Abstract: A method of the invention can produce a fiber-reinforced thermoplastic resin foamed product having less unevenness in a thickness of a surface layer and excellent mechanical strength. In the method, a fiber-reinforced thermoplastic resin sheet is continuously shaped into a hollow member, and a foaming resin composition containing a thermoplastic resin and a foaming agent is supplied into an interior of the obtained hollow member. The foaming agent is foamed so that the hollow member is shaped into a desired form by the foaming pressure.

Abstract: A method of making a resilient composite structure having an exposed reinforcing fabric layer free of structural foam and curable resin and for manufacturing a composite article utilizing the resilient composite structure. The method for manufacturing a composite article includes the steps of positioning at an attachment point within the first plastic shell a resilient foam core composite structure having an exposed reinforcing fabric layer attached to a non-woven fabric layer on one side thereof, the resilient foam core substantially filling interstices of the non-woven fabric layer, without substantially penetrating the reinforcing fabric layer; saturating said reinforcing fabric layer with a curable plastic resin; positioning said second plastic shell on said first plastic shell so that said resilient composite structure contacts an attachment point of said second plastic shell and is compressed between the plastic shells; and allowing said plastic resin to cure.

Abstract: A process for producing pipes insulated with foams comprises providing, between an inner carrier pipe and an outer pipe arranged parallel thereto, a holder which is provided with at least one aperture and is mounted so that it can be moved axially and positions the carrier pipe in the outer pipe and introducing into the vacant space between the two pipes, via the aperture(s) in the holder, a mixture for the preparation of foams, where during the introduction of the mixture, the holder moves in an axial direction with respect to the outer pipe and the carrier pipe, then after the mixture is charged, it is reacted to give the foam and the holder and, if desired, the outer pipe are removed.

Abstract: In the end portion of a weather strip, the projecting base end portion of a hollow seal portion is left as a first uncut-off portion, whereas the main portion of the hollow seal portion is cut off. The thus treated end portion is set in a split mold. In this setting, a cooling mold is brought into contact with a decorative high molecular layer. Also, the first uncut-off portion is pushed down in a direction away from the decorative high molecular layer is thereby pressed against the outer surface of the side wall of a trim portion. Also, a first middle mold is disposed opposed to the outer surface of the side wall to thereby form a cavity, while the cavity and decorative high molecular layer are separated from each other through the first uncut-off portion. Molding material is injected into the cavity to thereby form a mold forming portion.

Abstract: A method of an integrated molding by integrally pressurizing and compressing by use of means of an upper mold and a lower mold, by use of a silicone rubber. A silicone rubber has excellent resiliency, thermal resistance, separating ability from the molds and the like. By use of a silicone rubber, a working efficiency for carrying out the integrated molding can be improved and a compressing timing can be easily taken. A method according to the invention comprises steps of: uniformly coating a mixture of a foamed urethane body on a silicone rubber horizontally held; and integrally pressurizing and compressing for a certain period by an upper mold and a lower mold. The step of uniformly coating the mixture is carried out by using a spraying technique. The silicone rubber can be attached on an inner surface of the lower mold by use of means of vacuum suction.

Abstract: A composite spring-damper and method of making same. The spring-damper has an exposed fabric layer free of structural foam and curable resin. A core formed of resilient foam defines a spring shape and a fabric layer disposed on an outer surface of the core is attached to foam core by means of the foam having substantially filled only interstices of an inner portion of the fabric layer, without substantially penetrating an outer portion of said fabric layer; whereby the fabric layer of the composite spring-damper may thereafter be substantially completely saturated with a curable material for lamination to another structure. An attached reinforcing fabric layer may be provided on the exterior surface of the fabric layer, in which case the fabric layer may be entirely saturated and only the attached fabric layer substantially free of foam.

