A molded foam member manufacturing method including: a first process of placing a foam molded first portion and a rigid member in a second portion forming mold, and pressing and fixing the rigid member against the second portion forming mold; and a second process of pouring a second portion-forming synthetic resin raw material into the second portion forming mold and foam molding a second portion so as to surround at least a portion of the rigid member and to form an integral unit with the first portion.

Disclosed are methods and systems for preparing open-celled polyurethane foams by a discontinuous box foam process in which (a) a polyurethane foam-forming composition is deposited into a container having a gas-permeable base and (b) the polyurethane-foam forming composition is allowed to form an open-celled polyurethane foam in the container. In these methods and systems, the gas-permeable base is heated before, during, and/or after step (a) and heating is continued during at least a portion of step (b).

A hybrid structural member for an insulated structural panel includes a core member surrounded on at least two sides by a high-density structural foam. The hybrid structural member may be manufactured by placing a core member in a cavity of an injection mold and surrounding the core member by insulating foam on at least two sides. The core member may be held in place by screws, posts, pins, a vacuum, or other suitable means.

Disclosed are methods and systems for preparing open-celled polyurethane foams by a discontinuous box foam process in which (a) a polyurethane foam-forming composition is deposited into a container having a gas-permeable base and (b) the polyurethane-foam forming composition is allowed to form an open-celled polyurethane foam in the container. In these methods and systems, the gas-permeable base is heated before, during, and/or after step (a) and heating is continued during at least a portion of step (b).

The present invention provides an apparatus for use in mixing and dispensing a curable fluid stream (stream) into an open mold to fill the mold to make polishing pads for chemical mechanical planarization of substrates. The apparatus comprises an actuator frame on which is mounted (i) a set of two plates releasably attached to the actuator frame and adapted to cut the stream when the mold is full and to release from the actuator frame after cutting the stream, and (ii) a dispenser unit for continuous pouring of the stream into an open mold, the apparatus adapted to enable removal of the released plates from the actuator during the continuous pouring after the mold is full, e.g. by raising the actuator frame and the (ii) dispenser unit, whereby one can place a container above the mold to catch the plates.

The present invention provides an apparatus for use in mixing and dispensing a curable fluid stream (stream) into an open mold to fill the mold to make polishing pads for chemical mechanical planarization of substrates. The apparatus comprises an actuator frame on which is mounted (i) a set of two plates releasably attached to the actuator frame and adapted to cut the stream when the mold is full and to release from the actuator frame after cutting the stream, and (ii) a dispenser unit for continuous pouring of the stream into an open mold, the apparatus adapted to enable removal of the released plates from the actuator during the continuous pouring after the mold is full, e.g. by raising the actuator frame and the (ii) dispenser unit, whereby one can place a container above the mold to catch the plates.

The present invention relates to methods of manufacturing moulded products, for example building panels, and in particular, but not exclusively, to manufacturing a panel comprising natural stone or rock set into a polymeric layer. The method of manufacturing a moulded product as described herein comprises at least one article being set into a polymeric layer, followed by placing the at least one article and particulate ferrous material in a container so that at least a portion of the or each article is embedded in the particulate ferrous material, introducing a polymeric material into the container to form the moulded product, and removing the moulded product from the container.

The invention relates to a foaming and punching tool for producing foamed products from structural foam, and to a method for producing such foamed products.

The invention relates to a foaming and punching tool for producing foamed products from structural foam, and to a method for producing such foamed products.

A toy includes an overall package that holds an A+B molding foam. The overall package includes both a transparent or translucent outer package that contains a first or A part of the molding foam, and an inner transparent or translucent package that contains a second or B part of the molding foam. The A and B parts having contrasting colors. The overall package therefore resembles an egg. The user manually bursts the inner package and mixes the two substances together within the outer package, then pours the resultant molding foam into a mold to create a toy figure. The egg-like package enhances the child's play experience of giving birth to or hatching the toy figure.