined value of 5 mm or more;(c) step of injecting a fused resin into a cavity;(d) a second die clamping step in which the movable die is stopped at a desired last position;(e) step of cooling for a predetermined time after the second die clamping step;(f) step of removing the movable die from the fixed die and opening the dies and taking out a product.

Abstract: Processes using high temperature thermoplastic polymers in the in-situ fabrication in the formation of foamed composite sandwich or foam articles often result in weak unsound products which may be avoided by utilizing a high temperature thermoplastic in powder form (22), a blowing agent having a high decomposition temperature (24), and, if desired, reinforcers and/or fillers (28), admixing the thermoplastic, blowing agent and reinforcer and fillers (30), placing the admixture in a mold and, if forming a composite structure, in abutment with at least one skin (34), compacting the contents of the mold (37), and applying sufficient heat and/or pressure to the mold and its contents to melt the thermoplastic and generate gas within said mixture by decomposition of the blowing agent (38). Also, an activator may be included with the blowing agent which promotes the production of gas (26).

Abstract: Process of providing on the internal surface of the first and/or second elements of a ski a solid compatibilizer film made of polyurethane or acrylonitrile butadiene styrene or copolyamide. The film forms an interface between foam injected into the internal space of the first and second elements of the ski to promote adherence.