Abstract: A substrate is initially moulded from a cross-linked polymeric material reinforced with glass fibres, the substrate is subsequently placed in a die in which a facing layer is first moulded, and on that layer are injected the ingredients for a foam padding material which adhere the substrate to the facing layer. The facing layer is desirably polyurethane, although use can be made of flexible acrylic, polyvinylchloride, and some other polymeric materials.

Abstract: A method of producing a frame-installed seat pad structure, which includes by steps (a) preparing a mold assembly which includes a mold and a lid, the lid having a foamable material feeding tube connected thereto; (b) preparing an endless elongate member which defines therein and therealong a continuous way, the endless elongate member having an inlet portion matable with the feeding tube of the lid and a plulality of outlet portions; (c) detachably connecting the endless elongate member to the lid having the inlet portion thereof mated with material feeding tube; (d) putting the lid on the mold having the endless elongate member exposed to a cavity of the mold; (e) pouring a foamable plastic material into the material feeding tube, so that the material flows in and along the continuous way and falls into the cavity through the outlet portions; (f) curing the material; and (g) removing the lid from the mold when the material is hardened to a certain degree.

Abstract: A retainer for receiving a fastener and adapted for loading into a mold for embedment in a trim article molded of molding material. The retainer has a housing having an upper portion for accepting the fastener and a lower portion for embedment in the molded trim article. A flexible lip encompasses the housing for sealingly engaging with the mold thereby preventing the molding material from making contact with the upper portion of the housing and allowing the molding material to make contact with the lower portion of the housing.

Abstract: A water heater is made by shielding the space between a tank and a jacket, which space is intended to include a control apparatus accessible from outside the jacket, by making and installing an insulating dam provided of flexible, deformable insulating material, removing corner position from the dam, slitting the block lengthwise with a slit which is surrounded by the block, thereby forming connected body portions, moving the body portions apart from each other, thereby forming an open frame, turning the resulting open frame inside out to form a foam dam, inserting the resulting foam dam around the control apparatus, placing the jacket over the dam and introducing liquid foam forming material into the space between the tank and the jacket.

Abstract: A molding method in which a first expansion-molded layer is formed inside of the skin molded in the shape corresponding to the configuration of a molded product, an insert member is placed in a location inside of the first expansion-molded layer and, in this condition, a second expansion-molded layer is formed inside of the first expansion-molded layer so that the insert member may be embedded in the second expansion-molded layer.

Abstract: A vehicle body pillar has a cavity therein through which air flow creating undesirable noise and in which moisture and fluids such as water are not to be collected. An expandable sealant plug is inserted therein and retained in place. The sealant material forming the plug is later expandable under controlled conditions. It is preferably expandable under temperatures of about 275.degree. F. to 400.degree. F. over a period of time. Preferably during the electro-coated paint baking and curing operation, the sealant is exposed to appropriate temperatures for sufficient time to expand the sealant about 800% and cure it, sealing the cavity so as to prevent the flow of air through it. The expanded sealant also effectively blocks the intrusion of fluids such as water, minimizing corrosion within the pillar.

Abstract: An apparatus for manufacture of laminated panels having a foamed plastics core material includes an inclined press having a fixed platen surface and a movable platen surface hinged adjacent its lower edge. Panel thickness is adjustable by a mechanism which moves the hinge pivot relative to fixed platen surface. The platen surfaces are clamped at their upper edges by spaced clamps operable by lever and crank assemblies. A retractable seal spacer has liquid plastics injection nozzles and gas venting tubes in fluid communication with a hollow cavity in the press.

Abstract: Herein disclosed is a mold assembly for molding a frame-installed and skin-covered seat cushion structure, which includes a mold having a cavity formed therein; a retainer jig adapted to be put on the mold, the retainer jig being equipped with clamps for clamping a frame of the seat cushion structure to be produced; a lid adapted to be put on the mold with an interposal of the retainer jig therebetween; and a sealing element for achieving a sealing between the mold and the lid upon proper putting of the lid on the mold.