Abstract: A process and an apparatus for molding, in which a molten thermoplastic resin is firmly fitted onto a molding surface of a mold under a pressure lower than or equal to 100 kg/cm.sup.2 and is cured to obtain a molded product. The molding apparatus has a mold main body, and a mold body on which the molding surface is defined. The mold body is supported relative to the mold main body with maintaining a space on the back side of the molding surface in a heat insulative manner by a supporting member which includes at least a heat insulative supporting member having a thermal conductivity of 0.001 to 1 Kcal/mh.degree. C. and a longitudinal elastic modulus of 0.01 to 10 kg/cm.sup.2. In the space, a heating fluid for heating the molding surface from the back side to a temperature higher than or equal to Vicat softening temperature (T).degree. C.

Abstract: A foam composite material comprising a first isocyanate-based polymer foam comprising at least one uncontoured surface and a second, molded isocyanate-based polymer foam, the first isocyanate-based polymer foam and the second isocyanate-based polymer foam being: (i) of different composition, and (ii) fixed with respect to one another. A process for producing the foam composite material also disclosed. The foam composite material is useful in another of vehicular and non-vehicular applications.

Abstract: A phase separation apparatus such as a filter element or papermaking belt comprises an ormocer which provides abrasion resistance, cleanliness and stability.

Abstract: A corner reinforcement for use in strengthening screen frames, for example, includes at least a first segment and a second segment of screen bar, each formed into a desired profile and each having a hollow interior portion, a reinforcing channel and a rigid reinforcing and structural material. The reinforcing channel has a first leg and a second leg arranged at approximately ninety degrees to the first leg with ends of the channel securing first and second extensions to extend the first and second legs, respectively. At least a portion of (i) the first extension of the channel is inserted through a first end of the first segment of the screen bar into and substantially spaced from surfaces of the hollow interior portion thereof and (ii) the second extension is inserted through a first end of the second segment of the screen bar into and substantially spaced from surfaces of the hollow portion thereof.

Abstract: A small amount of a non-yellowing surface-forming polyurethane material containing a polyether polyol, a hexamethylene diisocyanate trimer, a coloring agent and an organic bismuth catalyst is initially injected into a mold cavity under reduced pressure to form e.g. the surface portion of a polyurethane covering for a steering wheel. An inner-forming polyurethane material is subsequently injected into the cavity under reduced pressure to form an inner portion of the covering.

Abstract: Convoluted tubing for automotive wiring harnesses and other elongated substrates is provided with sound dampening qualities by filling the valleys between convolutions with a flexible, resilient foamed composition, such as silicone rubber, and foaming the composition to cause expansion of the foam so that ribs of foam project radially from the valleys. In a preferred embodiment, spaced apertures are formed in the valleys to allow the expanding foam to form radially inwardly projecting fingers which contact the wiring harness and act to dampen vibrations. The corrugated tubing may be axially slit and the slit allowed to be filled with the foamed composition which, when foamed, eliminates noises caused by movement of the edge surfaces of the slit when torsional forces are applied to opposite ends of the tube.

Abstract: A method for producing a foam-containing structure. In a first embodiment, a defoamer is applied to the inner surface of an impermeable carrier. A foamed resin is introduced inside the carrier and contacts the defoamer to form a liquid resin layer on the inner surface. The foamed resin and liquid resin layer are cured to produce a foamed resin inner core and a solid resin outer layer. In a second embodiment, a permeable carrier is covered with an impermeable release material. A defoamer is applied to the carrier. A foamed resin is introduced inside the carrier and contacts the defoamer to form a liquid resin layer impregnating the carrier. The foamed resin and liquid resin layer are cured to produce a foamed resin inner core, the carrier as a facer material, and a solid resin layer impregnating the carrier. In a third embodiment, a defoamer and a catalyst are applied to a permeable carrier.

Abstract: In a process for extruding polymer melts (25) to form hollow chamber sections (21) by pressing the polymer melt through a shaping tool (24) with an internal shaping mandrel (26) and by subsequently sizing and cooling the hollow chamber section strand in a sizing and cooling unit (31) it is provided for the sizing and cooling of the hollow chamber section strand to be carried out in the sizing and cooling unit under extrusion pressure. A device for carrying out this process is characterized in that shaping tool (24) and sizing and cooling unit (31) are rigidly connected to form a closed system so that the strand extrusion pressure prevailing in the shaping tool can be propagated into the sizing and cooling unit, and that the shaping mandrel (26) protrudes out of the shaping tool (24) into the sizing and cooling unit (31).

