A method for the manufacture of a polymer foam composite includes forming a polymer foam that is at least partially uncured; contacting the formed polymer foam with a fibrous mat including a plurality of nonwoven fibers having an average diameter of 100 um or less under conditions effective to infiltrate a portion of the polymer foam into the mat, to provide a pre-composite; and curing the pre-composite to form the polymer foam composite. The pre-composite includes a polymer foam layer and an intermixed layer including the fibrous mat and the same polymer as the polymer of the polymer foam layer. The polymer foam composite includes a cured polymer foam layer and an intermixed layer integrally bonded to the first layer, wherein the intermixed layer includes the fibrous mat and a cured polymer the same as the polymer of the cured polymer foam layer.

The present invention relates to a method for producing a PUR/PIR foam body, comprising the steps of providing a mold adapted for applying an underpressure to the interior of the mold; introducing a reaction mixture comprising an isocyanate-reactive component A and an isocyanate B into the mold, and applying an underpressure to the interior of the mold, so the underpressure acts on the introduced reaction mixture. The underpressure is applied to the interior of the mold no later than the reaction mixture has started to set in the mold, and the isocyanate index of the reaction mixture is 300.

A reinforced composite structure and a method of making a reinforced composite structure are disclosed herein. The structure and methods disclosed herein include a reinforcing flexible material, a barrier layer, and a foam. The barrier layer can be perforated. The foam can pass through the barrier layer to contact and adhere or bond to the reinforcing flexible material. The structure and methods according to the disclosure are useful, for example, in any structural boat component such as stringers, bulkheads, hull and deck stiffeners, beams, fuel tank supports, structural members, long-span stiffeners, corner stiffeners, hull side-to-bottom strengthening, hatch and swim platform reinforcement, insulated compartments, fish boxes, and applications for flat-bed trailers, truck bodies, buses, recreational vehicles, or other types of vehicles, such as aircrafts.

A molded body for a seat component, in particular a backrest or a seat part of a seat may have at least one thermally solidified and three-dimensionally formed nonwoven element which is back-molded with a foam material or a foamable material. An additional molded body and a method for producing such a molded body are also disclosed.

The invention relates to parts having a foamed polymeric material attached to a fabric, and systems and methods for forming same. An example method of attaching foamed polymeric material to a fabric layer includes providing a mold having at least one cavity and at least one material injection channel in fluid communication with the cavity, disposing a fabric over the at least one cavity, closing the mold, injecting unfoamed polymeric material into the at least one cavity through the material injection channel, wherein the unfoamed polymeric material penetrates at least a portion of the fabric proximate the at least one cavity to attach the polymeric material to the fabric layer, and foaming the unfoamed polymeric material.

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 seat pad which can provide a favorable seating feeling while adhesion between a breathable member and a resin foam constituting the seat pad is ensured and a method of manufacturing such a seat pad are provided. A filling member including a breathable member having a ventilation function to an outside, used in a molding process of the seat pad for a vehicle integrally molded from a foam made of a foamable resin in a state where the breathable member is placed therein, and removed after the molding, is characterized by including a frame-shaped body attached to a peripheral side surface of an outside exposed surface of the breathable member and installed on a molding surface of a mold and a side-surface covering body installed upright on the frame-shaped body and partially covering a side surface of the breathable member.

Embodiments disclosed herein relate to polymer resins having a first thermoset and one or more additional components (e.g., a second thermoset and/or a thermoplastic), composite laminates including the same, methods of making and using the same, and composite laminate structures including the same.

Embodiments described herein relate to a composite structures or sandwiches that may have a relatively high bending stiffness and may have a relatively light weight as well as related methods of use and fabrication of the composite sandwiches. For example, a composite sandwich may include a core structure sandwiched between a two composite skins.

Embodiments described herein relate to a composite structures or sandwiches that may have a relatively high bending stiffness and may have a relatively light weight as well as related methods of use and fabrication of the composite sandwiches. For example, a composite sandwich may include a core structure sandwiched between a two composite skins.