Abstract: A method of producing platens for typewriters and similar office equipment. Conventional platens often include a large number of individual parts and are relatively expensive because of their high assembly and finishing costs. According to the invention, an impact-resistant polyolefin with the addition of a delayed-reacting foaming agent is employed in an injection molding process in such a fashion that, by means of differential cooling of the mold, the material on the platen surface and in areas of other functional elements such as line-advance wheel/notched wheel combinations hardens, while the core of the platen remains a foam. The process allows platens with other functional elements molded to them to be manufactured from a single material in a single operation and without any additional work, despite different demands made on the print backing and the other functional elements.

Abstract: The present invention is directed to a molded foamed automobile cushion having a deep groove and an upholstery cover secured thereto by a touch fastener having cooperating hook and loop elements carried by the cushion and cover. One element of the touch fastener is molded into a deep groove in the cushion and the other element is secured to the upholstery. The hook elements on both sides of the groove are unidirectional, when assembled, and have their concave surfaces facing in the same direction to permit easy entry of the upholstery into the groove and providing maximum resistance to removal of the upholstery from the groove.

Abstract: A method of preparing an annular skin tube for a foam product. Tubular skins are joined together end to end, at opposite ends thereof except at least one set of unjoined ends of at least one selected pair of the adjacent tubular skins, so as to prepare an intermediate skin tube such that a nominal outside of the intermediate skin tube is exposed. An unjoined portion is provided on the outer periphery of the intermediate skin tube, adjacent to the unjoined ends. The unjoined ends are joined, while end portions including the unjoined ends are superposed on each other and are passed through the unjoined portion outwardly of the intermediate skin tube such that one of the end portions is turned inside out. The above-indicated one end portion is turned over to expose its nominal outside. Thus, the intermediate skin tube is formed into the annular skin tube.

Abstract: A two-part for reinforcing a hollow strucutral members and its method of use are provided. A method of reinforcing a structural member having a hollow cavity comprises the steps of preparing a first dough which includes a thermal setting resin, a first filler and unexpanded, thermally-expandable microspheres. A further step includes preparing a second dough which includes a curing agent, a colorant and a second filler. The curing agent is compatible with the thermosetting resin to promoter cross-linking of the thermosetting resin upon contact with the curing agent. The hollow structural member may be preheated to enhance the rate at whcih the thermosetting resin cross-links. The two dough are blended together until a reactive third dough of substantially uniform mixture is formed. The uniformity of the blending is confirmed when the reactive third dough attains a uniform color intermediate the color between the colors of the first and second doughs.

Abstract: The apparatus includes a first female mold member defining a mold cavity for receiving a plastic skin or layer. A second mold member or slide is positioned with a surface thereon contiguous with the surface of the mold cavity. The surface of the second mold member receives and holds thereon a portion of the plastisol skin extending from the mold cavity. A third mold member, such as a mold core, positions a rigid insert in the mold cavity with an insert surface or edge adjacent the portion of the plastisol skin on the second mold member. The second mold member includes passages for directing fluid pressure against the portion of skin thereon to fold it over the adjacent insert edge. A fourth mold member, such as a mold lid, is movable toward the second and third mold members for pressing the folded-over skin against the insert during foam formation between the skin and insert.

Abstract: A profile for the coupling of adjoining channel members comprises a front wall for extending perpendicularly from a wall of the channel member, a back wall extending at least partially parallel to the front wall, a front flange connected to the front wall, a back flange connected to the back wall and a deformable sealing material in the space between the front wall, the back wall and the flanges. The profile is constructed by folding a strip of material along parallel fold lines. A deformable sealing material is applied to the strip, and when the strip is folded, the sealing material is deformed so as to fill a substantial portion of the space between the front wall, the back wall, the front flange and the back flange of the profile.

Abstract: An improved composite metal-elastomer styled automotive-type wheel with a three-dimensionally contoured ornamental outboard face formed by a plastic overlay body permanently adhered or affixed to the outboard face, and an improved molding apparatus and method for constructing such a wheel. A plastic overlay body has an annular row of outboard pockets disposed in radially offset, axially overlapping relation with a annular row of inboard pockets which in turn register with vent openings in the disc to thereby provide air passages through the wheel for brake ventilation. The outboard pockets preferably are disposed radially remote from the center of the wheel close to the wheel rim, and a relatively thin cross-section of plastic material is molded so as to overlie the outboard rim flange to provide a full-face appearance to the wheel.

