Abstract: A method of forming synthetic articles of polyester resin by resin transfer molding techniques or the like comprising combining a set of reactants including a major base mass of polyester resin in fluid form, at least one polyester cure accelerator, a selected quantity of isocyanate, a surfactant and at least one promoter. The isocyanate is added in sufficient quantity to react with at least one other component in the mixture to produce quantities of carbon dioxide throughout the mixture. The resultant mixture is transferred into a closed mold prior to substantial reaction. The promoter is allowed to react exothermically with at least one other component of the mixture to trigger the isocyanate to react to evolve carbon dioxide gas to generate pressure to fill the mold. Thereafter a curing reaction between the cure accelerator and the polyester occurs to cure and solidify the expanded resin to produce an expanded article.

Abstract: A method by which a previously molded hollow plastic retainer having an open end portion necessitated by the need to withdraw a mold core therefrom may be embedded in a molded trim article with the open end beneath the surface and yet the molding material is prevented from flowing through the open end portion and filling the hollow of the retainer.

Abstract: An inventive method for producing a laminated molded countertop includes the steps of placing the surface laminate material into a mold, applying a layer of polyurethane foam to an interior side of the laminate material, applying a reinforcing member, if necessary, on top of the layer of polyurethane foam, applying a second layer of polyurethane foam over the reinforcing member and closing the mold. A resultant molded article has an exterior surface laminated thereto due only to the forces generated by the polyurethane foam during the time when it is expanding and solidifying.

Abstract: A form box for manufacturing a form, which form box is adapted to hold a reinforcing preform in position during the period of time that an expanding foam mass is injected into the area between the reinforcing preform and the form box. Pins are secured to the form box and project inwardly into the form cavity in which is located the reinforcing preform. The free ends of the pins engage the reinforcing preform to hold same in a fixed position during the period of time that the expanding foam mass is injected into the cavity between the reinforcing preform and the form box.

Abstract: An apparatus for manufacturing insulating construction profiles having two metal profiles spaced from each other to define a channel filled with an insulating compound includes a supporting table to support a plurality of metal strands successively positioned in advanced movement along the table by transport rollers. Each strand includes a pair of metal profiles spaced from each other and connected with a temporary bridging strip in their advancing path. A first pouring device is positioned in the path of the advancing profiles to fill an insulating material into the channel between two metal profiles in each strand to form a first insulating core and a second pouring device is provided to introduce insulating material into the same channel to form a second insulating core. Between the two pouring devices a strip supply roll, a guide arrangement and a pressure roller are arranged to apply a separating strip between the two insulating cores which is vertically spaced from the temporary bridging strip.

Abstract: The sealing strip includes a channel-shaped attachment profile of rubber, in which a metallic reinforcing strip is embedded; this profile has an external coating layer of sponge rubber with an outer surface rendered velvety by abrasion.

Abstract: A system of constructing a building using prefabricated wall and roof panels, each of the panels comprising interior and exterior corrugated metal sheets disposed on opposite major faces of a foamed core. The panels are assembled together in edge-to-edge relationship with complementary mating edges for securing adjacent panels. The joints between adjacent panels and between panels and support members are secured by self-drilling threaded fasteners. Metal strips are embedded in the panels to provide anchors for the threaded fasteners. A specially adapted insulating member is disposed along one edge of each panel to provide mechanical support without sacrificing thermal efficiency.

Abstract: A method that relates to the manufacture of composite profiles made of metal and plastic, in which suitably shaped thin metal profiles are applied against the internal surface of a rigid mold and injecting a foamed plastic between the two profiles, the tightness between the two profiles being provided by an elastomer jointing.

Abstract: A tubular frame structure adapted for use as a tennis racket having a rigid outer shell of composite material and an inner reinforced foam core including a foam portion and honeycomb reinforcement layers. The honeycomb reinforcement layers are oriented so that string holes passing through the frame pass through the foam core and rigid shell, but do not pass through the honeycomb layers. The use of honeycomb reinforcement layers is particularly well suited for use with elastic polymer foam cores.

Abstract: Composite bowling pins and baseball bats are formed with foamed, cured-in place plastic bodies securely adhered to a central aluminum core by a somewhat thermoplastic adhesive coating. The exothermic reaction attendant to curing the plastic so softens the adhesive coating that it does not interfere with shrinkage of the plastic body relative to the core. This minimizes stress concentrations in the composite construction which otherwise tend to lead to cracking in use.

