Abstract: An irrigation device in the form of an elongated conduit of predetermined length wherein the conduit comprises a one piece wall of plastic material formed by extrusion in a continuous length. The conduit comprises at least two compartments having specific relative dimensions and disposed in fluid communication with one another wherein the configuration and disposition of the two compartments are defined by the configuration of the single wall portion which is formed from the single piece of extruded material. Dispersion means in the form of a strip of elongated liquid permeable material is mounted within one of the compartments and configured to extend outwardly to the exterior of the conduit whereby liquid is dispersed through the two compartments to the exterior of the conduit through the liquid permeable dispersion element by a capillary-type action.

Abstract: A flame-resistant cushion includes a frame, an inner core of foamed polyurethane material carried by the frame, and an exterior layer of foamed neoprene bonded to and completely covering the entire surface area of the top, front, back and both sides of the core material. A metal pan is also secured to the seat frame to enclose the bottom of the cushion. In making the cushion, a latex water emulsion of neoprene is foamed and deposited in a thin layer on a carrier sheet. This composite lines a mold with the foam side engaging the mold; and unreacted polyurethane foam is poured into the mold. The adhesive properties of the polyurethane cause it to bond to the carrier sheet as it gels forming an integral cushion material with a covering of neoprene for greater fire resistance.

Abstract: A method of making a foam-filled tire wherein a resilient elastomeric foam is formed and cured within a tire carcass while the carcass interior is at super-atmospheric pressure. Such superatmospheric pressure is believed to support the cell walls against internally generated gas (blowing) pressures, thereby stabilizing the cells at higher than usual internal cell pressure. The foaming operation is carried out so that the foam only partially fills the carcass interior. After the elastomeric foam has been cured the tire carcass interior is depressurized down to the pressure to be used in service. During the depressurization process the internal cell pressures cause the cells to expand and further fill the tire interior space. The depressurization processis carried out after the elastomeric foam has been cured, i.e. when the cell walls have attained their full potential strength.

Abstract: The disclosure is of a moulded light-weight panel and its manufacture, the panel comprising sheets of foamed material and cardboard, which may be corrugated, impregnated with a solution of elastomer which becomes polymerized to bond all the components of the panel together in a mould. Reinforcing and fastening elements may be incorporated in the panel.

Abstract: A system for sealing and repairing leaks in ruptured containers whereby an applicator including an open-celled sponge body is inserted into the rupture and the two interacting components of a binary fluid foam composition are mixed and injected into the sponge body, thereby expanding and forming a foam composite with the latter against the rupture to effectively seal and repair same upon curing of the foam in situ.

Abstract: A refrigeration apparatus enclosure and method of forming the same wherein an inner laminate wall is provided in an outer cabinet for providing the sheet liner and insulation portions of the refrigeration apparatus enclosure. The laminate wall is folded along lines cut through the insulation to conform to the configuration of the outer cabinet and insulation is provided for filling the resultant voids to complete the enclosure construction. The voids are filled by foamed-in-place plastic which may further serve to bond the laminate wall to the outer cabinet. The rear wall of the cabinet may comprise a flat laminate wall and a divider wall may be provided within the cabinet for dividing the space therein into separate compartments. The divider wall may comprise another laminate wall.

Abstract: Disclosed is a method and apparatus for forming a joint in a confined space between two abutting ends of conduit liners. In the method, an excavation is formed to provide access to a buried conduit. Thereafter, the conduit is opened and cleaned of debris and elongated sections of conduit liner are inserted through the opening into the conduit in opposite directions from the opening. Once insertion is completed, a sleeve is positioned concentrically around one of the conduit section ends. The ends of the sections are positioned in an abutting coaxial relationship and are aligned and attached together by tape. The sleeve is then moved to a position overlapping the intersection of the two sections and the annular space between the sleeve and the exterior of the conduit sections is closed by sealing with foam rubber stripping constrained by tape. A polyurethane material is injected through a port in the sleeve to fill the annular space. Thereafter, the polyurethane material is allowed to set.

Abstract: A method of manufacturing a flexible cushion of foamed plastics material with an integrated cloth cover, comprising forming under vacuum to apply the cloth cover to the inner wall of a mold, and casting a plastics material capable of forming flexible foam, wherein before vacuum forming the cover in the mold the cloth is preformed, and wherein the cloth is maintained adjacent its periphery in a frame which allows the cloth to slide inwards without substantially elongating and undergoes at the level of the frame a peripheral shrinkage while avoiding plait formation, the cloth thus shaped being then fixed at the level of the frame.

