Abstract: A process is provided for producing semi-rigid polyurethane foams having exceptional shock-absorbing properties, even after repeated compression, prepared by the reaction of a polyisocyanate; a polyether polyol having a molecular weight within the range from about 2,000 to about 10,000; from about 1 to about 5% by weight of water per part by weight of polyether polyol; from about 1 to about 6% by weight of urea and/or thiourea per part by weight of polyether polyol; and a cross-linking compound having at least three active hydrogen atoms per molecule that are reactive with isocyanate groups and having a molecular weight below about 1000 in an amount from about 5 to about 25% by weight per part by weight of polyether polyol; the amount of polyisocyanate being selected to give an isocyanate index within the range from about 0.7 to about 1.4.

Abstract: A method for forming a structural foam article having a cellular core, a high density integral skin with fiber reinforcement embedded therein, and exterior facing sheets so as to substantially avoid blistering of the facing sheets, is disclosed. The foam article is prepared by foaming an expandable resin composition between the fiber reinforcing material and facing sheets. The resin has a predetermined viscosity which is a direct function of the porosity of the reinforcing material and an indirect function of the foam initiation time.

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

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

Abstract: An apparatus and method are provided for forming large filament reinforced composite bodies. In one form a substrate is formed by rotational molding a plastic material in a mold cavity after which the molding is removed from the cavity and placed in a filament winding fixture wherein filamentary material is wound thereon to provide substantial reinforcement for the article and strengthen the outer stratum thereof. In a particular form, the rotational molding contains a rigid tubular member extending therethrough and secure therein during the rotational molding process and is utilized for the purpose of supporting the rotational molding in the filament winding fixture. In another form, an inflatable substrate is constructed with a rod or tubular member extending therethrough which member is utilized to support the inflated member in a filament winding fixture.

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 material into a mold after solidification of the other fluidized material having been poured into the mold for the formation of the outer laminate.

Abstract: A method of making a mattress comprising a framework of metal springs sandwiched between first and second sheets of foam, comprises applying a strip of foamable resin mixture around the periphery of the upper surface the first sheet of foam being disposed horizontally, and then laying the framework on the upper surface. The strip is allowed to foam to engulf at least a portion of the lower part of the framework which is thus adhered to the first sheet. The framework is then similarly adhered to the second sheet.

Abstract: A refrigerator structural support is provided by permitting polyurethane foam reactant material to impregnate a body of fibrous material and to subsequently harden. The result is a third material having desirable stiffening and support characteristics. Various means are disclosed for controlling and advantageously using the result of the impregnation of fibrous material by foam reactant material.

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

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

Abstract: Method of making a cylindrically shaped, partially collapsible, foam mandrel to be used for the manufacture of hollow resin impregnated fiber tubes. The mandrel is made of a substantially rigid foam cylindrical member, an extractable bar, and a means for aiding in collapsing the cylindrical member such as a groove. Both the extraction bar and the means for aiding in collapsing the cylindrical member are disposed in and along the entire length of the cylindrical member such that the longitudinal axis of the bar, the means for collapsing the cylindrical member, and the axis of the cylindrical member preferably lie on the same plane.The method of manufacturing the aforementioned mandrel comprises the steps of first providing a circular mold having upper and lower sections. A groove-forming member is placed in the lower section and the extraction bar is placed on the upper section. Foam forming material is poured into the lower section which is then covered with the upper section.

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

Abstract: An apparatus for forming a layer of low density foam of uniform thickness on a surface is disclosed. A plurality of upstanding studs spaced across the surface to be coated support a taut screen at a selected height above the surface. An applicator applies liquid, self-rising foam material in a uniform manner to said surface through said screen. 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. 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 disclosed refrigeration cabinet has an integrated construction of sheet material and insulating foam which substantially eliminates the need for mechanical fasteners and welding, minimizes assembly operations, and permits the use of prefinished sheet panels. An outer cabinet shell preferably includes a prefinished sheet wrapped into a rectangular tube. The shell tube is reinforced at one end by a perimeter frame and at the other end by a thermal breaker collar. After the shell tube and frame are assembled, a liner is positioned in the tube and the breaker collar is installed. Rigid insulating foam is then foamed in place between the shell and liner to produce a sandwich construction in which the form secures and reinforces both the shell and the liner.

