Abstract: A process for manufacturing a padded element using a mold having a mold cavity and including an upper mold having an interior surface complimentary to the upper surface of the padded element and a lower mold having an interior surface complimentary to the lower surface of the padded element. The process includes placing a trim cover on the upper mold, with the trim cover comprising an inner surface and a finished outer surface in contact with substantially the entire interior surface of the upper mold, placing a liquid foamable polymeric composition on the interior surface of the lower mold and closing the upper mold and the lower mold after the liquid foamable polymeric composition expands to fill from about 50 to about 90 volume % of the mold cavity and prior to expansion of the liquid foamable polymeric composition to a point corresponding to the interior surface of the upper mold in a closed position.

Abstract: In a process and apparatus for the production of a component including a support element and foam portions adhering to the top and bottom surfaces thereof, the support element is arranged with its bottom surface over a first mold cavity of a mold. A cover is then sealingly fixed on the mold in such a way that a second mold cavity is defined between the cover and the support element. A first reaction mixture is introduced into the second mold cavity and reacts to form a first foam portion on the top surface of the support element. The cover with support element and first foam portion are then removed from the first mold cavity. Thereupon a second reaction mixture is introduced into the first mold cavity which is then immediately sealingly closed again by the unit consisting of the cover and the support element with its first foam portion.

Abstract: A method of making a seat back which includes the steps of sewing a front panel and a back panel together along sewing seams which are exterior with respect to the interior surfaces of the panels so as to form a bag-like structure in a condition wherein the exterior surfaces of the front and rear panels are generally facing one another, sliding the bag-like structure onto a tongue-like mold while the bag-like structure is in the condition in which the panels thereof were sewn together and without inverting the same in any way so as to bring the exterior surface of the front panel into face-to-face relation with a mold surface of the tongue-like mold, contacting the exterior surface of the front panel with the mold surface of the tongue-like mold, forming a body of foam material on the interior surface of the front panel while the exterior surface thereof is in contact with the mold surface, inverting the bag-like structure with the body of foam material adhered to the front panel thereof, and mounting the inv

Abstract: A mould for moulding the moulded product is also provided which includes a bottom and side wall formation surrounding the bottom proximate the periphery of the bottom, the bottom carrying on its surface a design to be carried by the moulded product, the bottom being separate from the side wall formation so that the side wall formation can be spaced from the bottom and be lowered to engage the bottom proximate the periphery of the bottom. The bottom may be one piece or may include a base supporting a tongue moveable to a raised position for receiving a bag or sack of material for the purposes of injecting foamable thermoplastics material onto the bag or sack.

Abstract: Plastic panels which are useful as automotive interior trim panels, interior door panels and the like decorative and structural panels, are made by a method which integrates insert sections in the surfaces of the panels and eliminates insert edge trim molding strips. The method includes bonding at least the edge portions of the inserts upon a thin plastic sheet, pre-sized blank, then removing the plastic sheet portions that overlap the insert within the bonded portions; next, positioning the blank in a mold against a mold face and molding in situ and simultaneously bonding a plastic substrate against the blank and the exposed surface of the insert. A substantially continuous, channel forming means, such as a narrow rib or a groove, on the mold face, is overlapped by the bonded insert edge portions and sheet portion, which are folded by said means to form a narrow, relatively deep channel. The insert edges are part of and, consequently, are concealed within the channel.

Abstract: A vacuum mold and process for manufacturing a textile-covered cushion. The process broadly comprises back foaming, wherein (i) the cover is placed on the edge of a vacuum molding part at least partly containing a mold cavity and is stretched before a vacuum is applied to the mold cavity, (ii) the cover is sucked into position, (iii) a foamable reaction mixture is then applied to the back of the cover and (iv) when the reaction mixture has set to form the foam core, the cushion is removed from the mold, the improvement wherein prior to the application of the vacuum to the mold cavity, the cover is brought into contact with at least one moveable section of the wall of the mold cavity as it is positioned over the mold cavity, the cover is fixed to this section and the section together with the cover fixed thereto is then moved into the molding position.

Abstract: A vehicle inner panel with a padded fabric surface, and includes firstly moulding a substrate of polymeric material, suitably polyurethane, attaching the substrate to one die of a two part die set, stretching a fabric sheet on a stretch frame, interposing the stretched fabric sheet between the other die of the die set and the substrate, injecting foam forming polyurethane through the substrate and allowing it to foam while the dies are closed, opening the dies, removing the assembly, and trimming the fabric.

