Methods of forming a lightweight reinforced thermoplastic core layer and articles including the core layer are described. In some examples, the methods use a combination of thermoplastic material, reinforcing fibers and bicomponent fibers to enhance retention of lofting agents in the core layer. The processes permit the use of less material while still providing sufficient lofting capacity in the final formed core layer.

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.

The mat of the present invention includes a main body integrally formed by a plastic material. The main body at least has a first surface and a second surface adjacent to the first face. The first face and the second face have different surface physical characteristics. The first surface and the second surface are shaped into a third surface and a fourth surface respectively. The third surface and the fourth surface have a substantially same surface physical characteristic. An angle between the third surface and the fourth surface outside the main body is a specific value.

The present invention pertains to the field of functional materials technology, specifically relating to a preparation method, product, and application of modified melamine foam. The method described in this invention is simple, does not require special equipment or process conditions, and is easy to scale up for industrial production. The melamine foam produced by this method features a high open-cell rate and low density.

A seat trim cover for an automotive seat is formed into a 3-dimensional shape by compression molding a laminated moldable foam in a 3-dimensional. The laminated moldable foam comprises at least a layer of cellular polyurethane foam compression moldable in a temperature range of about 220 F. to about 260 F. The 3-dimensional mold is heated to a temperature range of about 150 F. to about 320 F. The layer of cellular foam is adhered to a cover material layer and precut into a pre-laminated blank prior to molding into the 3-dimensional shape. Optionally, seat heaters or other components can be integrated with the laminated foam prior to compression molding the seat trim cover.

A multi-material structure includes: a structural member that includes an isotropic material and at least one open-cell void formed in the isotropic material; and a skin that includes a polymetric material and is disposed on a surface of the structural member and within the at least one open-cell void.