Abstract: A method of making a particular type of arm rest for a chair, which arm rest is made from a foamed material. Embedded in the arm rest is a flexible tube for containing a control mechanism for the chair.

Abstract: A method for producing a simulated rock by spraying a high density polyurethane elastomer in a flexible rubber mold. The rubber may be natural rubber or synthetic rubber. A rock is produced in molded form, not limited in size. A flexible mold is prepared by applying numerous coats of liquid uncured rubber forming materials, such as latex rubber, upon the rock exterior in combination with a fabric embedded within the rubber latex layers. A supporting cradle for the rubber mold is produced by spraying a low density urethane foam composition over the mold. The mold and cradle are stripped from the rock and are sprayed with a two component structural urethane system employing an isocyanate component and a polyol component with appropriate catalysts, fillers and additives. The structural urethane elastomer is built up to substantial thickness to provide a strong rigid load bearing polyurethane molded rock simulating the original rock surface with curing taking place in a matter of seconds or minutes.

Abstract: A laminated article, for example a bath or shower-tray, is manufactured by providing a preformed shell, for example a thermoformed acrylic sheet, which shell is placed in a mould, together with, if required, a reinforcing board, for example of chipboard or plywood. The mould is then closed and materials are injected into the mould cavity which react to form a reinforcing layer on the shell. Preferably, the injected materials comprise a polyol reactant and an isocyanate reactant which form a layer of rigid polyurethane foam. A reinforcing agent, for example glass fibre, and a blowing agent may also be introduced into the mould cavity.

Abstract: A process for producing a urethane die. A heat-resistant epoxy adhesive is applied to the inner surface of a recess provided in the body of a die. A urethane primer is applied to the adhesive while the adhesive is still in a semi-hardened state. A punch is inserted into the recess to form a space between the recess and the punch and a urethane resin is injected into the space to form a resin layer on the recess having a shape corresponding to the outer surface of the punch. A reinforcing fibrous material may be incorporated into the resin layer by applying a urethane resin having a lubricant incorporated therein to the surface of the punch and adhering a fibrous material impregnated with the urethane resin to the coated surface of the punch prior to inserting the punch into the recess.

Abstract: A fastening tape (4) is attached to a molded item (2) such as a seat cushion with a face of gripping hooks (5) turned outwardly to hold a seat cover (3) having complementary fastening member thereon. The tape (4) is molded into the seat cushion (2) during the molding process. Since a liquid molding substance is used, the hooks (5) on the tape (4) are covered with a thin plastic film (17) which prevents the molding liquid from contaminating and clogging the hooks (5). In one embodiment, the film (17) has a relatively low disintegration temperature whereby the heat applied to the mold to cure the cushion (2) disintegrates the film (17) after the cushion has cured, leaving the exposed hooks (5) unclogged and ready for use. In another embodiment, film (17) has a relatively high disintegration temperature and is removed in a separate step subsequent to the molding process by additional heat, such as an open flame.

Abstract: A process for producing foam cushions having sections of different hardnesses using foam molding. The process broadly includes introducing a first reaction mixture into a mold, introducing a second reaction mixture into a mold, said second mixture already being in a creamed state, allowing the reaction mixtures to foam, and removing the resultant product from the mold. Prior to the introduction of the first mixture, a web with holes in it is clamped over a deepened section of the mold cavity. The first reaction mixture is then fed onto the web, with the first mixture being in a sufficiently liquid state so as to allow it to flow through the holes and into the space below the web. The second reaction mixture is then fed into the space remaining above and to the sides of the web. The second mixture is introduced at a time when itis sufficiently creamed up so that it cannot flow through the holes in the web.

Abstract: This invention discloses lightweight panels consisting of a honeycomb, boards on both sides, and phenolic foam of a density of 7-20 Kg/m.sup.3 in the cavities of the honeycomb and a method of making a honeycomb core, with the panels characterized by being light, fireproof, fire-resistant, thermally insulating, and of high strength and useful for building panels, particularly for panels in transportation equipment.

