A method of forming a shaped foamed polymer article and articles obtained from said method.

An apparatus and method for forming a design on an expanded bead foam article such as an exercise roller is provided.

An apparatus and method for forming a design on an expanded bead foam article such as an exercise roller is provided.

The present invention provides a process for preparing a polymer material filled composite element, comprising the steps of: i) providing a partially closed space, wherein a polyurethane foam is disposed at least at part of the periphery of the space to restrain the flow of the polymer material resin, and the polyurethane foam is formed by in situ application of a polyurethane composition and has an air flow value of greater than 1 L/min as determined by ASTM D3574 test; ii) applying the polymer material resin into the space and curing the polymer material resin to form a polymer material that fills the space.

The present invention provides a process for preparing a polymer material filled composite element, comprising the steps of: i) providing a partially closed space, wherein a polyurethane foam is disposed at least at part of the periphery of the space to restrain the flow of the polymer material resin, and the polyurethane foam is formed by in situ application of a polyurethane composition and has an air flow value of greater than 1 L/min as determined by ASTM D3574 test; ii) applying the polymer material resin into the space and curing the polymer material resin to form a polymer material that fills the space.

A mold, a molding machine, and a foamed molded body manufacturing method are provided that are capable of more reliably preventing ingress of foamed resin into a gas discharge hole using a gas-impermeable member and capable of adequately discharging gas inside the cavity to the cavity outside through the gas discharge hole during foam molding, and that are also capable of achieving good design characteristics in a foamed molded body. A gas discharge hole 5 is provided at a cavity 4 inner face of a mold 1 and discharges gas inside the cavity 4 to outside the cavity 4. A gas-permeable member 6 is disposed inside the cavity 4 of the mold 1 so as to cover the gas discharge hole 5, and a gas-impermeable member 8 is disposed on the gas discharge hole 5 side of the gas-permeable member 6 so as to face the gas discharge hole 5. A portion of the gas discharge hole 5, spanning at least from axial direction intermediate portion of the gas discharge hole 5 to the cavity 4 side of the gas discharge hole 5, is configured with a tapered profile portion 5a that increases in diameter on progression toward the cavity 4 side.

A process for making a molded flexible foam. The processes includes: (a) depositing a foam-forming reaction mixture onto a surface of a mold cavity, and (b) allowing the foam-forming reaction mixture to react in the mold cavity. The foam-forming reaction mixture includes: (1) a polyisocyanate present in an amount of less than 45% by weight, based on the total weight of the reaction mixture; (2) an isocyanate-reactive composition; (3) a blowing agent; and (4) a catalyst. The isocyanate-reactive composition includes: (i) at least 50% by weight, based on the total weight of polyol in the isocyanate-reactive composition, of a polyether polyol having a functionality of greater than 2, an oxyethylene content of 0 to 50% by weight, based on the total weight of the polyether polyol, more than 50 mol % of primary OH groups and an OH number of 8 to 112 mg KOH/g; and (ii) a component comprising: (A) an amine-initiated polyether polyol (II), wherein amine-initiated polyether polyol (II) has an OH number of at least 500 mg KOH/g and a functionality of 2.5 to 4, and wherein amine-initiated polyether polyol (II) is present in an amount of greater than 0 and no more than 10% by weight, based on the total weight of polyol in the isocyanate-reactive composition; (B) a CO.sub.2-producing carbamic acid which is present in an amount of greater than 0 and no more than 10% by weight, based on the total weight of polyol in the isocyanate-reactive composition; or (C) both (A) and (B).

A process for making a molded flexible foam. The processes includes: (a) depositing a foam-forming reaction mixture onto a surface of a mold cavity, and (b) allowing the foam-forming reaction mixture to react in the mold cavity. The foam-forming reaction mixture includes: (1) a polyisocyanate present in an amount of less than 45% by weight, based on the total weight of the reaction mixture; (2) an isocyanate-reactive composition; (3) a blowing agent; and (4) a catalyst. The isocyanate-reactive composition includes: (i) at least 50% by weight, based on the total weight of polyol in the isocyanate-reactive composition, of a polyether polyol having a functionality of greater than 2, an oxyethylene content of 0 to 50% by weight, based on the total weight of the polyether polyol, more than 50 mol % of primary OH groups and an OH number of 8 to 112 mg KOH/g; and (ii) a component comprising: (A) an amine-initiated polyether polyol (II), wherein amine-initiated polyether polyol (II) has an OH number of at least 500 mg KOH/g and a functionality of 2.5 to 4, and wherein amine-initiated polyether polyol (II) is present in an amount of greater than 0 and no more than 10% by weight, based on the total weight of polyol in the isocyanate-reactive composition; (B) a CO.sub.2-producing carbamic acid which is present in an amount of greater than 0 and no more than 10% by weight, based on the total weight of polyol in the isocyanate-reactive composition; or (C) both (A) and (B).

A foamed plastic foldable container has a first wall, a pair of mutually facing second walls hingedly coupled to the first wall, a pair of mutually facing third walls hingedly coupled to the first wall, and a closing wall defined by at least one panel hingedly coupled to one of the second walls.

A foam molded product capable of preventing generation of an underfill portion due to a concave portion and a convex portion formed on a surface of the foam molded product and suppressing increase in cost, a method for producing the foam molded product, a molding die structure of the foam molded product, and a vehicle seat pad using the foam molded product are provided. A foam molded product 10 formed by integrally molding a foam body 12 made of a foamable resin material M and including a shape deformation section 26 that is a concave strip or a convex strip on a surface, and a sheet-shaped support member 14 covering a surface opposing a formation face of the shape deformation section 26 of the foam body 12. In the support member 14 of the foam molded product 10, a projected portion 16 is provided in a region opposing the shape deformation section 26 and/or a vicinity of the region, and the projected portion 16 is in a columnar shape extending in an extending direction of the shape deformation section 26.