Abstract: A cover member for a safety air-cushion device is made up of a bag-shaped outer laminate of high density polyurethane foam, and a bag-shaped inner laminate of low density polyurethane foam which is integral with the outer laminate, the inner laminate being made by pouring the fluidized foamable material into a mold after solidification of the other fluidized foamable material having been poured into the mold for the formation of the outer laminate.

Abstract: A panel comprising fillers embedded in a closed cell expanded phenolic resin is made by making a mixture, which is initially fluid, of phenolic resin, a hardening agent, a surface active agent, a finely divided hydrophilic material and a porogenic agent, which has a boiling point above ambient temperature and below the polycondensation temperature of the mixture. This liquid mixture is mixed with fillers, for example balls or microspheres of glass or expanded material such as polystyrene. The resulting mixture is placed in a mould, only partially filling the mould, and heated progressively to a temperature in the neighborhood of the boiling point of the porogene agent, while evacuating the mould, and held at that temperature until the mixture has expanded to fill the mould. The temperature is then progressively increased to the polycondensation temperature to harden the expanded mixture.

Abstract: The instant invention is directed to a process for the production of molded polyisocyanate-based foam products having a compact, light- and yellowing-resistant polyurethane-based top layer comprising the steps of:A. coating a mold with a liquid polyurethane-polyurea-based coating agent, containing a binder, which reacts to form a light- and yellowing-resistant top layer andB. introducing a foamable reaction mixture into said mold,wherein said binder comprises:(i) at least one isocyanate prepolymer having at least two exclusively aliphatically and/or cycloaliphatically bound isocyanate groups and(ii) a hardener mixture composed of water and primary polyamines, at least partly in aldimine- or ketimine-blocked form, which have aliphatically and/or cycloaliphatically bound amino groups.

Abstract: A method for forming a layer of very uniform low density foam of uniform thickness on a surface is disclosed. A screen is positioned at a selected distance above a structure surface. The screen is positioned by lowering a tautly stretched screen over a plurality of studs upstanding from the structure surface to a selected height above said surface. A liquid, self-rising foam material is sprayed through the screen onto the structure surface. As the foam rises, it penetrates through the screen, leaving irregular projections above the screen. After the foam cures to at least a self-sustaining state, the screen is stripped away, leaving a uniform foam layer. The foam layer is bonded to the surface as it cures. Since the screen offers very little resistance to the rising foam, the resulting foam layer has a very uniform low density, highly desirable for thermal insulation application.

Abstract: A foam filled metal shell building column for dwellings and the like comprises one or more thin metal sheets formed as a hollow shell having a longitudinal load-bearing axis. The thin-walled hollow shell is filled with a core of a plastic foaming material including a suitable foaming agent which foams to fill the shell and to exert a force on the shell radially outwardly of the longitudinal axis thereby forming a solid composite column. The radially outward force deflects the shell and permanently places the shell in lateral tension to increase the load bearing capability of the column. When more than one sheet is used, the elongated edge portions of the sheets are configured to loosely interfit with one another when the shell is initially formed, and the plastic foaming material causes a positive locking of the interfitted edge portions. Thus thin, non-load bearing gauge aluminum is converted into a load bearing structural element.

Abstract: A method of manufacturing elements for an optical cable, such elements including a tube of an elastic material, e.g. a synthetic resin or an elastomer, which loosely encloses one or more optical fibers. Preferably, the fiber or fibers are longer than the enclosing tube and the tube is filled with a material which prevents the migration of water, etc. The tube in mechanically stabilized form and the optical fiber or fibers are advanced toward a traction zone where the tube is pulled. Prior to the traction zone, the tube is slit or cut longitudinally through one thickness of the wall, the cut edges are spread apart and the optical fiber or fibers are inserted into the tube through the gap between the cut edges. Optionally, filling material is also inserted into the tube through such gap or a downstream gap subsequently formed. The tube-optical fiber assembly follows a straight line downstream of traction zone to a collecting point.