Abstract: A method of filling an elongated generally lineal channel with polymeric resin foam, preferably polyurethane foam, using an application gun having a laser sight for accurately aligning the application gun relative to the longitudinal axis of the channel to be filled.

Abstract: The subject invention pertains to unique methods for producing articles with a polyurethane integral skin at low cost. The methods of the subject invention permit the production of highly detailed painted articles having an outer polyurethane layer and an inner polyurethane foam structure, wherein the outer layer is waterproof. The subject invention further pertains to the articles produced by the methods of the subject invention.

Abstract: A composite material having a skin layer, an intermediate, cushioning layer provided on one side of the skin layer, and a backing layer provided on the cushioning layer, wherein the backing layer is made of a non-crosslinked polypropylene resin foam and having a melting point MB in the range of 130-170.degree. C., wherein the cushioning layer is a crosslinked polypropylene resin foamed sheet having a gel fraction of 20-70% by weight. The cushioning layer has an endothermic peak in DSC curve at a peak temperature of PC which is in the range of 130-170.degree. C. and which is not smaller than (MB-15).degree. C. but not greater than (MB+10).degree. C. The endothermic peak has such an area at temperatures higher than MB that corresponds to a calorific value in the range of 3-30 J/g. The backing layer may be formed by expansion molding of expanded polypropylene particles within a mold cavity in which a laminate of the skin layer and the cushioning layer is placed in position.

Abstract: A corner reinforcement for use in strengthening screen frames, for example, includes at least a first segment and a second segment of screen bar, each formed into a desired profile and each having a hollow interior portion, a reinforcing channel and a rigid reinforcing and structural material. The reinforcing channel has a first leg and a second leg arranged at approximately ninety degrees to the first leg. At least a portion of (i) the first leg of the channel is inserted through a first end of the first segment of the screen bar into and substantially spaced from a surface of the hollow interior portion thereof and (ii) the second leg is inserted through a first end of the second segment of the screen bar into and substantially spaced from a surface of the hollow portion thereof.

Abstract: A foam-filled door manufactured in accordance with the present invention comprises a frame (11) having a pair of ledge areas (58) extending about substantially the entire inner periphery of the frame (11). The frame (11) is formed by the spaced parallel positioning of a pair of rails (12) and a pair of stiles (14). The ledge areas (58) formed in the frame (11) are of substantial width and depth to provide an area of bonding between the facers (20, 21) and the frame (11). The ledge areas (58) also form vents (100) that allow air to escape from a cavity (22) formed between the frame (11) and pair of facers (20, 21) when a foaming material is injected into the cavity (22) to prevent internal air pockets from forming. The facers (20, 21) have flanges (90, 92) that surround substantially the entire outer periphery of the facers (20, 21) and engage the outer periphery of the frame (11).

Abstract: A method of producing artificial rock formations such as rocks and waterfalls by (a) forming a flexible mold of latex, silicone or urethane from a master model; (b) forming a sectional fiberglass cradle to support the flexible mold; and (c) coating the flexible mold with layers of lacquer, non-foaming polyurethanepolyisocyanate, and foaming polyurethane-polyisocyanate; and (d) demolding and coating the final rock formation product with paint or a stain.

Abstract: A method and apparatus for protecting exposed pipeline joints on weight coated pipelines used in offshore applications. The method allows quick installation on a lay barge where pipeline sections are being welded together for offshore installation. The method does not require a long cure time before handling. The method protects the corrosion coating on pipeline joint sections not covered with weight coat by forming a pliable sheet of polyethylene into a cylindrical cover material sleeve over the exposed pipeline joint connection. Polyurethane chemicals are reacted to form a high density foam which fills an annular space between the pipe and the cover material sleeve. The cover material sleeve and the foam form a composite system to protect the joint connection whereby the foam provides continuous compressive reinforcements and impact resistance and the sleeve provides puncture resistance and protection from water jetting/post trenching operations plus abrasion resistance.

