A method for making a polymer with a porous layer from a solid piece of polymer is 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.

A process comprises placing a first foamable material inside of a first region of a mold space, and a second foamable material inside of a second region of the mold space, the first foamable material and the second foamable material comprising a physical, chemical or quantitative difference or any combination thereof. Both the first and the second foamable materials are concurrently foamed inside of the mold space to produce a heterogeneous foam comprising a first portion that differs from the second portion.

A method of making a vehicle headrest restraint and connecting first and second molds to form a mold cavity. A first material is injected with a first density into the mold cavity. A second material is injected with a second density into the mold cavity. The first and second materials are cooled to develop an integrally formed headrest.

An apparatus for forming a three-dimensional image includes: a print function unit that forms a first print image on one surface and a second print image on a region of another surface of a thermally expandable sheet with a photothermal conversion material; and an image processing unit that sets a density of the photothermal conversion material in the second print image based on a density of the photothermal conversion material in the first print image. The second print image is a mirror image of the first print image, and the region of the other surface corresponds to the first print image of the one surface. A three-dimensional image of the first print image is formed by selectively expanding a thermally expandable layer with thermal energy according to the density of the photothermal conversion material in the second print image when the sheet is irradiated with light from the other surface.

A method for making an insulated vehicle extension dash panel includes injection molding an extension dash panel from a structural polymer. The method further includes adding a plurality of components to a mixer to form an insulating foaming layer. The plurality of components includes a two-part liquid silicone compound, a catalyst, and a foaming agent. A screw is then coupled to the mixer and the insulating foaming layer is injection molded to an inner face of the extension dash panel. The insulating foaming layer is then cured to the inner face of the extension dash panel to form the insulated vehicle extension dash panel.

A foam molded body production device (20) including a plurality of molds (21); a cavity (23) that is delimited, between the plurality of molds (21), by cavity surfaces (22) of the plurality of molds (21); and a protrusion portion (28) that is formed on the cavity surfaces (22). The protrusion portion (28) is formed from an elastic body. The cavity surfaces (22) are provided with a holding portion (29) that contacts a tip of the protrusion portion (28) when the plurality of molds (21) are closed, and causes the protrusion portion (28) to elastically deform inside the cavity (23).

A foam part (5, 105, 205, 305), in particular for a vehicle seat, includes a first foam layer (11, 111, 211, 311) facing a user and a second foam layer (21, 221) facing away from the user. The first foam layer has a hardness and/or density that is different from the hardness or density of the second foam layer (21, 221). The first foam layer includes several comfort tubes (50, 150, 250, 350) facing the user. A method for producing such a foam part (5, 105, 205, 305) includes a first step in which the first foam layer, having the comfort tubes (50, 150, 250, 350), is foamed and a second step in which the second foam layer (21, 221) is foamed. A tool (500) for producing a foam part (5, 105, 205, 305) includes a bottom part (510), a frame (520), and a top part (530).

The present invention contemplates a method of forming a member comprising injection molding a first layer into a first tool cavity, overmolding a second layer into a second tool cavity selected from the group consisting of an expandable layer, a sealing layer, an acoustic layer, and adhesive layer, a reinforcement layer, a fastening layer, a second carrier layer, and any combination thereof, overmolding a third layer into the second tool cavity selected from the group consisting of an expandable layer, a sealing layer, an acoustic layer, an adhesive layer, a reinforcement layer, a fastening layer, a second carrier layer, and any combination thereof. The first layer, the second layer, and the third layer may be molded in one injection molding tool and the second and third layer may be segregated from one another prior to any overmolding steps.

The present invention contemplates a method of forming a member comprising injection molding a first layer into a first tool cavity, overmolding a second layer into a second tool cavity selected from the group consisting of an expandable layer, a sealing layer, an acoustic layer, and adhesive layer, a reinforcement layer, a fastening layer, a second carrier layer, and any combination thereof, overmolding a third layer into the second tool cavity selected from the group consisting of an expandable layer, a sealing layer, an acoustic layer, an adhesive layer, a reinforcement layer, a fastening layer, a second carrier layer, and any combination thereof. The first layer, the second layer, and the third layer may be molded in one injection molding tool and the second and third layer may be segregated from one another prior to any overmolding steps.

A method for making a polymer with a porous layer from a solid piece of polymer is 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.