There is described a foamed isocyanate-based polymer derived from a reaction mixture comprising: an isocyanate; a polyol composition comprising a first prescribed amount of polymer particles dispersed in a base polyol; a second prescribed amount of biomass-based carbonaceous particulate material; and a blowing agent. In one embodiement, the foamed isocyanate-based polymer having an Indentation Force Deflection when measured pursuant to ASTM D3574-11 which is within about 15% as that of a reference foam produced by omitting the biomass-based carbonaceous particulate material from the reaction mixture and increasing the amount of polymer particles in the polymer polyol composition to equal the sum of the first prescribed amount and the second prescribed amount. In another embodiment, the foamed polymer has a cellular matrix comprising a plurality of interconnected struts, the biomass-based carbonaceous particulate material conferring to the cellular matrix a load efficiency of at least about 5 Newtons/weight % of biomass-based carbonaceous particulate material. A process to produce the foamed isocyanate-based polymer is also described. A polyol-based dispersion to produce the foamed isocyanate-based polymer is also described. It has been discovered that a relatively expensive petroleum-based copolymer polyol can be fully substituted by a relative inexpensive bio-based (amorphous carbon) dispersion with no significant compromise in important physical properties in the resulting polyurethane foam.
40 - Treatment of materials; recycling, air and water treatment,
17 - Rubber and plastic; packing and insulating materials
42 - Scientific, technological and industrial services, research and design
Goods & Services
Custom manufacturing services for others of foam products for use in the automotive sector Foam for use in the manufacture of automotive parts, namely, headliners, seats, head-restraints, arm rests, sun visors, door trims, and interior vehicle trim Custom design services for others of foam products for use in the automotive sector
The subject disclosure provides a vehicle seat assembly comprising a seat component having a support surface, a foam layer, and a formed cloth. The foam layer has an A-surface and a B-surface. The formed cloth has an inner surface and an outer surface with the inner surface attached to the B-surface of the foam layer. The formed cloth comprises a plurality of fibers shaped to define a plurality of suspension springs each having a pre-defined 3- dimensional configuration defining a cavity. Each cavity is filled with a portion of the foam layer and the foam layer at least partially penetrates the formed cloth between the inner and outer surfaces to further define the suspension springs and to maintain the pre-defined 3- dimensional configurations of the suspension springs. A portion of the outer surface of the formed cloth on the suspension springs engages the support surface of the seat component. The suspension springs respond to dynamic input by partially deflecting to a deflected state and recovering to an initial state relative to the support surface of the seat component for isolating vibrations of an occupant during use of the vehicle seat assembly.
A mold is described for production of a molded element. The mold includes a first mold portion and a second mold portion engageable to define a mold cavity. The mold further includes at least one insert element having a textured surface and configured to create a first internal surface and a second internal surface opposed to one another in molded element. The textured surface may include a plurality of peak portions and a plurality of valley portions. The at least one insert element may be affixed to one of the first mold portion and the second mold portion, or is moveable with respect to one or both of the first mold portion and the second mold portion to facilitate demolding of the molded element.
Described is a vehicular seat having a back element. The back element includes: (a) a rigid support element having coupled thereto an anchor element, the anchor element for detachably coupling to an article; and (b) a resilient foam element secured with respect to the rigid support element. The resilient foam element is in contact with the back of an occupant of the vehicular seat. The article can be one or more of an occupant restraint element, a cargo element and an automotive accessory. Advantageously, this combination of elements results in a vehicular seat, which is of light weight construction and passes the FMVSS 225 test requirement.
A thermoplastic foam composition for low-density and high-stiffness articles includes a thermoplastic foam and an unactivated biomass-based carbonaceous particulate material encapsulated in the thermoplastic foam. The thermoplastic foam composition has a core density of between 12 grams per liter and 400 grams per liter as measured pursuant to ASTM-D3575-W Test Method A. The thermoplastic foam composition also has an elastic modulus of between 60 pounds per square inch and 3500 pounds per square inch as measured pursuant to ASTM-C203 Method I, Equation 13.
C08J 9/04 - Working-up of macromolecular substances to porous or cellular articles or materialsAfter-treatment thereof using blowing gases generated by a previously added blowing agent
A mold comprising a first mold element and a second mold element releasingly engagable between an open position and a closed position to define a mold cavity in the closed position and a first part line between the first mold element and second mold element. The first mold element comprises a first mold portion and a second mold portion configured to be reversible separable with respect to one another to define a second part line therebetween disposed interiorly with respect to a periphery of the first part line. At least one vent is disposed in the second part line. In one embodiment, the at least one vent comprises a passageway configured to permit mold material in the mold cavity to enter but not to exit the passageway to cause at least partial curing of the mold material in the passageway.
A ventilated seating assembly comprises a first rigid component, a foam layer, and a second rigid component. The first rigid component comprises formed cloth and has a bonding surface, a ventilation surface opposite the bonding surface, and a 3-dimensional profile. The foam layer has an A-surface and a B-surface opposite the A-surface with the first rigid component bonded to the B-surface of the foam layer such that a portion of the B-surface includes the 3-dimensional profile. The second rigid component comprises a polymeric material affixed to a portion of the ventilation surface of the first rigid component. The first and second rigid components define a cavity including a plurality of air passageways defined by the 3-dimensional profile of the first rigid component.
A47C 7/18 - Seat parts having foamed material included in cushioning part
B32B 5/24 - Layered products characterised by the non-homogeneity or physical structure of a layer characterised by the presence of two or more layers which comprise fibres, filaments, granules, or powder, or are foamed or specifically porous one layer being a fibrous or filamentary layer
B32B 3/20 - Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shapeLayered products comprising a layer having particular features of form characterised by a discontinuous layer, i.e. apertured or formed of separate pieces of material characterised by an internal layer formed of separate pieces of material of hollow pieces, e.g. tubesLayered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shapeLayered products comprising a layer having particular features of form characterised by a discontinuous layer, i.e. apertured or formed of separate pieces of material characterised by an internal layer formed of separate pieces of material of pieces with channels or cavities
B32B 7/12 - Interconnection of layers using interposed adhesives or interposed materials with bonding properties
B32B 5/02 - Layered products characterised by the non-homogeneity or physical structure of a layer characterised by structural features of a layer comprising fibres or filaments
B32B 5/26 - Layered products characterised by the non-homogeneity or physical structure of a layer characterised by the presence of two or more layers which comprise fibres, filaments, granules, or powder, or are foamed or specifically porous one layer being a fibrous or filamentary layer another layer also being fibrous or filamentary
B32B 3/30 - Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shapeLayered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layerLayered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shapeLayered products comprising a layer having particular features of form characterised by a layer with cavities or internal voids characterised by a layer formed with recesses or projections, e.g. grooved, ribbed
B32B 37/12 - Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by using adhesives
A composite foam article is disclosed herein. The composite foam article comprises a surface layer and a base layer with an interface therebetween. The surface layer comprises a high-resiliency polyurethane foam having an impact resilience of greater than about 50% when tested in accordance with ASTM D3574-17, and presents a seating surface. The base layer comprises a viscoelastic polyurethane foam having an impact resilience of less than about 50% when tested in accordance with ASTM D3574-17, and presents a mounting surface opposite the seating surface. The surface layer and the base layer are present in a thickness ratio of from about 17:3 to about 2:3.