Abstract: A metal seat pan is placed inside a rotational casting mold to define part of a rotational casting cavity into which is introduced rotationally castable material for forming a flexible plastic seat cover. A rotational casting operation produces a closed, hollow seat cushion shell defined by the seat pan and the flexible plastic cover. Foaming ingredients are introduced into the hollow shell to form a resilient foamed plastic interior. The resulting seat cushion is monolithic, without seams or joints and has no removable parts or mechanically joined components which will come apart from each other.

Abstract: An improved method of making syntatic modules which includes the following steps. A preform mold and a casting mold are formed of predetermined configuration. A woven roving of predetermined size is formed to provide a skin. Additionally a layer of spacer material is formed which includes a plurality of voids. The roving is attached to the spacer material to form a laminate. The laminate is formed to the insidewalls of the preform mold and then the preform mold is filled with a plurality of hollow balls. A thin layer of resin is poured into the preform mold to connect the balls. The composite is removed from the preform mold and placed into the casting mold after spacer material is attached to the exposed end portions of the composite. A syntatic foam resin is added to the casting mold interior so as to fill all spaces between the balls and all voids in the spacer material. The syntatic foam resin is then cured and the mold parts are removed thereby producing a module.

Abstract: A lightweight, thermally insulated block form for reinforced concrete construction, having voids extending between the top and bottom for the reception of concrete, is formed with a sheath of a non-combustible porous material, and a core of foamed plastic. The concrete receiving voids in the core are lined with circular cardboard tubes. In the finished construction the organically based plastic foam is enclosed in the inorganic non-combustible sheath and the surface of the sheath is sufficiently non-resilient so that when properly coated to seal and protect the surface it may act as a finished building surface. The cardboard tubes contain the concrete slurry so as to isolate the low tensile strength, low modulus of elasticity block against forces which might crack or distort the block.The block is formed by joining four rectangular slabs of the sheath material at their ends to form an open-ended rectangular tube.

Abstract: An open pore liquid purification apparatus containing semipermeable membranes, is made by: (1) placing a module, made of bonded, resin coated filler particles, having a plurality of spaced circular bores therethrough, in a stationary vertical position, (2) placing a viscous casting composition into each of the bores, the composition containing 10 parts polysulfone resin and 10-40 parts of an organic solvent, the solvent being effective to homogeneously disperse and partly dissolve the polysulfone, (3) gravity dropping a casting bob, having a circular cross-section at its widest point, down through each bore to form a continuous film of casting composition on the inside of each bore, and then (4) immediately exposing the film to a low humidity atmosphere, and (5) contacting the film with a suitable leaching liquid, to form a polysulfone ultrafiltration membrane on the inside of each module bore; the membrane being resistant to solvents and operable at a pH of about 1 to 12 and a temperature of about 5.degree.

Abstract: A method and apparatus for forming large fiber-reinforced foamed plastic panels is disclosed. The panels are produced by a process comprising filling a flat mold with freshly mixed foam plastic precursors, including fibrous material for reinforcement of the panels, closing the mold until the plastic precursors have foamed and set, then opening the mold and removing the finished panel. The apparatus comprises a platen mounted for traversing under the dispensing outlet of a mixing device, whereby the platen is filled with foamed plastic precursors, and a press into which the platen travels before the mixture has begun to mold. The press is provided with a novel mechanism for closing the mold by placing a cover on top of the platen before the plastic begins to foam. The same mechanism is adapted to open the mold by lifting the platen cover. Thereafter, the platen is moved in a reverse of its entry movement, returning to its starting position for removal of the finished panel.

Abstract: A procedure for refurbishing hollow metal buoys that have been surveyed out of service. The buoy repair method involves removing a metal section, filling the buoy interior with polyurethane foam, welding back the removed metal section and coating the metal exterior with fiber glass-resin composition. Buoys repaired in this manner are essentially maintenance free.

Abstract: Improved insulation system for cryogenic vessels wherein substantially uniform stress levels under loads are maintained in various parts of the foam insulating material layers applied to the wall structures of such vessels and methods for applying foam insulating materials to the said vessel wall structures.

Abstract: A method for preparing and an apparatus for supporting appliances thereon, the support being a base member with means on the top side thereof for mounting an object thereto. The base member is comprised of a conduit member having disposed at preselected portions therein hollow inserts arranged with axes at right angles to the axis of the conduit member and surrounded by resilient foam materials which maintains the base member in a preselected configuration to support the object mounted thereto.