Abstract: In a method for the production of thermally insulated composite sections a free space (4) formed between at least two metal sections (1,2), held spaced apart, and sealed at the bottom is filled from its open side with an insulating material (10) which at first is in liquid form and then hardens. In order to produce such sections, particularly also those of large size, with the least possible expense for labor and material, and at the same time to achieve the most favorable heat insulation values in the insulating region, solid insulating material layers (12,13) positively and frictionally joining together the metal sections (1,2), and insulating layers (14) hardening with a porous structure are introduced in succession into the free space (4), each layer only partly filling the free space.

Abstract: A method of manufacturing a thermally insulating sash bar from an elongated hollow metallic sash bar including a pair of spaced outer members connected by a pair of spaced first and second inner members so as to define between the outer members a pair of longitudinally extending first and second channels and a longitudinally extending hollow chamber. A mass of foamable and thermally insulating synthetic resin is introduced into the first channel and then cured to fill the latter with the cured or thermally insulating synthetic resin. Then, a longitudinal gap is formed in and along each of the first and second inner members. The longitudinal gap in the second inner member is covered with a thermally insulating strip. Finally, a mass of the foamable and thermally insulating synthetic resin is introduced into the second channel and then cured to fill the latter with the cured or foamed thermally insulating synthetic resin.

Abstract: A structural material formed of a fiber and honeycomb reinforced foamed resin is disclosed, which is constructed by arranging a honeycomb material, the voids of which contain a foamable thermosetting resinous liquid, between two fibrous layers and heating the assembly to foam the resinous liquid and simultaneously cover and impregnate the fibrous layers whereby the fibrous layers and the honeycomb material are completely impregnated with and encased in the foamed resin.

Abstract: Manufacturing process for covering panels, involving the use of a die-counterdie unit in which the die is divided into two separate portions with at least one plate protrusion. The various phases in this procedure comprise the laying of a first sheet on the die surface, with locking by elastic means, of the folded edge of the sheet at the end of said protrusion, followed by the laying of a second sheet adhering to the first and to the remaining part of the die-counterdie unit with pressure injection of synthetic resin in the hollow space between the second sheet and the surface.

Abstract: The invention relates to a method of producing molded bodies of expanded plastic having a predetermined density, based on a starting material in granulate form to which a blowing agent and optionally a cross-linking agent have been added, said starting material being introduced into an injection molding machine/press in which it is heated and injected/pressed into a mold. In order to obtain an efficient production process without loss of raw material and a product whose density can be determined in advance, the material in the injection molding machine/press is heated to a temperature which is below the temperature required to initiate the reaction of the blowing agent/cross-linking agent, and the blank thus formed is subsequently transferred to an expansion mold having the shape of the desired final product, but larger, than the blank. The blank is caused to expand in the expansion mold and final expansion takes place outside the expansion mold.

Abstract: A process for the production of foamed products from an unsaturated polyester resin composition, said composition comprising polyester resin, unsaturated monomer, a promotor, initiator, physical blowing agent, and compatible surfactant whereby a known gel time "T" results, foaming said composition by exposing it to microwave radiation prior to 1 T, thereafter permitting said foam structure to exotherm to obtain a fully cured product. Preferably the resin composition is exposed to the radiation between 0.2 and 0.7 T. Due to the foamed nature of these products, they will find many uses where insulation and light weight is important. End products include foamed unsaturated polyester resins and products incorporating the same such as patio blocks containing a polyester gel-coat, the gel-coat containing sand, decorative chips, or other decorative aggregate. The foam is a mixture of polyester resin and fillers and has a density of about 35 pounds per cubic foot.

Abstract: A fiber reinforcement is positioned on the female part of a matched die, and a reactive foaming mixture of polyol and isocyanate is placed on the reinforcement, the male part of the die set being then closed on the female part so as to compress the reinforcement and holding the die parts together while the mixture's foaming reaction occurs. So that the reinforcement can comprise finer than usual individual fiber thicknesses and be compressed more than usual by closing of the die while still filling all the voids between the fibers of the reinforcement with the foam produced by the mixture's reaction, from 5 to 30% by weight of a neutral ester having a boiling temperature higher than the foaming reaction temperature of the mixture, is initially added to the mixture before it is placed on the reinforcement and prior to closing of the die.