Abstract: A plastic foam rigid swimming pool cover is fabricated by forming an amorphous plastic foam material into a shape conforming generally to the periphery of the pool and into a shape for covering the swimming pool. The cover is also shaped for lifting as an integral unit from a covering position to an uncovered position above the pool via the intermediary of a plurality of lifts such as electric or hydraulic jacks coupled to the pool cover at a plurality of points spaced around the periphery thereof. The amorphous plastic foam material is formed to the desired shape by either casting or spraying the material into or onto a form of proper shape. In some embodiments, the reinforcing members are embedded in the foam to provide added strength and rigidity. The foam cover may include soil and plant receptacles for landscaping. The cover may be formed in situ or at a remote location to a template and segmented for transport to the pool and reassembled in situ.

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

Abstract: Vessel insulation is displaced from the adjacent surface of the vessel by fluid pressure and additional insulating material interposed between the insulation and the vessel.

Abstract: A method of making a foam filled panel by clamping two sheets together at one end thereof, spreading the sheets at the opposite ends, introducing foamable material into a hollow, closed space between the sheets where clamped, and progressively clamping and filling space between successive adjoining portions of the sheets working toward the free ends until a foam filled panel is formed. The sheets are kept at a fixed location and a sprayer is manipulated to introduce the foamable material. Panels of unusual shapes can be formed.

Abstract: A panel door comprised of a rectangular wood frame defining a generally rectangular central opening which may be subdivided by one or two spaced apart transverse frame members to define two or three smaller central openings. A thin plywood panel is laminated to a front side of the door and routed out in the central open area or areas and a reinforced polyurethane sculptured panel is molded into each opening. A thin plywood panel is laminated to the back side of the door. Both the front and back plywood panels are prelaminated with a polyvinyl chloride film.

Abstract: A pipeline retard, support and protection method wherein a fast-setting expandable foam is placed in a trench at spaced locations below and around a pipeline to create spaced retards and support pads in situ. Each retard and/or support pad is created in the absence of forms or other foam molding means for the expanding foam. The retards may be keyed to the trench walls and base for securement. The system is also adaptable to encapsulating a portion of the pipeline which transverses a roadbed.

Abstract: An improved method for forming bodies of foamed plastisol resin characterized by the steps of solidifying a flowable plastisol containing a chemical blowing agent to form a solidified body, grinding the body to form a body of uniformly sized aggregate, depositing the aggregate in a mold, and heating the mold to a temperature above that at which the plastisol fuses and the blowing agent decomposes.

Abstract: A contruction member, usable in exterior or interior walls, ceilings or floors, including: a stiff, planar, can-supporting panel or board; cylindrical or otherwise non-rectangular, parallel-axes cans having end covers fixed to the panel or board, these cans being preferably of metal but optionally of dense, strong plastic or glass, of the new or used type, having lengths that are less than twelve times their diameters; optional insulation inside the cans; large-mesh metal or plastic fencing, fixed to can ends; and porous, insulating, strength-providing adhesive material around portions of the can sidewalls, bonding and bracing the cans together into a bar, panel or block, part of this material being in layers within recesses of the can-end covers that are spaced from the panel or board.

Abstract: In the production of a structural element such as a door or a panel forming part of the surround of a swimming pool, a rigid framework is placed on an upwardly presented surface of a mould. The mould is then closed and a foamed plastics material is injected into the mould cavity part of the periphery of which is defined by the framework which becomes an integral part of the moulded product.