Abstract: An abrasive tool includes a rotatable hub from which extends a bundle of plastic abrasive monofilaments. The bundle has a high filament count and each filament includes a substantial amount of abrasive uniformly entrained therein. After the bundle is secured to the hub, the tool is placed in a mold completely enclosing at least the projecting bundle and a foamable elastomer is injected into the mold to produce a light density cellular matrix bond encapsulating the filaments. The preferred plastic for the plastic monofilaments is nylon 6-12 and the preferred elastomer is a low density (2-20 lbs/cu/ft) polyurethane. The cellular matrix bond for the preferred applications upon wear does not produce a liquid phase at even high tool pressures. Radially extending enlarged coolant passages may be formed during the encapsulation and injection process step. The tool may be in disk, cup or twisted stem form.

Abstract: A method of manufacturing a molded plastic product prepares a core and a skin. The core has a pad supporting face, a sidewall surrounding the supporting face, and a pad housing defined by the supporting face and sidewall. The skin has a side face to be fitted to the sidewall of the core. The method sets the core on an upper mold so that the pad supporting face is oriented toward a lower mold, and places the skin on the lower mold so that the back face of the skin is oriented toward the pad supporting face. The method closes the upper and lower molds and injects foam ingredients between the core and the skin. The foam ingredients is reacted and adheres to the skin to form the pad as well as to the pad housing, to thereby integrate them into one body. The method is characterized by arranging an elastic seal on the side face of the skin so that the side face of the skin is attached to the sidewall of the pad housing through the elastic seal by the pressure of the reacted foam ingredients.

Abstract: In order to make a personalised helmet liner using a rigid injection shell, a cast of the user's skull is made from a quick-setting product; the desired position of the user's head and the cast relative to a predetermined helmet reference frame is determined on an optical bench and a reference support (30) is fixed to the cast; a dummy head provided with a positioning support relative to the rigid shell is moulded in the cast by comparison with the reference support; the dummy head is placed inside the rigid shell and the dummy head and the shell are positioned relative to one another by using an indicator (31) on the support, and an expandable foam is injected into the space between the rigid shell and the dummy head.

Abstract: Fluoropolymer is advantageously foamed by first forming a composite structure of a layer of the fluoropolymer to be foamed and a layer of different material such as a different fluoropolymer not to be foamed, followed by heating the composite structure to the foamable state for the layer of fluoropolymer to be foamed, pressurizing the heated composite structure with supercritical carbon dioxide, rapidly depressurizing the heated composite structure, whereby the foamable layer foams and the other layer foams less or not at all, and cooling the foamed composite structure.

Abstract: A method for forming a composite profile having a foam material introduced therein. The invention provides an inline method for the introduction of a foam material into a composite profile.

Abstract: A method of manufacturing a skin for foamed product involves the steps of: (a) not only preparing a plurality of flat skin forming pieces 2 to 5 by defining a skin 13 for covering an annular foamed body Y into a plurality of skins in radial directions and flatly developing the thus defined skins 131 to 134 while cutting apart at a single position along a circumference, and forming an opening 2a on a single skin surface out of these flat skin forming pieces; (b) overlapping adjacent flat skin forming pieces in such a manner that decorated surfaces of the skin forming pieces confront each other to thereby form a skin body 6 while joining side edges of the flat skin forming pieces 2 to 5 together; and (c) reversing the skin body 6 so that the front side thereof faces outward, joining diametrically opposite portions of both opening end edges of the skin body after such opening end edges have been pulled out of the opening 2a inside out, and pushing the joined opposite portions back through the opening 2a to there

Abstract: A method for masking components of a hot water tank from insulation wherein a carrier sheet containing a pair of inflatable rings is insertable into the space between the inner tank and outer shell of the hot water tank. The inflatable rings surround electrical components on the inner tank to prevent insulation injected into the space from covering the electrical components. Inflatable bags are insertable into threaded bores on fittings connected to the inner tank to prevent the insulation from covering the threaded bores, and to prevent insulation from escaping to the outside of the outer shell.

