A shaped object production method includes a first preparation step (S30) of preparing a molding sheet that includes a base, a thermally expansive layer laminated on a first main surface of the base, the thermally expansive layer including a thermally expandable material, and a brushed layer laminated on a surface of the thermally expansive layer on a side that is opposite to the base, the brushed layer including fiber; a first heat conversion layer laminating step (S40) of laminating a heat conversion layer that converts electromagnetic waves into heat onto a surface of the molding sheet on a side that is opposite to the brushed layer; and a first unevenness forming step (S50) of forming an unevenness on the surface of the thermally expansive layer on the side that is opposite to the base by irradiating the heat conversion layer with electromagnetic waves, thereby causing the thermally expandable material to expand.

An insulation board assembly, having: a foam insulation board; a top facer attached onto a top side of the foam insulation board, the top facer being made of woven material; and a bottom facer attached onto a bottom side of the foam insulation board, the bottom facer being made of woven material. The top and bottom woven facers may have upper and lower coatings and non-woven layers on either side and woven and non-woven layers may be held together with a tie layer.

A thermoplastic composite article comprising a porous core layer comprising a plurality of reinforcing fibers, a lofting agent and a thermoplastic material is provided. In certain instances, the article further comprises a skin layer disposed on the core layer and an adhesive layer between the core layer and the skin layer. In some configurations, the adhesive layer comprises a thermoplastic polymer and an effective amount of a thermosetting material to provide a post-molding peel strength between the skin layer and the post lofted core layer of at least 0.5 N/cm (in either or both of the machine direction or cross direction) as tested by DIN 53357 A dated Oct. 1, 1982.

A press (10) for manufacturing a sandwich panel comprises a first and second press plate (12; 14) that are movable with respect to one another. The press (10) has a fluid circulation loop for heating and cooling the press plates(12; 14). The fluid circulation N loop comprises a heater (22) for generating a hot fluid connected to a fluid supply conduit(24)in fluid communication with an inlet(18) of at least one internal flow channel (16) in each press plate (12; 14) and connected to a fluid return conduit(26) in fluid communication with an outlet (20) of the at least one internal flow channel(16). The fluid circulation loop is also provided with a controlled expansion valve (34) for cooling by conversion of hot pressurized water into steam, and a water source (38) for slow cooling.

Flooring material has an anti-slip, noise reducing pad directly self-adhered to a bottom surface. The pad is formed by applying a foamable PVC material is directly on the bottom surface of the flooring and heating the PVC material to foam the PVC material. The PVC material may then be cooled to form the pad with a definite formed shape having a resilient outer surface layer and a spongy foamy inner structure.

A method of producing a laminated article comprising placing a first metal skin, a core, and a second metal skin freely onto each other as discreet layers to provide a layered component; and forming the layered component into a shaped article via a die prior to producing a laminated article by applying pressure and heat to the shaped article, wherein at least the first skin moves relative to the core and/or second skin during the forming.

Light weight composites with high flexural strength comprise epoxy foam sandwiched between two layers of facing material have high strength and low weight and can be used to replace steel structures. The facing layer may be fibrous material especially glass or carbon fibres, the facing material is preferably embedded into the epoxy matrix. Alternatively they may be matching box structures or concentric metal tubes. The sandwich structures may be prepared by laying up the fibre; coating and/or impregnating the layer with epoxy resin, laying a layer of heat activatable foamable epoxy material, providing a further layer of the fibrous material optionally coated and/or impregnated with epoxy resin on the foamable material and healing to foam and cure the epoxy materials. Alternatively they may be formed by extrusion of the foamable material between the surface layers.

A fibrous vehicle underbody shield and method for manufacturing the same is provided. A binderless core of non-woven fibrous material defines first and second surfaces of the fibrous vehicle underbody shield. The second surface of the fibrous vehicle underbody is opposite the first surface such that the first and second surfaces are separated by a final product thickness. The first and second surfaces include at least one molded contour that gives the first and second surfaces a non-planar shape. The non-woven fibrous material of the binderless core includes a plurality of fibers that are mechanically entangled with each other and have a coating that withstands a heat exposure of 200 degrees Celsius. The fibrous vehicle underbody shield includes a latex impregnation. The latex impregnation is disposed on at least one of the first and second surfaces and penetrates the non-woven fibrous material of the binderless core an impregnation distance.

Provided is a building material that is lightweight, exhibits excellent formability, and is inhibited from being damaged during transportation, and a method for producing the same. Specifically, provided is a method for producing a building material, including: a first step of curing a core layer material including a hydraulic material, a silica-containing material, and an aluminum powder, to react the aluminum powder and form bubbles, and incompletely hardening the hydraulic material and the silica-containing material, to form a foamed core layer; a second step of dispersing a surface layer material including a hydraulic material, and a silica-containing material, to form an unfoamed surface layer; a third step of stacking the foamed core layer on the unfoamed surface layer, to form a stack including the unfoamed surface layer and the foamed core layer; and a fourth step of pressing and curing the stack, and a building material produced therewith.

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 pre-cut 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.