Abstract: A process and device for the continuous production of slabstock foam by foaming a polyurethane reactive mixture containing carbon dioxide dissolved under pressure, comprising the steps ofa) feeding said polyurethane reactive mixture into a linear extended pressure distribution chamber at a pressure above that of the solubility vapor pressure of said dissolved carbon dioxide,b) reducing pressure to a pressure below said solubility vapor pressure of said dissolved carbon dioxide in a linear extended pressure reduction zone,c) feeding said polyurethane reactive mixture from said pressure reduction zone into a foaming chamber with a widening cross-section of flow to form a foamed reactive mixture, andd) applying said foamed reactive mixture (froth) substantially perpendicularly and free-flowing onto a conveyer belt of a continuous slabstock foam plant.

Abstract: An elongated member, for example, a bowling pin, has a core of foamed plastic material, which has areas of greater density, generally toward the lower end of the bowling pin, so as to provide desired weight distribution along the member. In the bowling pin, providing a denser core area near the bottom lowers the center of gravity. In a baseball bat, the increased density can be provided in the "sweet spot" area, if desired.In producing the variation in density, the mold in which the foamed core is formed is heated in those areas in which the density is to be light and chilled in those areas in which the density is to be increased.In making a baseball or softball bat, a foamed core can be wrapped directly with graphite filament or graphite and glass filaments, or synthetic fibers such as Aramid fibers of the type marketed by Dupont de Nemours as KEVLAR.RTM. either dry wrapped and subsequently embedded in epoxy or the like, or wrapped with adhesive coated fiber that is then cured.

Abstract: This invention relates to a one-step process for preparing polyurea elastomers comprising reaction at an isocyanate index of from 90 to 200 of(a) one or more aliphatic and/or cycloaliphatic diisocyanates;(b) 25 to 70 equivalent percent, relative to the total of components (b) and (c), of one or more liquid amine-terminated polymers containing at least two aromatically bound isocyanate-reactive primary or secondary amino groups and/or aliphatically bound isocyanate-reactive secondary amino groups and having a molecular weight of from 400 to 6000; and(c) 75 to 30 equivalent percent, relative to the total of components (b) and (c), of one or more aromatic diamine chain extenders having a molecular weight of from 108 to 399, optionally in admixture with one or more crosslinkers.

Abstract: An apparatus for manufacturing articles made of polyurethane that includes a mold assembly in communication with a mix chamber. The mix chamber is positioned below the mold assembly. The mix chamber includes a propeller for mixing the liquid polyurethane chemicals. The mix chamber further includes a pneumatically actuated bladder that causes the mixed chemicals to move from the mix chamber to the mold assembly. The chemicals expand to take on the shape of the mold. The method of the present invention comprises the steps of: (a) selecting polyurethane chemicals having certain specific weights; (b) placing said chemicals in a mix chamber wherein chemicals stratify according to their specific weights to prevent detrimental reaction among the chemicals until final mixing; and (c) allowing the chemicals to expand to form an article.

Abstract: A glove, especially for a glove box containing radioactive materials, and a method for producing the same, includes a polyurethane glove body having two sides, a first layer of thermoplastic monocomponent polyester urethane being based on an aromatic diisocyanate and being free of reinforcing fabric, a second layer of synthetic rubber on at least one of the sides, and a connecting layer between the first and second layers formed of a mixture of the polyester urethane and the synthetic rubber.

Abstract: A process for the production of composite bodies of polyurethane foams and covering layers, which includes at least partly lining a mold with a covering layer, and filling the mold with a reaction mixture which reacts to form a polyurethane foam. The reaction mixture which forms a polyurethane foam consists of a polyisocyanate component, a component consisting of at least one organic compound having at least two isocyanate reactive groups, blowing agents, and salts with water of crystallization as additives for improving the bond between the foam and the covering layer.

Abstract: A process formulation and apparatus for producing formed parts of polymeric binders and elastic or inflexible particularized ingredients. A formulation for forming a formed material upon the application of heat and pressure comprising a mixture of: (a) 75 to 95.5 wt. % of elastic or inelastic particles; (b) 2.5 to 25.0 wt. % of a polymer binder; (c) 0 to 20.0 wt. % of a coloring pigment; and (d) 0.1 to 0.5 wt. % of a catalyst.