Abstract: The present invention is directed to a device for manufacturing foam cushions with coverings. The device broadly includes:(i) a mold having an upper half and a lower half and having a mix head associated therewith, wherein at least one half of said mold consists of a cavity and a surrounding stretching rim, the inner walls of said cavity having suction channels therein, said suction channels being connected to a vacuum source such that when a vacuum is applied, a covering is sucked into said cavity and against said inner walls, and(ii) a tenter adapted to be placed over said rim, said tenter having(1) an elastic, flexible roller element rotatably mounted in a groove in said tenter, said roller element being further characterized as(a) being capable of twisting around its axis,(b) being located in the region of the tenter which comes into contact with said rim, and(c) allowing said covering to slide when said covering is being sucked into said cavity.

Abstract: A process for producing a thermoplastic polyester resin foam comprising melting a thermoplastic polyester resin, mixing the molten resin with a blowing agent and extruding the mixture into a low-pressure zone to carry out expansion molding, characterized in that a compound having two or more acid anhydride groups per molecule, optionally together with a compound of a metal of Group I, II or III elements of the Periodic Table is added to the thermoplastic polyester resin. There is also disclosed a process for producing a thermoplastic polyester resin foam comprising cooling a high-temperature foam immediately after expansion and then re-heating the foam. Further, a thermoplastic polyester resin foam sheet and a food container prepared from the foam sheet are also disclosed.

Abstract: A method for making a portion of a vehicle seat or back having a surface contour of predetermined shape by placing a sheet of an impermeable film against one side of a portion of a sheet of a permeable cloth fabric to make an impermeable composite portion of a fabric trim material. The composite portion is then positioned on a forming tool having a shaped upper surface complementary to the predetermined shape desired for the final product. A vacuum is then drawn between the forming tool and the impermeable composite portion so as to draw the portion into conformity with the shaped upper surface of the forming tool. A foam bun having an adhesive coated surface is then positioned against the portion on the forming tool. Heat is then applied to deteriorate the impermeable film thus enabling the adhesive to bond the cloth fabric material to the foam bun and maintain the desired shape.

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 tear away seam stabilizer for a vehicle seat component is provided for use with the pour-in-place molding process. The stabilizer, or welt, has an annular body attached to a notched tab portion by a tapered portion and neck portion which is sewn between covering members to form the desired shape of a component. A mold is provided within which the sewn cover, with the seam stabilizers in place, is inserted. The stabilizers maintain alignment of the seams in the cover member during the pour-in-place process and also prevent wrinkles in the cover. The end result is a vehicle seat component with the cover member tightly adhered to the foam body and conforming to a surface of predetermined shape. Once the foam pad is adhered to the cover member, the annular body of the stabilizer is readily torn off.

Abstract: An improved process for producing a laminated resin foam composed of two resin foam layers of different characteristic properties wherein the layers are integrally bonded together. A first foamable resin liquid for forming flexible foam is poured into a first space in a foam processing mold on one side of a barrier projecting from the wall of the mold and pouring a second foamable resin liquid for forming a foam less flexible than the first flexible foam into a second space in said foam processing mold on the other side of said barrier. The two foamable resin liquids foam beyond the barrier into contact with each other to form the two laminated foam layers. One improvement in the process includes wetting a substantial portion of the mold cavity with the first foamable resin liquid. Various shapes of molds and barriers will produce different shapes and characteristics of the resultant foam pad, such as for a car seat.

Abstract: Apparatus for stabilizing the location of a skin or shell in a mold for foaming a part includes magnets on the mold adapted to be releasably interconnected to a shell retention and draw bar. The draw bar connects to an integral shell connector. The draw bar is adjustable to pull the shell with respect to the magnets for removing wrinkles from the shell prior to foaming the part.

Abstract: The present invention relates to an apparatus for the production of back-foamed products. The apparatus broadly consists of two mold halves, a stretching frame attached to one of the mold halves, and a pulsator device for applying pulsations to the edge region of the mold cavity.