Abstract: A composite expanded sheet reinforcing material especially useful as a stiffening, vibration and sound dampening, reinforcing laminate, and methods of manufacturing such sheet reinforcing material and of reinforcing articles therewith are disclosed. Formable sheet material having a layer of a foamable adhesive laminated thereon is passed through an expanding apparatus which forms rows of spaced, longitudinally staggered slits through the laminated sheet to form a series of elongated strands integrally joined at their ends by a series of joints or bonds. The slit material is expanded in a direction transverse to the longitudinal direction of the slits, causing the adhesive-coated surfaces of the strands and joints to be inclined at an acute angle to the principal plane of the formed reinforcing sheet.

Abstract: A process for preparing an innersole for footwear by means of molding and curing. The molding and curing is conducted under pressure in a silicone rubber mold by means of electromagnetic radiation. By means of this process, a composite board is fused to a polymeric base to form the innersole.

Abstract: A method for producing stuffing for a spring-type mattress, including the steps of forming grooves on the whole circumference of edge portions of upper and lower mold members, fixing dense and sparse seats on flat surfaces of the upper and lower mold members, respectively, bending whole edge portions of both seats into the grooves, inserting and fixing elastic plates into the grooves, pouring a certain predetermined quantity of an undiluted solution of foaming plastics onto the flat surface of the lower mold member and tight contacting both mold member before forming the undiluted solution, horizontally and symmetrically cutting and dividing the stuffing into two parts, turning over the two parts and assembling them so as to cover a spring assembly thereonto thereby covering the two parts by an outer decorative member as a mattress unit.

Abstract: A method of manufacturing a panel, provided with a frame of a synthetic material at least at one side edge face thereof, a laminate composed of a particled board core coated on either side with a coating, with reservation of a molding cavity along the entire or partial panel circumference for the frame to be formed, being applied in the bottom portion of a mold likewise containing a cover portion, after which the mold is closed, while the cover portion is sealingly clamped onto the bottom portion, after which a curing bi-component synthetic material foaming through exothermic reaction is admitted substantially pressure-less into the mold cavity and the panel is removed from the mold after curing, whereby the exothermic reaction of the bi-component synthetic material is utilized for increasing the pressure and the temperature in the molding cavity during the foaming and curing.

Abstract: A method of forming a panel structure useful in building construction and the like includes the steps of heating a heat expandable plastic in a separable mold having a cavity with the configuration of the resultant panel to form a panel core and adhering thin reinforcing strips to the front and back surfaces of the core. Control over the dimensions and configuration of the panel is obtained by adhering the strips to the core in the mold while applying heat thereto whereby core shrinkage is minimized. The strips may be adhered to the core during initial heating of the plastic material to form the core or may be adhered to the core in the mold subsequent to core formation.

Abstract: Novel polyester diols are described containing aliphatically saturated divalent diacyl moieties and olefinically unsaturated divalent diacyl moieties in a mole ratio of 0.25:1 to 3:1; and divalent dioxy moieties which are linear and/or branched, preferably divalent branched dioxy moieties and divalent linear dioxy moieties in a mole ratio of 0.3:1 to 3:1, the diacyl moieties being bonded through ester linkage to the dioxy moieties in a mole ratio of at least 1.75 dioxy moieties per diacyl moiety, wherein the polyester diol is end-blocked essentially only by alcoholic hydroxyl groups and has an acid number of less than 3. The novel polyester diols are highly useful in the production of polyurethane/vinyl polymer copolymers by reaction with polyisocyanates and polymerizable ethylenically unsaturated monomers.

Abstract: Expandable styrene-maleic anhydride copolymer particles in which the base copolymer is chemically modified with a hydroxy compound such as 1,4-butanediol, diethylene glycol, glycerine or bisphenol which are useful in the production of various foamed articles having low density without overcharging thereof and good thermal stability.

Abstract: A heat insulating pillar for use in constructing a heat insulating vehicle body comprises inner and outer metallic frame members joined by a plurality of relatively short load bearing plastic inserts. The inserts are encapsulated in a rigid polyurethane foam which is cured in situ and forms a bond with the frame members. The spacer members ensure sufficient mechanical strength for the pillar and in particular resist tension forces tending to separate the frame elements.

