A method of forming a composite vehicle components (e.g. walls, floor, roof) having interleaved foam core members and pre-pultruded reinforcing pillars by pultruding the cores and pillars into a vehicle component (e.g. bus sidewall formed as integral component front to rear) and cutting apertures therein for insertion of vehicle accessories (e.g. windows). Also, vehicle components can be formed having interlocking profiled edges where a first component is inserted into a second component, and rotated to bring the two components into locking engagement. A plurality of components can be formed with the same geometry, and oriented 180 degrees offset from each other to bring their profiled edges adjacent to each other.

A polymerizable liquid, or resin, useful for the production by additive manufacturing of a three-dimensional object of polyurethane, polyurea, or a copolymer thereof, is described. The resin includes at least one of (i) a blocked or reactive blocked prepolymer, (ii) a blocked or reactive blocked diisocyanate, or (iii) a blocked or reactive blocked diisocyanate chain extender.

A method of sub-ambient pressure processing of blow-molded polymer foams and skin-over-foam sandwich panel configurations for lightweight components having improved structural properties. The method can create either skinned or un-skinned foams that offer smooth interior and exterior surfaces, zero or controlled surface porosity, skins of pre-defined thickness, and foam cells that are expanded and oriented normal to the material plane, effectively spherical or polyhedral in nature, and offering improved bending and compressive strength.

A cable core includes: an internal conductor; a foamed dielectric that includes a fluororesin and is formed on the internal conductor by extrusion molding; and a skin layer that covers the foamed dielectric, and is configured such that a foaming rate of the foamed dielectric is 80% or more, an average foamed cell diameter of the foamed dielectric is 10 m or less, and a standard deviation of a foamed cell diameter of the foamed dielectric is 2.5 or less.

A polymerizable liquid, or resin, useful for the production by additive manufacturing of a three-dimensional object of polyurethane, polyurea, or a copolymer thereof, is described. The resin includes at least one of (i) a blocked or reactive blocked prepolymer, (ii) a blocked or reactive blocked diisocyanate, or (iii) a blocked or reactive blocked diisocyanate chain extender.

Provided is a structure of foam-injection molding including an EL sheet. The structure includes: a base material; an electro luminescence(EL) sheet which is able to emit a light, and which is disposed on an upper side of the base material; a foam layer disposed on an upper side of the EL sheet; and a skin layer disposed on an upper side of the foam layer.

Provided is a structure of foam-injection molding including an EL sheet. The structure includes: a base material; an electro luminescence (EL) sheet which is able to emit a light, and which is disposed on an upper side of the base material; a foam layer disposed on an upper side of the EL sheet; and a skin layer disposed on an upper side of the foam layer.

A seal for a vacuum lifter and method of manufacture wherein the seal has a continuous unbroken outer fluid resistant skin of elastomer which forms a boundary around a homogeneous cellular structure with no interior seams or joints.

A formulation for producing a polymeric material including polypropylene, a chemical blowing agent, and optional components as described.

A thermoplastic elastomer (TPE) foam having a soft open-cell inner layer and a washable closed-cell outer layer which surrounds and substantially seals the inner layer, and which may be used alone or in combination with other components to produce useful articles. The TPE foam includes a base resin which is a styrenic block copolymer, and a foaming agent. A process of forming and molding the TPE foam includes using a shutoff nozzle to prevent the foaming agent from activating before reaching the mold cavity, using an oversized gate to minimize shear heat, and using oversized vents. An earplug may be constructed by molding the TPE foam over a core or body formed from a material which is denser than the TPE foam. A first earplug design may employ a constrained layer damping effect, while a second earplug design may employ an adjustable sound attenuation effect.