Abstract: In manufacturing an insulating box used for a low-temperature show case having a slidable transparent windows on the top opening thereof, a recess is formed on the upper front ends of inner and outer boxes of an insulating box, said recess being provided with a frame covering the gaps between said inner and outer boxes and having a groove for receiving therein a multi-layer transparent panel. After the multi-layer transparent panel is installed in the groove and fixed with a fixation frame, an expandable insulating material is injected into the spaces between said inner and outer boxes to form said insulating box.

Abstract: A deep drawn, synthetic-foil-sealed textile with foamed backing is perforated by applying hot pressurized air towards the foil, locally and in discrete spots, so that the foil melts locally, and foil material is blown into the textile under formation of a perforation duct that is bonded to the textile material underneath.

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 refrigerator liner of a vacuum formed plastic with a thickness of about 0.007" to 0.050" has each corner formed without crinkling when thermal insulation material is foamed against the outer surface of the liner. The non-crinkling of each corner of the refrigerator liner is accomplished through forming each of the corners with a flat surface having its periphery as a circle during vacuum forming of the refrigerator liner rather than with a spherical radius. This enables the flat surface to be placed in tension when moved against a corresponding flat surface of a foam plug by the pressure produced during foaming of the foamed thermal insulation material. This results in each corner having a central portion with a convex cross section and an outer portion surrounding the central portion and concave in cross section whereby it does not appear to be crinkled.

Abstract: A process for the production of foam cushions having textile covers by inserting a textile cover into a mold cavity having gates which project into the mold cavity, initially preforming the textile cover by applying a vacuum through holes in the mold cavity such that the textile cover conforms to the contour on both sides of the gates, clamping the textile cover against the gates, optionally further positioning the textile cover such that it conforms to the contours of both the gates and the mold cavity, releasing the clamps and introducing a foam-forming reaction mixture into the mold cavity. The present invention is also directed to a form tool having gates, means for applying a vacuum through holes in the mold cavity in gates and clamping means for clamping the mold cover to the gates.

Abstract: A method of producing a skin-covered pad for a seat, which includes by steps (a) preparing a lower mold which has a cavity formed therein, the mold having projections on a bottom of the cavity; (b) putting a bag-shaped outer skin member into the cavity, the skin member being thermally plastic; (c) putting an upper mold on the lower mold to close the cavity, the upper mold having an aperture formed therethrough; (d) projecting a press member into the cavity through the aperture, the press member having at its work head recesses which are shaped to match with the projections of the lower mold; (e) pressing the recessed work head of the press member against the projections of the lower mold with an interposal of a part of the outer skin member therebetween; (f) heating the work head of the press member thereby to soften the part of the outer skin member; (g) separating the work head of the press member away from the projections of the lower mold; and (h) pouring a liquid material for foamed plastic into the cavi

Abstract: The invention relates to a vacuum mold for manufacturing cushions with back-foamed covers, wherein a section of cover material is stretched across a mold cavity, held down at the rim of the cavity, but allowed to slide into the mold cavity under the influence of a vacuum. The cover is also placed against and fitted to contourings (ridges and/or grooves) of the mold cavity, and subsequently back-foamed. The resulting flexible foam core is allowed to harden and the finished cushion is removed from the form.

Abstract: In a method of making an integrally foam-molded seat by disposing a trim cover in a molding cavity of a mold used for molding a polyurethane foam and having a seat surface pattern embossed on its inner wall of the molding cavity, injecting a polyurethane resin solution into the molding cavity of the mold and foaming the polyurethane resin to mold the polyurethane foam integrally combined with the trim cover, a material not adhesive to the polyurethane resin is applied onto an inner surface of at least a side part of the trim cover, so that at least the side part of the trim cover may not adhere to the corresponding portion of the molded polyurethane foam, and a defect such as a void present in the moded polyurethane foam can be easily repaired is such a void is found in the product.

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 method of manufacturing a portion of a seat. A cover member is shaped to a predetermined shape and placed in a foam molding tool into which is injected an expandable liquid foaming material to mold a foam pad which is integrally bonded to the cover member. In the manufacturing of seat backs, the cover member includes a tubular envelope cover positioned on a cantilever forming tool. Once the foam pad is molded, the cover member is turned inside out to enclose the foam pad with the cover member. The cover is then telescoped over a seat frame. Alternatively, the foam pad can be molded to a shaped fabric sheet, the envelope cover formed by sewing a second cover member to the fabric sheet. A seat cushion is made by shaping a cover member, placing the cover member in a foam molding tool which also holds the seat frame and injecting an expandable liquid foaming material into the mold to mold the foam cushion, bond the cushion to the cover and embed the seat frame in the foam.