B32B 5/18 - Layered products characterised by the non-homogeneity or physical structure of a layer characterised by features of a layer containing foamed or specifically porous material
A folding head restraint comprises a head restraint support frame and a head restraint body. The head restraint support frame comprises a first and a second mounting post, a cross-member fixed to the first and second mounting posts and defining a pivot axis, and a latching plate mounted on the cross-member and defining a notch. The head restraint body comprises a housing, a locking member, and an actuator. The housing is pivotably mounted on the head restraint support frame to pivot about the pivot axis between a use position and a folded position. The locking member has an upper and a lower arm and is rotatably mounted on the housing to define an axis of rotation between the arms. The actuator is mounted to the housing and partially moveable relative to the housing.
There is disclosed composite container comprising a thermally insulated inner container disposed within a thermally insulated outer container. The thermally insulated inner container is configured to receive one or more phase change material (PCM) elements to define a payload enclosure. The one or more PCM elements are configured to maintain a payload disposed in the payload enclosure initially at −20° C. between 8° C. and −25° C., such as between 2° C. and 8° C. or between −15° C. and −25° C., for a period of at least 48 hours in an ambient temperature of up to 35° C. when tested pursuant to ISTA 7D Test Procedure. The composite container can be used to ship temperature-sensitive payloads such as perishable goods (e.g., a COVID-19 vaccine such as the Moderna COVID-19 vaccine).
B65D 81/38 - Containers, packaging elements, or packages, for contents presenting particular transport or storage problems, or adapted to be used for non-packaging purposes after removal of contents with thermal insulation
14.
ISOCYANATE-BASED FOAM AND PROCESS FOR PRODUCTION THEREOF
There is described an isocyanate-based polymer foam having the combination of: (i) a Limiting Oxygen Index (LOI) of greater than or equal to 26.5% when measured pursuant to ASTM D2863-17a, and (ii) a Total Volatile Organic Content (TVOC) when measured pursuant to VDA 277 of less than or equal to 225 μg/g C. Preferably, the foam is produced from a foamable composition comprising: an isocyanate; a reactive compound containing: (1) at least one hydrogen which is reactive with the isocyanate, and (2) one or both of a halogen and a phosphate moiety; a blowing agent comprising one or both of water and carbon dioxide; and a catalyst; wherein the reactive compound is present in an amount in the range of from about 30% to about 95% of total ISO equivalents excluding water, if present in the foamable composition.
C08J 9/12 - Working-up of macromolecular substances to porous or cellular articles or materialsAfter-treatment thereof using blowing gases generated by a previously added blowing agent by a physical blowing agent
An assembly for molding a composite article including a foam core and a layer is disclosed. The assembly includes a mold. The mold has an inner surface and at least partially defines a cavity, one or more gas discharge ports, and one or more retaining elements. Each of the one or more gas discharge ports has a passageway opening in fluid communication with the cavity of the mold the mold. The assembly further includes one or more sealing elements moveably engaged with the mold. Each of the one or more sealing elements includes a head and is shaped to engage the retaining element on the mold in a vented position. Further, each of the one or more sealing elements corresponds with each of the one or more gas discharge ports.
B29C 44/16 - Incorporating or moulding on preformed parts, e.g. inserts or reinforcements the preformed part being a lining shaped by the expansion of the material
B29C 44/34 - Component parts, details or accessoriesAuxiliary operations
B29C 44/42 - Feeding the material to be shaped into a closed space, i.e. to make articles of definite length using pressure difference, e.g. by injection or by vacuum
A composite foam article is disclosed herein. The composite foam article comprises a polyurethane foam core presenting a first surface and a second surface facing opposite the first surface. A first skin is disposed on the first surface and a second skin is disposed on the second surface. The first and second skins comprise a plurality of fibers and a polymeric binder. The composite foam article also comprises at least one supplemental layer comprising an ethylene and acrylic acid copolymer dispersed in and/or disposed between any of said aforementioned skins and core.
B32B 5/18 - Layered products characterised by the non-homogeneity or physical structure of a layer characterised by features of a layer containing foamed or specifically porous material
B29C 43/00 - Compression moulding, i.e. applying external pressure to flow the moulding materialApparatus therefor
B29C 43/20 - Making multilayered or multicoloured articles
B29C 51/00 - Shaping by thermoforming, e.g. shaping sheets in matched moulds or by deep-drawingApparatus therefor
B32B 5/02 - Layered products characterised by the non-homogeneity or physical structure of a layer characterised by structural features of a layer comprising fibres or filaments
B32B 5/24 - Layered products characterised by the non-homogeneity or physical structure of a layer characterised by the presence of two or more layers which comprise fibres, filaments, granules, or powder, or are foamed or specifically porous one layer being a fibrous or filamentary layer
B32B 9/02 - Layered products essentially comprising a particular substance not covered by groups comprising animal or vegetable substances
B32B 9/04 - Layered products essentially comprising a particular substance not covered by groups comprising such substance as the main or only constituent of a layer, next to another layer of a specific substance
B32B 27/06 - Layered products essentially comprising synthetic resin as the main or only constituent of a layer next to another layer of a specific substance
B32B 27/08 - Layered products essentially comprising synthetic resin as the main or only constituent of a layer next to another layer of a specific substance of synthetic resin of a different kind
B32B 27/12 - Layered products essentially comprising synthetic resin next to a fibrous or filamentary layer
B32B 37/04 - Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the partial melting of at least one layer
B32B 37/06 - Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the heating method
B32B 37/10 - Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the pressing technique, e.g. using direct action of vacuum or fluid pressure
B32B 37/18 - Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with all layers existing as coherent layers before laminating involving the assembly of discrete sheets or panels only
B60N 2/90 - Details or parts not otherwise provided for
B29K 23/00 - Use of polyalkenes as moulding material
B29K 75/00 - Use of polyureas or polyurethanes as moulding material
B29K 105/04 - Condition, form or state of moulded material cellular or porous
A composite foam article comprises a foam core layer presenting a first surface and a second surface facing opposite the first surface. A first polymeric bonding layer is disposed on the first surface, one or more first reinforcing layers comprising a plurality of fibers and a polymeric binder are disposed on the first polymeric bonding layer, and a first polymeric containment layer is disposed on the one or more first reinforcing layers. A second polymeric bonding layer is disposed on the second surface, one or more second reinforcing layers comprising a plurality of fibers and a polymeric binder are disposed on the second polymeric bonding layer, and a second polymeric containment layer is disposed on the one or more second reinforcing layers. At least one catch layer comprising particles of carbon is dispersed in and/or disposed between any of the aforementioned layers.