Abstract: A method of producing an annular foam product having a foam filler covered by a tubular skin. A core embedded in the filler includes a connecting portion and a U-shaped portion which form an annular frame. Opposite edges of each of at least one skin member are joined together to form a U-shaped skin tube surrounding the U-shaped portion, such that the joined edges are located inside of the U-shaped skin tube. A skin sheet is jointed at opposite ends to corresponding opposite ends of the U-shaped skin tube so as to surround the connecting portion, while the end portions of the skin sheet are turned outside in. The end portions of the skin sheet are then turned over to expose its nominal outside outwardly, and opposite edges of the skin sheet along the connecting portion are joined together to form a connecting skin tube which surrounds the connecting portion of the annular frame. The U-shaped skin tube and the connecting skin tube constitute the tubular skin which encloses the annular frame.

Abstract: A method of producing an instrument panel of a motor vehicle or similar molding of forming resin which includes a section for fitting an electrical part. The electrical part fitting section is constituted by a coupler engageable with the electrical part and an opening which is contiguous with the interior of the coupler. The opening is surrounded in a liquid-tight configuration by a pressing member for sealing which is disposed on one of coactive parts of a metal mold. The coupler is removably mounted on the other metal mold part. When the metal mold parts are clamped, a peripheral edge portion of the coupler abuts against a portion of the pressing member which surrounds an opening of the pressing member. A flexible printed circuit to which the electrical part is electrically connectable is interposed between the coupler and the pressing member such that terminal portions of the circuit face the inside of the coupler.

Abstract: A method is provided for producing an integral skin foam article made up of a skin, foam and core member. According to the method, an expanded layer which is of the same material as the skin is formed on the back of the skin prior to forming the article.

Abstract: An anodized aluminum sheet is prepared by applying an aqueous polyurethane 40 percent dispersion coating with a threaded roller having 20-1/32 inch deep triangular threads per inch. The coating is heated by graduated heating from about 125 degrees F. to about 240 degrees F. for about 20 minutes until the material is set and non-tacky. Thereafter, without special storage or handling requirements, the coated side of the anodized aluminum is bonded in a mold under reaction injection molding pressure to a reaction injection molding material.

Abstract: A method and a foamed resin molding in which a skin layer is formed by pressing an expansible film against and into conformity with cavity walls of a mold or a bag-like cover member by foaming pressure of a foamable resin and a foamed resin body molded concurrently and integrally under the skin layer, which facilitate the easy parting of the moldings from the mold without parting agent.

Abstract: A laminated guide bar is provided with a center or core laminate comprised of an adhesive-foam material that is configured to form the guide groove. The adhesive-foam core resists deformation, strongly adheres to the interfacing outer laminate sides, and is inert and impervious to oil. The core is formed in place between the outer laminates with a fixture surrounding the outer laminates and maintaining their spaced relationship. A cavity is provided in the fixture that conforms to the desired core configuration. The foam material has a controlled activation to allow assembly of the fixture and upon activation, produces the desired properties mentioned. It is desirable to roughen the inner sides of the outer steel laminates to assist the bonding action of the foam material.

Abstract: An infrared burner with an extremely low pressure drop is described. The burner comprises a corrosion resistant mesh screen having a thick porous coating of ceramic fibers deposited thereon. In addition to a low pressure drop the burner has structural integrity and ability to generate radiant energy at a high rate. The burner is produced by admixing alumina and ceramic fibers with a clathrate-forming halocarbon material which is removed upon drying.

Abstract: An adapted separable fastener and method of making the same for attachment to foam objects such as seat cushions. A separable fastener member of the hook and loop-type is attached, in back-to-back relation, to a second member. The second member has upstanding elements such as loops or hooking elements which elements are ultimately surrounded and encapsulated by the foam during polymerization. The adapted fastener is thereby attached to the foam member. The elements are positioned in order to allow venting of the gaseous byproducts of polymerization. This promotes superior adhesion to the foam material and prevents delamination at the fastener-foam interface. A metal strip may be disposed within the adapted fastener so it may be magnetically held in the foam mold. A method and apparatus for adapting the fastener is also disclosed.