Abstract: A method for forming finished coverstocks includes automatically heating and indexing slightly overlapped rough seams of coverstock segments with respect to a single thermoforming tool that automatically opens and closes to vacuum fold the rough seams interiorly of the tool and thereafter the folds are pinched to form a finished styling line on the class A surface of the coverstock. An apparatus is provided in which a single thermoforming tool has relatively moveable mold parts that shape the coverstock and include an expandable joint line configured to fold the rough seams and further including slide members responsive to closure of the mold parts to provide space to accommodate the fold for pinching it off with respect to the class A surface. The product of the invention includes multiple coverstocks with finished styling lines formed by pinched off folds on the hidden side of the coverstock.

Abstract: A cushion article, such as a seat cushion or the like, for snapping in place onto an appropriate seat support without additional attaching means. The seat cushion has a foam body with a snap-ring member molded integral with a peripheral portion of the body, the snap-ring member providing means for snapping the seat cushion over the seat support. A process and a mold assembly are disclosed for molding the seat cushion, utilizing the snap-ring member as an integral part of the process and mold assembly to evacuate entrapped air from the mold cavity.

Abstract: An arcuate concrete section (13) for forming a tunnel has a groove (12) around its edges for accommodating a rectangular frame sealing ring (11) of moulded rubber for sealing adjacent sections (13) together. The sealing ring (11) has a section (FIG. 3) with holes (20, 21, and 22) and grooves (23) for allowing distortion as the concrete sections are forced together edge to edge. At the corner of the sealing ring the section is moulded solid (FIG. 6), but with larger grooves (34) to allow for distortion.

Abstract: Herein disclosed is a method of producing a skin-covered foamed polyurethane article, such as a seatback proper of an automotive seat, a seat cushion proper of the same or the like. A bag-shaped skin member which is to constitute the skin of the article consists of two parts which have respective inwardly projected peripheral portions stitched up. One of the peripheral portions is folded back fully to constitute a thicker peripheral portion. A mold used for molding the article has a groove which extends around the side wall of the cavity. The skin member is put into the cavity of the mold in such a manner that the thicker portion is forcedly received in the groove, and then a liquid material of polyurethane is poured into the bag-shaped skin member.

Abstract: The present invention relates to sanitary wares of acrylic or methacrylic resins, such as bathtubs, shower trays, sinks, and so forth, comprising a sheet of thermoformed resin and a reinforcing layer of fiberglass-filled foamed unsaturated polyester.

Abstract: The present invention is directed to an apparatus for the production of foam cushions having textile covers by inserting a textile cover into a mold cavity having gates which project into the mold cavity, initially preforming the textile cover by applying a vacuum through holes in the mold cavity such that the textile cover conforms to the contour on both sides of the gates, clamping the textile cover against the gates, further positioning the textile cover such that it conforms to the contours of both the gates and the mold cavity, releasing the clamps and introducing a foam-forming reaction mixture into the mold cavity. The present invention is also directed to a form tool having gates, means for applying a vacuum through holes in the mold cavity in gates and clamping means for clamping the mold cover to the gates.

Abstract: The present invention is directed to an apparatus for the production of foam cushions having a textile cover in which the cover is inserted into a mold cavity and adapted to the contour of the mold cavity by the application of a vacuum wherein movable gates assist in improving the adaptation of the cover to the contour of the mold cavity.

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: The apparatus includes a first female mold member defining a mold cavity for receiving a plastisol 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: The invention relates to a method for producing shaped articles comprising a thermoplastics show surface and a backing layer of a rigid polyurethane or polyisocyanurate foam by applying a foamable polyurethane or polyisocyanurate composition which is substantially free from appreciable amounts of halocarbon blowing agents, in a closed mould to one face of a shaped thermoplastic sheet provided to one of the matching parts constituting said mould.