B32B 5/24 - Layered products characterised by the non-homogeneity or physical structure of a layer characterised by the presence of two or more layers which comprise fibres, filaments, granules, or powder, or are foamed or specifically porous one layer being a fibrous or filamentary layer
B32B 5/18 - Layered products characterised by the non-homogeneity or physical structure of a layer characterised by features of a layer containing foamed or specifically porous material
B32B 7/12 - Interconnection of layers using interposed adhesives or interposed materials with bonding properties
B32B 5/02 - Layered products characterised by the non-homogeneity or physical structure of a layer characterised by structural features of a layer comprising fibres or filaments
B32B 27/12 - Layered products essentially comprising synthetic resin next to a fibrous or filamentary layer
B32B 5/24 - Layered products characterised by the non-homogeneity or physical structure of a layer characterised by the presence of two or more layers which comprise fibres, filaments, granules, or powder, or are foamed or specifically porous one layer being a fibrous or filamentary layer
B29C 43/00 - Compression moulding, i.e. applying external pressure to flow the moulding materialApparatus therefor
B29C 43/20 - Making multilayered or multicoloured articles
B29C 51/00 - Shaping by thermoforming, e.g. shaping sheets in matched moulds or by deep-drawingApparatus therefor
B32B 5/02 - Layered products characterised by the non-homogeneity or physical structure of a layer characterised by structural features of a layer comprising fibres or filaments
B32B 5/18 - Layered products characterised by the non-homogeneity or physical structure of a layer characterised by features of a layer containing foamed or specifically porous material
B32B 9/02 - Layered products essentially comprising a particular substance not covered by groups comprising animal or vegetable substances
B32B 9/04 - Layered products essentially comprising a particular substance not covered by groups comprising such substance as the main or only constituent of a layer, next to another layer of a specific substance
B32B 27/06 - Layered products essentially comprising synthetic resin as the main or only constituent of a layer next to another layer of a specific substance
B32B 27/08 - Layered products essentially comprising synthetic resin as the main or only constituent of a layer next to another layer of a specific substance of synthetic resin of a different kind
B32B 27/12 - Layered products essentially comprising synthetic resin next to a fibrous or filamentary layer
B32B 37/04 - Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the partial melting of at least one layer
B32B 37/06 - Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the heating method
B32B 37/10 - Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the pressing technique, e.g. using direct action of vacuum or fluid pressure
B32B 37/18 - Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with all layers existing as coherent layers before laminating involving the assembly of discrete sheets or panels only
B60N 2/90 - Details or parts not otherwise provided for
B29K 23/00 - Use of polyalkenes as moulding material
B29K 75/00 - Use of polyureas or polyurethanes as moulding material
B29K 105/04 - Condition, form or state of moulded material cellular or porous
A ventilated seating assembly comprises a first rigid component, a foam layer, and a second rigid component. The first rigid component comprises formed cloth and has a bonding surface, a ventilation surface opposite the bonding surface, and a 3-dimensional profile. The foam layer has an A-surface and a B-surface opposite the A-surface with the first rigid component bonded to the B-surface of the foam layer such that a portion of the B-surface includes the 3-dimensional profile. The second rigid component comprises a polymeric material affixed to a portion of the ventilation surface of the first rigid component. The first and second rigid components define a cavity including a plurality of air passageways defined by the 3-dimensional profile of the first rigid component.
A47C 7/74 - Adaptations for incorporating lamps, radio sets, bars, telephones, ventilation, heating or cooling arrangements or the like for ventilation, heating or cooling
The present invention relates to an automotive trim device and a process for making the same. The automotive trim device comprises a foam body with a cavity, into which a mechanism comprising both functionality-conferring elements and a frame element can be inserted. The foam body is manufactured from liquid foam and uses tooling for the inner core. After the foam body has formed, the tooling is removed and the mechanism can be inserted into the foam body, thereby preventing the mechanism from being exposed to liquid foam. An advantage of the present invention is that the automotive trim device can be used with electrical and/or mechanical devices containing components sensitive to the intrusion and curing of liquid foamable materials. The process may also provide mass and cost savings due to reductions in scrap and material, as compared to other known methods of manufacture.
There is described an isocyanate-based polymer foam having the combination of: (i) a Limiting Oxygen Index (LOI) of greater than or equal to 26.5% when measured pursuant to ASTM D2863-17a, and (ii) a Total Volatile Organic Content (TVOC) when measured pursuant to VDA 277 of less than or equal to 225 µg/g C. Preferably, the foam is produced from a foamable composition comprising: an isocyanate; a reactive compound containing: (1) at least one hydrogen which is reactive with the isocyanate, and (2) one or both of a halogen and a phosphate moiety; a blowing agent comprising one or both of water and carbon dioxide; and a catalyst; wherein the reactive compound is present in an amount in the range of from about 30% to about 95% of total ISO equivalents excluding water, if present in the foamable composition.
C08L 75/00 - Compositions of polyureas or polyurethanesCompositions of derivatives of such polymers
C08J 9/12 - Working-up of macromolecular substances to porous or cellular articles or materialsAfter-treatment thereof using blowing gases generated by a previously added blowing agent by a physical blowing agent
C08G 18/10 - Prepolymer processes involving reaction of isocyanates or isothiocyanates with compounds having active hydrogen in a first reaction step
A composite foam article is disclosed herein. The composite foam article comprises a surface layer and a base layer with an interface therebetween. The surface layer comprises a high-resiliency polyurethane foam having an impact resilience of greater than about 50% when tested in accordance with ASTM D3574-17, and presents a seating surface. The base layer comprises a viscoelastic polyurethane foam having an impact resilience of less than about 50% when tested in accordance with ASTM D3574-17, and presents a mounting surface opposite the seating surface. The surface layer and the base layer are present in a thickness ratio of from about 17:3 to about 2:3.
B32B 5/18 - Layered products characterised by the non-homogeneity or physical structure of a layer characterised by features of a layer containing foamed or specifically porous material
There is described a vehicular seat comprising a back element. The back element comprises: (a) a rigid support element having coupled thereto an anchor element, the anchor element configured to be detachably coupled to an article; and (b)a resilient foam element secured with respect to the rigid support element, the resilient foam element configured to be in contact with the back of an occupant of the vehicular seat. In a preferred embodiment, the the article is one or more of an occupant restraint element, a cargo element and an automotive accessory. Advantageously, this combination of elements results in a vehicular seat which is of light weight construction and passes the FMVSS 225 test requirement.
An assembly for molding a composite article including a foam core and a layer is disclosed. The assembly includes a mold. The mold has an inner surface and at least partially defines a cavity, one or more gas discharge ports, and one or more retaining elements. Each of the one or more gas discharge ports has a passageway opening in fluid communication with the cavity of the mold the mold. The assembly further includes one or more sealing elements moveably engaged with the mold. Each of the one or more sealing elements includes a head and is shaped to engage the retaining element on the mold in a vented position. Further, each of the one or more sealing elements corresponds with each of the one or more gas discharge ports.
A composite foam article is disclosed herein. The composite foam article comprises a polyurethane foam core presenting a first surface and a second surface facing opposite the first surface. A first skin is disposed on the first surface and a second skin is disposed on the second surface. The polyurethane foam core has a density of 15-80 kg/m3. The first and second skins comprise a plurality of fibers and a polymeric binder. The composite foam article has a weight per unit area of 500-1000 g/m2and a strength of greater than 17 N at a post-compression thickness of greater than 2 mm when tested in according with SAE J949 at 23°C.