Abstract: The apparatus includes a first female mold member defining a shaped mold cavity for receiving a plastisol layer or skin. A second mold member is pivotally disposed on the female mold member between an open and closed position. In the open position, the second mold member receives and holds thereon a portion of the plastisol skin extending from the mold cavity. An insert is positioned in the mold cavity by a third mold member such as a mold lid on which the insert is releasably retained. After the insert is positioned in the mold cavity, the second mold member is pivoted toward the mold lid to fold the skin portion thereon over and against an edge of the insert. The skin is folded adjacent the pivot axis of the second mold member. Foam can then be introduced and cured between the skin and insert.

Abstract: A water heater comprising a water tank having a component intended to be kept substantially free from contact with an expandable foam insulating material, and a method of making same, is provided. The water heater has a jacket surrounding the tank and providing an insulating space therebetween. Positioned within this space is a pair of flexible sheets forming an apron. The sheets are joined to form a seal protecting the components from contact with the foam. The apron is positioned over a part of the tank surface so that the seal surrounds the component. The sheets of the apron are substantially unsealed along the top and a side. Foam is introduced between the sheets of the apron and flows out of the unsealed side of the apron to fill the space between the tank and the jacket.

Abstract: A thrust reverser cascade basket and method including an elongated metal frame having elongated metal strongbacks and metal transverse end portions joining opposite ends of respected strongbacks. Reinforced hard plastic is pressure injection molded on the strongbacks, and transverse vanes formed of the plastic extend between the strongbacks and are integral therewith. The strongbacks have openings having the plastic molded therein, the openings being between the vanes, and substantially all plastic knit lines are formed along strongback surfaces, spaced adjacent mid-span locations between the vanes. The vanes are free of the knit lines.

Abstract: A vehicle spoiler includes a first rigid body part having an external surface contour, a second resiliently deformable foam body part having an external surface contour complementary to the first surface contour, and means for integrally securing the first and second body parts together. Preferably, the deformable foam body part is molded in situ on the rigid body part. A finishing groove extending between adjacent edges of the first external surface contour and the second external surface contour prevents recognition of differences between the materials and processes used to form the first and second body parts and prevents inconsistent transition between the body parts. A method for forming the spoiler includes fabrication of injection molded body shell parts bonded together by a foam material to form a rigid first body section. The rigid body section is then positioned within a molding cavity while foam material is introduced into the cavity and against engagement surfaces on the rigid body part.

Abstract: A method for producing simulated rocks by spraying a high density polyurethane elastomer in a flexible mold. The method includes reproducing a rock in molded form, not limited in size. A flexible mold is prepared by applying numerous coats of latex rubber upon the rock exterior in combination with a fabric embedded within the rubber latex layers. A supporting cradle for the latex mold is produced by spraying a low density urethane foam composition over the latex mold. The mold and cradle are stripped from the rock and are sprayed with a two component structural urethane system employing an isocyanate component and a polyol component with appropriate catalysts fillers and additives. The structural urethane elastomer is built up to substantial thickness to provide a strong load bearing polyurethane molded rock simulating the original rock surface with curing taking place in a matter of seconds or minutes.

Abstract: The present invention relates to polyurethane foam materials with sound insulating and vibration damping properties. They are obtainable by reacting a polyisocyanate or polyisocyanate prepolymers with an excess of polyols or a mixture thereof while maintaining an NCO index of .ltoreq.80, in particular .ltoreq.70 and as a result they have an adhesive (frictional) surface and are further characterized by a density of 80 to 250 kg/m.sup.3, a modulus of elasticity less than 300 OOO N/m.sup.2 and a loss factor of at least 0.4. The production is preferably done by adding the reaction components (polyol system on the one hand and polyisocyanate system on the other) to the mixture head of an RIM machine. The polyurethane soft foam materials with an adhesive surface according to the invention are particularly suitable for use as vibration damping sound insulation systems in automobiles.