Abstract: An object to be packaged is suspended in an upwardly open mold whose walls are formed with an array of throughgoing perforations and lined with a gas-pervious sheet. A similarly perforated and lined cover is placed over the mold and foamable polyurethane material is poured into the mold through an elastic hose-like conduit connected to a filling aperture on the mold cover. This material expands within the mold completely filling the space around the object and thereby forms a fitted package around the object. The gas-pervious sheet material lining the mold may be a plurality of synthetic-resin panels formed of parallel inner and outer walls spaced apart by parallel webs defining between the inner and outer walls a plurality of parallel passages. These inner and outer walls are formed with throughgoing perforations opening into the passages so that as the synthetic-resin material expands it passes through the perforations on the inner walls only and projects into the passages.

Abstract: This invention relates to a method of making fabric-faced upholstered items. The items are made by vacuum forming under heat a laminate of a cast highly plasticized vinyl chloride homopolymer or copolymer sheet and a readily extensible fabric, and the resulting shaped cover is filled with a foam which is foamed in situ, the foam bonding to the thermoplastics sheet of the laminate and holding the laminate in shape. The laminate must have an extensibility in two directions at right angles of at least 25% under a load of 51b per 2 inch wide strip when subjected to loads of 51b applied at right angles to one another to the edges of a 2 inch side square of the fabric, and be capable of increasing its surface area by at least 50%. The fabric can have this high degree of extensibility and still be suitable as a cover because the laminate is bonded to the foam filling and so held to shape.

Abstract: In a lubrication system for an apparatus having a bearing assembly in a lubricant cavity therefor, there is provided means in the lubricant cavity for storing a liquid libricant and for releasing it to effect a supply thereof to the bearing assembly. The storing and releasing means is generally constituted by a mixture of the liquid lubricant, a particulate mass of synthetic fibers, and a particulate mass of discrete, non-fibrous, multi-digited, resilient-type foam particles and wherein the foam particles of the particulate mass thereof are generally saturated with the liquid lubricant.

Abstract: Method of making a heat-insulation-lined tank for low temperature liquids comprising a foamed insulation layer secured to the inner wall surface of the tank to be insulated, a plurality of wires in layers assembled crosswise in a netlike fashion and embedded in the insulation, and a liquidtight wall that covers the inner surface of the insulation, the spacings of the wires in netlike layers and of the layers themselves being made narrower on the low-temperature side or with the approach to the innermost layer of the lining. The tank has no possibility of cracking in the insulation layer due to thermal strains on exposure to low temperatures. A method of easily and satisfactorily manufacturing such an insulation-lined tank is also provided.

Abstract: An insulating building block which is a composite of masonry material and a foam material is disclosed. The building block is obtained by applying a layer of foam material to a longitudinally extending side face of a cavity located within the block. A shield insert may be employed to define that portion of a block cavity which is to receive the foam.

Abstract: An improved process for preparing foamed articles of thermoplastic resin having a hard, mar-resistant surface that is flat and smooth and resembles natural wood, and an extrusion die therefor. In the process a softened thermoplastic is extruded through apertures of the extrusion die of the invention which is a fiered die having a resin discharge plate having a peripheral recessing portion and a protruding interior portion which are formed on the resin discharge plate by one or more step-ups. Each of the peripheral and interior portions of the resin discharge plate is provided with a plurality of apertures, the aperture density of the peripheral portion being greater than that of the interior portion. A longitudinally extending cooling frame is mounted adjacent the resin discharge plate and extends in the direction of extrusion to at least the forward face of the interior portion of the plate.

Abstract: Disclosure is made of a universally fitting electrical insulator for mounting between the armature shaft and the windings and laminations of an armature. The disclosure is also of a method for mounting the insulator in the armature. The insulator and method are particularly useful in the production of double insulated electrical hand tools.

Abstract: An apparatus in which a sheet is folded as a wrapper and filled with heat expandable plastic material and heated to expand said material by passing heated fluid through perforations in the sheet.

Abstract: A method of making an insole having a heel positioner and an arch support, in which the positioning support for the heel is made in situ, in one discrete section of the foot support, and the arch support is then made, in situ, in a second discrete section.The first discrete section is made at the heel portion of the foot, in a manner so as to stabilize the plantar surface of the heel section of the foot under the cancaneous bone. This is for the purpose of eliminating, reducing or minimizing the rotation forces applied to the heel section of the foot by the weight of the body, which would normally tend to produce a pes valgus (outward bending) or a pes varus (inward bending) condition, as well as stabilizing the anterior - posterior position of the leg in its function of bearing body weight.