Abstract: A method of manufacturing polymer seals consisting of bonding together a combination of cured pre-polymers to form a single multi-layered seal of varying hardness urethane with at least one pre-polymer being a polyester based pre-polymer and at least one pre-polymer being a polyether-based prepolymer.

Abstract: A method and apparatus (20) for batch molding open-cell soft polyurethane foam within a mold (22a, 22b, 104) is provided by introducing into a mixing chamber (26) of a mixing pot (24) a highly activated polyol component and an isocyanate component which are mixed and permitted to foam to provide upward expansion in a viscous state through an upper outlet (28) by free rise that fills the mold (22, 104). Such batch molding provides "one age of foam" that enables molding to be performed which was not previously possible. Both a rigid mold (22) and a flexible mold (104) can be utilized. The mixing pot (24) includes a mixer 38 preferably embodied by a rotatable screw (74) that is moved axially to purge the mixing chamber (26) of foam after each cycle.

Abstract: A cover member for an air bag installation, includes a shaped cap-link member of soft urethane molded directly onto and in covering relation to a pair of thermoplastic, L-shaped, angle members, the urethane adhering to the thermoplastic and operating to prevent inadvertent release of the urethane during deployment of the bag.

Abstract: Cellular glass structures are made by foaming select silicone resins. A foaming agent is reacted together with the silicone resin to form a foam that carries the resin as a continuous separate phase distributed throughout the foam. The foaming agent is removed by decomposition, and the remaining silicone resin is crosslinked to retain the foamed structure. The silicone resin is then heated in a non-oxidizing atmosphere at a temperature that will pyrolize the resin. During pyrolysis, the resin densifies to foam a unique glass composition comprised of silicon, oxygen and carbon, where carbon is chemically bonded to silicon, but there are essentially no chemical bonds between carbon and oxygen.

Abstract: Laminated composites including method for the preparation thereof comprising forming in combination in a mold at least one layer of a rigid polyurethane modified polyisocyanurate by reacting in said mold, a reaction mixture of an organic di- or polyisocyanate, a cyclic alkylene carbonate and a polyether polyol in the presence of a soluble adduct aminecarbonate catalyst, and at least one layer of material selected from metal, plastic, cellulose, glass and ceramic or combinations thereof. The electrically conductive "metal clad" laminates are especially usefual as printed circuit boards.

Abstract: A process is disclosed for producing a medical prosthesis by forming the prosthesis from an uncrosslinked polyurethane and then at least partially crosslinking the polyurethane with a vaporizable halo alkylisocyanate. The haloalkylisocyanate (e.g. chloromethylisocyanate) is reacted with the uncrosslinked polyurethane at a temperature which will not degrade or soften the polyurethane, (in its uncrosslinked form) in order to crosslink the polyurethane.

Abstract: A method for making weather strips in which a polyurethane film is positioned along an anvil having longitudinal parallel spaced anvil surfaces and recesses therebetween with elongate channel-like portions of the film in the recesses. Resiliently compressible polyurethane foam is pressed against the polyurethane film along the anvil so that the foam is compressed against the anvil surfaces and extends into the channel-like portions of the film in the recesses. The compressed foam and film along the spaced anvil surfaces are then sonically welded to fuse the foam together in its compressed state and fuse the compressed foam to the film, and the fused foam and film are slit along the anvil surfaces to form separate weather strips.

Abstract: A method for molding articles where a composition is used to treat at least one shape determining face of a mold to impart durable release characteristics to said face which last through multiple molding cycles. The compositions comprise by weight 20 parts of primarily hydroxyl endblocked polydimethylsiloxane, 2 to 10 parts of alkyltriacetoxysilane, 20 to 80 parts of nonreactive organic solvent, and, optionally, 0.001 to 2 parts organometallic catalyst.

Abstract: Polyaddition products containing urethane groups are produced by reacting an isocyanate group containing distillation residue with a compound having a molecular weight less than 600 containing at least two alcoholic hydroxyl groups. The distillation residue is obtained in the commercial production of tolylene diisocyanate. The distillation residue and hydroxyl compound are reacted in amounts such that the NCO/OH equivalent ratio is less than 1.5:1. The polyaddition reaction is carried out at a temperature in the range of 50.degree. to 220.degree. C. The reaction is carried out in a reaction screw extruder preferably having self-cleaning screw geometry. The polyaddition products are useful as molding compositions, reactive fillers and starting materials in the production of flame-resistant polyurethane plastics.