Abstract: A process of manufacturing a structural body for an automotive vehicle, the structural body comprising a hollow member having an inner space, and a foamed body filling the inner space, the process including the steps of disposing, in the inner space of the hollow member, a hard foamable material having expansion absorbing means, the expansion absorbing means being formed in a longitudinal direction of the hollow member; and foaming the hard foamable material into a highly rigid foamed body for filling the inner space of the hollow member, such that the expansion absorbing means absorbs volume expansion of the highly rigid foamed body so as to prevent application of an excessive foaming pressure generated by the highly rigid foamed body, to inner surfaces of the hollow member.

Abstract: The present invention pertains to a polymeric sealing/spring strip and method of producing same. The polymeric sealing/spring strip of the present invention has several various embodiments which are based upon the incorporation of silicone rubber. Some of the embodiments are based on the formation of a resilient silicone rubber surface to provide a sealing/spring contact with an opposing surface period. Other embodiments of the invention incorporate the silicone rubber in such way as to utilize its resilient properties to produce a sealing/spring strip which has improved mechanical resilience properties. The method of the present invention allows the production of a sealing/spring strip in accordance with the present invention by using extrusion techniques.

Abstract: In forming a headrest for automotive seat, a three-dimensional trim cover assembly with an opening formed therein is subjected to a foaming process. The trim cover assembly has a pair of extensions formed in that opening and a foldable sealing portion defined in one of those two extensions. The foldable sealing portion is formed with a hole. In operation, both two extensions are turned over via the opening into the trim cover assembly, and during the foaming process, an injection nozzle is inserted through the opening and into the hole of foldable sealing portion. Then, a liquid base foaming material is injected from the injection nozzle into the trim cover assembly and cured therein, during which, the foldable sealing portion is folded about another of the two extension by a pressure applied thereto from the liquid base foaming material being cured, so as to close and seal the opening against leakage of the liquid base foaming material from that particular opening.

Abstract: The invention relates to an obturating stopper plug as well as to a method of manufacture of this stopper plug.The stopper plug for obturating any opening (2) and comprising a bead of heat-fusible adhesive (7) deposited upon the said stopper plug is characterized in that the bead of heat-fusible adhesive (7) comprises:(a) an adhesive mixture,(b) a cross-linking agent,(c) an expansion agent decomposing at a temperature close to the cross-linking temperature of the adhesive mixture (a),(d) additives for working purposes.The invention is applicable to the obturation, for example, of an opening in a plate to be passed into a drying oven for paint.

Abstract: Thermal insulating device with an open celled polyurethane foam core, evacuated and refilled with an insulating gas.

Abstract: A method of integrally bonding a foam seat pad or other article to a cover material includes steps of positioning a two ply cover material in a set stand of a lower mold. The set stand positions a main surface portion of the cover material in a desired alignment while a retaining member is used for provisionally maintaining the alignment. Side mold portions are moved in position to firmly surround the set stand and and the retaining member is removed. Then, foam resin is introduced into the space defined by the set stand and side mold portions and an upper mold is used to sealingly cover the molding apparatus. After the upper mold is closed pressurization of the internal space of the molding apparatus is effected for a desired time during setting of the foam resin.

Abstract: An interior trim component, such as a door panel, having an outer skin backed by a low density molded mat foam substrate and an energy absorbing foam backing is manufactured in a single mold tool in a multiple stage foaming operation in which the outer skin and a glass reinforcement mat are positioned in the mold cavity and a mold insert corresponding to the energy absorbing foam layer is mounted to the lid of the mold tool. A polyurethane precursor mixture is poured into the open mold and the lid closed to generate the low density molded mat substrate. The mold is opened and the mold insert removed and a second urethane precursor mixture is poured onto the substrate and the mold closed to generate the energy absorbing foam backing within the space of the mold cavity previously occupied by the mold insert.

Abstract: A shoe that conforms to foot contours and provides cushioning is comprised of a shoe sole and a shoe upper attached to the shoe sole. The shoe upper is comprised of an outer layer, an inner layer and a conforming layer therebetween, wherein a first portion of the conforming layer is comprised of viscoelastic gel and a second portion of the conforming layer is comprised of environmentally-responsive gel. The environmentally-responsive gel is preferably a temperature-responsive gel that will react to the heat emanating from a foot inserted into the shoe to express a liquid. The viscoelastic gel is preferably a soft, flowable gel that conforms to foot contours.