Abstract: A composite building module such as a wall panel having a core of rigid foam such as urethane foam encased in a shell made of fiber (e.g. glass fiber) reinforced cement. The shell has a bottom half and a top half. The bottom half has a peripheral ledge and a rib extending above the level of the ledge. The top half has side walls forming a channel with the rib when the top half is in place on the bottom half. The core is foamed in the enclosed shell and fills the interior thereof including the channel.

Abstract: The invention relates to a method for the continuous manufacture of panels of synthetic material with at least one surface covered with a rigid facing by means of a machine comprising: devices for the continuous advance of the facings; a distributing station to deposit, on a lower facing, in liquid form, expandable synthetic material which will constitute the inner layer of the panel; and continuous conveyor means, arranged above and below the plane of advance of the panels.

Abstract: A method of making a covered article such as an automobile seat cushion is disclosed. The method includes the steps of forming covering members from a covering material which is impervious to a foam material formed by reacting a foamable composition. The covering members are sewed together along sew lines to form a cover. A peripheral edge of the cover is joined to an interior peripheral edge of a locating member. A plurality of small openings are formed along the sew lines of the cover in the sewing operation. These openings are sealed so that the foam material produced upon the foaming of the foamable composition cannot flow therethrough. The cover and attached locating member are positioned in a foaming mold. The locating member aligns the cover properly with respect to the foaming mold so that a vacuum can be drawn on a die surface of the mold to draw a surface of the cover into contact with the die surface.

Abstract: A composite foamed synthetic resin bowling pin is formed by first placing a base support element composed of a disc element and having a central sleeve with a hollow reinforcing tube secured thereto and an annular collar with an outwardly extending transverse flange thereon of lesser diameter than the disc element in one end of an undesired mold cavity. The peripheries of the disc elements and flange are disposed in recesses in the mold cavity wall. A foamable thermosetting resin reaction mixture is cast in the mold cavity and foamed and cured. The resulting assembly is then inserted in second mold of larger diameter and of the size of the final product. A molten thermoplastic resin is then introduced into this second mold cavity to form a thermoplastic shell on the assembly and which shell is interlocked with the collar on the base support element.

Abstract: A hollow structural member formed of thin sheet steel is formed with one or more longitudinal joints and the interior is filled with a rigid lightweight synthetic plastics foam such as polyurethane. Each joint includes folded lips or flanges which are designed to provide a restricted clearance or gap into which the foaming material penetrates and changes from a cellular to a non-cellular composition and also provides an adhesive bond at each joint and a moisture proof seal.

Abstract: Method and apparatus for building construction wherein the building is formed as an integral unit of synthetic material. A first form means is provided which defines cavity portions representative of a building construction, walls and ceiling portions including predetermined utility component openings, window and door openings. Utility components including electrical environmental control and plumbing are positioned within the cavity portions of the first form means adjacent the predetermined utility component openings. Door and window frame means are positioned within the first form means adjacent the window and door openings. An additional form means is added to the first form means for effecting a substantially enclosed cavity portion representative of a pre-designed building. Means is provided for filling the enclosed cavity portions defined by the first form means and the additional form means with synthetic building material.

Abstract: The opposed moulded plastic shells of a shell covered foam filled structural member suitable for boat hulls and decks are connected together by a strip of material extending between the shells and anchored in the foam filling. Flaps are provided on the connector strip overlying the periphery of the plastic shells in sealing relation therewith. The flaps can be provided on a separate strip with a tongue seated in a recess of the strip anchored in the foam. The connector strip has an outer edge portion secured in the parting line of moulds carrying the shells and providing a cavity for the foam which is severed from the connector strip after removal from the moulds.

Abstract: Apparatus for molding a composite styled wheel for use on automotive passenger vehicles and the like, a method of constructing such a wheel employing the molding apparatus and a method of constructing such molding apparatus, wherein a portion of the mold comprises a conventional metal vehicle wheel having a drop center rim secured to a central disc or body having the usual bolt circle holes and a central aperture so that the disc can be mounted on an axle, drum or disc brake assembly. The metal wheel is employed in conjunction with an upper back-up clamp and lower mold part to define therewith a sealed cavity for molding and attaching a three-dimensional contoured plastic overlay, the overlay thus being molded in situ and permanently attached to the outboard side of the wheel in the mold apparatus.

Abstract: For manipulating a length of non-rigid tubing into position around a swing joint (which includes a 90.degree. fitting) in an underground pipe, a rigid guide tube (through which the non-rigid tubing may be passed) is utilized. The lower end of this guide tube is landed in the 90.degree. fitting, and a wedging member or whipstock, manipulatable from the surface, is operated to hold this end of the guide tube solidly in position in the 90.degree. fitting. After the guide tube is thus secured, the non-rigid tubing is passed down through the guide tube and around the 90.degree. fitting into a laterally-extending pipe; then, a foam-forming composition is pumped through the non-rigid tubing into this latter pipe to form a foamed plug therein.

