Disclosed are methods and systems for preparing open-celled polyurethane foams by a discontinuous box foam process in which (a) a polyurethane foam-forming composition is deposited into a container having a gas-permeable base and (b) the polyurethane-foam forming composition is allowed to form an open-celled polyurethane foam in the container. In these methods and systems, the gas-permeable base is heated before, during, and/or after step (a) and heating is continued during at least a portion of step (b).

A formation assembly for use in manufacturing a reinforced insulation panel including a foam material and a reinforcing structure includes a back plate including a first surface configured to receive the foam material, and a first support sheet spaced from the first surface to form a gap therebetween, wherein the first support sheet supports the reinforcing structure. The formation assembly also includes a second support sheet spaced from the first support sheet, wherein the second support sheet defines an upper boundary of the reinforced insulation panel. A rigid structure is coupled to the second support sheet, wherein the rigid structure restricts movement of the reinforced insulation panel.

A process of manufacturing a foam molded article includes opening an open-closed molding system; applying a release agent into a female cavity section of the molding system; injecting PU into the female cavity section; closing the molding system; placing the closed molding system in a foaming device; activating the foaming device to heat the PU; forming a plurality of interconnecting first air pockets in an air permeable foam core of a foam molded article to be formed; forming a plurality of interconnecting second air pockets in each of a top surface and a bottom surface of the foam molded article respectively by involving a chemical reaction with the release agent wherein the second air pockets are in air communication with the first air pockets; opening the molding system; and removing the finished foam molded article from the molding system.

Disclosed, among other things, are ways to manufacture reduced density thermoplastics using rapid solid-state foaming and machines useful for the saturation of plastic. In one embodiment, a foaming process may involve saturating a semi-crystalline polymer such as Polylactic Acid (PLA) with high levels of gas, and then heating, which may produce a reduced density plastic having high levels of crystallinity. In another embodiment, a foaming process may produce layered structures in reduced density plastics with or without integral skins. In another embodiment, a foaming process may produce deep draw structures in reduced density plastics with or without integral skins. In yet another embodiment, a foaming process may utilize additives, blends, or fillers, for example. In yet another embodiment, a foaming process may involve saturating a semi-crystalline polymer such as Polylactic Acid (PLA) with high levels of gas, and then heating, which may produce a reduced density plastic having high levels of crystallinity.

A weight device with handle comprises a body (3) of approximately spheroidal and hollow shape containing a ballast (5) and comprises a handle (7) having an approximately C shape and with ends (9) incorporated in the wall (11) of the body (3) or in respective protrusions (13) of said wall (11). The wall (11) of the body (3) comprises an outer layer (15) and an inner layer (17) which are mutually adherent and extending in almost every portion of the body (3). The outer layer (15) is made of soft and/or shockproof material of the closed-cell or open-cell foam type or of the elastomeric type with impact energy absorption. The inner layer (17) is made of rigid or semi-rigid material and of a type that ensures the stability of the shape of the body (3) over time, of cross-linked thermoplastic resin or other stable material with a high elastic modulus.

A method of forming a polymeric foam material is provided and includes providing a precursor material having a first thickness, the precursor material being an open-cell foam material and applying a uniaxial compressive force to the precursor material to compress the precursor material to a second thickness, the compressive force causing a cell structure of the precursor material to collapse. The method also includes heating the precursor material at a molding temperature for a first time period while the compressive force is applied, the first time period being sufficient to heat the precursor material to a softening temperature, removing the compressive force from the precursor material, and maintaining the cell structure of the precursor material in a collapsed state.

An illustrative embodiment of the present disclosure provides a method of manufacturing a composite structure. A composite material having a closed cross-section or a partially closed cross-section is cured to form the composite structure, wherein the composite material is in contact with a foam mandrel assembly when curing begins. A supportive foam mandrel in the foam mandrel assembly is collapsed during curing.

Disclosed are methods for making foam laminates having a concave surface. The methods include: (a) placing the foam sheet-containing sandwich structure in a mold; and (b) shaping the laminate in the mold to form the foam laminate having a concave surface. In the methods, the foam sheet is a slice from a foam bun in which a foaming reaction occurs such that the foam rises in a direction away from a base, such that one major surface of the sheet is a foam rise direction facing surface and the opposed major surface of the sheet is a base facing surface, and prior to placing the foam laminate in the mold, the foam sheet is oriented so that the shaping forms the foam laminate having the concave surface wherein the foam rise direction facing surface of the foam sheet faces the concave surface of the foam laminate. Also disclosed are automotive headliners and hoodliners made thereby.

Methods and combinations of a curing catalyst with a mold release mixture, which is then subsequently applied to the surface of a mold prior to the application of polyurethane reactants to said mold, where the curing catalyst component has the effect of catalyzing the reaction at the surface of the molded part. This catalysis results in greater reactivity at the surface between reacting portions and lower delamination of the surface of the foam, thereby leading to more attractive skins with a more consistent cell structure, and lower de-mold times due to skins whose nature makes them less likely to adhere to the surface of the mold. These foams will be less likely to tear upon opening of the mold, and production quality and output will be improved.

A heat-insulating housing (21) includes: a wall body; and an open-cell resin body (4) of thermosetting resin with which a heat-insulating space formed by the wall body is filled by integral foaming, the open-cell resin body including: a plurality of cells (47); a cell film portion (42); a cell skeleton portion (43); a first through-hole (44) formed so as to extend through the cell film portion; and a second through-hole (45) formed so as to extend through the cell skeleton portion, wherein the plurality of cells communicate with one another through the first through-hole and the second through-hole.