Abstract: A process and mold for producing padded motor vehicle seat backs containing a metal framework surrounded by polyurethane foam in a plastic coating. The framework is inserted through a slit in the coating which is then sealed. Then the polyurethane foam is injected through a flexible filler neck into the coating and allowed to polymerize. After polymerization the filler neck is cut off. The framework may be contained in a plastic bag together with a relatively resilient foamed plastic body. The coating may be pressurized inwardly and pressure in the mold may be reduced during injection of the polyurethane foam. The mold comprises a pair of lateral mold parts and a central mold part together defining the mold cavity. The lateral mold parts are movable toward and away from the central mold part by hydraulic or pneumatic rams.

Abstract: A structural and insulating panel for fabricating walls of buildings. A series of panels are interconnected into a wall at the job site and are thereafter filled with insulation by spraying liquid insulating material onto the panel-formed walls. The panels include meshes forming lateral surfaces, zig-zag wires joining the meshes together and webs and backings acting to contain the flow of liquid insulation as it is sprayed onto the walls. Conventional wall covering materials are applied over the hardened insulation, the lattice members acting as a lath. The processes of fabricating the panel and forming a wall with such panels are described.

Abstract: Manufacture of ornamental vehicle wheels wherein a mold surface of desired decorative contour is sprayed with one or more layers of a polyurethane reaction mixture and partially cured in situ. A steel wheel is then placed over the mold surface and a polyurethane reaction mixture which includes a foaming agent is poured into the mold cavity formed therebetween. The poured mixture is then cured and the layers are finish-cured in situ to form an integral ornamental elastomeric structure adhered to the wheel.

Abstract: Water skis (1) are constructed with a reinforced, foamed-in-place, plastic hull (6) bonded to an aluminum deck (5 l ). The foamed plastic hull (6) is reinforced, usually with a plurality of reinforcing elements (13-17). Preferably, the aluminum deck (5) is directly bonded to foamed plastic hull (6) without the use of any intermediate adhesives. Desirably, the lower surface of aluminum deck (5) is surface activated and primed before use.

Abstract: A method of making a gas delivery device in which a delivery conduit and a core are located in a vibratory mold, and refractory granular material with a binder are poured into the mold. The core is removed, and a porous element is inserted in the resulting recess. The assembly is then heat treated to form the completed device.The device is especially useful for degasifying aluminium, copper, and their alloys.

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

Abstract: An improved molding process is provided which comprises treating a mold surface with certain curable silicone compositions to improve the release of a molded article from the mold. The curable silicone release composition is obtained by mixing a vinyl-endblocked polydiorganosiloxane, a xylene-soluble vinyl-containing resinous polysiloxane, a methylhydrogenpolysiloxane crosslinking agent and a hydrosilylation catalyst. The curable silicone release composition is easily applied to and rapidly cured onto the mold surface and, when cured, provides many easy releases of molded articles such as high resiliency polyurethane foam cushions, polyurethane elastomeric shoe soles and polyester boat hulls.

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

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

Abstract: A novel diaphragm suitable for use in electrolytic cells and a novel method of making the diaphragms are provided. The diaphragm according to the invention is characterized in that a reinforcing element is associated with a microporous membrane by integrating it with the anode face of the said membrane. The novel diaphragms are particularly suitable for use in the electrolysis of alkali chlorides.

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

Abstract: A synthetic foam roofing system having roofing sections with a relatively broad undersurface and exposed surface configured to resemble interlocked and overlapping roofing shingles. Ridge, valley, hip, starter gable and starter course shingles are all constructed in a manner similar to the roofing sections to interface and interlock with the roofing sections. The roofing sections and interfacing components may be affixed by conventional means such as nails and adhesives to roof boards, rafters or over old existing roofing structures utilizing wood batting.

Abstract: Foamed, low density polymeric articles have been fabricated from a non-tacky hydrogel obtained by blending normally solid thermoplastic polymer resin with a normally liquid organic solvent and water, at lower molding temperatures and energy requirements than those conventionally used in melt extrusion foam processing.

Abstract: An improved construction and method of making an artificial foot characterized by a rigid keel portion comprising a molded plastic material having a metal reinforcing strip imbedded within said plastic keel portion near the lower surface thereof. This keel portion is surrounded by a typical flexible foamed plastic material molded to said keel to form the outer surface of the foot. Preferably the reinforcing strip includes a metal receiver fixed to the strip and also is imbedded within the rigid keel to receive connecting means to attach the foot to the remainder of the prosthetic leg portion.