B32B 5/18 - Layered products characterised by the non-homogeneity or physical structure of a layer characterised by features of a layer containing foamed or specifically porous material
B32B 27/04 - Layered products essentially comprising synthetic resin as impregnant, bonding, or embedding substance
B32B 37/06 - Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the heating method
B32B 37/10 - Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the pressing technique, e.g. using direct action of vacuum or fluid pressure
B32B 5/26 - Layered products characterised by the non-homogeneity or physical structure of a layer characterised by the presence of two or more layers which comprise fibres, filaments, granules, or powder, or are foamed or specifically porous one layer being a fibrous or filamentary layer another layer also being fibrous or filamentary
B32B 5/28 - Layered products characterised by the non-homogeneity or physical structure of a layer characterised by the presence of two or more layers which comprise fibres, filaments, granules, or powder, or are foamed or specifically porous one layer being a fibrous or filamentary layer impregnated with or embedded in a plastic substance
A composite foam article comprises a foam core layer presenting a first surface and a second surface facing opposite the first surface. A first polymeric bonding layer is disposed on the first surface, one or more first reinforcing layers comprising a plurality of fibers and a polymeric binder are disposed on the first polymeric bonding layer, and a first polymeric containment layer is disposed on the one or more first reinforcing layers. A second polymeric bonding layer is disposed on the second surface, one or more second reinforcing layers comprising a plurality of fibers and a polymeric binder are disposed on the second polymeric bonding layer, and a second polymeric containment layer is disposed on the one or more second reinforcing layers. At least one catch layer comprising particles of carbon is dispersed in and/or disposed between any of the aforementioned layers.
B32B 5/18 - Layered products characterised by the non-homogeneity or physical structure of a layer characterised by features of a layer containing foamed or specifically porous material
B32B 27/04 - Layered products essentially comprising synthetic resin as impregnant, bonding, or embedding substance
B32B 37/06 - Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the heating method
B32B 5/26 - Layered products characterised by the non-homogeneity or physical structure of a layer characterised by the presence of two or more layers which comprise fibres, filaments, granules, or powder, or are foamed or specifically porous one layer being a fibrous or filamentary layer another layer also being fibrous or filamentary
B32B 5/28 - Layered products characterised by the non-homogeneity or physical structure of a layer characterised by the presence of two or more layers which comprise fibres, filaments, granules, or powder, or are foamed or specifically porous one layer being a fibrous or filamentary layer impregnated with or embedded in a plastic substance
B32B 7/02 - Physical, chemical or physicochemical properties
B32B 7/10 - Interconnection of layers at least one layer having inter-reactive properties
A composite foam article is disclosed herein. The composite foam article comprises a polyurethane foam core presenting a first surface and a second surface facing opposite the first surface. A first skin is disposed on the first surface and a second skin is disposed on the second surface. The first and second skins comprise a plurality of fibers and a polymeric binder. The composite foam article also comprises at least one supplemental layer comprising an ethylene and acrylic acid copolymer dispersed in and/or disposed between any of said aforementioned skins and core.
B32B 5/18 - Layered products characterised by the non-homogeneity or physical structure of a layer characterised by features of a layer containing foamed or specifically porous material
B32B 27/04 - Layered products essentially comprising synthetic resin as impregnant, bonding, or embedding substance
B32B 27/08 - Layered products essentially comprising synthetic resin as the main or only constituent of a layer next to another layer of a specific substance of synthetic resin of a different kind
B32B 37/06 - Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the heating method
B32B 37/10 - Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the pressing technique, e.g. using direct action of vacuum or fluid pressure
B32B 5/26 - Layered products characterised by the non-homogeneity or physical structure of a layer characterised by the presence of two or more layers which comprise fibres, filaments, granules, or powder, or are foamed or specifically porous one layer being a fibrous or filamentary layer another layer also being fibrous or filamentary
B32B 5/28 - Layered products characterised by the non-homogeneity or physical structure of a layer characterised by the presence of two or more layers which comprise fibres, filaments, granules, or powder, or are foamed or specifically porous one layer being a fibrous or filamentary layer impregnated with or embedded in a plastic substance
The present invention relates to an automotive trim device and a process for making the same. The automotive trim device comprises a foam body with a cavity, into which a mechanism comprising both functionality-conferring elements and a frame element can be inserted. The foam body is manufactured from liquid foam and uses tooling for the inner core. After the foam body has formed, the tooling is removed and the mechanism can be inserted into the foam body, thereby preventing the mechanism from being exposed to liquid foam. An advantage of the present invention is that the automotive trim device can be used with electrical and/or mechanical devices containing components sensitive to the intrusion and curing of liquid foamable materials. The process may also provide mass and cost savings due to reductions in scrap and material, as compared to other known methods of manufacture.
B60R 21/04 - Padded linings for the vehicle interior
B60R 21/207 - Arrangements for storing inflatable members in their non-use or deflated conditionArrangement or mounting of air bag modules or components in vehicle seats
Disclosed is a vehicular seat element comprising a first major surface, a second major surface and a foam core element disposed therebetween. The first major surface is configured to be in contact with an occupant of the vehicle and the second major surface is configured to be in contact with a support surface of the vehicle. The first major surface comprises a rate sensitive foam element secured with respect to the foam core element. The foam core element and the rate sensitive foam element are different from one another.
17 - Rubber and plastic; packing and insulating materials
Goods & Services
(1) Furniture and bedding foam in the nature of polyurethane foam used in the manufacture of furniture, beds and mattresses; furniture and bedding foam in the nature of plastic foam used in the manufacture of furniture, beds and mattresses; furniture and bedding foam in the nature of molded foam used in the manufacture of furniture, beds and mattresses
(2) Furniture and bedding foam in the nature of foam used in the manufacture of furniture, beds and mattresses
A composite foam article is disclosed herein. The composite foam article comprises a surface layer and a base layer with an interface therebetween. The surface layer comprises a high-resiliency polyurethane foam having an impact resilience of greater than about 50 % when tested in accordance with ASTM D3574 – 17, and presents a seating surface. The base layer comprises a viscoelastic polyurethane foam having an impact resilience of less than about 50 % when tested in accordance with ASTM D3574 – 17, and presents a mounting surface opposite the seating surface. The surface layer and the base layer are present in a thickness ratio of from about 17:3 to about 2:3.
B32B 5/18 - Layered products characterised by the non-homogeneity or physical structure of a layer characterised by features of a layer containing foamed or specifically porous material
C08J 9/34 - Chemical features in the manufacture of articles consisting of a foamed macromolecular core and a macromolecular surface layer having a higher density than the core
C08J 9/35 - Composite foams, i.e. continuous macromolecular foams containing discontinuous cellular particles or fragments
12 - Land, air and water vehicles; parts of land vehicles
17 - Rubber and plastic; packing and insulating materials
35 - Advertising and business services
40 - Treatment of materials; recycling, air and water treatment,
42 - Scientific, technological and industrial services, research and design
Goods & Services
Seating for vehicles, namely, automobile seat cushions, motor car seats, vehicle seats, motorcycle seats, golf cart seats; vehicle seat cushions Padding for motor vehicle seats, namely, padding materials of polyurethane foam Industrial management assistance and consulting for manufacturers of products made from polyurethane foam, namely, business management consultancy, business consulting and business information concerning industrial operations and management, and business management assistance Industrial management assistance and consulting for manufacturers of products made from polyurethane foam, namely, consulting services in the field of custom automotive manufacturing; Industrial management assistance and consulting for manufacturers of products made from polyurethane foam, namely manufacturing process consulting services for automotive parts manufacturers and automotive manufacturers; Industrial management assistance and consulting for manufacturers of products made from polyurethane foam, namely, technical consulting services in the field of custom automotive manufacturing Custom development, design and manufacture of foam products for others, namely, new product design consulting services, design and testing of automotive parts for others, product development services, industrial design, and design of automotive parts
33.