Abstract: A composite molded article and a method of fabricating such an article is disclosed, which is especially well-suited for forming one-piece interior vehicle panels, by way of a single molding operation, wherein the one-piece interior panel can be easily installed as a unit within the vehicle. In the fabrication of the one-piece molded composite article, a deformable sheet material, such as vinyl, is positioned on a female molding surface and drawn into conformity with the female molding surface of the mold cavity, either with or without preheating or vacuum forming. The mold apparatus is closed and a first moldable material is introduced into the mold assembly, with certain predetermined portions thereof being blocked off. Subsequently, a second moldable material is introduced at least into the predetermined areas previously blocked off during the introduction of the first moldable material.

Abstract: A method and apparatus for foam molding packaging using a staged vacuum system to place a plastic sheet used as a release agent in conformity with the surface of the mold is provided. A mold having a complex image divides the mold image into separate and distinct sections. A plastic sheet is placed loosely over the mold in covering relation to the image and a vacuum is drawn on the surfaces of the separate and distinct sections of the mold image in a staged sequence to cause the plastic sheet to conform to the surfaces of the mold image on the mold.

Abstract: A method and apparatus of foam molding packaging using a positive vertical mold is provided in which a vertical mold with sides having channeled vertical flap areas is automatically covered with a plastic sheet. Brushes, assisted by a vacuum assure the plastic sheet conforms to the mold including the flap areas. An open-ended carton having upper and lower flaps is placed over the mold so that the lower flaps are disposed vertically and cover the vertical flap areas. Foam precursors are dispensed into the carton and its top sealed to allow foaming within the carton. The carton is then removed from the mold with the foam cushioning fully formed therein including the carton flaps which cover the top of the article to be packaged therein.

Abstract: In a process and apparatus for the production of a cushion element with a cover means enclosing same, at least one cover means is clamped with edge portions thereof between first and second clamping frames in such a way that the cover means defines a space therewithin. The clamping frames with the cover means clamped thereby are then held between first and second mold portions, with the cover means disposed in the mold cavity defined by the co-operation of the clamping frames and the mold portions. The cover means is drawn by suction against the mold cavity surface and a reaction mixture is then introduced into the space defined by the cover means within the mold cavity, through at least one feed opening. After reaction of the mixture the mold portions are separated and the cushion element with cover thereon from the mold.

Abstract: A relatively thin thermoplastic sheet material, vacuum molded to form a sign letter base including hollow wall members and hollow light-fixture supports upstanding from a single-thickness horizontal bottom member. The base inverted forms a mold itself for receiving a flexible plastic foam inserted to a suitable height and disposed within the vertical walls and fixture supports for providing compressible elasticity to the thin molded sheet in predetermined locations for enabling cooperative interaction of the same with retainer members used to secure a display sign face and gas filled lighting tube structures in proper location onto the base. A rigid polyester resin is cast as a ring encircling the letter walls, located and supported by the flexible foam to stabilize and support the thin nature of the base.

Abstract: A differential pressure thermoforming machine has a female mold with a female mold cavity, and an opposing mold, with a mold closing portion cooperable therewith. A foam injection head is perimetrally separated from the mold closing portion and is provided on the opposing mold. When the molds are initially closed, a differential pressure is created in the molds to cause the heated plastic sheet to move into contact with the mold cavity and form a configured pocket in the sheet. Mechanism is provided for releasing the plastic sheet from the carriage in which it has been moved between the molds, after the molding operation, to the cavity in the female mold, after which the molds are restored to spread-apart position.

Abstract: The molded shell of an article, while still warm from being molded, and while remaining within the mold or fixture in which it has been created, for instance by blow-molding of a parison of polyolefin plastic material into contact with the mold walls, is filled with a fluid, settable foaming plastic material, for instance polyurethane. This may be done by injecting the foaming mixture directly into the cavity of the shell. In this manner time, labor and materials are saved, and the resulting product is characterized by better adhesion of the foamed core to the internal wall surface of the shell.

Abstract: The present invention relates to a method for the manufacture of moulded bodies such as cornices from foam plastics material, the visible side of these bodies being heavily textured or profiled, smooth, non-porous and free from separation elements, with a unit weight of less than 200 kg/m.sup.3. In the method, a thin, elastic, heat-deformable film (3) is inserted between two heated mould portions (1, 2) in such a way that the film edges are clamped between the superimposed mould edges of the two mould portions (1, 2), a reactive, heat emitting, foaming plastics mixture is introduced through the upper mould portion (1) in such a way that it may be distributed on the film, and the hollow chamber formed between the film and the lower mould portion is evacuated during foaming, such that the film intimately conforms to the shape of the lower mould portion.

