Methods of compression molding polymeric parts for improved impact resistance are provided. The components are particularly suitable for use in a vehicle or an automobile. The compression molded polymeric component comprises a central region or core comprising integrally formed foam, e.g., a foam core, that can sustain high impact load and does not lead to visible surface cracking or material cracking. The polymeric component may be a reinforced plastic composite (FRP). Such methods can produce lightweight, impact resistant, FRP components that may be used in various structural applications, including in automobiles.

A household appliance includes a functional compartment, and an insulation arrangement provided on an outer side of the functional compartment for thermal and/or acoustic insulation of the functional compartment. The insulation arrangement includes an insulation element which is made in one piece from a plastic material selected such that a surface of the insulation element in facing relation to the functional compartment adheres to the functional compartment and is separable therefrom in a non-destructive manner A component arranged outside the functional compartment is at least substantially encapsulated in the insulation element.

A composite article having an elastomeric composition with a blowing agent having an activation temperature and providing at least one structural member defining a fixed gap. The composition is formed below the blowing agent's activation temperature into a solid elastomeric member approximately the thickness of or larger than the gap. The elastomeric member is assembled into the gap, which may place the elastomeric member in a state of compression in the gap. The elastomeric member is then expanded by heating it above the activation temperature. During expansion, the escape of the gas produced is limited to increase the state of compression of the elastomer in the gap by means of confining any free surfaces or by including a platy filler such as nanoclay in the composition.

There is provided a vehicle seat including a seatback frame including: a first base member formed of a thin plate member made of resin; a second base member formed of a thin plate member made of resin and disposed facing the first base member; a pass-through portion that is formed to at least one of the first base member or the second base member, and that enables insertion of an injection nozzle for injecting a foaming liquid for a foamed body; and a core section that is configured by the foamed body, that is disposed between the first base member and the second base member, and that is adhered to the first base member and the second base member.

The present invention provides an engine cover that can be manufactured easily and at a lower cost and has an attachment member that is high in quality and may not easily fall off. The engine cover has a cover body made of urethane foam, a skin layer disposed on a surface of the cover body, and an attachment member made of an elastic body and integrally molded with the cover body. The attachment member has a recess into which an attachment pin provided to project from an engine member is fitted, and a sealing portion that is provided to project at least one of the opening end surface of the recess and the side surface of the opening end part of the recess and that suppresses entry of a foamed urethane resin material that forms the cover body into the recess during integral molding.

A cover for closing a vehicle surface opening is provided which has a frame part secured to the underside of the cover on one side at a frame part securing section by an application of plastic foam on the cover, and which contacts the underside of the cover on the other side at a free section of the frame part via at least one spacer. The frame part may also include at least one filling opening on the free section thereof for introducing a reactive plastic material forming the spacer, and the plastic material introduced through the filling opening into a gap between the free section of the frame part secured to the cover and the underside of the cover retains the free section of the frame on the underside of the cover in a positioned and/or fixed manner as a spacer after reacting or curing.

A surrogate multilayered material and manufacturing method thereof includes a first fiber reinforced layer, the first reinforced layer including a crosslinked polymer and fibers, and a second fiber reinforced layer, the second reinforced layer including the crosslinked polymer and the fibers. A foam layer is disposed between the first and second fiber reinforced layers. Opposite faces of the foam layer are in direct contact with the first fiber reinforced layer and the second fiber reinforced layer. The foam layer has a compressive strength of about 3.5 to about 4.5 MPa, when measured as per ASTM-D-1621-73, and a shear strength of 1.50 to about 2.15 MPa, when measured as per ASTM-C-273.

A method of manufacturing a cover for a spa includes the steps of vacuum molding a first shell member and a second shell member, bringing the first and second shell members into registration with one another to define a hollow cavity therebetween, and injecting a foam into the hollow cavity, wherein the foam is configured to bond with the shell members to create a unitary structural part that provides increased strength and rigidity.

An apparatus and method for manufacturing a crash pad with a foaming layer formed by injecting a foaming solution between a core and a skin are disclosed. The apparatus includes a first mold and a second mold used to form the skin by injecting molten resin of a skin material into a skin forming cavity when the first and second molds are combined. In addition, a third mold and the fourth mold form the core by injecting molten resin of a core material into a core forming cavity when the third and fourth molds are combined. The first mold has a vacuum aperture in an inner surface of the first mold to adsorb and fix a thread to implement a stitch before the forming of the skin, and the vacuum aperture exerts a vacuum suctioning force to absorb and fix via a vacuum pressure applied from a vacuum pressure providing unit.

A device for manufacturing inner trim elements which are formed by a rigid carrier and a cover layer, between which elements a polymer foam layer is arranged. The carrier is fixable on a first moulding tool element, and the cover layer is fixable between the outer edge of the first moulding tool element and the outer edge of a second moulding tool element. In the moulding tool, a cavity is formed between the carrier and the cover layer, wherein a foamable polymer is introducible into the cavity via at least one through-hole which is formed in the carrier and the first moulding tool element. The distance between the first and the second moulding tool element is enlargeable during the foaming process. At least one through-hole for an escape of air and reactively formed gases out of the cavity is formed in the carrier and in the first moulding tool element.