Abstract: A flexible foamed product with skin, characterized in that on the surface of the foamed product there is formed a skin composed of the reaction product of a linear urethane polymer, a polyol or an urethane prepolymer with an OH-terminal group compatible with the linear urethane polymer, and a blocked isocyanate; and the process for manufacturing such a product.

Abstract: A method for the preparation of composite products wherein a foam expands in contact with a laminated sheet, one of the layers of which is metallic, the pressure generated during expansion of a foam forces the laminated sheet to adopt a desired configuration and the foam adheres to the laminated sheet. Composite products having a mirror-like appearance may be prepared by the method.

Abstract: Machines and process for making in a continuous operation a prestressed glass reinforced, thermally insulating panel, structurally stiff, and totally impervious, of indefinite length and with a cross-section shaped as an elongated parallelogram.Steps for manufacture include making the surface of the panel out of a tubular envelope of knitted or woven glass fabric, stretched over a special holding frame, to give it the desired parallelogram shape. Fastened by a continuous knitting process to the opposite faces of the glass fabric envelope, other glass fibers are stretched inside the envelope and arranged according to three principal directions, all of them oblique with respect to the panel faces. The glass fabric envelope is then coated with a plastic resin to make it impervious to gas and covered on one face at least with a metal liner. This liner, made of cryogenic alloy, has its edges upturned and folded, so as to be fastened to the glass reinforced plastic envelope.

Abstract: Method for making a filter which comprises a plurality of closely juxtaposed tubes made of a filter material and packed tightly in a tubular envelope. Both ends of the tubes are initially closed. The envelope with the tubes is then dipped to a small depth into a hardenable substance, e.g. latex, which fills the gaps between the tubes and on hardening forms a solid bottom on the envelope. A small length of the envelope and tubes is then severed to open one end of the tubes.

Abstract: A multidensity polyurethane foam article suitable for use as a seat cushion includes a supportive layer of firm foam and a comfortable layer of softer foam. The multidensity article has a sag factor of about 3.0 to about 4.5, and the two foam layers are bonded together without employing adhesives.

Abstract: A method and building construction element for manufacturing thermally insulated buildings, in which building construction elements are applied which have the form of half a truss with an outer arch side, an inner arch side and two sides of shape plate truss, comprising a core of synthetic hard foam of which the outer arch side and the inner arch side are provided with plate-like coverings and of which sides are uncovered, which half trusses are combined at the construction site to form complete trusses, arranged in adjacent relationship, whereafter the adjoining surfaces are sealingly interconnected. In the method for manufacturing the building construction elements, a mold of corresponding shape is provided comprising an open side and arranged with the open side up, while the upright bent walls of the mold are provided on the inside with a plate-like lining, whereafter the mold is supplied through the open side with the foaming reaction mixture.

Abstract: A method of making a business machine platen core wherein a cylindrical body including a hollow tube extending co-axially thereof is encapsulated with an insulative foam with a pair of opposed plugs inserted in each end thereof.

Abstract: A grip is placed inside a mold and the grip and mold are filled with a foam material. The handle pieces of a metal sport racket are placed inside the grip, so that as the foam rises and hardens, the foam becomes a handle around the handle pieces with the grip covering the handle.

Abstract: One or more thin metal sheets are formed as a hollow shell having a longitudinal load-bearing axis. The thin-walled hollow shell is filled with a core of a plastic foaming material including a suitable foaming agent which foams to fill the shell and to exert a force on the shell radially outwardly of the longitudinal axis thereby forming a solid composite column. The radially outward force deflects the shell and permanently places the shell in lateral tension to increase the load bearing capability of the column. When more than one sheet is used, the elongated edge portions of the sheets are configured to loosely interfit with one another when the shell is initially formed, and the plastic foaming material causes a positive locking of the interfitted edge portions. Thus thin, non-load bearing gauge aluminum is converted into a load bearing structural element.

