Woodbridge Foam Corporation

Wilfred W Cheng

Leslie E Clark

Robert B Magee

Craig A Hunter

Gerry V Wetering

Mohammad Allohverdi

Gerry Vande Wetering

Nick Morano

Anthony G Di Marco

A process and system for mixing at least two independent streams in a mixing device having independent inputs for each of the at least two independent streams, comprising structure and steps for: (i) feeding a first stream, provided as a free-flowing solids stream, to a pressure chamber; (ii) compressing the first stream in the pressure chamber; (iii) feeding the first stream to a first input in the mixing device; (iv) feeding a second stream to a second input in the mixing device; (v) impinging the first stream and the second stream on one another in a mixing device to produce a mixture; and (vi) dispensing the mixture from the mixing device; wherein the compressing in Step (ii) is conducted to achieve a substantially linear relationship between a weight of the first stream and a period of impingement of the weight in Step (v). Preferably, the process and system are adapted to produce a filled foamed isocyanate-based polymer (e.g. filled polyurethane foam).

High pressure mixing system and process for producing foamed

A mold for producing foamed articles includes an upper mold and a lower mold which define a mold cavity. A vent is provided in communication with the mold cavity and has a vent passageway with an entrance and an exit. Structure is also provided for sealingly engaging the upper mold with the lower mold to cause, in cooperation with the predetermined size and shape of the vent passageway, liquid foam polymeric composition expanding inside the mold cavity to enter the vent entrance but to not exit from the vent exit to cause at least partial curing of the foam composition within the vent passageway. Preferably, the vent may be ribbon-shaped so that a ribbon of foamed composition adheres to the foamed article and may be folded flat against the article thus avoiding the labor step of trimming the flash from the product. Additionally, or alternatively, the vent may comprise a vent passageway with an obstruction disposed therein to provide one or more openings between the outer surface of the obstruction and the inner surface of the vent passageway. The foam composition in these openings may be expelled by driving the obstruction axially within the passageway. Again, the labor step of hand trimming the flash is avoided.

Mold having vent passageways to obivate trimming of flash

A mold for producing foamed articles includes an upper mold and a lower mold which define a mold cavity. A vent is provided in communication with the mold cavity and has a vent passageway with an entrance and an exit. Structure is also provided for sealingly engaging the upper mold with the lower mold to cause, in cooperation with the predetermined size and shape of the vent passageway, liquid foam polymeric composition expanding inside the mold cavity to enter the vent entrance but to not exit from the vent exit to cause at least partial curing of the foam composition within the vent passageway. Preferably, the vent may be ribbon-shaped so that a ribbon of foamed composition adheres to the foamed article and may be folded flat against the article thus avoiding the labor step of trimming the flash from the product. Additionally, or alternatively, the vent may include a vent passageway with an obstruction disposed therein to provide one or more openings between the outer surface of the obstruction and the inner surface of the vent passageway. The foam composition in these openings may be expelled by driving the obstruction axially within the passageway. Again, the labor step of hand trimming the flash is avoided.

Mold having vent passageways to obviate trimming of flash

A novel method of molding an article includes providing a mold with a vent of a pre-determined size such that, due to the difference in viscosities, gases to be vented from the mold may easily pass through the vent while the material to be molded cannot quickly pass through the vent. In fact, the vent is designed such that the material to be molded which enters the vent, does not exit the end of the vent. In the most preferred embodiment, the vent is in the form of a thin ribbon-like groove so that the material to be molded which does enter the vent forms a thin ribbon of extruded material which need not be removed prior to a finish cover being applied to the molded article.

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Oakville, Canada

Wilfred W Cheng