Abstract: The physical properties of reaction injection molded (RIM) polymeric articles are substantially improved by internally reinforcing them with flake glass filler particles. The flake glass is incorporated in the liquid chemical polymer precursors, and is co-injected with them into the mold. The flow of the liquids in the mold orients the glass flake to provide maximum improvement in physical properties in the hardened polymerized article. Molding with glass flake filler also substantially alleviates problems of surface waviness in RIM panels.

Abstract: A method for molding elongated workpieces wherein the mold is comprised of three vertically oriented quadrants and a fourth quadrant pivotally mounted relative to the three quadrants between a mold open position and a generally vertically oriented mold closed position. A workpiece is loaded into the mold by positioning end plates on the workpiece and locating the combination on the fourth quadrant by positioning of the end plates on locating pins projecting from a frame member or tilt beam associated with the fourth quadrant. Slide assemblies are then moved into workpiece engaging positions on each end of the workpiece to accurately locate the workpiece relative to the fourth quadrant. The fourth quadrant with the workpiece locked thereon is then moved into a mold closed position for molding.

Abstract: A method of manufacturing a resilient side bearing of the type utilized between a truck and body of a railway vehicle includes the steps of providing a bearing housing; sealing the bearing housing to form an enclosed bearing chamber, pouring liquid resilient bearing material into the bearing chamber; permitting the liquid resilient bearing material to cure and become bonded to the interior surface of the housing to form the bearing; and removing the seals after the bearing material has cured.

Abstract: An expandable vinyl chloride resin composition for foaming under atmospheric pressure which comprises a resin ingredient comprising (A) a vinyl chloride homopolymer or copolymer having substantially no active hydrogens, (B) a vinyl chloride copolymer having active hydrogens and (C) a thermoplastic polyurethane resin, and a crosslinking agent, a foaming agent, a thermal stabilizer and a plasticizer, the ratio of the components (A), (B) and (C) being 30 to 90:5 to 40:5 to 40 by weight. The composition is expanded under atmospheric pressure to give a foam of a high expansion ratio which has uniform and fine cells and shows an excellent rubber-like elasticity.

Abstract: Two component polyurethane soles for footwear are molded continuously in an apparatus including a turntable with a plurality of mold stations therearound. While a first sole portion is being molded at one mold station, a second sole portion interconnecting the first sole portion to a lasted upper is molded at the same mold station. Such simultaneous molding is achieved using a mold bottom or top which retains the first sole portion and with such first sole portion forms part of the mold for forming the second sole portion. The second sole portion mold is completed by mold sides and a lasted upper.

Abstract: A method of releasing molded articles from a mold by coating the mold with zero grain soft water prior to insertion of the material to be molded into the mold, zero grain soft water meaning the substantially total absence of divalent ions, such as calcium or magnesium, in the water.

Abstract: Method of preparing polyurethane composite mold by injecting a composite reaction mixture onto a master form in a mold cavity, curing said reaction composite and removing it from the master form in a step-wise process involving a pressure manipulation. Said composite comprises 100 parts by weight inorganic water insoluble inert granular material and about 50 to about 200 parts by weight liquid polyurethane reaction mixture substantially free of volatile solvents.

Abstract: The instant invention is directed to novel mold release agents for polyurethane resins and to the use thereof, particularly in the closed mold forming of polyurethane foams. The mold release agents disclosed herein are applied to the surface of the mold prior to molding and broadly comprise talc dispersed in an emulsion of water and an organic solvent.

Abstract: A fibre bundle is first formed from loosely entangled fibres. A sheath is formed over the fibre bundle and one end is dipped into an urethane prepolymer to fill the spaces among fibres with the urethane prepolymer. After removal from the prepolymer it is left to stand for a period of time during which the constituents in the urethane prepolymer react to form polyurethane and generate carbon dioxide gas which forms many capillary passages for the transudation of ink. By grinding the dipped end a marking pen is obtained having a nib and an ink reservoir integral therewith.