Abstract: Method for making a solar collector or converter, the converter comprising a series of at least three spaced wall members defining a plurality of flow passageways for the same or different heat exchange fluids, each passageway being in communication with a storage device for converted energy, preferably a multi-compartmented storage device having a separate compartment for each heat exchange fluid.

Abstract: A building structure and method of making the same are disclosed wherein an inflatable form is inflated and an insulation layer of urethane form is applied to the undersurface of the foam. Hanger members are secured to the foam layer by adhesively affixing planar base portions of the hangers to the foam layer whereafter additional foam is applied to embed the hanger bases. Reinforcing mesh is secured to and supported by the hangers followed by the application of one or more layers of a cementitious material which is allowed to cure. Air pressure beneath the form is progressively increased to maintain a substantially constant uplift force on the foam. The inflatable form may be removed after curing and a protective coating applied to the outer exposed surface of urethane foam to protect it from ultraviolet degradation.

Abstract: Polyurethane foam is used in a three-piece vehicle wheel as a load bearing and load transmitting structural element. The rim of the wheel, an inner wheel disc, and an outer decorative wheel disc are bonded together by the polyurethane foam. The rim includes an interlock lip to interlock the rim with the inner disc and an interlock lip that interlocks the rim with the outer decorative disc. The wheel can be manufactured by placing the rim, inner disc, and outer disc in a die and injecting the polyurethane foam composition into the interconnected volume enclosed and defined by those wheel components. The foam curing process then occurs in situ. Alternatively, the rim, inner disc, and outer disc can be adhesively bonded to a preformed polyurethane foam member. The resultant vehicle wheel, manufactured by either process, is characterized by high strength, light weight, and a decorative appearance.

Abstract: The disclosure relates to a method for producing hollow cylindrical structures, and more particularly for producing hollow cylindrical structures which may serve as collector electrodes for electrostatic precipitators; the method comprising the forming of a first resin and fiberous structural layer on a rotating mandrel, then applying a foam structure forming resin on the first structural layer, then permitting the foam structure to cure into a structural condition, then lathe turning the periphery of the foam structure to a uniform annular cylindrical surface, then applying a second layer of resin and fiberous material to form an external structural layer and then finishing the exterior of the last mentioned structural layer to a uniform annular shaped surface, and finally coating the last mentioned surface with a water resistent resinous material and then removing the glossy surface from said last mentioned material to prevent surface tension of water from separating flow on said last mentioned surface; the

Abstract: Two opposed endless conveyor belts, together with side dams respectively mounted on the conveyor belts form a molding tunnel for producing a continuous sheet of foamed and cured resin. A cover sheet, usually of paper, is provided between the molding surfaces of the side dams and conveyors and the product being formed. The side dams are movable toward and away from an abutting surface of the conveyor opposite to the one that they are mounted on so as to clamp the paper therebetween and prevent leakage of foam. A mechanism, particularly a spring bias and cam track, is provided to release the paper clamping pressure to permit the foaming resin briefly to permit the expanding resin to move the paper into conformity with the molding tunnel. The points along the length of the molding tunnel wherein this release occurs are adjustable as desired.

Abstract: Here is disclosed a method of manufacturing building blocks filled with a cured aminoplast resin foam by forming a curable foam, presenting the cavity to and in sealing relationship with one end of a delivery pipe for the foam and injecting the curable foam through the delivery pipe into the cavity until a back pressure is developed in the delivery pipe. Apparatus for manufacturing the building blocks is also described.

Abstract: Multi-station reaction injection molding apparatus, and method, are disclosed for in-place foaming of polymerizable resins in articles advanced along a production line, as for example in the manufacture of insulated appliance housings such as refrigerator cabinets. The articles are selectively diverted from a feed conveyor, one to each of a plurality of pour stations adjacent the feed conveyor. At the stations, injection of foamable resin mix is accomplished by reaction injection type molding heads which combine at least two liquid resin components. These components are suitably catalyzed to react and form a cellular or foamed polymerized resin. The liquid components are separately but continuously supplied to respective supply manifolds to which all of the heads are connected in parallel by shunting ducts. Excess unmixed liquid components are returned separately from each of the heads through recycle shunting ducts to respective recycle manifolds.

