Described herein is an acoustic structural panel having a first exposed major surface opposite a second exposed major surface and side surfaces extending between the first and second exposed major surfaces, the acoustic structural panel comprising a first protective layer comprising at least a portion of the first exposed major surface, a second protective layer comprising at least a portion of the second exposed surface, a core structure located between the first and second protective layers, the core structure comprising, a foam body; and a fibrous body, wherein the first major exposed surface of the acoustic structural panel comprises a plurality of apertures exposing the fibrous body.

Certain configurations are described herein of a multi-layer assembly comprising a core layer and one or more reinforced thermoplastic layers. In some configurations, the core layer may comprise a directionally compressive material. In other configurations, the reinforced thermoplastic layer may comprise a thermoplastic material and reinforcing fibers. Vehicle load floors, wall panels, flooring panels and the like including the multi-layer assembly are also described.

A vehicle interior panel includes a decorative skin layer and a backing layer. The backing layer can include a barrier material that helps prevent outgassing of a plasticizer of the decorative skin layer in a direction toward an underlying substrate of the panel. The backing layer can be formed by vacuum coating and/or formed while a slush molded layer remains on a slush molding tool surface on which it was formed. In some cases, a slush molding tool thus finds new uses in a vacuum coating process or in some other process apart from slush molding.

A process for fabricating a unitized structure comprises creating a multilayer structure by applying a flame-retardant resin to a first layer and stacking, on the first layer, an intermediate layer comprising a honeycomb structure. Further, a second layer is stacked on the intermediate layer and the flame-retardant resin is applied to the second layer. The multilayer structure is then heated to a desired temperature and a pressure is applied about the multilayer structure for a predetermined process time. Moreover, the flame-retardant resin is prevented from entering spaces of the honeycomb structure. After elapse of the predetermined process time, the pressure is released, creating the unitized structure.

Panels for coupling stone or brick units to a wall structure are disclosed herein. The panels can include an expanded polystyrene foam having a plurality of laterally extending channels formed on one or more of a first and second side of the panel. The channels can aid in adhering a plurality of stone or brick units to the panel. The width of the channels can be less than the width of the stone or brick units such that the stone or brick units are disposed outside the channels when coupled to the panel.

Provided are wallboard panels that include a foam material layer and a core material, with one or more sheets of facer material and/or one or more sheets of backing material. The foam material layer may include one or more pores having an open pore geometry. Additionally, provided are methods of manufacturing such wallboard panels.

Methods for manufacturing a metal foam and a metal foam reinforced back plate may be used to provide high-strength and low weight structural elements in portable information handling systems. A method for manufacturing a metal foam may include selectively adding iridium oxide and ceramic particulate to a light-metal allow to create desired mechanical properties of the metal foam.

To provide a palette, etc. on which an article is placed, including: a foamed synthetic resin-base material; and a polyurea-resin coating layer covering a front surface of the base material; and manufactured by a method including: injecting a polyurea-resin coating material onto a front surface of a foamed synthetic resin-base material; and drying the coating material after the injecting. The injecting may have injecting the coating material onto all surfaces of the base material. A thickness of the coating material formed on a front surface of the base material in the injecting may be controlled proportionally to an expansion ratio of the foamed synthetic resin. The thickness of the coating material may be controlled by adjusting a speed of conveyance of the base material and/or a distance between an injection port for the coating material and the base material. Heating-pressing the base material may further be included before the injecting.

A battery insulation sheet including an aerogel layer. The aerogel layer includes: a fibrillized polymer matrix comprising a dry binder; and aerogel particles distributed in the fibrillized polymer matrix.

An acoustical ceiling panel including a first layer having a first major surface opposite a second major surface and a side surface extending therebetween, a second layer having a first major surface opposite a second major surface and a side surface extending therebetween, and a sealing layer having a first major surface opposite a second major surface and a side surface extending therebetween. The sealing layer may be positioned between the first major surface of the first layer and the second major surface of the second layer. The side surface of the sealing layer may extend beyond the side surface of the first layer and the side surface of the second layer.