An expanded polypropylene resin particle includes a polypropylene resin (X) as a base resin, the polypropylene resin (X) containing a polypropylene resin (I) and a high density polyethylene resin (II). The polypropylene resin (I) has a melting point of 145 to 165 C., and the high density polyethylene resin (II) has a density of 0.93 to 0.97 g/cm.sup.3. The polypropylene resin (X) contains no or one foam nucleating agent.

A method is provided for making an annular reinforcement structure having inner and outer reinforcement bands maintained in concentric alignment by a resilient spacing element positioned between the bands. The method includes the steps of placing the spacing element against the inside face of the outer reinforcement band and compressing the spacing element with a jig, adjacent the top edge of the outer reinforcement band. The spacing element is sufficiently compressed to allow the inner reinforcement band to slide into concentric alignment with the outer reinforcement band, with a minimum of deflection and/or distortion of the inner reinforcement band.

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 method of manufacturing a foam having a Poisson's ratio which varies across at least a region of the foam in a gradient distribution involves the steps of: a) providing a housing defining an internal space having an inlet aperture and an outlet aperture; b) providing an open-cell foam of a size and shape configured to fit inside the internal space of the housing; c) positioning the foam inside the internal space of the housing; d) establishing a flow of air through the foam via the inlet and outlet apertures; e) heating the foam to a predetermined temperature while maintaining the flow of air through the foam; and f) subsequently cooling the foam while continuing to maintain the flow of air through the foam. A foam of such a type is also presented.

A method for the manufacture of a polymer foam composite includes forming a polymer foam that is at least partially uncured; contacting the formed polymer foam with a fibrous mat including a plurality of nonwoven fibers having an average diameter of 100 um or less under conditions effective to infiltrate a portion of the polymer foam into the mat, to provide a pre-composite; and curing the pre-composite to form the polymer foam composite. The pre-composite includes a polymer foam layer and an intermixed layer including the fibrous mat and the same polymer as the polymer of the polymer foam layer. The polymer foam composite includes a cured polymer foam layer and an intermixed layer integrally bonded to the first layer, wherein the intermixed layer includes the fibrous mat and a cured polymer the same as the polymer of the cured polymer foam layer.

Engine mounted trim part for a vehicle engine comprising a fibrous carrier layer and at least one mounting system for mounting the trim part to a vehicle engine characterised in that the mounting system is built such that it can form a vibration-coupled connection upon mounting to the engine and the fibrous carrier layer is at least self-damping such that it can dampen the vibrational energy.

A supper hydrophobic surface (e.g., autoclean surface) and methods of making such a surface. The method includes forming an open porosity on a surface of a product, the open porosity including pores having undercuts and attaching functional nano-particles to the surface, such that the functional nano-particles are located inside the open porosity. The open porosity is formed by various methods such as, for example, co-extruding or applying a polymeric material with a blowing agent and/or etching the surface and/or directly printing a porous layer on the surface.

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.

A composite orthotic device for use with footwear includes a resiliently deformable base part and a resiliently deformable upper part, forming a plurality of foot supporting portions of differing durometer adapted to guide the wearer's foot along a Center of Pressure path from heel strike to toe-off to follow a biomechanically corrected gait path.

A cellular cushioning system includes cells or support units arranged in one or more stacked arrays. The cells are hollow chambers that resist deflection due to compressive forces, similar to compression springs. The arrays are attached to one or more intermedial binding layers. The intermedial binding layer(s) links the cells together while allowing the cells to deform independently of one another. An external load compresses one of the void cells within an independent compression range without significantly compressing at least one void cell adjacent the compressed void cell. The independent compression range is the displacement range of the compressed void cell that does not significantly affect the compression of adjacent void cells. If the void cell is compressed beyond the independent compression range, the intermedial binding layers may be deflected and/or the void cells adjacent the compressed void cell may be compressed.