Abstract: A building panel in which two sprayed concrete layers, one on top of the other, are affixed to a paper base honeycomb core. The inner layer on each side comprises concrete without fibers, and the outer layer on each side comprises concrete with 4% to 6%, by weight, of fiberglass fibers.

Abstract: Disclosed herein is a method for producing foamed articles, such as seat cushions for a riding lawn mower or the like, which method includes the steps of providing a mold having at least two separable, electrically insulated mold sections, which, when positioned together in a molding position, cooperate to define a molding chamber having the shape of the article, providing each mold section with a separate radio frequency electrode, introducing a foamable and heat curable material into the mold cavity, and applying a radio frequency voltage across the electrodes, and thus through the foamable and heat curable material, after the mold sections are positioned together in a molding position. The resultant internal heating of the material rapidly cures the material to a hardened condition and without generating high internal pressure forces inside the molding chamber.

Abstract: A plastic-like container liner having spaced apart ridges at the bottom of said liner has a non-adhering material positioned on the upper inner surface of each ridge. A lower container body is positioned into a female foaming fixture and an expanding exothermic foam is injected onto the inside bottom surface of the lower container body. A male foaming fixture having spaced apart recesses conforming to the ridges of the liner intimately receives the liner and urges the peripheral flat portion of the liner toward the bottom surface of the lower container body. The foam expands exothermally such that heat released by the foam causes the non-adhering material to flow. The expanding foam is bonded to the lower container body and to the portion of the liner not in contact with the non-adhering material. Resultingly, an integral insulated container is formed having projecting ridges on the bottom surface thereof which assist in resisting the shock of items dropped into the container.

Abstract: A method for making a support for an object wherein a hollow conduit member having closed ends has cut therein an opening to receive resilient foam reacting materials therethrough. In the cutting of the hollow member, a flap remains at the opening so that upon reacting of the foam mix, the foam rises or increases in volume forcing the flap into its original position thereby closing the opening. In a preferred embodiment the hollow conduit member includes at preselected positions therein hollow inserts arranged with axes at right angles to the axes of the hollow conduit member, the inserts being surrounded by the resilient foam materials.

Abstract: A novel structural member, such as a tennis racket frame, having an unusually high strength to weight ratio is provided comprising an expanded foamed plastic core integrally bonded to a shell comprising at least one layer of resin-coated unidirectionally oriented graphite fibers, the shell completely encasing the core at any transverse cross section of the structural member, with a seamless sleeve made of a thin, flexible cellulosic film between the core and the shell.The structural member is prepared by arranging within a mold cavity an outer shell comprising at least one sheet of resin-coated unidirectionally oriented graphite fibers and a core comprising a foamable resin composition while the core is maintained within a seamless sleeve made of a thin, flexible cellulosic film, sealing the mold cavity and activating the foamable resin composition to cause expansion and generate pressure within the mold cavity and thereby provide intimate bonding of the core to the shell.

Abstract: A novel structural member, such as a tennis racket frame, having an unusually high strength to weight ratio is provided comprising an expanded foamed plastic core integrally bonded to a shell comprising at least one layer of resin-coated unidirectionally oriented graphite fibers, the shell completely encasing the core at any transverse cross section of the structural member with a veiling strip wrapped around said core beneath the innermost or beyond the outermost of the graphite fiber layers, or both.

Abstract: To provide a frame with members having two outer elements which are interconnected by an insulator, each member is formed from a hollow bar in which the insulator is molded and then two longitudinal strips are removed from the bar, the two remaining parts of the bar forming the outer elements of the frame member. The bar is provided with longitudinal weakening grooves to facilitate removal of the strips, or the strips constitute mold members which clamp the outer elements and, together with the outer elements, define the hollow cavity within the bar.

