Methods of compression molding polymeric parts for improved impact resistance are provided. The components are particularly suitable for use in a vehicle or an automobile. The compression molded polymeric component comprises a central region or core comprising integrally formed foam, e.g., a foam core, that can sustain high impact load and does not lead to visible surface cracking or material cracking. The polymeric component may be a reinforced plastic composite (FRP). Such methods can produce lightweight, impact resistant, FRP components that may be used in various structural applications, including in automobiles.

The present invention relates to a novel device to manufacture polyurethane foam boards used in structurally insulated panel known as insulated building material press. The press enables the application of pressure across a large area while foaming and curing polyurethane under pressure, curing glue or otherwise bonding materials into a finished product or to form multiple panels in a single press at the same time. The building material press can be used to manufacture multiple structurally insulated panels simultaneously. The press is mobile and can be transported by means of a vehicle to a remote location.

The present invention relates to a novel device to manufacture polyurethane foam boards used in structurally insulated panel known as insulated building material press. The press enables the application of pressure across a large area while foaming and curing polyurethane under pressure, curing glue or otherwise bonding materials into a finished product or to form multiple panels in a single press at the same time. The building material press can be used to manufacture multiple structurally insulated panels simultaneously. The press is mobile and can be transported by means of a vehicle to a remote location.

A method of manufacturing building panels includes assembling a frame of a building panel. The frame defines at least one cavity and at least one injection aperture in fluid communication with the at least one cavity. The method also includes positioning the frame on one of a base and a shelf of a multi-panel consolidation device having a plurality of shelves, with the shelves being in an expanded configuration, and at least substantially enclosing the at least one cavity. The method also includes forcing the shelves of the multi-panel consolidation device into a collapsed configuration, and injecting an expandable polymer through the at least one injection aperture into the at least one cavity. The method further includes forcing the shelves into an expanded configuration after a predetermined period of time selected to permit the expandable polymer to form a foam bonded to the frame.

A method of manufacturing building panels includes assembling a frame of a building panel. The frame defines at least one cavity and at least one injection aperture in fluid communication with the at least one cavity. The method also includes positioning the frame on one of a base and a shelf of a multi-panel consolidation device having a plurality of shelves, with the shelves being in an expanded configuration, and at least substantially enclosing the at least one cavity. The method also includes forcing the shelves of the multi-panel consolidation device into a collapsed configuration, and injecting an expandable polymer through the at least one injection aperture into the at least one cavity. The method further includes forcing the shelves into an expanded configuration after a predetermined period of time selected to permit the expandable polymer to form a foam bonded to the frame.

A method for producing an automotive equipment part includes the following steps: arranging a porous layer in a foaming mold; injection, on one side of the porous layer, of a foam precursor; expansion of the precursor material to form a foam base layer bonded to the porous layer; and extraction from the mold of the equipment part including the porous layer and the foam base layer bonded to the porous layer. The method further includes a step for injecting a pressurized fluid on a second side of the porous layer to form a counter-pressure to the expansion of the precursor material.

An apparatus and method for forming a design on an expanded bead foam article such as an exercise roller is provided.

An apparatus and method for forming a design on an expanded bead foam article such as an exercise roller is provided.

According to a method for manufacturing a structure that is provided, it is possible to prevent creases on a skin sheet when the skin sheet and a molten resin sheet are integrally molded using a mold. The method provided by the present invention is a method for manufacturing a structure including the step of integrally molding a skin sheet and a molten resin sheet using a mold. The molding is performed with the skin sheet under tension.

According to a method for manufacturing a structure that is provided, it is possible to prevent creases on a skin sheet when the skin sheet and a molten resin sheet are integrally molded using a mold. The method provided by the present invention is a method for manufacturing a structure including the step of integrally molding a skin sheet and a molten resin sheet using a mold. The molding is performed with the skin sheet under tension.