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.

The invention relates to a process used to produce open-cell and extremely fine-cell PUR/PIR rigid foams, said process using a polyol formulation comprising a specific isocyanate-reactive component, a catalyst component having zerewitinoff-active hydrogens and a cell-opener component.

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.

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.

The invention relates to modifying synthetic fiber sponge, such as polyester or polyurethane foam, with an epoxy-, polyester, or acrylic-resin to induce an engineered rock product for use as stone replacement in a variety of applications. The method for manufacturing comprises: producing a foam block; shaping the foam block into any regular or irregular shape; weathering the shaped foam block; infusing the weathered foam block with a resin; curing the infused foam block; and finishing the cured foam block. The artificial rock comprises a foam block shaped to resemble a rock, an exterior of the foam block infused with a resin.

The present invention is for open cellular polyurethane foam comprising virgin foam and previously cured foam, methods of making the same, as well as inner soles for footwear made therefrom.

The present invention is directed to a device for at least partially covering a vehicle floor pan of a motor vehicle, comprises a carrier element made at least by a hard foam material, a vibration decoupling element made at least by a soft foam material, a surface layer to visually cover the device from the top, wherein the device has a shield element, which is made at least by a plastic material and is configured for accepting, absorbing and distributing the energy of a localized impact stress, which is applied on the device from above against the shield element. The present invention is also directed to a method for producing the device.

A resin foamed body 1 is a resin foamed body made of flexible resin, the resin foamed body entirely includes a skeleton part 2, the skeleton part includes a plurality of bone parts 2B and a plurality of connection parts 2J connecting end parts of a plurality of bone parts, and an average value AV(A0/A1) of a ratio A0/A1 of cross-sectional area A0 of a bone change part of each bone part at an edge 2B22 on a bone constant part side relative to cross-sectional area A1 of the bone change part at an edge 2B21 on the connection part side satisfies
0.15?AV(A0/A1)<0.5.

This provides an improved process for making a flexible, porous, dissolvable solid sheet article with improved pore structures.

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.