Abstract: A novel structural member, such as a tennis racket frame, having an unusually high strength to weight ratio is provided comprising an expanded foamed plastic core integrally bonded to a shell comprising at least one layer of resin-coated unidirectionally oriented graphite fibers, the shell completely encasing the core at any transverse cross section of the structural member, said core comprising from about 25 to about 75 volume percent of a low density cellular filler material, such as chopped cork, and from zero to about 60 weight percent of a high density weight control material, such as barium sulfate.

Abstract: A mandrel of sponge rubber or gel has a tension element for withdrawing the mandrel from a graft tube grown from living tissue. In a first embodiment the tension element comprises a strip of cloth embedded in a sponge rubber mandrel. In a second embodiment the tension element comprises a rubber tube containing the sponge rubber and in a third embodiment the tension element comprises a rubber tube containing a gel. The mandrel assembly includes cloth reinforcing tubes surrounding the mandrel.

Abstract: Foamed articles are made by causing the cross-linking of a thermosetting in, preferably a polyester resin, concurrently with the production of carbon dioxide by the reaction of a carbonate with an inorganic acid. The carbonate is mixed with the resin and the acid then folded in in a progressively accelerated blending operation, whereupon carbon dioxide is generated to foam the resin, the carbonate, acid and setting time of the resin being selected to obtain an appropriate match between the progress of the foaming operation and the setting of the foam. The foam may be made in a mold coated with resin impregnated glass fibers, the impregnating resin becoming cross-linked with the foam. The impregnating resin may also be cross-linked with a resin gel coat, the glass fibers forming a tough layer between the gel coat and the foam.

Abstract: A method of controlling the foaming of foamed-in-place insulation in a cabinet structure having an inner liner and an outer shell with the liner having an outer surface and the shell having an inner surface in outwardly spaced confronting relationship to the outer surface of the liner at a front opening of the cabinet. A flexible sheet is secured to either the outer surface of the liner or the inner surface of the shell at the front opening and has a preselected stiffness so as to cause the sheet to project away from the surface to which it is secured whereby the foaming of the insulation may carry the projected portion to the front opening of the insulation space. A backup member may be disposed across the opening so as to limit the outward deflection of the strip by the foam whereby the strip defines the outer boundary of the foamed insulation across the opening.

Abstract: A method and apparatus are disclosed for preshaping a sheet material, more particularly a textile and/or a plastic sheet, under differential pressure in a molding die, whereby to form a sack-like structure which becomes integrally incorporated as the cover of a foamed plastic cushion, vehicle seat, protective padding element or similar article, by the introduction of a self-foaming elastomeric material into the sack while it is being held in the molding die.

Abstract: An impact energy-absorbing, relatively low density, urethane foam for use in automobile bumpers has a high content of urea linkages and is relatively temperature insensitive, i.e. gives approximately the same physical performance over a wide range of temperature. The foam is water blown in a closed mold from a quasi-prepolymer system. The pack factor is preferably in the range of 1.5 to 8 and the molded density is in the range of 5 to 20 lbs./ft..sup.3.The foam formulation is based on a polyol of a poly (oxypropylene/ethylene) triol reacted with a styrene/acrylonitrile monomer mixture which triol thus modified is reacted with (1) a 50 to 150 equivalent weight polyol cross linker of 2 to 6 functionality, (2) a MDI or TDI/glycol or triol quasi-prepolymer and (3) some water.

Abstract: An integrated cushion structure, such as automobile or aircraft seat or seat back, an office chair, or the like and the method of making it, are disclosed. The cushion structure is comprised of fabric or other pliable cover sheet material forming an envelope constituting the exposed surface as well as defining the shape or configuration of the cushion structure. The structure includes at least one internal pliable sheet material partitioning member disposed parallel to and co-extensive area-wise with the active seat or back-forming area of the finished product. The envelope is thus divided interiorily by the partitioning member into several compartments into which a foam mix is introduced. The method of manufacture involves first peripherally bonding together an assemblage of congruent cover and internal partitioning sheets, together with one or more similarly configured annular profile strips, to form a peripherally closed envelope.

