Abstract A molded upholstery article of expanded polyurethane is formed with an inner core and a preformed polyurethane skin in which the skin is microporous and intimately joined to the inner core. The skin has cells uniformly distributed in its thickness as a fine cellular structure, which cells are for the most part nonintercommunicating, and having a diameter smaller than 0.02 mm. The skin is waterproof and its density is between 0.4 and 0.8. The process for preparing said molded upholstery article involves coating the mold surface with a thin coat of a first liquid mixture of polyurethane forming substances, then pouring in the so-coated mold a second liquid mixture of polyurethane forming substances without waiting for the components of the first mixture to have completed their reaction. The formation of the expanded foam by its pressure and release of heat controls the final step of the formation of the microporous polyurethane skin and provides an intimate union with it. No heat is provided to the reaction and air at room temperature remains in direct contact with the mold walls.
AN UPHOLSTERY ARTICLE OF EXPANDED POLYURETHABE MOLDED IN A SHAPE OF ANY DESIRED CONFIGURATION, CONSTITUTED OF AN INNER CORE OF SAID POLYURETHANE AND OF A PREFORMED POLYURETHANE SKIN WHICH IS MECHANICALLY RESISTANT AND WHICH PRESENTS AND APPEALING APPERANCE, WHEREIN SAID SKIN IS MICROPOROUS AND IS DIRECTLY JOINED TO SAID INNER CORE BY CHEMICAL BOND, HAS CELLS UNIFORMLY DISTRIBUTED WITHIN ITS THICKNESS IN A FINE CELLULAR STRUCTURE, SAID CELLS BEING FOR THE MOST PART NOT INTERCOMMUNICATING WITH ONE ANOTHER, AND HAVING A DIAMETER SMALLER THAN 0.02 MM, THE VISSIBLE SURFACE OF SAID SKIN BEING SUSTANTIALLY CONTINUOUS AND WATERPROOF AND THE VALUE OF THE DENSITY RANGE OF SAID SKIN BEING BETWEEN 0.4 AND 0.8 G/M3, SAID SKING BEING FURTHER CHARACTERIZED BY HAVING A PLACING SOFTENESS TO THE TOUCH AND A THICKNESS OF NO MORE THAN 3MM.
Claim 2
Dependent Claim
134 words
AN UPHOLSTERY ARTICLE OF EXPANDED POLYURETHABE MOLDED IN A SHAPE OF ANY DESIRED CONFIGURATION, CONSTITUTED OF AN INNER CORE OF SAID POLYURETHANE AND OF A PREFORMED POLYURETHANE SKIN WHICH IS MECHANICALLY RESISTANT AND WHICH PRESENTS AND APPEALING APPERANCE, WHEREIN SAID SKIN IS MICROPOROUS AND IS DIRECTLY JOINED TO SAID INNER CORE BY CHEMICAL BOND, HAS CELLS UNIFORMLY DISTRIBUTED WITHIN ITS THICKNESS IN A FINE CELLULAR STRUCTURE, SAID CELLS BEING FOR THE MOST PART NOT INTERCOMMUNICATING WITH ONE ANOTHER, AND HAVING A DIAMETER SMALLER THAN 0.02 MM, THE VISSIBLE SURFACE OF SAID SKIN BEING SUSTANTIALLY CONTINUOUS AND WATERPROOF AND THE VALUE OF THE DENSITY RANGE OF SAID SKIN BEING BETWEEN 0.4 AND 0.8 G/M3, SAID SKING BEING FURTHER CHARACTERIZED BY HAVING A PLACING SOFTENESS TO THE TOUCH AND A THICKNESS OF NO MORE THAN 3MM.
Claim 3
Dependent Claim
26 words
A molded upholstery article as defined in claim 1, wherein the skin has a value of steam permeability higher than 150 gr/100 mm2/24h (DIN 53.333 Standard).