Abstract: A load bearing, thermally insulating panel for use to cover an ice surface is made up of a plurality of modular, polymeric floor members having a structural dense body structure and a flat upper wall over which a vehicle can travel. Each floor member has an undersurface with integral, downwardly projecting, load distributing, support pillars within a floor member-surrounding, downwardly projecting marginal wall. A polymeric foam insulative layer of substantially lesser density than said floor member and substantially lesser thermal conductivity is molded within the floor member surface surrounding the pillars to fill the space around the pillars and the space between the pillars and marginal wall.

Abstract: A process is presented for fabricating composite bodies of thermoplastic material including a foamed core bonded to a compatible thermoplastic sheet. A sheet of thermoplastic material is first preheated and then thermoformed on a first half-mould. The first half-mould with the thermoformed sheet is positioned opposite a second half-mould to form a hollow chamber therebetween. A foamable thermoplastic material containing one or more liquid hydrocarbons is injected into the hollow space at a temperature sufficiently high to permit the foamable material to expand and bond to the thermoformed sheet.

Abstract: In a method of making a linear composite member, a hollow carrier is provided having a cavity and an inner surface. A curable liquid or gelled resin is applied to the inner surface. A curable foam is introduced into the cavity. The foam contacts the resin when the resin is not more than partially cured, and preferably when the resin has a viscosity not greater than 250,000 centipoise at 25.degree. C. The foam and resin, which are preferably both polyurethanes, are cured together to form a linear composite member having a foam core and a hard resin skin formed integrally. In a preferred embodiment, a reinforcement material, such as a glass fiber web, is embedded in the resin skin.

Abstract: A control for dispensing foam into hollow body cavities includes an index hole positioned adjacent to a dispense hole to receive the foam. The index hole carries information that is read by a sensor associated with a foam spray gun, wherein the information is selected to correspond to the desired amount of foam for the particular body cavity. With the inventive foam spray gun and method, an operator merely inserts the dispense nozzle into a dispense hole, and the sensor reads the information from the index hole. The sensor signal then allows control of the amount of foam dispensed into the dispense hole. This eliminates problems that have been experienced in the past wherein operators were forced to remember the amount of "shots" of fixed volumes of foam for each hole. In the past, operators may sometimes have dispensed too little foam or too great an amount of foam for a particular hole. Further, in the past, operators may sometimes have dispensed foam into a hole that should not have received any foam.

Abstract: A composite structure and method of making the composite structure are disclosed. A reinforcing fabric such as fiberglass is mechanically attached, for example, by stitching to a non-woven polyester fabric. The attached fabrics are placed in a mold with the non-woven fabric facing the inside of the mold. A self-expanding, self-curing foam is filled into the mold in an amount sufficient so that upon expansion in the closed mold, the foam penetrates into the interstices of the non-woven fabric which upon curing forms a bond therewith. The resulting structure can be used in a number of applications wherein the reinforcing fabric is later impregnated, for example, with a resin, and allowed to cure. Typical use of such a structure is as a stringer in fiberglass boat construction.

Abstract: A paint brush handle has an outer layer of a comfortable, relatively soft elastomeric material that surrounds a rigid core of foamed polyolefin. The handle is made using a co-injection process in which a mold cavity is first coated by an initial partial shot of the elastomeric material and then filled by injecting more elastomeric material and polyolefin material containing a foaming agent simultaneously. The simultaneous shot of these materials is achieved by injecting the materials through a single inlet passage into the mold cavity in which the flows are concentric, with the elastomeric material surrounding the polyolefin material. The ferrule is attached to the handle using nails or other suitable fasteners which penetrate into the rigid inner core.