Abstract: Apparatus for fabricating a cushion contoured and fitted to the sitting support surfaces of a user includes a generally flat plate having a plurality of apertures in the upper surface thereof. Each aperture is coupled to and continuous with a duct within the flat plate, with all of the ducts coupled to a vacuum source by appropriate fittings and hoses. Mounted to the upper surface of the flat plate and in sealed engagement therewith are a plurality of rails arranged so as to form a generally rectangular structure, or form, open at the top and closed about its lateral periphery. A plaster positive having a generally flat lower surface and an upper surface conforming with the support surface to which the cushion is to be fitted is positioned within the rectangular form and a flexible, nonporous membrane is positioned over the open form and in contact with that portion of the flat plate therein as well as with the plaster positive.

Abstract: An improved method for making custom molded seat cushions wherein a bead-filled latex bag is used as a trail buttocks supporting cushion and likewise another bead-filled latex bag is used as back-supporting cushion in a frame which is similar in function to the seat frame of the chair. An impression of a desired portion of a user's body is formed on each of the bags and air is removed from the bags thereafter to fix the impression. A positive mold of the individual's respective backside and buttocks impression are made. Corrective changes may be made either to the latex bag impression as it is being formed or the positive mold impression. The positive mold impression is then utilized along with a mold frame to mold a custom fitted seat cushion for the individual who will utilize the wheelchair.

Abstract: A process for forming cloth-covered cushion articles. A mold is provided having the shape of the desired cushion article. In one form, a cloth covering is drawn into the mold. Foamable material is poured into the mold and cured to form the cushion article. The covered, cured article is removed from the mold and heated to at least the heat-fixable fiber set temperature of the cloth, as the cured foam acts as a male mold to hold the cloth in contour during heat setting. In another form, the foam is poured directly into the mold and cured. The cloth covering then is placed over the cured cushion and set.

Abstract: A process for developing porosity in air impervious film. The process is disclosed for fabricating a cushion article having a cover provided with increased air flow capabilities. A covering is provided for a cushion body, the covering including a laminated film and, preferably, an outer fabric layer. The film includes a first layer having a relatively high temperature melting point and a second layer having a relatively low temperature melting point. The first layer includes perforations, and the second layer is continuous and air impervious. The laminated film is heated at a temperature which approaches or is above the melting temperature of the second layer but below the melting temperature of the first layer to melt the second layer at least in areas coincident with the perforations in the first layer to form air flow passages through the film laminate.

Abstract: The molded shell of an article, while still warm from being molded, and while remaining within the mold or fixture in which it has been created, for instance by blow-molding of a parison of polyolefin plastic material into contact with the mold walls, is filled with a fluid, settable foaming plastic material, for instance polyurethane. This may be done by injecting the foaming mixture directly into the cavity of the shell. In this manner time, labor and materials are saved, and the resulting product is characterized by better adhesion of the foamed core to the internal wall surface of the shell.

Abstract: A cushion article, such as a seat cushion or the like, for snapping in place onto an appropriate seat support without additional attaching means. The seat cushion has a foam body with a snap-ring member molded integral with a peripheral portion of the body, the snap-ring member providing means for snapping the seat cushion over the seat support. A process and a mold assembly are disclosed for molding the seat cushion, utilizing the snap-ring member as an integral part of the process and mold assembly to evacuate entrapped air from the mold cavity.

Abstract: A sanding tool (8) or surface finishing tool for sanding or finishing a work piece such as profiled moldings or edges of panel type work pieces has a foam material body (17), at least one surface of which has a contour corresponding to the cross-sectional shape of the surface to be sanded or finished. A sanding or finishing belt (11) is secured to the contoured surface of the foam material body. The tool is produced in a simple, economical manner by casting or molding. For this purpose a profiled body having a surface configuration corresponding to that of the work piece is inserted into a mold. A length of sanding belt or sandpaper is inserted into the mold so that the rough surface faces the profiled body. The mold is then filled with a foam material which, after curing, is intimately bonded to the sanding belt or paper with the desired contour.