Stock material or miscellaneous articles – Web or sheet containing structurally defined element or... – Composite having voids in a component
Reexamination Certificate
1994-09-27
2001-09-25
Kuhns, Allan R. (Department: 1732)
Stock material or miscellaneous articles
Web or sheet containing structurally defined element or...
Composite having voids in a component
C264S046400, C264S046600, C264S255000, C264S309000, C428S319300
Reexamination Certificate
active
06294248
ABSTRACT:
BACKGROUND OF THE INVENTION
The present invention relates to soft molded composites such as seat cushions, particularly polyurethane and polyurethane/polyurea composites, and to a one-step process for the production of these composites.
Soft composite materials are used in seating applications, exercise equipment pads, support pads in spas and jacuzzis, etc. These composite materials are typically made from a foam which is subsequently covered with a flexible material such as vinyl or fabric.
Processes for the production of flexible foams covered with a soft material such as vinyl are known. In these known processes, the foam is generally molded into the desired form and then covered with a flexible membrane or a material such as vinyl or fabric. In addition to equipment for molding the foam, such processes also require equipment or significant manual labor to cover the foam. The foam covering operation is separate from the molding operation. These two separate operations increase the cycle time and effort necessary to produce the final composite article. Waste is generated in these processes due to inadequate coating, damaged foam, “fitting” the covering to the foam, etc. This waste has a significant effect upon the economy of the production process.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide novel soft molded composites, particularly polyurethane and polyurethane/urea composites.
It is also an object of the present invention to provide soft molded polyurethane and polyurethane/urea composites having complex shapes.
It is another object of the present invention to provide a one-step process for molding soft polyurethane and polyurethane/urea composites.
It is a further object of the present invention to provide a process for the production of molded soft polyurethane/urea composites in which cycle time and waste are substantially reduced.
It is also an object of the present invention to provide a process for the production of molded soft composite polyurethane and polyurethane/urea composites characterized by improved foam/elastomer adhesion with reduced sag.
It is a further object of the present invention to provide a process for building a seam in a composite article in which a foam-forming mixture acts as an adhesive bonding layer between two soft-elastomeric layers.
These and other objects which will be apparent to those skilled in the art are accomplished by (1) applying (preferably by spraying) a composition which forms a soft, elastomeric layer after application to all of the interior walls of an open mold; (2) closing the mold; (3) introducing a composition which will form a low density, high resiliency, flexible foam under molding conditions to the mold in a manner such that the foam-forming composition will be substantially completely within the elastomer-forming composition; and (4) allowing the foam-forming composition introduced in (3) to complete foam formation. The foam-forming mixture may be introduced into the mold before the mold is closed but the mold must be closed prior to completion of foam formation. The resultant molded, composite article may then be removed from the mold. As can be seen from
FIGS. 1 and 2
, the foam-forming composition may act as an adhesive which bonds the “upper” and “lower” elastomeric layers present on the mold walls.
REFERENCES:
patent: 4190697 (1980-02-01), Ahrens
patent: 4294880 (1981-10-01), Nishida
patent: 5116557 (1992-05-01), Debaes et al.
patent: 5223193 (1993-06-01), Bianchin et al.
Fair David L.
Jasenak James R.
Madan Sanjeev
Bayer Corporation
Gil Joseph C.
Kuhns Allan R.
Whalen Lyndanne M.
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