Abstract: A first wooden surface layer and a second wooden surface layer are arranged in a mold, a core wire is arranged within the space defined by the first wooden surface layer and the second wooden surface layer, and resin introduced into that space. The first wooden surface layer and the second wooden surface layer are pressed against the inner surface of the mold by means of the internal pressure of the resin, thereby molding the first wooden surface layer and the second wooden surface layer. It is possible to obtain a molded article in which a wooden surface layer, a resin core and a core wire have been unitarily integrated without the production of cracks in the wooden surface layer.

Abstract: A method of making an article of footwear includes the steps of constructing an upper having an inner surface material and an outer surface material which define an upper formation cavity, disposing the upper on a mold core, positioning the mold core and the upper in a base portion of a mold such that the upper formation cavity is accessible from above when the mold cavity is open, pouring a plastic foam material into the upper formation cavity of the upper, closing a top portion of the mold onto the base portion of the mold to thereby sealingly close the mold and the upper formation cavity, curing the plastic foam material within the upper formation cavity of the upper to form a molded article of footwear upper, and opening the top portion of the mold and removing the article of footwear upper.

Abstract: An improved vehicle wheel construction having an injection molded generally annular filler ring disposed in a radially inwardly facing circumferential cavity of the wheel to prevent material from accumulating in the circumferential cavity of the wheel and causing an out-of-balance wheel condition and method for producing the same is disclosed.

Abstract: A syntactic structural foam product in flat sheet form or curved three-dimensional form adaptable to such uses as a light weight structural core for composite laminates, is made of a mixture of hollow ceramic microspheres and dry resin powder, of either thermosetting or a high-temperature thermoplastic resin, distributed in the interstices of the mass of microspheres for integration of the mixture into desired form upon heating and cooling. The dry resin powder in another embodiment of the invention includes unexpanded expandable powder which will expand into microballoons in the confined spaces in which they reside and effect a bonding relation with surrounding particles upon supply of heat to the mixture. The foam product is produced by thoroughly intermixing and depositing the mixture as a layer over a surface having a release agent thereover within a dimension defined region.

Abstract: The present invention is directed to an improved method for preparing a product by introducing a rigid polyurethane foam formulation into a cavity defined by two spaced apart formed sheets and allowing the formulation to foam. In one embodiment, the improvement resides in providing at least one of the sheets with a portion having the shape of a gate of the type used in polyurethane reaction injection molding and introducing the formulation through that gate so that the formulation enters the cavity as a laminar stream.

Abstract: The invention relates to a method and system for producing a composite structure, consisting of a foam core surrounded by an exterior shell. More specifically, the invention relates to a method of manufacturing a unitary composite article of a desired shape. The method broadly includes fabricating an exterior shell, which can be composed of either a single member or multiple portions, having the desired shape of the composite article. If there are multiple portions, those portions have peripheral edges which allow the portions to be assembled together to form the exterior shell. The exterior shell of the invention defines an internal cavity. A foam reaction mixture is injected into the cavity where it reacts exothermically and expands. During expansion, the foam adheres to the surface of the cavity. Prior to injection of the foam, the exterior shell is positioned within a structural frame which surrounds the shell. The frame resists movement of the exterior shell as the foam reaction mixture expands.

Abstract: A method for the manufacturing of a headrest or a steering wheel or an armrest for motor vehicles comprises the steps of forming a pillow element, laying an upholstery flexible sheet onto the front surface of the pillow element, and introducing the pillow element with the flexible sheet as an insert into a foaming mould having a complementarily shaped seat. An outer body is thus foamed within the mould around the seat, so as to permanently secure the outer body simultaneously to the pillow element and to the perimetral edge of the flexible sheet.

Abstract: A plastic molding has a core and a skin-provided foam provided on an outer surface of the core. The core is provided with side walls, a foaming material receiving portion defined by the side walls, and through holes provided in the bottom surface of the foaming material receiving portion to extend through the core to connect the foaming material receiving portion to the outside of the core. The skin-provided foam includes a foam which is received in the foaming material receiving portion of the core to be adhered to the bottom surface thereof and enters the through holes of the core to constitute engaging portions with the core, and a skin member which covers the outer surface and side surfaces of the foam and is held at the end portions thereof between the foam and the side walls of the core. The disclosure is also directed to a method for producing such a plastic molding.