Abstract: An improved joint seal for a clay tile pipe having bell and spigot configurations is provided with unsaturated polyester resin in a foamed, low density state, preferably below about 50 pounds per cubic foot.

Abstract: A body to be packaged is suspended on filaments in an upwardly open porous mold which is lined with a gas-pervious sheet material. The mold is capped and a synthetic resin is introduced therein and expanded, the air in the mold being displaced out through the mold walls, to completely encapsulate the body. The supporting filaments, extending from the package so formed can be drawn across each other to cut an opening in the package permitting the packaged body to be removed. The sheet material covers the outside of the package, being integral therewith, and protects the package while permitting it to be written on.

Abstract: A method of making a resilient storage insert for holding fragile compone comprising the steps of first vacuum forming a sheet of flexible acrylonitrile butadiene styrene in a male die and then placing said vacuum-formed sheet in a female die, then filling the underside of said vacuum-formed sheet with polyurethane foam material and then curing said polyurethane foam material.

Abstract: Disclosed is a method and apparatus for repairing a buried main having connected lateral service conduits. In the method, a main is opened and cleaned of debris. Thereafter, an elongated conduit liner is axially inserted into a length of the buried main. The lateral service conduits are opened and cleaned from a point remote from their connection to the main. A dispenser is axially inserted through the service conduit to a point adjacent to the connection. At the connection, polyurethane material is dispensed into a portion of the service conduit and in the annular space between the main and the liner. Thereafter, the dispenser means is removed from the service conduit and the polyurethane material is allowed to set. A cutter apparatus is axially inserted into the service conduit and is manipulated to form a port through the polyurethane material and the wall of the liner to connect the service conduit to the liner.

Abstract: A method of restoring the shape of an anatomical model comprising placing mold inserts in the undercut portions of the model, charging the model with a foaming thermosetting plastic, and enclosing the model and mold inserts in a fixture. As the foaming thermosetting plastic expands, the model is pressed against the inserts and the fixture causing the model to assume the shape of the fixture and inserts.

Abstract: A foam cushion with a covering of an elastic textile sheet structure is produced in a vacuum deep-draw mould by holding the sheet structure down during the suction cycle with a hold-down plate, but allowing it to slip through locally.

Abstract: A polyurethane pre-foam formulation having improved adhesion to polyester resins is disclosed. The polyurethane is of the type formed by the reaction of an isocyanate and a polyol together with a blowing agent. The improved formulation contains a polyester resin between about 1 and 10% by weight of the polyurethane together with a sufficient amount of a free radical catalyst to bring about a cure of the added polyester resin. Preferably, the improved polyurethane prefoam is foamed and cross-linked in contact with a partially uncured but gelled unsaturated polyester laminating resin which contains an unsaturated monomer such as styrene. When such a polyester and a polyurethane foam are cured together, a superior bond between them results when the polyurethane formulation is compounded in accordance with the teachings of the present invention.

Abstract: The invention pertains to a process for the continuous production of thin polyurethane foam layers, in which a band-like supporting layer is moved longitudinally and locally guided so as to take a nearly cylindrical shape, the axis of which is horizontal and perpendicular to the general direction of the band motion, and a reacting mixture is projected on the supporting layer by means of a vertical, rotating projection disk, reciprocating along the axis of the said cylindrical shape.

Abstract: A process for making composite articles, such as upholstery, filled with a cellular polyurethane foam covered by a breathable, porous fabric includes coating one surface of the fabric and the pores therein with a strippable coating. The fabric is then placed in a mold with the coating against the inside of the mold and is pulled down into conformity with the mold by vacuum. A liquid polyurethane foam resin is poured in place behind the fabric and foamed to a flexible solid state. The article is removed from the mold and the coating is stripped to complete the process.

Abstract: 1. A method for erecting a building structure comprising: inflating a form, .[.positioning thickness gauges within the inner surface of the form, said thickness guages being preformed from a plastic foam material,.]. spraying a .[.n additional quantity of the same.]. plastic foam material against the inside of the form to build up a .[.layer having a thickness determined by the thickness gauges which become integral with the.]. layer, .[.and.]. allowing the plastic foam to harden and become rigid and self-supporting .[...]. .Iadd.and coating the inside of the layer of foam with a layer of concrete..Iaddend.