Basf Corporation

Basf Se Corporation

Jon P Pavlinac

Richard P Harrison

Joseph Ogonowski

L Patrick Chang

David Debiasi

Berend Eling

Raymond A Neff

Stephan Goettke

Mark Jason Hughes

Juergen Mertes

Mathew P Varughese

David DeBiasi

Mark Joseph Hughes

A unique combination of a hydrophilic polyol (A) and a hydrophobic polyol (B) having a terminal ethylene oxide cap are used in a resin composition and a polyurethane system, and are used to form a polyurethane article, such as a polyurethane foam. The hydrophilic polyol (A) is ethylene oxide (EO) rich and the hydrophobic polyol (B) is propylene oxide (PO) rich. The hydrophilic polyol (A) and the hydrophobic polyol (B) are present in the resin composition and the polyurethane system in a weight ratio (A:B) of from 1.5:1 to 20:1. The polyurethane article exhibits excellent comfort for use in vehicle applications, such as automotive and motorcycle seating, due to reduced resonance frequency and reduced peak vibration transmissivity relative to previous polyurethane articles.

Polyurethane article with increased comfort

A method of forming a composite article having a decal occurs in a mold. The mold includes a surface that defines a mold cavity. A decal is introduced to the surface of the mold. A polyurethane elastomer composition is applied into the mold cavity to form an elastomeric layer over the decal. The composite article including the elastomeric layer and the decal may then be demolded from the mold. Alternatively, a paint composition is applied into the mold cavity to form a paint layer over the decal. The polyurethane elastomer composition is applied into the mold cavity to form an elastomeric backing layer over the paint layer. The composite article including the paint layer, the decal, and the elastomeric backing layer may then be demolded from the mold. The composite article may be a seat for an all-terrain vehicle.

Method of forming a composite article in a mold

A mask is used to make an article having two or more layers. The layers are formed from either a paint or polyurethane elastomer composition. The article is made in a mold including a surface defining a mold cavity and having a first and second effect region. For the method, a mask is placed into the mold cavity adjacent the first effect region. Pressure is applied to the mask to retain the mask adjacent the first effect region. A first composition is applied into the mold cavity to form a first layer adjacent the second effect region. The mask is removed from the first effect region. A second composition is applied into the mold cavity to form a second layer adjacent the first effect region. Benefits of pressure applied to a mask are also realized when making the article from a preformed part using the mask outside of a mold.

Method of making an article

The aromatic polyurethane elastomers of the present invention are particularly suited for methods of making objects in a mold cavity. The objects generally include an elastomeric layer formed from an aromatic polyurethane and a foam layer which is subsequently applied to the elastomer. The aromatic elastomer of the present invention lends itself to being precoated with an in-mold coating or being painted after demolding the resulting part.

Decorative components having an elastomeric outer surface and methods of making such components

The method of the present invention is particularly suited for making decorative objects in a mold cavity. The method enables one to form a decorative component having an outer elastomeric layer that is integral with an inner layer of foam. Because the chemical formulation for the outer layer and the inner layer is identical, other than the inner layer includes a foaming agent, the decorative component does not suffer from the drawbacks of the previous methods such as, for example, poor adhesion between the elastomeric layer and the foam layer causing delamination of the two layers, sinks or holes in the foam layer leading to imperfections in the elastomeric layer, and bleed through to the elastomeric layer from the foam layer. The method permits the mold to be pre-coated with an in-mold paint prior to the molding process. Coatings can also be applied after demolding the resulting part.

Method for producing decorative components having an outer elastomeric layer that is integral with an inner foam layer

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South Lyon, MI, United States of America

Jon P Pavlinac