Low-density thermoplastic expandable microspheres are disclosed. Various low-density structures, in particular, sandwich panels, based on foam prepared from the low-density microspheres, are also disclosed. Process of preparing low-density polymeric microspheres, per se, and the corresponding low-density structures, based on the microsphere foam, are also disclosed.

Some embodiments of the present disclosure relate roofing membranes that may include at least one first layer including a first plurality of protrusions; at least one second layer including a second plurality of protrusions; and a plurality of inner regions disposed between a raised protrusion of the first plurality of protrusions and a raised protrusion of the second plurality of protrusions. Some embodiments of the present disclosure relate to methods of forming roofing membranes. The methods may include applying a blowable ink onto at least one porous layer; sandwiching the at least one porous layer between the at least one first layer and the at least one second layer; and expanding the blowable ink, so as to form the first plurality of protrusions, the second plurality of protrusions, and the plurality of inner regions.

Methods of manufacturing of aerospace structures are disclosed. More specifically, methods of manufacturing relatively lightweight yet strong aerospace structures. In one embodiment, the method includes the addition of a volume of a rigid and flexible polyurethane mixture into a mold to create a composite structure. In one aspect, the method includes the integration of special structures within a larger structure to remove traditionally structurally weak or vulnerable areas.

An electrically decoupled jet engine. The electrically decoupled jet engine includes a combustion chamber which creates a toroidal flow of air and a rotational electric motor which drives a fuel supply into the combustion chamber. The toroidal flow of air is mixed with the fuel and combusted in the combustion chamber to create thrust.

A method of post manufacture processing of 3D printed parts involves a step of forming at least one treatment aperture through an exterior shell of a 3D printed part to provide access to a lattice of multiple layers of extruded thermo-plastic filaments within a hollow cavity of the part. The method involves a step of inserting a stabilizing substance that flows before it is set and then hardens when set through the at least one treatment aperture into the hollow cavity of the part. The method involves a step of coating the lattice with the stabilizing substance to fill spaces between the multiple layers and between individual thermo-plastic filaments, such that, when set, the stabilizing substance fixes the multiple layers of extruded thermo-plastic filaments of the lattice in position. The method reinforces and stabilizes the internal lattice structure of the part, without significantly adding material or increasing manufacturing cost.

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 composite layer for use in a bedding product such as a mattress and a method of manufacture are disclosed. The composite layer generally includes an extruded three dimensional fibrous layer and a foam material, e.g., polyurethane, latex or the like, disposed within the fibrous layer and occupying at least a portion of the free volume in the layer. Also disclosed are processes for manufacturing a foam-fiber composite.

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 are insulative apparatus and methods of forming insulative apparatus. As an example, a method of forming an insulative apparatus can include connecting a barrier material to a mold; injecting a polyurethane foam composition into the mold, wherein the polyurethane foam composition includes a polyol, an isocyanate, and supercritical carbon dioxide; curing the polyurethane foam composition to form a polyurethane foam and applying a vacuum to the mold to provide a pressure from 1 millibar to 500 millibar.

Various embodiments of the teachings herein include an electrical insulation system for an electric motor comprising a conductor with wire winding in a slot of a laminated core of a stator. The wire winding is embedded in an encapsulation. The encapsulation includes volume-increasing particles.