Process for producing a low density free-rise polyurethane foam
There is described a process for producing a free-rise polyurethane foam having a density of less than or equal to about 0.75 pcf. the process comprises the steps of: (a) contacting: (i) an isocyanate, (ii) a first polyol comprising a first polymer chain consisting essentially of propylene oxide units and alkylene oxide units selected from ethylene oxide, butylene oxide and mixtures thereof in a weight ratio of propylene oxide units to alkylene oxide units in the range of from about 90:10 to about 25:75, the polymer chain being terminally capped with the ethylene oxide units, the first polyol having a primary hydroxyl content of at least about 70% based on the total hydroxyl content of the first polyol, (iii) water (iv) a surfactant and (v) a catalyst to form a foamable reaction mixture; and (b) expanding the foamable reaction mixture to produce the free-rise polyurethane foam.
A mold comprising a first mold element and a second mold element releasingly engagable between an open position and a closed position to define a mold cavity in the closed position and a first part line between the first mold element and second mold element. The first mold element comprises a first mold portion and a second mold portion configured to be reversible separable with respect to one another to define a second part line therebetween disposed interiorly with respect to a periphery of the first part line. At least one vent is disposed in the second part line. In one embodiment, the at least one vent comprises a passageway configured to permit mold material in the mold cavity to enter but not to exit the passageway to cause at least partial curing of the mold material in the passageway.
There is disclosed a vehicular seat element comprising a first major surface, a second major surface and a foam core element disposed therebetween. The first major surface is configured to be in contact with an occupant of the vehicle and the second major surface is configured to be in contact with a support surface of the vehicle. The first major surface comprises a rate sensitive foam element secured with respect to the foam core element. The foam core element and the rate sensitive foam element are different from one another.
There is described a foamed isocyanate-based polymer derived from a reaction mixture comprising: an isocyanate; a polyol composition comprising a first prescribed amount of polymer particles dispersed in a base polyol; a second prescribed amount of biomass-based carbonaceous particulate material; and a blowing agent. In one embodiment, the foamed isocyanate-based polymer having an Indentation Force Deflection when measured pursuant to ASTM D3574-11 which is within about 15% as that of a reference foam produced by omitting the biomass-based carbonaceous particulate material from the reaction mixture and increasing the amount of polymer particles in the polymer polyol composition to equal the sum of the first prescribed amount and the second prescribed amount. In another embodiment, the foamed polymer has a cellular matrix comprising a plurality of interconnected struts, the biomass-based carbonaceous particulate material conferring to the cellular matrix a load efficiency of at least about 5 Newtons/weight % of biomass-based carbonaceous particulate material. A process to produce the foamed isocyanate-based polymer is also described. A polyol-based dispersion to produce the foamed isocyanate-based polymer is also described. It has been discovered that a relatively expensive petroleum-based copolymer polyol can be fully substituted by a relative inexpensive bio-based (amorphous carbon) dispersion with no significant compromise in important physical properties in the resulting polyurethane foam.
C08G 18/76 - Polyisocyanates or polyisothiocyanates cyclic aromatic
C08J 9/04 - Working-up of macromolecular substances to porous or cellular articles or materialsAfter-treatment thereof using blowing gases generated by a previously added blowing agent
C08J 9/35 - Composite foams, i.e. continuous macromolecular foams containing discontinuous cellular particles or fragments
There is described a foamed isocyanate-based polymer derived from a reaction mixture comprising: an isocyanate; a polyol composition comprising a first prescribed amount of polymer particles dispersed in a base polyol; a second prescribed amount of biomass-based carbonaceous particulate material; and a blowing agent. In one embodiement, the foamed isocyanate-based polymer having an Indentation Force Deflection when measured pursuant to ASTM D3574-11 which is within about 15% as that of a reference foam produced by omitting the biomass-based carbonaceous particulate material from the reaction mixture and increasing the amount of polymer particles in the polymer polyol composition to equal the sum of the first prescribed amount and the second prescribed amount. In another embodiment, the foamed polymer has a cellular matrix comprising a plurality of interconnected struts, the biomass-based carbonaceous particulate material conferring to the cellular matrix a load efficiency of at least about 5 Newtons/weight % of biomass-based carbonaceous particulate material. A process to produce the foamed isocyanate-based polymer is also described. A polyol-based dispersion to produce the foamed isocyanate-based polymer is also described. It has been discovered that a relatively expensive petroleum-based copolymer polyol can be fully substituted by a relative inexpensive bio-based (amorphous carbon) dispersion with no significant compromise in important physical properties in the resulting polyurethane foam.
C08J 9/04 - Working-up of macromolecular substances to porous or cellular articles or materialsAfter-treatment thereof using blowing gases generated by a previously added blowing agent
C08J 9/35 - Composite foams, i.e. continuous macromolecular foams containing discontinuous cellular particles or fragments
There is described a mold comprising a first mold element and a second mold element releasingly engagable between an open position and a closed position to define a mold cavity in the closed position and a first part line between the first mold element and second mold element. The first mold element comprises a first mold portion and a second mold portion configured to be reversible separable with respect to one another to define a second part line therebetween disposed interiorly with respect to a periphery of the first part line. At least one vent is disposed in the second part line. In one embodiment, the at least one vent comprises a passageway configured to permit mold material in the mold cavity to enter but not to exit the passageway to cause at least partial curing of the mold material in the passageway.
There is disclosed a vehicular seat element comprising a first major surface, a second major surface and a foam core element disposed therebetween. The first major surface is configured to be in contact with an occupant of the vehicle and the second major surface is configured to be in contact with a support surface of the vehicle. The first major surface comprises a rate sensitive foam element secured with respect to the foam core element. The foam core element and the rate sensitive foam element are different from one another.
1. In another embodiment, the padded element comprises a molded foam topper portion and a molded foam substrate portion secured with respect to the molded foam topper portion via an interference fit.
A47C 27/15 - Spring, stuffed or fluid mattresses specially adapted for chairs, beds or sofas with foamed material inlays consisting of two or more layers
A47C 7/18 - Seat parts having foamed material included in cushioning part
A47C 7/72 - Adaptations for incorporating lamps, radio sets, bars, telephones, ventilation, heating or cooling arrangements or the like
B68G 5/02 - Resilient upholstery pads of cellular material, e.g. sponge rubber
B29C 44/04 - Shaping by internal pressure generated in the material, e.g. swelling or foaming for articles of definite length, i.e. discrete articles consisting of at least two parts of chemically or physically different materials, e.g. having different densities
B29C 44/56 - After-treatment of articles, e.g. for altering the shape
Provided is a reusable composite container comprising a thermally insulating inner container fitted within a durable outer container. The outer container can also be thermally insulating. In preferred embodiments, the inner container comprises expanded polystyrene and the outer container comprises one or more of expanded polypropylene (EPP), EPS (Polystyrene), EPE (Polyethylene), PEPP (porous EPP) and PS/PE (Polystyrene/Polyethylene). The composite container can be used to ship temperature-sensitive payloads such as perishable goods.
B65D 81/38 - Containers, packaging elements, or packages, for contents presenting particular transport or storage problems, or adapted to be used for non-packaging purposes after removal of contents with thermal insulation
42.