Abstract: Method of producing an entrainer for squeezing or dyeing textile fabric webs with the aid of a foulard which includes inserting a spread-out endless textile web into an annular mold both the web and the annular mold having a periphery and a width corresponding to the periphery and width of the entrainer to be formed and thereafter filling the annular mold with a material that hardens to form a sponge; and endless entrainer produced by the foregoing method.

Abstract: A method of manufacturing refrigerating units (equipment), such as refrigerating and refrigerated showcases, store fixtures and the like, including forming walls, partitions and/or panels having a layer of plastic foam formed in situ. Standard modular elements are produced, each constituting a portion of a wall, bottom or upper portion of the unit to be constructed. Each element is provided with respective stepwise tiers formed along its two longer edges and along its two shorter edges with respective outwardly extending protuberances formed from the layer of plastic foam. The modular elements are assembled along their longer edges, at least some of the shorter edges also being in contact. Units made by the method are described.

Abstract: A low toxicity, castable, fast curing, polyurethane high strength elastomer is prepared from a liquid prepolymer diol, a cycloaliphatic diisocyanate, a polyalkanol amine and a small amount of soluble metal salt catalyst. The composition can be formulated by either a prepolymer or "one-shot" technique and cures at ambient temperature.

Abstract: A snow ski having a plastic foam core formed in situ between preformed top and bottom subassemblies.

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

Abstract: A method for making an article such as a chair seat or the like is disclosed with the method including: attaching a rigid insert to one-half of a mold with an air permeable material extending from between the rigid insert and the mold outward toward the edges of the first half of the mold; inserting a liquid foamable reaction mixture into the cavity of a second half of the mold, placing the two mold halves together with the air permeable material extending from the cavity of the mold to the exterior thereof; allowing the reaction mixture to cure and form a rigid hard structure throughout while expanding around the sides of the rigid insert; and removing the finished article from the mold.

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

Abstract: A plastics structure, such as the center-board for a sailing boat or a vehicle body panel, comprises a foamed plastics material containing arrays of high tensile steel reinforcing wires having a diameter in the range 0.040 to 0.125 inches and a yield strength of not less than 200,000 psi, located in the surface layers thereof at a distance of not less than 0.06 inches below the surface, to yield a structure having improved impact resistance and enhanced rigidity. The wires may be preformed plastic spacer elements or on a plastic sheet material which then forms the outer surface skin of the structure. Polyurethane is the preferred plastics material. Additional layers of reinforcing wires may be included if required and it is preferred that all wire be pretreated by e.g. shot blasting to improve adherence to the plastics material.

Abstract: A form molded synthetic foam roofing section having a relatively broad undersurface and an exposed surface configured to resemble interlocked and overlapping roofing shingles which is united to a support surface such as wood, metal, etc. during molding process. This section may be affixed by any conventional means such as nails and adhesives to roof boards, rafters or over old existing roofing structure.

Abstract: Walled structures are prepared from foam-in-place components such as those used to prepare rigid polyurethane foams wherein successive strips of foam are deposited and hardened within a three-sided enclosure having a generally H-shaped configuration. A foraminous scrim such as glass fiber mesh forms part of the vertical legs of the H and foam is disposed below the cross piece of the H to bond to adjacent scrim facing sheets and scrim of a previously disclosed strip. The foam is significantly reinforced, joined to the previously deposited structure and foaming components are isolated from depositing apparatus.

Abstract: A fire-resistant door or other building panel for cold storage compartments includes a sheet-metal casing containing a core of plastic foam insulation with a layer of a hydrous sodium silicate composition between the plastic foam core and the walls of the casing. In case of fire or high temperature conditions near the panel the silicate composition expands, forming a thick, cellular heat barrier that shields the foam plastic and affords fire protection equivalent to that of an approved fire door.

Abstract: A shaped synthetic resin article varying in cross-sectional area and shape of longitudinal section along at least a part of the length is continuously produced by introducing a molten synthetic resin composition, extruded from an extruder die, between at least one pair of rolls rotating in the direction of extrusion so that the rolls of each pair contact each other on their periphery, the peripheral surfaces of the rolls being engraved so as to form a cavity corresponding to the shape of said shaped article when the rolls of each pair contact each other while being rotated, in which cavity the molten resin composition is remolded into an article having the desired shape and at the same time the surplus resin composition overflowing from said cavity is cut off by the edges of said rolls contacting each other, and then cooling the molded article to solidify the same.

