A register box for HVAC installations has a body with a plurality of side panels arranged in a generally rectangular or square configuration and a wall extending across the rectangular configuration, a duct opening through the wall so as to communicate with an interior of the body, and an expandable foam polymeric material affixed to an inner side of the side panels. The wall has a surface extending from the opening of the duct to the side panels. The expandable foam polymeric material is affixed to the surface of the wall. The expandable polymeric material is polyurethane.

A register box for HVAC installations has a body with a plurality of side panels arranged in a generally rectangular or square configuration and a wall extending across the rectangular configuration, a duct opening through the wall so as to communicate with an interior of the body, and an expandable foam polymeric material affixed to an inner side of the side panels. The wall has a surface extending from the opening of the duct to the side panels. The expandable foam polymeric material is affixed to the surface of the wall. The expandable polymeric material is polyurethane.

A process for forming a register box has a body formed with a plurality of side panels arranged in a generally square or rectangular configuration with a wall extending transverse to the side panels. A plurality of circular areas are cut into the wall. An expandable polymeric foam material is introduced into an interior of the body. The body is positioned in a fixture such that the wall is juxtaposed against a surface of the fixture. A plug is inserted into the interior of the body. The expandable polymeric foam material is expanded in the interior of the body such that the expandable polymeric foam material solidifies across the wall and around the plug. The plug is then removed from the body and the body is then removed from the fixture.

A process for forming a register box has a body formed with a plurality of side panels arranged in a generally square or rectangular configuration with a wall extending transverse to the side panels. A plurality of circular areas are cut into the wall. An expandable polymeric foam material is introduced into an interior of the body. The body is positioned in a fixture such that the wall is juxtaposed against a surface of the fixture. A plug is inserted into the interior of the body. The expandable polymeric foam material is expanded in the interior of the body such that the expandable polymeric foam material solidifies across the wall and around the plug. The plug is then removed from the body and the body is then removed from the fixture.

In a method for producing a lining part, in particular for the interior of a vehicle, a support substrate is positioned opposite a flexible decorative layer with the interposition of a foam coating, and the support substrate is adhesively connected thereto, wherein the raw foam compound used to form the foam layer is foamed using a gas as a physical blowing agent and is applied onto the rear face of the decorative layer and/or the support substrate face facing the decorative layer in the form of an expanded foam. As long as the expanded foam coating is still flowable, the support substrate is positioned at a defined distance to the rear face of the decorative layer with the interposition of the expanded foam coating so that the decorative layer is connected to the support substrate by the foam coating and is held until the cross-linking process of the foam coating has at least mostly concluded, wherein a part of the foam layer which fills the original distance between the decorative layer and the support substrate is displaced and plastically compressed at least in some regions by the support substrate during the process of positioning same.

An apparatus for dispensing a reactive foam formulation to produce laminated panels includes a mixhead, a distribution system that defines multiple flowpaths for the reactive foam to outlets fitted with nozzles. The nozzles have multiple, spaced-apart outlets arranged at angles to each other to distribute the foam formulation evenly onto a moving bottom facing layer.

A method for filling a cavity with an expanding insulating foam component includes the following. First, providing a closed cavity comprising at least one elongated wall surface that extends along a first direction and includes first and second opposite sides, a top side and a bottom side. Next, forming a plurality of openings in the elongated wall surface arranged along the first direction and being alternating close to the first or the second opposite sides. Next, inserting a dispense tube through a first opening of the plurality of openings, and injecting a first portion of the expanding insulating foam into the closed cavity. The first opening is located close to the bottom side and close to the first side of the elongated wall surface. The injected foam expands along the bottom side and the first side and forms a first sloped top surface that has a positive slope angle. Next, inserting the dispense tube through a second opening of the plurality of openings located close and above the first opening and close to the opposite second side, and injecting a second portion of the expanding insulating foam into the closed cavity. The injected foam expands along the first sloped top surface and the second side and forms a second sloped top surface that has a negative slope angle.

A plug apparatus for sealing an interior of a duct for use in a process for forming an insulated register box has a frame, a shaft extending outwardly of the of the frame, and a plurality of layers of flexible material radiating outwardly of the shaft adjacent to an end of the shaft opposite the frame. The plurality of layers of flexible material are adapted to have an outer periphery bearing against an interior surface of the duct. Each layer of flexible material has an outer diameter greater than an inner diameter of the duct. The flexible material is formed of a neoprene material. The frame is affixed to a support surface having an opening therein. The opening is adapted to receive an outer diameter of the duct therein.

A plug apparatus for sealing an interior of a duct for use in a process for forming an insulated register box has a frame, a shaft extending outwardly of the of the frame, and a plurality of layers of flexible material radiating outwardly of the shaft adjacent to an end of the shaft opposite the frame. The plurality of layers of flexible material are adapted to have an outer periphery bearing against an interior surface of the duct. Each layer of flexible material has an outer diameter greater than an inner diameter of the duct. The flexible material is formed of a neoprene material. The frame is affixed to a support surface having an opening therein. The opening is adapted to receive an outer diameter of the duct therein.

A mold 200 is a mold for molding a foam body, the mold including: a mold body portion 260; and a degassing tool 270 attached to the mold body portion. The degassing tool is formed of porous metal, and a surface 270a of the degassing tool that is on a side of a cavity of the mold forms part of a molding surface S of the mold.