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.

A method for preparing a construction board, the method comprising (i) providing a non-woven mat having a coating layer disposed on a planar surface thereof, where the coating layer includes an inorganic filler dispersed within a polymeric matrix; (ii) contacting an A-side stream of reactants including an isocyanate compound with a B-side stream of reactants including an isocyanate-reactive compound to prepare a developing foam; and (iii) depositing the developing foam on to said coating of said non-woven mat.

The present invention relates to a panel and method for manufacturing panels for wall or floor coverings, comprising two or more thermoplastic layers including at least one thermoplastic substrate layer and at least one top layer comprising at least a decor layer, a print layer and a transparent wear layer, and wherein both said thermoplastic substrate layer and said top layer are provided with a reinforcement layer, wherein said transparent wear layer is provided with a relief.

A device for deadening the sound of a component having a damping layer of a foamed material and a stiffening layer, which is fixedly connected to the damping layer and which is stiffer than the damping layer, wherein the damping layer is formed by a foamed hot-melt adhesive.

A multilayer material, including a first polymer foam layer having a density of less than 481 kg/m.sup.3, a compression force deflection of 5 to 1,035 kPa, at 25% deflection determined in accordance with ASTM D3574-17, and a thickness of less than 3.5 millimeters; and a second polymer foam layer having a density of greater than 240 kg/m.sup.3, wherein the density of the second polymer foam layer is at least two times greater than the density of the first polymer foam layer, and a thickness of less than 0.3 millimeters, wherein the thickness of the first polymer foam layer is at least two times greater than the thickness of the second polymer foam layer; wherein the first polymer foam layer and the second polymer foam layer include a flame retardant composition, and wherein the multilayer material has a thickness of 3.5 millimeters or less, and a UL-94 rating of V1.

The present disclosure relates to a foam machine. Liquid for generating foams is conveyed onto a laminating member through a liquid pump. The laminating member further conveys the liquid onto a foam forming device. On the foam forming device, a rotating ring is provided with a plurality of forming rings and a plurality of forming ribs, so that a plurality of foam film forming holes are formed in the rotating ring; afterwards, as the rotating ring rotates, the laminating member can form foam films on the respective foam film forming holes, and continuous foams are formed after an air flow is blown through; the foams are pushed by the air flow to be continuously sprayed out; and new foam films are continuously formed on the respective foam film forming holes.

The present disclosure relates generally to cladding for covering a building surface. The present disclosure relates more particularly a method of manufacturing a building surface panel. The method includes providing a foam piece having a 30 day/23? C. residual shrinkage of no more than 0.2%. The foam piece having the 30 day/23? C. residual shrinkage of no more than 0.2% is attached to a rear side of an outer shell so as to form the building surface panel. In some embodiments, a front side of the outer shell forms a visible surface of the building surface panel. The foam piece can be provided, e.g., by aging the foam piece for a time and at a temperature such that the 30 day/23? C. residual shrinkage is no more than 0.2%. The foam piece to be aged can, in some embodiments, be cut from a body of foam.

A continuous process for preparing insulation panels having thick (0.2 mm to 1 mm) metal facing panels and a fiber-reinforced polymer foam core is disclosed. In the process, a bottom metal facing panel is continuously supplied. A mat of reinforcing fibers and a foamable resin composition are applied to the bottom facing panel. A flexible barrier layer is applied atop the foamable resin composition, and the assembly is passed through nip rolls to compress the assembly and force the resin composition into the fiber mat. An adhesive layer and top metallic facing layer are then applied on top of the flexible barrier layer, and the resulting assembly is gauged and cured by passing it through a double band laminator.

A method and device for manufacturing a sandwich structure comprising at least one foam layer of a first thermoplastic comprising a chemical blowing agent and two cover layers. The decomposition temperature of the chemical blowing agent is higher than the melting point or range of the first thermoplastic. The method comprises a series of steps performed on an advancing starting structure including heating under pressure in order to cause decomposition of the blowing agent, intermediate cooling, foaming at a constant volume and further cooling.

A construction board comprising (a) a foam core having a first planar surface and a second planar surface; (b) a facer, having first and second planar surfaces, including an inorganic fabric and a coating; and (c) an interfacial region between the foam core and said facer.