Abstract: A method of producing a bow holding handle by providing a first mold cavity in the same shape as said bow holding handle but in smaller size; placing required parts of said bow holding handle in corresponding positions of said first mold cavity; sealing said first mold cavity; injecting liquid foam plastic into said first mold cavity; activating said plastic foam to cause expansion thereof and form a core of said bow holding handle as the same shape of said first mold cavity; removing said core away from said first mold cavity; wrapping said core with a plurality of layers of fiber reinforced plastics; providing a second mold cavity shaped in the form of said bow holding handle; inserting said wrapped core into said second mold cavity; sealing said second mold cavity; heating said second mold to cure said layers of fiber reinforced plastic and to cause re-expansion of said core for generating pressure within said second mold cavity pressing said core against said layers of fiber reinforced plastic and thereby

Abstract: An improvement for a process wherein a strip of fastener material is formed into the surface of urethane foam or the like during molding in a mold. The fastener material includes a backing strip having an outer surface adapted to mate with the foam material during molding and a fastener strip having an outer surface comprising one-half of a fastening system such as hook and loop fastening material. The backing strip and the fastener strip are attached to one another with their respective inner surfaces in face-to-face relationship with their outer surfaces facing outward. The fastener material fits within a longitudinal groove in the mold and the backing material overlaps the groove.

Abstract: A method for producing a foamed innerspring unit using a foamable reaction mixture that will provide a flexible foam using diphenylmethane diisocyanate and at least one polyol is provided. The process comprises the steps of preparing the foamable reaction mixture, spraying the foamable reaction mixture into a tray, loading an innerspring unit into the foamable reaction mixture containing tray and permitting the foamable reaction mixture to rise to form a foam that is at least partially adhered to the unit. The process is especially well suited to be carried out on a continuous conveyor. A novel foamed innerspring unit is also provided.

Abstract: A method making a sailboard or surfboard is described, in which a prefabricated foam core has fibrous material wound about it and resin specially set with a reaction retarder is poured onto the fibrous material, whereupon the thus treated foam core is inserted in a molding tool and the mold is closed for curing the resin. Desirably, the mold is lined with a surface layer, particularly a deep drawn thermoplastic film, before the treated foam core is inserted. In this way one can make low-weight boards of high strength with relatively low production and material costs.

Abstract: This invention relates to a process and a laminator for the continuous production of laminates of foam with facings. An upper facing and a lower facing and a web of meshwork are introduced into the foaming space of a laminator and a fluid reaction mixture is spread over the lower facing before it runs into the foaming space. The reaction mixture penetrates the web of meshwork as it foams up on its journey through the foaming space and becomes bonded to the facings.

Abstract: The present invention relates to a process for molding a foamed article comprising mixing a polyphenylene sulfide resin with about 0.1 to 10% of an oligomeric sulfone carbonate as a foaming agent and with 0.1 to 2% of a basic catalyst at a temperature of about 150.degree. to 180.degree. C. and then heating the resulting mixture at a temperature of 280.degree.-350.degree. C. to affect a reaction mixture and introducing the reaction mixture into a suitable mold for producing a foamed article.

Abstract: A fastening tape (4) is attached to a molded item (2) such as a seat cushion with a face of gripping hooks (5) turned outwardly to hold a seat cover (3) having complementary fastening member thereon. The tape (4) is molded into the seat cushion (2) during the molding process. Since a liquid molding substance is used, the hooks (5) on the tape (4) are covered with a thin plastic film (17) which prevents the molding liquid from contaminating and clogging the hooks (5). In one embodiment, the film (17) has a relatively low disintegration temperature whereby the heat applied to the mold to cure the cushion (2) disintegrates the film (17) after the cushion has cured, leaving the exposed hooks (5) unclogged and ready for use. In another embodiment, film (17) has a relatively high disintegration temperature and is removed in a separate step subsequent to the molding procoess by additional heat, such as an open flame.

Abstract: A method of assembling a refrigerator having an outer metal casing, an inner plastic liner and foamed-in-place thermal insulation between the casing and liner bonding them together including a high stress area in the liner that can cause the liner to crack due to a difference in expansion and contraction relative to the outer metal casing. The method comprises forming the metal casing, vacuum forming the liner from plastic material, placing at least one elongated slot open at one end and closed at the opposite end in the liner located in the high stress area, placing the liner inside the casing in spaced relationship thereto, and foaming the space between the casing and liner to bond them together.