ISOCYANATE-BASED POLYMER FOAM HAVING IMPROVED FLAME RETARDANT PROPERTIES
There is described an isocyanate-based polymer foam having a V-0 rating according to Underwriters' Laboratories Standard 94 Flammability Test after aging of separate samples of the foam (i) for 168 hours at 150° C., and (ii) for 600 hours at 120° C. The foam may be in the form of a molded foam or a slabstock foam. The foam may be used in vehicular applications, such as an under hood application.
There is described a foam article comprising: a base foam having a textured surface; a trim cover covering at least a portion of the textured surface, the trim cover comprising: (i) a finished outer layer comprising an occupant-contact outer portion and inner portion; (ii) a compressible buffer layer secured with respect to the inner portion of the finished outer layer; and (iii) a contact layer secured with respect to the compressible layer and configured to be in contact with the textured surface of the base foam, the contact layer having a secant modulus at 5% strain of at least about 7 when measured according to modified ASTM D3574-11, Test E, Tensile Test. There is also described a foam article comprising: a base foam having a textured surface; a trim cover comprising a finished outer layer; and optionally, a contact layer interposed between the foam element and the trim cover, the contact layer in contact with at least a portion of the textured surface of the base foam and comprising a contact material; the foam article having a read through score of at least 20 when measured pursuant to modified ASTM D3575-11 I2 (Procedure B). The present inventors have discovered that the occurrence of "read through" may be obviated or mitigated if the contact layer having a secant modulus at 5% strain of at least about 7 when measured according to modified ASTM D3574-11, Test E, Tensile Test is used.
B32B 3/30 - Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shapeLayered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layerLayered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shapeLayered products comprising a layer having particular features of form characterised by a layer with cavities or internal voids characterised by a layer formed with recesses or projections, e.g. grooved, ribbed
B32B 27/08 - Layered products essentially comprising synthetic resin as the main or only constituent of a layer next to another layer of a specific substance of synthetic resin of a different kind
B32B 5/16 - Layered products characterised by the non-homogeneity or physical structure of a layer characterised by features of a layer formed of particles, e.g. chips, chopped fibres, powder
In a preferred embodiment there is disclosed a vehicular seat element comprising a foam substrate, the foam substrate comprising an A-surface for contact by an occupant and a B-surface opposed to the A-surface, a central portion of the A-surface have a first surface area and comprising a plurality of channels, the central portion of the A-surface comprising an occupant contact portion having a second surface area, wherein the first surface area is greater than the second surface area, a plurality of apertures disposed in the plurality of channels, each aperture interconnecting the A-surface and the B-surface of the foam substrate. The plurality of channels acts a distribution manifold for air to be moved laterally with respect to the A-surface of the foam pad and also through the holes in the seat pad to allow for circulation of air. In other words, the through holes in the foam provide a pass for air to flow from the B-surface of the foam pad to the A-surface of the foam pad, and vice versa. This air flow is further promoted by compressing and decompressing of the foam by the mass of the occupant while the vehicle is in motion. This compression and decompression of the foam creates a so-called bellows effect to push or pull air through the vehicular seat. Ideally, the series of channels molded in the A-surface of the foam pad form a manifold that enhances air distribution by providing multiple paths for the air flow around (not just beneath) the occupant and through the seat.
12 - Land, air and water vehicles; parts of land vehicles
35 - Advertising and business services
40 - Treatment of materials; recycling, air and water treatment,
42 - Scientific, technological and industrial services, research and design
Goods & Services
Seating and seating parts for vehicles; seats and seating pads. Industrial (business) management assistance and consulting for manufacturers of products made from polyurethane foam. Custom manufacture of automotive seating urethanes, automotive seat cushions, backs and bolsters, seating, armrests, engineered foam materials for further use in manufacturing of automotive parts and fittings, all undertaken on behalf of others. Custom development, design and manufacture of foam products for others.
46.
FOAM SEAT ELEMENT, AND PROCESS AND MOLD FOR PRODUCING SAME
There is described a padded element comprising a foam substrate having disposed therein a first internal surface and a second internal surface opposed to the first internal surface, the first internal surface being interposed between an outer surface of the foam substrate and the second internal surface, at least one of the first internal surface and the second internal surface comprising a textured portion. In a highly preferred embodiment, the pair of internal surfaces disposed within the body of the foam substrate combine to form one or more cavities in the foam substrate (e.g., by the provision of one internal surface have a textured portion and the other internal surface being untextured). The provision of such a textured surface creates a contacting interface (either at rest or when an occupant sits on the seat) between below or remote from the A-surface of the foam element. This interface has different properties than the exposed surface of the seating element. By adopting this internal interface approach to one or more zones of foam element, it is possible to confer different qualities of comfort and feel to the outer surface of the foam element (e.g., A-surface of a vehicular seat element) even though the appearance of that outer surface may be relatively non-textured. In this manner, the occurrence of “read through” described above is obviated or mitigated. A process and mold for produce the padded element are also described.
12 - Land, air and water vehicles; parts of land vehicles
20 - Furniture and decorative products
35 - Advertising and business services
40 - Treatment of materials; recycling, air and water treatment,
42 - Scientific, technological and industrial services, research and design
Goods & Services
(1) Seating for vehicles, namely automobile seat cushions, motor car seats, vehicle seats, motorcycle seats, golf cart seats; padding for motor vehicle seats; seat pads, chair pads. (1) Industrial management assistance and consulting for manufacturers of products made from polyurethane foam, namely business management consultancy, consulting and information concerning industrial operations and management, automotive manufacturing consulting services, business management assistance, consulting services for automotive parts manufacturers and automotive manufacturers, and technical consulting in the field of automotive manufacturing; custom development, design and manufacture of foam products for others, namely product design consulting services, design and testing of automotive parts for others, product development services, industrial design, and design of automotive parts.
48.
FOAM COMPOSITE PRODUCT AND PROCESS FOR PRODUCTION THEREOF
There is described a molded foam composite having improved acoustic properties. These improved acoustic properties result from the provision of an acoustic barrier layer formed in situ at an interface between a foam substrate layer and a porous layer comprised in the molded foam composite. The acoustic barrier layer comprises at least a densified portion of the polymer foam substrate layer penetrating into at least a portion of the porous layer such that the molded foam composite has increased sound absorption and reduced sound transmission compared to the polymer foam substrate layer alone. A process for producing the mold foam laminat is also described.
B32B 7/02 - Physical, chemical or physicochemical properties
B32B 5/32 - Layered products characterised by the non-homogeneity or physical structure of a layer characterised by the presence of two or more layers which comprise fibres, filaments, granules, or powder, or are foamed or specifically porous both layers being foamed or specifically porous
B60N 2/00 - Seats specially adapted for vehiclesArrangement or mounting of seats in vehicles
B60N 2/90 - Details or parts not otherwise provided for
C08J 9/35 - Composite foams, i.e. continuous macromolecular foams containing discontinuous cellular particles or fragments
49.
Vented mold and method for producing molded article
The invention relates mold, particularly a mold for producing foam articles. In a preferred embodiment, the mold comprises a lid and a bowl releasingly engageable to define a mold cavity, the lid comprising: (i) a vent having a passageway for gas to escape from the mold cavity, and (ii) a plurality of grooves connected to the vent. The use of a plurality of grooves/slots in the mold cavity surface effectively acts as a siphon to draw gas away from the composition to be molded. The plurality of grooves/slots is connected to one or more vents which then allows for escape of the gas from the mold cavity to the exterior of the mold.
