Devices and methods for making a polymer with a porous layer from a solid piece of polymer are disclosed. In various embodiments, the method includes heating a surface of a solid piece of polymer to a processing temperature and holding the processing temperature while displacing a porogen layer through the surface of the polymer to create a matrix layer of the solid polymer body comprising the polymer and the porogen layer. In at least one embodiment, the method also includes removing at least a portion of the layer of porogen from the matrix layer to create a porous layer of the solid piece of polymer.

The disclosure provides an injection molding apparatus, including a mold unit, an injecting unit, and a counter pressure unit. The mold unit is adapted to provide a first cavity and a second cavity. The injecting unit is adapted to inject a first material into the first cavity to form a first molded object. The second cavity is adapted to accommodate the first molded object. The injecting unit is adapted to inject a second material into the second cavity to form a second molded object, such that the first molded object and the second molded object in the second cavity are combined. The second material is a foaming material. And the counter pressure unit is adapted to provide gas into the second cavity to increase the pressure in the second cavity.

An injection molding method includes providing a molding device including a first mold, a second mold over the first mold and a first mold cavity defined by the first mold and the second mold; injecting a first material into the first mold cavity; forming a first layer from the first material; replacing the second mold by a third mold; injecting a second material into a second mold cavity defined by the first mold and the third mold; and forming a second layer from the second material disposed over the first layer, wherein the first material is different from the second material.

A non-pneumatic tire, comprising a polyurethane composite layer which comprises a polyurethane matrix material and a thermoplastic expandable polymer material dispersed in the polyurethane matrix material. The polyurethane matrix material is obtained by a reaction comprising the following components: (A1) a polyisocyanate composition; (B1) at least one polyalkylene oxide-based polyether polyol having a number average molecular weight of 2000-7000 g/mol, calculated according to GB/T 7383-2007: test method for hydroxyl value, and containing 15-35 wt % of solid particles based on the total weight of the polyether polyol; (B2) one or more chain extenders; (B3) one or more catalysts; and (B4) one or more foaming agents. Also provided herein is a method for preparing a non-pneumatic tire, a process for manufacture of a non-motor vehicle, and a non-motor vehicle.

A molding thermal expansion structure includes a thermoplastic material and a thermal expansion material, wherein the thermoplastic material is 50 wt % to 90 wt % based on a weight of the molding thermal expansion structure; the thermal expansion material is 50 wt % to 10 wt % based on a weight of the molding thermal expansion structure; wherein, the thermal expansion material is expanded from a foaming original material through a pre-foaming process; the thermoplastic material and the thermal expansion material are mixed to form a mixed material; the mixed material is thermally expanded to form a thermal expansion structure in a molding apparatus. The molding thermal expansion structure provided in the present invention could satisfy various needs of light-weighted products. A molding method of the thermal expansion structure is also provided herein.

Fabricate a panel (5) by building a sacrificial relief (10) by an additive process of multilayer deposition, applying a facade layer (20,30) over the sacrificial relief so as to conform to the contour of the sacrificial relief, depositing a foamable composition (40, 50, 60) over the facade layer.

Provided is a printed matter producing method including a foaming liquid layer forming step of applying a foaming agent-containing composition, which contains: a foaming agent; and a polymerizable compound containing a multifunctional monomer, over a print target, to form a foaming liquid layer, a defoaming agent applying step of applying a defoaming agent containing a polymerizable compound selectively over the foaming liquid layer, a defoaming agent curing step of curing the defoaming agent applied, a foaming step of heating the foaming liquid layer after the defoaming agent curing step to foam the foaming liquid layer, and a curing step of performing curing by electron beam irradiation after the foaming step.

The present invention provides means for improving bondability between a vehicle seat core and a cushion in a vehicle seat pad formed by integration of them without significantly impairing mechanical properties. A vehicle seat core is characterized in that it is a vehicle seat core for forming a vehicle seat pad by integration with a cushion, which comprises a foamed resin molded body obtained by filling a cavity of a mold with a plurality of foamed resin particles and performing in-mold foam molding, and that at least a partial region of a surface of the foamed resin molded body to which the cushion is bonded when forming the vehicle seat pad has a surface expansion rate of 40% to 85%, and the foamed resin molded body has a first fusion rate of 95% or more or a second fusion rate of 60% or more.

A method for selectively producing a first or a second variant of a multi-layer plastic component, where both variants have a substrate part, a decorative layer, and a foam layer between the substrate part and the decorative layer, includes producing the foam layer in a foaming mold which has a first mold half, into which the substrate part is inserted before the foaming process. To produce the first variant, the decorative layer is inserted into a second mold half of the foaming mold before the foaming process. To produce the second variant, a spacer layer is inserted into the second mold half before the foaming process where, after the foaming process, the spacer layer is removed from the foam layer and the decorative layer is applied to the foam layer. The foam layer includes at least one first portion having a higher contour stability than a second portion.

According to the present invention, in a plan view of a seat surface (10a), a plane area of a part surrounded by an inner edge (17a) of a rear part (17) in a left-right direction (X) and a contour (L) is larger than a plane area of a part sandwiched by an inner edge (18a) of a front part (18) in the left-right direction (X) and the contour (L) in the left-right direction (X). In addition, a part of a pair of left and right second synthetic resin materials forming a lower part having a maximum gap therebetween in the left-right direction (X) is positioned in a thigh rest part (14) and a part having a minimum gap is positioned in a hip rest part (15), and a maximum value (W1) of the gap between the pair of left and right second synthetic resin materials forming the lower part in the left-right direction (X) is two times or more a minimum value (W2) of the gap in the left-right direction (X).