Abstract: A battery separator envelope is provided having two walls of battery separator connected together by a foam member. In a method, two walls of battery separator are secured on a mandrel by sandwiching the mandrel and the walls of battery separator in a jig. A foam bead is then extruded between the walls and the bead is tamped and squeezed to complete the final formation of the foam member. The apparatus includes the mandrel, jig, extruder and support for guiding the jig assembly past the extruder.

Abstract: A method for producing articles of a cellular plastics material provided with a surface covering comprising a film or foil of a thermoplastic material or a metal or a textile where the side of the covering facing the cellular plastics material is treated with or comprises a chemical substance acting as a retarder for the chemical reaction providing the bonding between the covering and the cellular plastics material. The cellular plastic material is able to expand freely in a mold and to bond to the covering without forming a deformed cellular structure in the cellular plastic material in the boundary layer adjacent to the covering.

Abstract: A welding method for joining self-supporting structures made of thermoplastics by assembling said structures to form an area of mutual overlap, generating heat in said area to produce a welding zone having an elevated temperature and containing said thermoplastics in an at least plastic state for mutual coalescence of said structures in said area; an expanding agent is provided in the welding zone to generate a gas pressure therein for promoting coalescence of the weld. The invention is particularly suitable for welding tubes and other pipeline elements, such as fittings or sleeves, of thermoplastics and produces a tumescent weld which fills any macroscopic voids while including a plurality of minute closed cell voids.

Abstract: A method is disclosed of reshaping a sheet of resiliently deformable material impervious to fluid by conforming it to the cavity of a female mold and casting a flexible plastic foam into contact with said sheet material, whereby said material is integrated with the foam and forms a cover sheet therefor. A perforated elastic diaphragm is interposed, during the reshaping and foam casting process, between the cover sheet and surface of the mold cavity so that the cover sheet is in superimposed direct contact with the diaphragm throughout its area. The two are clamped to the periphery of the mold to form a seal thereat, and a differential pressure is applied across the cover sheet and diaphragm. The sheet is therefore deformed against the walls of the mold simultaneously with the diaphragm and is stretched evenly with the diaphragm in order to produce uniform thickness.

Abstract: Method is disclosed for preparing a honeycomb insulation structure having its cells partially filled with a low density foam and a high density integral skin completely covering one edge of the honeycomb. Method comprises placing one edge of a honeycomb in an inert material; introducing a foamable or foaming substance into the cells and allowing it to rise from the surface of the inert material until it overflows slightly. The overflowing foam comes into contact with a pressure platen just above the honeycomb thereby forming the high density integral skin. The level of the material in the cell determines the thickness of the void on one edge. Structure has utility in cryogenic storage.

Abstract: A fiber bundle is first formed of entangled fibers by passing fibers through the tapered mole of an extruder, and then the fiber bundle is provided with at least one longitudinal groove which provides an air passage in the final product communication between the ink reservoir and the atmosphere. Subsequently, one end of the fiber bundle with the longitudinal groove is dipped into a liquid urethane prepolymer to form a nib portion by impregnating the dipped portion with the prepolymer. After removal from the liquid prepolymer it is left to stand. During this standing or setting period the reactions among the constituents of the prepolymer and the volatilization of solvent produce a set urethane nib portion having capillary passages therein, and an air passageway where the groove was formed. The fiber bundle thus produced which is called "core portion" of the pen, is machined at its impregnated end to form a nib. Thus, the product consists of a nib material portion and an ink reservoir integral therewith.

Abstract: A process for environmentally sealing and strain relieving at least one electrical lead wire connected to an interior terminal of a connector of the type which possesses a tubular orifice through which the lead wire extends comprising the steps of disposing a laminated disc comprising a lower layer of foaming adhesive, an upper layer of fusible adhesive, and an aperture corresponding to each electrical lead wire within the tubular orifice with the lead wires extending through the corresponding apertures; and heating the disc whereby the foaming adhesive is caused to foam and the fusible adhesive is caused to melt and flow.