There is disclosed a padded element. In one embodiment, the padded element comprises a molded foam topper portion and a molded foam substrate portion secured with respect to the molded foam topper portion. The molded foam topper portion and the molded foam substrate portion have a different indentation force deflection at 25% thickness when measured pursuant to ASTM 3574-B1. In another embodiment, the padded element comprises a molded foam topper portion and a molded foam substrate portion secured with respect to the molded foam topper portion via an interference fit.
A47C 27/15 - Spring, stuffed or fluid mattresses specially adapted for chairs, beds or sofas with foamed material inlays consisting of two or more layers
A47C 7/18 - Seat parts having foamed material included in cushioning part
A47C 7/72 - Adaptations for incorporating lamps, radio sets, bars, telephones, ventilation, heating or cooling arrangements or the like
B60N 2/90 - Details or parts not otherwise provided for
B68G 5/02 - Resilient upholstery pads of cellular material, e.g. sponge rubber
In a preferred emobidment there is disclosed a vehicular seat element comprising a foam subtstrate, the foam substrate comprising an A-surface for contact by an occupant and a B-surface opposed to the A-surface, a central portion of the A-surface have a first surface area and comprising a plurality of channels, the central portion of the A-surface comprising an occupant contact portion having a second surface area, wherein the first surface area is greater than the second surface area, a plurality of apertures disposed in the plurality of channels, each aperture interconnecting the A-surface and the B-surface of the foam substrate. The plurality of channels acts a distribution manifold for air to be moved laterally with respect to the A-surface of the foam pad and also through the holes in the seat pad to allow for circulation of air. In other words, the through holes in the foam provide a pass for air to flow from the B-surface of the foam pad to the A-surface of the foam pad, and vice versa. This air flow is further promoted by compressing and decompressing of the foam by the mass of the occupant while the vehicle is in motion. This compression and decompression of the foam creates a so-called bellows effect to push or pull air through the vehicular seat. Ideally, the series of channels molded in the A-surface of the foam pad form a manifold that enhances air distribution by providing multiple paths for the air flow around (not just beneath) the occupant and through the seat.
A47C 7/74 - Adaptations for incorporating lamps, radio sets, bars, telephones, ventilation, heating or cooling arrangements or the like for ventilation, heating or cooling
A47C 21/04 - Devices for ventilating, cooling or heating
A47C 7/18 - Seat parts having foamed material included in cushioning part
There is described an isocyanate-based polymer foam having a V-0 rating according to Underwriters' Laboratories Standard 94 Flammability Test after aging of separate samples of the foam (i) for 168 hours at 150°C, and (ii) for 600 hours at 120°C. The foam may be in the form of a molded foam or a slabstock foam. The foam may be used in vehicular applications, such as an under hood application.
12 - Land, air and water vehicles; parts of land vehicles
17 - Rubber and plastic; packing and insulating materials
40 - Treatment of materials; recycling, air and water treatment,
42 - Scientific, technological and industrial services, research and design
Goods & Services
Seats for vehicles and cars; seat covers, seat cushions and seat backs for vehicles and cars; covers and protective covers for vehicles and for cars; parts and fittings for vehicles and cars; parts and fittings for vehicles and cars being made of foam and polyurethane foam. Polyurethane foam components for the automotive industry; polyurethane foam components for use in vehicles and cars. Manufacture of parts and fittings for vehicles and cars; manufacture of parts and fittings made of foam for vehicles and cars; custom manufacture of foam products for use in the automotive sector. Design of parts and fittings for vehicles and cars; design of parts and fittings made of foam for vehicles and cars; custom design of foam products for use in the automotive sector.
54.
PROCESS FOR PRODUCING A LOW DENSITY FREE-RISE POLYURETHANE FOAM
There is described a process for producing a free-rise polyurethane foam having a density of less than or equal to about 0.75 pcf. the the process comprises the steps of: (a) contacting: (i) an isocyanate, (ii) a first polyol comprising a first polymer chain consisting essentially of propylene oxide units and alkylene oxide units selected from ethylene oxide, butylene oxide and mixtures thereof in a weight ratio of propylene oxide units to alkylene oxide units in the range of from about 90:10 to about 25:75, the polymer chain being terminally capped with the ethylene oxide units, the first polyol having a primary hydroxyl content of at least about 70% based on the total hydroxyl content of the first polyol, (iii) water (iv) a surfactant and (v) a catalyst to form a foamable reaction mixture; and (b) expanding the foamable reaction mixture to produce the free-rise polyurethane foam.
There is described a padded element comprising a foam substrate having disposed therein a first internal surface and a second internal surface opposed to the first internal surface, the first internal surface being interposed between an outer surface of the foam substrate and the second internal surface, at least one of the first internal surface and the second internal surface comprising a textured portion. In a highly preferred embodiment, the pair of internal surfaces disposed within the body of the foam substrate combine to form one or more cavities in the foam substrate (e.g., by the provision of one internal surface have a textured portion and the other internal surface being untextured). The provision of such a textured surface creates a contacting interface (either at rest or when an occupant sits on the seat) between below or remote from the A-surface of the foam element. This interface has different properties than the exposed surface of the seating element. By adopting this internal interface approach to one or more zones of foam element, it is possible to confer different qualities of comfort and feel to the outer surface of the foam element (e.g., A-surface of a vehicular seat element) even though the appearance of that outer surface may be relatively non-textured. In this manner, the occurrence of "read through" described above is obviated or mitigated. A process and mold for produce the padded element are also described.
There is disclosed an improved seat element having a seating surface element that incorporates a plurality of peak portions and a plurality of valley portions. Preferably, the plurality of peak portions and the plurality of valley portions is incorporated in an outermost surface of the seating surface element. The term “outermost surface” is intended to include an area of the seating surface element for contact by and/or support of an occupant of the seat element and does not include, for example, grooves or trenches in which there is disposed a component for attachment of a trim cover. A process and a mold for production of such a seat element are also described.
There is described a process for purifying the crude glycerol obtained from the production of fatty acid alkyl esters via transesterification. The process comprises the steps of; (a) adding an aqueous liquid to the crude glycerine composition to cause phase separation to produce at least two phases comprising an organic phase and an aqueous phase; (b) separating the organic phase from the aqueous phase; and (c) separating the fatty acid alkyl ester from the organic phase. When preferred amounds of aqueous liquid and temperature are used, it is possible to extract a significant amount of residual fatty acid alkyl ester from the crude glycerine composition.
C11B 13/00 - Recovery of fats, fatty oils or fatty acids from waste materials
C07C 29/86 - SeparationPurificationStabilisationUse of additives by physical treatment by liquid-liquid treatment
C07C 67/56 - SeparationPurificationStabilisationUse of additives by solid-liquid treatmentSeparationPurificationStabilisationUse of additives by chemisorption
A laminate product comprising a foam core having a pair of opposed major surfaces and a cover layer secured with respect to each major surface is described. The cover layer contains a fibrous reinforcement layer that is substantially encapsulated by a polymer. It has been found that the use of a fibrous polymer layer (e.g., in place of conventional polyethylene film) results in a laminate product having significantly lower resistance to air flow resistance and significantly improved sound absorption properties.
