[54] PROCESS FOR MOLDING AN INTEGRAL
SKIN FOAM AND A POLYURETHANE
MATERIAL FOR MOLDING THE SAME
[75] Inventors: Michihiko Nakamura; Masanao
Ishikake; Yukio Kawakita; Akira
Mabuchi; Osamu Yamanaka, all of
Aichi-ken, Japan
[73] Assignee: Toyoda Gosei Co., Ltd., Nishikasugai, Japan
[21] Appl. No.: 213,014
[22] Filed: Mar. 14,1994
[30] Foreign Application Priority Data
Mar. 16, 1993 [JP] Japan 5-082660
Mar. 16, 1993 [JP] Japan 5-082661
[51] Int. CI.6 C08J 9/34
[52] U.S. CI 521/51; 521/159; 521/170;
521/174; 521/176; 528/48; 264/51
[58] Field of Search 521/51, 159, 170,
521/174, 176; 264/51; 528/48
[56] References Cited
U.S. PATENT DOCUMENTS
3,824,199 7/1974 Nadeauetal..
3,954,537 5/1976 Alfter et al. .
3,970,732 7/1976 Slaats et al. .
4,042,540 8/1977 Lammerting et al. .
(List continued on next page.)
FOREIGN PATENT DOCUMENTS
0006381 1/1980 European Pat. Off. .
0044226 1/1982 European Pat. Off. .
0211495 2/1987 European Pat. Off. .
0353061 1/1990 European Pat. Off. .
(List continued on next page.)
OTHER PUBLICATIONS
Patent Abstracts of Japan, vol. 5, No. 190 (M-100) (1981).
Patent Abstracts of Japan, vol. 8, No. 057 (M-283) (1984).
Patent Abstracts of Japan, vol. 4, No. 105 (M-023) (1980).
Patent Abstracts of Japan, vol. 88, No. 1007 (M-750)
(1988).
Primary Examiner—Nathan M. Nutter
Assistant Examiner—Due Truong
Attorney, Agent, or Firm—Cushman Darby & Cushman
Intellectual Property Group of Pillsbury Madison & Sutro,
LLP
A process and a polyurethane material for molding a semirigid integral skin foam which comprising an integral skin having a low degree of foaming and a core having a high degree of foaming. The process includes evacuating a mold cavity to reduce the pressure thereof below atmospheric pressure; injecting into the evacuated mold cavity a polyurethane material; and foaming the material to fill the cavity. The polyurethane material contains a polyol component and an isocyanate component with, at most, 5 parts by weight of a solvent for 100 parts by weight of the polyol component, in the absence of freon.
11 Claims, 17 Drawing Sheets