Abstract: A disclosed refrigeration cabinet has an integrated construction of sheet material and insulating foam which substantially eliminates the need for mechanical fasteners and welding, minimizes assembly operations, and permits the use of prefinished sheet panels. An outer cabinet shell preferably includes a prefinished sheet wrapped into a rectangular tube. The shell tube is reinforced at one end by a perimeter frame and at the other end by a thermal breaker collar. After the shell tube and frame are assembled, a liner is positioned in the tube and the breaker collar is installed. Rigid insulating foam is then foamed in place between the shell and liner to produce a sandwich construction in which the form secures and reinforces both the shell and the liner.

Abstract: The method includes use of a stationary hollow mandrel supported at one end, a pair of forming shoes over which strips of material are respectively pulled longitudinally of the mandrel to provide a cylindrical inner liner surrounding the mandrel and a cylindrical outer jacket surrounding the inner liner in spaced relationship thereto, a conduit having an outlet end portion disposed within the outer jacket above the inner liner, supply means for supplying foamable hardenable exothermic reacting liquid material to an inlet end portion to the conduit, additional supply means for separately supplying a fast acting catalyst to the foamable material in the conduit, means for reciprocating the outlet end portion of the conduit transversely over the inner liner, conveyor-mold means confining the outer jacket as the foamable foams and cures, rotatable tire means for pulling the insulation formed by the outer jacket, the cured foam, and the inner liner off the mandrel longitudinally thereof, a traveling saw for cutting

Abstract: An improved seal for closing the space between a pipe and the wall of an opening through which it passes, using a linear extrusion of elastomeric material, of predetermined length to form a gasket. The extrusion has a hollow, pear-shaped head formed integrally with a T-shaped anchoring flange. It is curled into the form of a right cylinder, and its mating ends are vulcanized together. The pear-shaped portion is deflected radially inwardly and the T-shaped anchoring flange outwardly, the latter being then embedded in concrete used to wall the opening for the pipe. The pear-shaped portion is free in space and provides a pneumatic cushion for the pipe.

Abstract: Cavities are filled with a foam insulating material by introducing the reaction mixture through the outlet nozzle of a mixing head which is drawn lengthwise through the cavity at a rate adapted to the rate of foaming, wherein the reactivity of the reaction mixture is accelerated during the filling procedure so that the reaction mixture is foaming up simultaneously over the length of the cavity.

Abstract: Method of making a mold for vacuum thermoforming is made by (a) applying a polyester gel coat to a master pattern; (b) applying a rigidizing mixture of a thermosetting resin and glass to the gel coat; (c) constructing and bonding an egg crate framework to the cured thermoset resin and glass fiber mixture; (d) filling the spacings of the egg crate framework with a polymeric rigidizing foam; (e) forming a vacuum plenum on the foam-filled egg crate; (f) attaching to the vacuum plenum a means for introducing a vacuum and; (g) forming air passageways through the gel coat which communicate with the vacuum plenum.

Abstract: A pipeline retard, support, and protection method wherein a fast-setting, expandable, organic spray foam is sprayed at spaced locations in a trench to create support pads and retards in the trench. The foam constituents are mixed in a spray apparatus and directed as a spray foam into the trench where it rapidly expands and stiffens into a layer of foam. Rapid expansion and corresponding rapid stiffening is believed to cause the cells in each layer of the foam structure to be elongated essentially normal to the plane of the layer. This cellular configuration in each layer imparts vertical strength and limited lateral flexibility to the structure. A plurality of layers of foam are sequentially formed in the trench to fabricate the desired structure. The placement of each layer is sequenced so as to permit a membrane to form on the surface of each layer for improved strength and inhibition of water penetration.

Abstract: A process for molding structural members, as for example a boat hull, from plastic sheets. The main body and the deck of the hull are separately vacuum-formed. Plastic foam is then adhered onto the interior surfaces of the sheets. The main body and hull thereafter joined along the gunwale.