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 method for forming a building includes obtaining a mould, spraying a first spray material onto the outside of the mould so that it sets generally in the shape of the mould to provide a core. The core has side walls, and end wall integral with the side walls and a roof integral with both the side walls and end wall. A second spray material different to the first spray material is sprayed onto the inner and outer surfaces of the core to give it a rigid skin.

A method for dielectrically heating foamable composition to foam and set the composition is described. In particular, radio frequency (RF) heating is used to heat the foamable composition to provide insulation in the manufacture of an article.

A method of manufacturing building panels includes assembling a frame of a building panel. The frame defines at least one cavity and at least one injection aperture in fluid communication with the at least one cavity. The method also includes positioning the frame on one of a base and a shelf of a multi-panel consolidation device having a plurality of shelves, with the shelves being in an expanded configuration, and at least substantially enclosing the at least one cavity. The method also includes forcing the shelves of the multi-panel consolidation device into a collapsed configuration, and injecting an expandable polymer through the at least one injection aperture into the at least one cavity. The method further includes forcing the shelves into an expanded configuration after a predetermined period of time selected to permit the expandable polymer to form a foam bonded to the frame.

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 ad heating to foam and cure the epoxy materials. Alternatively they may be formed by extrusion of the foamable material between the surface layers.

A vehicle interior panel includes a seal between a substrate and an airbag chute and around an opening in the substrate through which the airbag chute is installed. The seal prevents a foam layer from extending into the opening when the foam layer is being molded. The seal is attached to the airbag chute prior to assembly with the substrate and is made from a material that is more flexible than the airbag chute material. The seal can be attached to the airbag chute in a two-shot molding process and spaced from the perimeter of the airbag chute along its back side. During molding of the foam layer, foam expansion pressure acts to improve the function of the seal as a foam barrier.

A molding tool and method for producing an interior trim part. A cavity is embodied between a first element and a second element, and a slide is displaceably connected to the first element. A decorative layer is arranged on the first element and a backing is arranged on the second element. A foamable mixture is added to the hollow area between the backing and a reverse side of the decorative layer, such that a foam layer fills the hollow area. A distance between the first element and the second element is increased to enlarge the hollow area. During this process, the slide is pressed against a side facing away from the reverse side of the decorative layer, such that the hollow area is sealed with the reverse side of the decorative layer pressed against a lateral surface of the backing and/or against a lateral surface of the second element.

A vehicle seat includes a headrest, a seat back to which the headrest is attached, and a seat cushion connected to the seat back. The headrest includes pillar frames attached to the seat back, a core member that includes a pouring passage penetrating from one end to the other end, a cover that covers the core member and a part of the pillar frames, and a cushion member that is formed in a gap between the outer surface of the core member and the inner surface of the cover and inside the pouring passage. The pouring passage extends in a first direction from the one end of the core member to reach a predetermined position, extends in a second direction from the predetermined position to reach the other end, and includes a bent part at the predetermined position.

The present disclosure provides a foam molded product and a manufacturing method. The foam molded product is includes a foam body, an insert material having a display unit or a detection unit attached to the foam body, and a surface material affixed to a surface to which at least the insert material is attached. A manufacturing method includes: preparing a pair of molds including a first mold and a second mold; affixing an insert material and a surface material together such that the surface material is in contact with a molding surface of the first mold; closing the pair of molds; injecting a foam resin into a molding space formed by closing the molds; foaming the foam resin to form a foam body; opening the pair of molds; and removing a molded product in which the affixed part and the foam body are integrated.

There is provided a skin foam-in-place foamed article comprising a pad (15) and a bag-like outer material (20) covering the pad (15). The outer material (20) has a top layer (21) and a liner layer (22) made of a foamed resin. The liner layer (22) has a closed cell structure. A pad-side skin layer (27a) having a density higher than that of a bulk layer (26) is provided on the liner layer (22), on a side of the pad (15). A corona treatment is applied to the pad-side skin layer (27a).