The invention relates to a method of manufacturing a sandwich panel comprises the steps of: a) providing a plate-shaped assembly of a first cover part and a second cover part and between these cover parts a core part of a thermoplastic material containing a physical blowing agent, b) heating the assembly resulting from step a) under pressure between press tools in a press to a foaming temperature below the glass transition temperature of the thermoplastic material in the core part, thereby effecting adhesion of the foamed core part to the first and second cover parts c) foaming the thermoplastic material in the core part under pressure and at the foaming temperature wherein the spacing between the press tools is increased; d) a cooling step of cooling the foamed sandwich panel resulting from step c), while the sandwich panel is maintained under pressure between the press tools; e) removing the thus cooled sandwich panel from the press; and f) drying the sandwich panel thus obtained; wherein the cooling step d) comprises.a first substep d1) of cooling the foamed assembly from the foaming temperature to an intermediate temperature in the range of 70-100° C. at a first cooling rate and a second substep d2) of cooling the foamed assembly from the intermediate temperature to ambient temperature at a second cooling rate, the second cooling rate is less than the first cooling rate.

The invention relates to a method of manufacturing a sandwich panel comprises the steps of: a) providing a plate-shaped assembly of a first cover part and a second cover part and between these cover parts a core part of a thermoplastic material containing a physical blowing agent, b) heating the assembly resulting from step a) under pressure between press tools in a press to a foaming temperature below the glass transition temperature of the thermoplastic material in the core part, thereby effecting adhesion of the foamed core part to the first and second cover parts c) foaming the thermoplastic material in the core part under pressure and at the foaming temperature wherein the spacing between the press tools is increased; d) a cooling step of cooling the foamed sandwich panel resulting from step c), while the sandwich panel is maintained under pressure between the press tools; e) removing the thus cooled sandwich panel from the press; and f) drying the sandwich panel thus obtained; wherein the cooling step d) comprises.a first substep d1) of cooling the foamed assembly from the foaming temperature to an intermediate temperature in the range of 70-100° C. at a first cooling rate and a second substep d2) of cooling the foamed assembly from the intermediate temperature to ambient temperature at a second cooling rate, the second cooling rate is less than the first cooling rate.

The present application provides a structure excellent in sound absorbing performance According to the present invention, provided is a structure comprising a foam molded body and a porous skin sheet, wherein the skin sheet is integrally molded with the foam molded body; the foam molded body and comprises a wide space therein; and Sw/Ft≥0.5, where Ft represents the thickness of the foam molded body at a position in which the thickness of the wide space is maximum, and Sw represents the width of the wide space.

A novel disc brake shim and a disc brake that can effectively suppress vibration and squeal are provided. The disc brake shim that is formed of a multilayer structure with three layers or more including at least a base material layer formed of a metal sheet, and a foamed rubber layer that is laminated on a main surface on one side of the base material layer, wherein the foamed rubber layer is an intermediate layer of the multilayer structure, and the disc brake including pad materials on both sides in an axial direction of a disc rotor, and shims on opposite sides from the disc rotor, of the pad materials adjacently, wherein each of the shims is the disc brake shim according to the present invention.

A novel disc brake shim and a disc brake that can effectively suppress vibration and squeal are provided. The disc brake shim that is formed of a multilayer structure with three layers or more including at least a base material layer formed of a metal sheet, and a foamed rubber layer that is laminated on a main surface on one side of the base material layer, wherein the foamed rubber layer is an intermediate layer of the multilayer structure, and the disc brake including pad materials on both sides in an axial direction of a disc rotor, and shims on opposite sides from the disc rotor, of the pad materials adjacently, wherein each of the shims is the disc brake shim according to the present invention.

A system for manufacturing a thermoplastic prepreg product includes a belt or conveyor, a prepreg applicator that positions a thermoplastic prepreg atop the belt or conveyor, a foam applicator that applies a foam mixture atop the thermoplastic prepreg, a heating mechanism that heats the thermoplastic prepreg and the foam mixture to cause the foam mixture to react atop the thermoplastic prepreg, and a laminator that is configured to press the thermoplastic prepreg and foam mixture to control a thickness of the resulting thermoplastic prepreg product. The thermoplastic prepreg includes a fabric, mat, or web of fibers and a thermoplastic material that is impregnated within the fabric, mat, or web of fibers. The thermoplastic material is formed from in situ polymerization of monomers and oligomers. The foam mixture includes an isocyanate, a polyol blend, and a blowing agent.

The present disclosure is related to a composite sandwich panel having a first layer including mica paper, a folded core or honeycomb structure including mica paper and a second layer including mica paper. The first and second layers are glued onto the foldcore using mineral adhesive made of one or more alkali metal silicate(s).

The present disclosure is related to a composite sandwich panel having a first layer including mica paper, a folded core or honeycomb structure including mica paper and a second layer including mica paper. The first and second layers are glued onto the foldcore using mineral adhesive made of one or more alkali metal silicate(s).

Decorative panel, in particular a floor panel, ceiling panel or wall panel, including a core layer having an upper side and a lower side, a decorative top layer connected to said upper side of the core layer, a first panel side edge including a first coupling profile, and a second panel side edge including a second coupling profile designed to interconnect with a first coupling profile of a second, identical panel, both in horizontal direction and in vertical direction. The core layer includes a layer of foam concrete which is constituted by a matrix of concrete material in which air pockets in the form of cells are present.

Laminated light-blocking decorative articles are prepared by applying an aqueous foamed opacifying composition to a non-woven fabric, drying, laminating a decorative fabric to the resulting dry foamed opacifying layer, and densifying that layer to have a thickness that is at least 20% less than before densifying. This operation can be carried out so that non-woven fabric, decorative fabric, and aqueous foamed opacifying composition are supplied in a single-pass, in-line operation to make any desired quantity of a laminated light-blocking decorative article. The applied aqueous foamed opacifying composition has 35%-70% solids and a foam density of 0.1-0.5 g/cm.sup.3. It is composed of (a) porous particles, (b) a binder material, (c) two or more additives comprising at least one foaming surfactant and at least one foam stabilizer, (d) an aqueous medium, and (e) at least 0.0001 weight % of an opacifying colorant that absorbs electromagnetic radiation having a wavelength of 380-800 nm.