Abstract: The manufacture is carried out by impregnating bundles of filaments of fibrous-reinforcing material in a bath made up of an emulsion of a thermoplastic resin and a blowing agent. The emulsion-impregnated reinforcing filament bundles are then squeezed and dried to form resin coatings, and then collected to provide a single bunch of the fiber-reinforced thermoplastic resin material. This bunch is subsequently heated and allowed to expand in a tunnel and also cooled in a tunnel to produce a fiber-reinforced thermoplastic resin of a cellular structure. During the impregnation with the emulsion in a bath, the bundles are slackened and repeatedly beaten in the condition of free tension to cause the filament bundles to be substantially frayed to facilitate the impregnation. An apparatus utilizable in the practice of the above method is also disclosed.

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

Abstract: A molding composition is disclosed for forming in a single step a natural sandwich foam product having a cellular core and a thick, densified outer layer. A hard, particulate filler material such as fly ash is admixed with an unreacted, rigid polyurethane foam system, together with a density distribution control agent such as carbon tetrachloride which lowers the viscosity of the admixture. In molding, the mold cavity is charged with the admixture and the foam reaction is permitted to occur with the mold closed. The resultant, filled foam product has a thick outer layer formed adjacent the mold surface of substantially greater density than its core. In the densified layer, both the polyurethane and filler material components of the resultant product are concentrated to provide over three times the density of the core structure. Formulations are set forth which provide substantial layer thickness and an outer surface having a durometer hardness value of 50 or greater over the entire surface area.

Abstract: A method of manufacturing a fiber-reinforced thermoplastic resin of cellular structure comprises immersing bundles of filaments of fibrous reinforcing material in a bath containing an emulsion of thermoplastic resin added with a blowing agent, drying the emulsion-impregnated reinforcing filaments, preheating the dried reinforcing filaments, compressing the preheated reinforcing filaments to provide an integrally bonded block of fiber-reinforced thermoplastic resin, and allowing the block to expand. The fiber-reinforced thermoplastic resin of cellular structure is advantageously employed as a light-weight, high strength construction material.

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

Abstract: A foam-producing mixture is poured directly into a mold, whose base is constituted by an inner movable wall and outer stationary wall which is provided with supports passing through holes in the inner wall in order to retain mattress springs by the frustums of cones. The springs also bear against an upper wall of the mold and are held solely by the forces of cohesion of the solidified foam.

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

Abstract: Lightweight glass fiber reinforced plastic articles are produced in matched dies by combining fibrous reinforcing materials, such as glass fibers, with a foamable unsaturated polyester resin composition. The matched dies are closed and compressed so that the resin composition fills the mold cavity and wets the fibrous reinforcing material. Thereafter the matched dies are separated to increase the volume of the mold cavity by at least 50 percent greater than the closed volume. The matched dies are retained in this relationship until the unsaturated polyester resin composition has cured and expanded to fill the mold cavity. The resulting product has a density less than 67 percent of the density of a corresponding reinforced plastic article fabricated from the same composition (unsaturated polyester resin, fillers and reinforcement), which is not foamed. The unsaturated polyester resin composition preferably includes 0.

Abstract: This invention relates to filter material consisting substantially of a microporous and/or macroporous sheet structure obtained by coagulation of a polymer solution in which at least one surface area of the sheet structure is abraded more or less, depending on the desired pore size and a process for producing said filter materials.

Abstract: A fabric backed cellular cushioning material is produced in a mold by introducing a liquid reaction mixture into a mold cavity and then covering the mold cavity with a coposite material consisting of a fabric backing and a thin layer of preformed cellular material attached to the backing. The preformed cellular material is presented toward the mold cavity. The reaction mixture expands into a cellular cushioning material, which assumes the shape of the cavity, the expansion being sufficient to enable the molded cellular material to completely fill the cavity and diffuse partially into as well as adhere to the preformed cellular material. The air displaced by the expanding reaction mixture passes out of the mold cavity through the preformed layer of cellular material, but once the expanding cellular material reaches the preformed layer, the mold cavity is sealed.

Abstract: This invention involves the method and apparatus for simultaneously placing a coating of a selected material on the outer surface of an extended cylindrical object such as a pipe or conduit, and holding the coating in position by wrapping the coating with a strip of thin film formed to a cylindrical contour and sealed with a longitudinal seam. This is accomplished in one mode by inserting the pipe through a tubular concentric mandrel, wrapping and sealing the plastic film against the mandrel and injecting the coating material through the annular space between the pipe and the mandrel and thus into the space between the pipe and the sealed plastic film. Using heat shrinkable plastic the film forms a tightly fitting cover for the pipe coating material.