Abstract: The processing temperatures of thermoplastic polyurethane elastomers are reduced, and the extrudability and the sensitivity to degradation by shear and by moisture are improved, by including a minute proportion (from 0.0005 to 0.05 equivalents, per equivalent of isocyanate) of a monohydric aliphatic alcohol in the reaction mixture (diisocyanate, polymeric diol and difunctional extender) employed to prepare thermoplastic polyurethane elastomers by the one-shot procedure.

Abstract: The method of this disclosure relates to the application of a foam layer, in fluid form, to either an impervious or a relatively porous substrate and to the formation of a contoured foam laminate using a relatively rigid foam. The method of applying foam to a porous substrate includes heating the substrate prior to the application of the fluid foam. Upon striking the heated substrate, the foam forms a blow barrier to prevent foam bleedthrough. The method also optionally includes forming the laminate in a die prior to completion of foaming.The laminate includes a flexible substrate, preferably a polyurethane foam layer and an optional lattice skrim located between the substrate and the exposed surface of the foam layer.

Abstract: Disclosed is a process for the uniform cure of polyurethane elastomers including the steps of mixing polyurethane prepolymers, having free isocyanate groups, with a stable curing agent complex to form a blend, thereafter transferring it to a suitable mold and subjecting it to a predetermined amount of microwave energy until it is substantially cured.

Abstract: The method of this disclosure permits the application of a foam layer, in fluid form, to a relatively porous substrate and the formation of a contoured foam laminate using a relatively rigid foam. The method includes heating the substrate prior to application of the fluid foam and forming the laminate in a die prior to completion of foaming. The laminate includes a flexible substrate, preferably a polyurethane foam layer and a lattice skrim located between the substrate and the exposed surface of the foam layer.

Abstract: This invention relates to a process for producing finished and/or irreversibly embossed microporous sheet structures by coagulation of a polyurethane solution, in which prior to the coagulation of the polyurethane solution a finishing agent is mixed into it or a finishing agent is applied to the free surface of the polyurethane solution which has been spread out flat and embossing is then carried out during or shortly after the coagulation or after the washing, but still before the drying, or else the microporous sheet structure obtained and into which the finishing agent has been mixed previously is, after drying, pressed between two plates or passed under pressure between at least two oppositely rotating rolls, at least one of which is highly polished.

Abstract: A method of casting liquid compositions in elastomeric molds wherein the casting composition has a reaction temperature below about 235.degree. F comprising:A. introducing an organic solvent soluble polyol, a liquid polyisocyanate and a basic curing catalyst having a pK.sub.b value from between 7 and about 11 into an open elastomeric mold,B. controlling the ratio of polyol to polyisocyanate and the concentration of the curing catalyst and casting the resin such that the cured resin is: substantially free from entrapped air at the mold surface, free from foaming, has a cast time of generally less than about 15 minutes, has a tensile strength of at least about 2500 psi,C. removing the cast resin from the mold shortly after the composition is cast thereby providing unexpected prolonged mold life. The resin undergoes substantially no change in volume from the liquid to the cured state.

Abstract: In accordance with a preferred embodiment of this invention, a controlled phase change is used to trigger an exothermic polymerization reaction in an injection molding process. The subject method comprises first, dispersing a crystalline urea reactant, 1,3-bis-(3-isocyanatotolyl) urea, in a liquid polyoxyalkylene polyol or mixtures thereof. Since the polyols do not dissolve the urea at room temperature, the dispersion is storage stable over an extended period of time. This is unexpected because the isocyanate and hydroxyl functionalities are normally quite reactive. In the barrel of the injection molding machine, the dispersion is heated to a temperature at which the polyol will begin to dissolve and thereby react with the crystalline urea to initiate a controllable polyurethane-forming reaction.

Abstract: This invention relates to composite articles of manufacture and to a method for the preparation of these articles. The articles are impact-resistant, three-dimensional and rigid. The articles are comprised of two essential elements: (1) A pliable, hollow premolded outer plastics layer and (2) an essentially rigid non-cellular organic plastics structural backing member solidified in the hollow interior of the plastics skin, and essentially solidly filling said hollow interior. The hollow outer layer is prepared in a manner to have an access opening to its hollow interior. A liquid plastics composition is next prepared in a separate step that comprises an organic binder which solidifies at room temperature, in most cases by converting to a thermoset stage. This liquid composition is then introduced through the access opening into the cavity of the premolded outer layer.