The present invention is directed to a process for making combustible foam celluloid munition parts having high aspect ratios, different densities or having an insert embedded into the foam celluloid munition part. The process for making such foam celluloid munition part requires pre-soaking dry particles of celluloid, placing the celluloid particles into a munition part mold, exposing the celluloid particles to high heat and pressure until the celluloid particles expand and fuse into the shape of the mold. Varying the density or the size of the celluloid particles used in the process produces munition parts having different densities. In addition, the placement of inserts into the particles prior to exposure to high heat and pressure produces munition parts having inserts that are useful for identification and tracking of such parts.

An environmentally friendly shoe material and method of manufacturing the same is disclosed, wherein the method includes: mixing scraps and a foaming material to provide a shoe material mixture, the scraps including bottle scraps formed by crushing plastic bottles; putting the shoe material mixture into a mold and compression molding the shoe material mixture into the environmentally friendly shoe material; and separating the environmentally friendly shoe material from the mold. In this way, the environmentally friendly shoe material may not only maintain its due function, but also take environmental protection into account.

A method of making personal protective equipment, such as a push-in earplug, is disclosed. The method includes the steps of covering a substrate with an outer layer that includes an unactivated foaming agent, positioning at least a portion of the outer layer in a mold, and activating the foaming agent such that a portion of the outer layer expands.

A package delivery apparatus uses an unmanned aerial vehicle (UAV) to deliver a package containing a product to a delivery destination area. The UAV uses GPS signals to guide it to the delivery destination area and an altimeter to determine its height above the delivery destination area. The UAV then adjusts its height to a preferred drop or release height for that package and product and releases the package. An optional camera allows a human operator to view the delivery destination area. An expandable foam package surrounds the product to protect the product from impact and moisture. The package may be streamlined to reduce air resistance and increase the range of the UAV. The package characteristics, such as its thickness, are determined based one or more of the weight and fragile nature of the product, and the drop height.

A process and assembly for producing a structural article, as well as an article produced according to any process and assembly. A mold has a base and a hinged lid, either or both of which include a cavity interior which defines a negative of the structural article to be produced. A structural insert placed within the mold, prior or subsequent to a plasticized and structural forming foam material also being placed within the mold. The foam cures and sets in encapsulating fashion around the insert so that, upon removal, the insert is coated within the formed material.

A method and apparatus includes a substrate, a foam that is applied to the substrate to form a least a portion of an interior trim part, at least one holder fixed to the substrate, and at least one reinforcement member supported by the at least one holder such that, when the foam is applied, the at least one reinforcement member is suspended within the foam.

A customizable knee pad includes a foam main body having an anterior surface A and a posterior surface molded to the shape of the knee. The anterior surface is formed with an array of spaced recesses covering the knee to be protected. Each recess defines a negative incremental area and, cumulatively, define an area A.sub.r. The effective area A.sub.eff of the anterior surface is equal to A.sub.eff=AA.sub.r. A fabric sheet covers the posterior surface. A gel pad is provided within the main body in close proximity to the fabric sheet. The main body of the knee pad is injection molded with the gel pad and fabric sheet in place to bond the fabric sheet and gel pad to the molded main body to be effectively integrated therewith. Changing the recesses' shape and spacing alters the flexibility of the knee pad and renders it harder or softer.

A door panel manufacturing process is provided by constructing a high load conveyor line capable of controlling speed and duration, subsequently placing a finished door panel mold on the high load conveyor line. The conveyor line can be used to control a shifting speed and duration, and a de-molding agent can be sprayed inside the door panel mold, followed by spraying a high-density foam resin to form a shell. The door panel mold further has a framework or a reinforcement member mounted therein, and a low-density foam resin is injected; after the foam resin is formed and cooled, the door panel made of foam resin is completed. The process solve issues of high defective rate and insufficient surface strength associated with the conventional foam door panel, and is capable of significantly reducing the electricity required as well as reducing logging of woods, thereby realizing environmental protection.

The invention relates to a process for producing complex, mould-foamed rigid foam materials, more particularly of poly(meth)acrylimide (P(M)I) cores, preferably of polymethacrylimide (PMI) cores, which may be employed, for example, in carmaking or aircraft construction. A feature of the process is that through use of a particulate core during foam, it is possible to achieve an additional weight saving relative to foam materials or sandwich materials of the prior art.

A pressure sensing system (24), seat cushion (20) incorporating the pressure sensing system, and method of sensing a weight group associated with an occupant of an automotive seat are described. The pressure sensing system includes a layer of an electrically conductive foam (28) and a flexible printed circuit (26) that includes a flexible substrate (26a) and N horizontal sensing wires (26b) and M vertical sensing wires (26c) securely placed on a top surface of the flexible substrate. The horizontal sensing wires intersect with the vertical sensing wires and form NM intersections. The layer of an electrically conductive foam is placed on top of the N horizontal sensing wires and the M vertical sensing wires. When a pressure is applied to the layer of the electrically conductive foam, each intersection generates in real time an electric flux density value to reflect a degree of a compression caused by the pressure to a corresponding point of the electrically conductive foam.