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

Abstract: A method of forming a spring cushion construction comprising a foamed pad having a generally flat inner surface with a depending peripheral edge, the flat inner surface including a dense outer crust. A spring assembly is disposed so that the terminal face portions thereof contact the outer crust and with the depending edge of the pad confiningly receiving the spring assembly to prevent lateral displacement therebetween. The pad is formed by a method which includes foaming a foamable material in an open top mold while leveling the upper surface of the foamable material in a manner which does not interfere with the formation of a dense outer crust thereon. The depending foam edge may then be formed by adding additional foamable material along the periphery of the pad, or by suitably attaching a preformed foam strip therealong.

Abstract: Encapsulating an insert in plastics by injection moulding with one face of the insert bearing against the mould thus supporting the insert against movement during injection with subsequent relative movement between insert and the supporting mould face to allow the injected material to flow round that face of the insert.

Abstract: A body for a container or for a road or rail vehicle. The body comprises an inner tube formed of a wound laminate of synthetic resin impregnated material; an outer tube formed of a wound laminate of synthetic resin impregnated material and spaced from the inner tube, an insulation material and reinforcing material in the space between the tubes, the tubes insulation material, and reinforcing material all being securely interconnected. The synthetic resin impregnated material preferably comprises filaments and/or fabric.

Abstract: A uniform, porous, homogeneous diaphragm for use in electrolysis cells is provided by bringing together a homogeneous, stable suspension of asbestos fibers in water and a fluorinated polymeric resin latex with a pore-forming agent in the presence of a sulfonated anionic surfactant, the resulting suspension being shaped to the desired form of the diaphragm by filtration, the desired shape of the diaphragm then being dried and sintered at a temperature above the crystalline melting point of the fluorinated polymeric resin, the pore-forming agent finally being removed from the resulting diaphragm by decomposition or extraction.

Abstract: A method of making a unitary structure, such as, a conveyor idler, having a heat-sensitive subassembly with at least one moving part therein, such as, a lifetime lubricated bearing structure, wherein the subassembly is preassembled, the preassembled subassembly is placed in a mold, and a plastic, having a sufficiently low temperature of formation to prevent damage to the heat-sensitive subassembly and, upon hardening, a sufficient compressive strength to hold the subassembly together and form a pressure resistant unitary body, such as, a hard polyurethane foam having a compressive strength of at least about 90 kp/mm.sup.2, is formed about the subassembly. A protective covering, such as, a plastic sleeve, resistant to abrasion, can also be placed in the mold and made to adhere to and surround the outside surface of the unitary plastic body during the formation of the unitary plastic body.

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

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

Abstract: Foamed structures such as those formed of rigid polyurethane can be easily reinforced by a plurality of layers of reinforcement material spaced relatively uniformly throughout their thickness by coating or covering the layers of reinforcement material with absorbent material such as paper, stacking the layers at the bottom of a mold, adding the liquid resin, and curing the resin after it has had sufficient time to wet the absorbent layers. As the resin on the absorbent layers foams, the layers of reinforcement will be simultaneously lifted and spaced from each other to provide uniform reinforcement without the need for special molds or the labor usually required to position spaced layers of reinforcement.

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

Abstract: Synthetic-resin bodies, preferably composed of hardenable synthetic resins and especially thermosetting resins are formed by introducing a foamable resin into a mold cavity, setting the foamable resin upon permitting the same to expand to fill the mold cavity, and thereafter introducing into the mold cavity, without changing the volume thereof, at least one additional synthetic resin while the foamed body is plastically deformable but possesses sufficient rupture strength to prevent penetration. The resulting body thus has a surface layer of the second material which displaces the foamed first material.

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