An integral skin foam molded article includes: a skin formed by sewing a plurality of skin pieces in a hag shape; and a resin foam which is molded inside the skin integrally with the skin, wherein: at least one skin piece among the plurality of skin pieces has a surface material made of a natural leather, and includes a wadding material stacked on a back side of the surface material in a non-surface joined state and a lining material stacked on the wadding material; and in a shrinkage rate with respect to an in-plane compression load, a shrinkage rate of the liming material is smaller than a shrinkage rate of the wadding material.

A method of fabricating a composite structure includes laying at least one composite ply about a bladder, the bladder comprising a phase change material in a first phase having a first volume, positioning an outer mold about the bladder and the at least one composite ply, and curing the at least one composite ply to form the composite structure. Curing causes the phase change material contained within the bladder to change to a second phase to expand from the first volume to a second volume and apply a pressure to an interior surface of the composite ply and press an outer surface of the composite ply against the outer mold to form an interior cavity. The bladder is not removable from the formed interior cavity.

A process for producing a molded article involves providing a thin-walled, gas-permeable shell; filling the shell with a foamed pelletized material composed of a polymer; and welding the foamed pelletized material to obtain the molded article. Molded articles are obtainable or obtained by such a process, and can be used as a footwear sole, part of a footwear sole, a mattress, a seat cushion, an underlay, a grip, a protective film, a component in automobile interiors and exteriors, a gymnastics mat, a body protector, a trim element in automobile construction, a sound insulator, a vibration damper, a cushion, a bicycle saddle, a toy, a tire or part of a tire, a covering for a track and field surface, a covering for a sports hall or a pathway, a damping layer or a damping core in a sandwich element, or a packaging.

A bag for producing a foam-in-bag dunnage material comprises a closed edge portion and, in a non-sealed state of the bag, an open edge portion, the closed and open edge portions delimiting an inner bag volume. The invention proposes that a bag structure of the bag comprises a mixing chamber which is adapted to receive foam precursor substances, which is arranged within the inner bag volume, which is at least partially and initially delimited against the remainder of the inner bag volume, and which in the non-sealed state of the bag is connected to the open edge portion.

A machine for producing a foam-in-bag dunnage material comprises first and second foam precursor inlets for first and second foam precursor substances, a first mixing chamber for mixing the first and second foam precursor substances into a first mixture, and a first dispenser for dispensing the first mixture. It is proposed that the machine comprises a branch-off-device fluidly arranged between the first and second foam precursor inlets and the first mixing chamber and having first and second foam precursor outlets towards the first mixing chamber and third and fourth foam precursor outlets towards an interface device, the interface device being adapted to fluidly connect to a second mixing chamber for mixing the first and second foam precursor substances into a second mixture.

A system includes a dip tube, a feed line, and a check valve. The dip tube is inserted through an opening in a source of chemical precursor and into the chemical precursor in the source. A portion of the feed line is located in the dip tube. The feed line passes out of the dip tube. The chemical precursor is capable of flowing out of the source through the feed line in a downstream direction. The check valve is located in the portion of the feed line in the dip tube. The check valve permits the chemical precursor to pass substantially only in the downstream direction. The feed line is coupled to a transfer pump that draws the chemical precursor out of the source through the portion of the feed line in the dip tube.

A method of fabricating a composite structure includes laying at least one composite ply about a bladder, the bladder comprising a phase change material in a first phase having a first volume, positioning an outer mold about the bladder and the at least one composite ply, and curing the at least one composite ply to form the composite structure. Curing causes the phase change material contained within the bladder to change to a second phase to expand from the first volume to a second volume and apply a pressure to an interior surface of the composite ply and press an outer surface of the composite ply against the outer mold to form an interior cavity. The bladder is not removable from the formed interior cavity.

A foam cushion pad formation assembly that includes a conveyance assembly having at least one moving conveyor component presenting a pad shape formation surface, which surface is convoluted and arranged to shape sealed enclosures of a pad chain received by the conveyance assembly. A separation device is provided to separate shaped pads of the pad chain received by said conveyor device. The shaped pads include convoluted surface that are formed by way of gripping projection and recesses combinations in the moving conveyor component. Embodiments include sensing for non separated pads from a downstream end of the bag chain, pad chain separation enhancement devices, and various control system including the requirement of confirmation of separation before feeding a new pad enclosure as in one containing liquid polyurethane precursor chemicals. An embodiment includes a pad chain path disruption sensor and a form feed control which implements the formation of pad enclosures free of filler material in a bridging region between the outlet end of the enclosure formation means and the conveyance assembly.

Apparatus for supplying multiple foam machines with foam precursor chemicals. The apparatus comprises first and second totes having a top opening and a bottom drain and containing first and second foam precursor chemicals, first and second supply lines connected to the bottom drains of the first and second totes and in fluid communication with first and second sets of batcher stands, and first and second sets of batcher pumps each of which is positioned in a respective one of the first and second sets of batcher stands. Each batcher pump is adapted to be in fluid communication with a respective one of the foam machines.

A machine produces foam-in-bag from foam precursors mixed within the bag. The machine comprises a base and a shell. The base and shell are moveable relative each other between a base/shell disengaged position and a base/shell engaged position. In the base/shell engaged position, the base and shell divide the bag so that a mixing chamber is isolated from the remainder portion of the bag. First and second nozzles inject foam precursors into the mixing chamber. A mixer engages the mixing chamber to provide mixing energy to facilitate the foam reaction.