B32B 5/24 - Layered products characterised by the non-homogeneity or physical structure of a layer characterised by the presence of two or more layers which comprise fibres, filaments, granules, or powder, or are foamed or specifically porous one layer being a fibrous or filamentary layer
B32B 27/08 - Layered products essentially comprising synthetic resin as the main or only constituent of a layer next to another layer of a specific substance of synthetic resin of a different kind
B60R 13/02 - Trim mouldingsLedgesWall linersRoof liners
17 - Rubber and plastic; packing and insulating materials
40 - Treatment of materials; recycling, air and water treatment,
Goods & Services
Custom-manufactured polyurethane foam components for use in the manufacture of automotive parts by others [ Custom manufacture of foam products for use in the automotive sector ]
B60N 2/42 - Seats specially adapted for vehiclesArrangement or mounting of seats in vehicles for particular purposes or particular vehicles the seat constructed to protect the occupant from the effect of abnormal g-forces, e.g. crash or safety seats
B60R 22/28 - Safety belts or body harnesses in vehicles incorporating energy-absorbing devices
12 - Land, air and water vehicles; parts of land vehicles
17 - Rubber and plastic; packing and insulating materials
40 - Treatment of materials; recycling, air and water treatment,
Goods & Services
(1) Automotive parts, namely seat cushions and bolsters, seat frames, headliners, sunshades, structural load-floors, sound insulators for dashboards, hoods, and undercarpet. (1) Custom manufacturing of automotive parts for others.
17 - Rubber and plastic; packing and insulating materials
40 - Treatment of materials; recycling, air and water treatment,
Goods & Services
(1) Polyurethane foam in slab form, and in precut foam pieces and moulded foam pieces. (1) Custom manufacture of products made of polyurethane foam for others.
63.
FOAM LAMINATE PRODUCT AND PROCESS FOR PRODUCTION THEREOF
A laminate product particularly useful in vehicular applications is described. The laminate product comprises a foam core having a first major surface and a second major surface. One or both of the major surfaces comprises a fibrous layer and an adhesive layer adhering the fibrous layer to the foam core. The process for producing the laminate product involves exposing an initial laminate product to infrared radiation. A portion of the adhesive layer between fibres in fibrous layer being ablated. The foam laminate product has improved sound absorption properties and while maintaining desirable strength and stiffness properties, hi addition, in certain cases, the peel strength of the fibrous reinforcing layer to the foam core is significantly improved in the present foam laminate product compared to the conventional approaches.
B32B 5/24 - Layered products characterised by the non-homogeneity or physical structure of a layer characterised by the presence of two or more layers which comprise fibres, filaments, granules, or powder, or are foamed or specifically porous one layer being a fibrous or filamentary layer
B32B 27/08 - Layered products essentially comprising synthetic resin as the main or only constituent of a layer next to another layer of a specific substance of synthetic resin of a different kind
There is described a process for adhering a first elongate foam element having a first end portion to a second elongate foam element having a second end portion. The process comprises an initial step of melting a first surface portion of the first end portion to produce a first molten portion. Next the first end portion is abutted to the second end portion. Thereafter, the first molten portion is caused to solidify to create a seam bond between the first end portion and the second end portion. Thus, the present invention relates to adhering two elongate foam elements together at their end portions. The bond between the foam elements is created by melting at least a portion of the surface of one or both of the end portions of the two foam buns. This creates in situ a molten region which acts as an adhesive when the end portions of the two buns are abutted or otherwise contacted with each other.
B29C 65/10 - Joining of preformed partsApparatus therefor by heating, with or without pressure using hot gases
B29C 44/02 - Shaping by internal pressure generated in the material, e.g. swelling or foaming for articles of definite length, i.e. discrete articles
B32B 37/26 - Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with at least one layer which influences the bonding during the laminating process, e.g. release layers or pressure equalising layers
C08J 5/12 - Bonding of a preformed macromolecular material to the same or other solid material such as metal, glass, leather, e.g. using adhesives
C08J 9/22 - After-treatment of expandable particlesForming foamed products
65.
Vented mold and method for producing molded article
The invention relates mold, particularly a mold for producing foam articles. In a preferred embodiment, the mold comprises a lid and a bowl releasingly engageable to define a mold cavity, the lid comprising: (i) a vent having a passageway for gas to escape from the mold cavity, and (ii) a plurality of grooves connected to the vent. The use of a plurality of grooves/slots in the mold cavity surface effectively acts as a siphon to draw gas away from the composition to be molded. The plurality of grooves/slots is connected to one or more vents which then allows for escape of the gas from the mold cavity to the exterior of the mold.
There is described a novoel isocyanate-based polymer foam. The isocyanate- based polymer foam is derived from a reaction mixture comprising: (a) an isocyanate; (b) a mixture of active hydrogen-containing compounds; and (c) a blowing agent. The mixture of active hydrogen-containing compounds comprises: (i) a bio-based polyol having an OH functionality of greater than about 2.0, an OH number in the range of from about 90 to about 200 and a molecular weight (Mn) of at least about 1100, and (ii) a petroleum-based active hydrogen-containg compound. It has been surprisingly and unexpectedly discovered that relatively high amounts (compared to the prior art) of such a bio-based polyol may be incorporated into an isocyanate-based polymer foam while maintaining a desirable balance of properties in the foam. Use of such a bio- based polyol (as a single bio-based polyol or a mixture of bio-based polyols) allows for displacement of at least a portion of petroleum-based polyols conventionally used in the production of isocyanate-based polymer foam while maintaining a desirable balance of properties in the foam, particularly molded foam. The addition benefit is that such displacement is of a component that this non-renewable and relatively more expensive than bio-based polyols.
C08L 91/00 - Compositions of oils, fats or waxesCompositions of derivatives thereof
C08G 18/64 - Macromolecular compounds not provided for by groups
C08G 18/76 - Polyisocyanates or polyisothiocyanates cyclic aromatic
C08J 9/12 - Working-up of macromolecular substances to porous or cellular articles or materialsAfter-treatment thereof using blowing gases generated by a previously added blowing agent by a physical blowing agent
There is disclosed a mold comprising a first mold portion and a second mold portion engageable to define a mold cavity in a closed position of the mold. The first mold portion comprises a first part-line surface and the second mold portion comprises a second part-line surface. The first part-line surface comprises a projection portion and the second part-line surface comprising a resilient portion for substantially sealing engagement with the projection portion in the closed position of the mold. The present mold allows for the production of a so-called “positive seal” between the two mold halves at the part-line of the mold, particularly in the areas of the part-line where there is no vent. This allows for production of a molded part having minimal or no flash produced at the part-line of the mold.
The invention relates mold, particularly a mold for producing foam articles. In a preferred embodiment, the mold comprises a lid and a bowl releasingly engageable to define a mold cavity, the lid comprising: (i) a vent having a passageway for gas to escape from the mold cavity, and (ii) a plurality of grooves connected to the vent. The use of a plurality of grooves/slots in the mold cavity surface effectively acts as a siphon to draw gas away from the composition to be molded. The plurality of grooves/slots is connected to one or more vents which then allows for escape of the gas from the mold cavity to the exterior of the mold.
17 - Rubber and plastic; packing and insulating materials
40 - Treatment of materials; recycling, air and water treatment,
42 - Scientific, technological and industrial services, research and design
Goods & Services
(1) Foam products for use in the production of headliners by manufacturers in the automotive sector. (1) Custom design and manufacture of foam products to be used in the production of headliners for the automotive sector.
