Expandable substrates, which are referred to as blanks, are created by compressing thermobonded nonwovens after heating the binder material above its melting temperature, and then cooling the compressed nonwovens so that the binder material hardens and holds the fibers of the nonwoven together in a compressed configuration with stored kinetic energy. A mold for the component to be manufactured can be partially filled with a number of boards (or blanks) in a stacked, vertically, adjacent or even random orientation. Upon application of heat to the boards or blanks or parts in the mold, the binder material is melted so as to allow the nonwoven material to expand in one or more directions, and thereby fill all or part of the mold. Upon cooling, the binder material again hardens, and the molded component is retrieved from the mold.

A composite core material and methods for making the same are disclosed herein. The composite core material comprises mineral filler discontinuous portions disposed in a continuous encapsulating resin. Further, the method for forming a composite core material comprises the steps of forming a mixture comprising mineral filler, an encapsulating prepolymer, and a polymerization catalyst; disposing the mixture onto a moving belt; and polymerizing said encapsulating prepolymer to form a composite core material comprising mineral filler discontinuous portions disposed in a continuous encapsulating resin.

This invention relates to the production of cured polymeric skin materials. In particular, the invention relates to methods and substrates for the production of skin materials, for example, for use in building, furniture, and as architectural components for example in roofing materials such as roofing tiles, or for brick wall effect materials.

The present invention relates to fiber composite plastic (11, 13) comprising a polymer (40, 41) and at least one textile (50), which has at least one palpably inhomogeneous surface (60, 61) with a textile structure and is entirely surrounded by polymer (40, 41), wherein the fiber composite plastic (11, 13) has at least one palpably inhomogeneous surface (60, 61), wherein inhomogeneities of this fiber composite plastic surface are caused by the textile structure, and a method for producing the fiber composite plastic (11, 13).

A rubber product that includes a cylindrical molded body in having a plurality of reinforcing layers coaxially layered between inner and outer layers. In producing/vulcanizing the molded body, a rubber product including a cylindrical portion, each of multiple reinforcing layers composed of cord fabrics including a large number of fiber cords aligned and subjected to a predetermined adhesion treatment and coating rubber layers covering both surfaces of the cord fabric, and a bias structure in which the fiber cords of the reinforcing layers extend in an intersecting direction is formed. Each of the cord fabrics has: a tensile strength of 4320 N/cm in a cord extension direction and a weight of 950 g/m.sup.2, each of the cord fabrics has a bending hardness of 30 g/cm after the predetermined adhesion treatment, and each of the coating rubber layers has a layer thickness of 0.2 mm and 1 mm.

In one aspect, waxy build material inks are described herein which, in some embodiments, exhibit desirable print quality and associated mechanical properties for three-dimensional printing applications. A build material ink, in some embodiments, comprises 20-40 wt. % rosin component, 5-35 wt. % non-polar wax component, and 40-65 wt. % alcohol wax component comprising one or more waxes of the formula (C.sub.nH.sub.2n+1)OH wherein n is an integer from 15 to 40. In another aspect, a build material ink comprises a eutectic mixture including rosin component, a non-polar wax component, and an alcohol wax component comprising one or more waxes of the formula (C.sub.nH.sub.2n+1)OH wherein n is an integer from 15 to 40.

A foam part for a vehicle seat having a textile layer and a foam body made from a polyurethane foam. The textile layer may be designed as a three-dimensionally formed non-woven layer. The non-woven layer may have a grammage of 800 to 1200 grams per square meter. A method for producing the foam part and for providing the vehicle seat having at least one foam part are described.

A repair method is provided during which a thermoplastic patch is arranged on a thermoplastic aerospace component. An ultrasonic horn is arranged on the thermoplastic patch. The thermoplastic patch is vertically between the thermoplastic aerospace component and the ultrasonic horn. The thermoplastic patch contacts the ultrasonic horn. The thermoplastic patch is continuous ultrasonic welded to the thermoplastic aerospace component using the ultrasonic horn.

A repair method is provided during which a thermoplastic patch is arranged on a thermoplastic aerospace component. An ultrasonic horn is arranged on the thermoplastic patch. The thermoplastic patch is vertically between the thermoplastic aerospace component and the ultrasonic horn. The thermoplastic patch contacts the ultrasonic horn. The thermoplastic patch is continuous ultrasonic welded to the thermoplastic aerospace component using the ultrasonic horn.

A rubber product that includes a cylindrical molded body having a plurality of reinforcing layers coaxially layered between inner and outer layers. In producing/vulcanizing the molded body, a rubber product including a cylindrical portion, each of multiple reinforcing layers composed of cord fabrics including a large number of fiber cords aligned and subjected to a predetermined adhesion treatment and coating rubber layers covering both surfaces of the cord fabric, and a bias structure in which the fiber cords of the reinforcing layers extend in an intersecting direction is formed. Each of the cord fabrics has: a tensile strength of 4320 N/cm in a cord extension direction and a weight of 950 g/m.sup.2, each of the cord fabrics has a bending hardness of 30 g/cm after the predetermined adhesion treatment, and each of the coating rubber layers has a layer thickness of 0.2 mm and 1 mm.