Abstract: A precast composite plastic reinforcement insert, method of making the reinforcement insert and method of reinforcing a structural member. The insert includes pellets which are formed of a mixture of a thermoplastic polymeric resin and a blowing agent. Polymeric resins disclosed include a one-part epoxy with a thermal curing system or a thermoplastic polyester resin. The pellets in one embodiment are retained within a matrix of expanded polystyrene and in combination form the insert. The insert is formed in a mold cavity which receives the pellets and unexpanded polystyrene which is expanded during the process by heating the same within the mold cavity. The insert is used to reinforce a structural member by placing it in the structural member prior to a thermal paint curing operation.

Abstract: Method for obtaining a plastic water-heater body, wherein(1) a plastic shell is used which is intended to form the interior of the water heater and also serves as an internal molding wall, the said shell having at least one orifice,(2) the said shell is positioned inside a mold consisting of two parts, while providing a space between the outside of the shell and the inside of the mold, the mold having an opening,(3) water is introduced into the internal shell via the said orifice,(4) a liquid mixture consisting essentially of a polyester resin composition capable of foaming and polymerizing is cast via the said opening of the mold, by cooling the outside of the mold to a temperature of approximately 10.degree. to 15.degree. C. during casting of the resin, so as to obtain a skin effect on the surface of the foam which comes into contact with the mold during polymerization of the said foam, by controlling the temperature of the expanding and polymerizing resin so that it does not exceed approximately 40.degree.

Abstract: The invention relates to a method for producing insulations of foamed plastic material, in cabinets and doors of refrigerators, freezers and the like.According to the invention, a metered quantity of a foamable mixture is fed into the gaps between the inner and outer walls of a cabinet or door, placed in a foaming jig; the foaming process is controlled by sensing characteristic parameters, for example, the temperature of the jig, cabinet or door, or the pressure of the foaming plastic material, comparing them with reference parameters or data stored in a data processing unit. A control signal is generated to open the foaming jig and to unmold or remove the cabinet or door when at least one of the processing parameters has reached a pre-established value. The metered quantity of mixture fed in each subsequent foaming operation is corrected each time according to the changes in the peak pressure of the foam with respect to the previous foaming operation.

Abstract: A one-piece fishing rod handle is provided in which an integral handle portion is molded together with preformed rod handle components such as a reel seat is disclosed for use in through-rod-type construction wherein the rod blank extends axially through the entire length of the handle and foregrip. The individual preformed rod handle components are assembled onto either a mold core pin or fishing rod blank and properly registered in a mold cavity having the configuration of the finished rod handle. Molding resins such as polyurethane are then injected into the mold cavity and provide a handle portion which is bonded to the preformed reel seat. By the use of two differently dimensioned molds in conjunction with different density molding resins, dual composition one-piece fishing rod handles can also be molded.

Abstract: A method and an apparatus for waterproofing and gastightening a cable or tube passage (9) in a wall (11) or the like, using a foamable synthetic resin (8). A box-shaped or cover-shaped element, e.g. a cap (1, 2) is attached to one side of the wall, after which through an opening in cap (1, 2) the foamable resin (8) is supplied therein and the opening is stopped. The cap (1, 2) may consist of two parts (1, 2) and the two parts may be provided with rupturable closures or closable openings.

Abstract: A precast composite plastic reinforcement insert, method of making the reinforcement insert and method of reinforcing a structural member. The insert includes pellets which are formed of a mixture of a thermosetting polymeric resin and a blowing agent. Polymeric resins disclosed include a one-part epoxy with a thermal curing system or a thermoplastic polyester resin. The pellets in one embodiment are retained within a matrix of expanded polystyrene and in combination form the insert. The insert is formed in a mold cavity which receives the pellets and unexpanded polystyrene which is expanded during the process by heating the same within the mold cavity. The insert is used to reinforce a structural member by placing it in the structural member prior to a thermal paint curing operation.