Disclosed is a method of placing a magnetic wire such as a magnetic heating wire into a molded vehicle seat, wherein the heating element is kept closely adjacent to the inner surface of the outer seat material of the seat during the molding process through the use of magnets in the mold. In many embodiments, the outer seat material is vinyl and the magnetic wire is an iron/chromium wire.

A method for fabricating emulated wood with pores and fibers, comprising: immersing a plurality of synthetic fibers configured parallel in a plane into a resin so that the resin is coated on the surfaces of the plurality of synthetic fibers and in the gaps between the plurality of synthetic fibers; placing the plurality of synthetic fibers between two sheets, wherein the two sheets are planar sheets made from a uniform composition comprising a thermoplastic elastomer, a foaming agent, and a crosslinking agent; carrying out a heat-press process on the two sheets so that the foaming agent undergoes microcellular foaming and forms dense closed pores in the two sheets, and so that the composition on inner surfaces of the two sheets expands towards the plurality of synthetic fibers and penetrates through the gaps between the plurality of synthetic fibers; and cooling the two sheets to yield an emulated wood board.

A method of integrating a device in upholstery of a foam seat element, including the steps of: placing the device in a plastic bag or surrounding it with a plastic film; placing the assembly in an injection mold; and injecting foam to form the seat element in one piece.

A prefabricated building product structure made of sintered expanded polystyrene includes a composite assembly formed by aggregating steel to the sintered expanded polymeric mass, preferably of high density, and by embedding therein rod-like steel elements, preferably pre-assembled and forming a cage of electrowelded elements. A method of related production includes positioning the rod-like steel elements, preferably pre-assembled forming a cage of electrowelded elements, in the mold for the expansion of the polystyrene, pouring in the mold incoherent granules or pearls obtained from the polymerization of the styrene, with grain size and volume appropriate for the attainment of a high density finished product, expanding and sintering or amassing the incoherent polystyrene through contact with water vapor at a temperature higher than ninety degrees centigrade, and trapping the armor in the monolithic mass thus obtained to attain a solid geometry, according to the mold, of armored sintered expanded polystyrene.

The method of manufacturing a hybrid mattress discloses a novel molding process to embed springs into foam, comprising the following steps: (1) creating a mold board with a number of pegs positioned in a specific configuration; (2) placing springs around the pegs positioned on the mold board; (3) placing the mold board on a pouring table with the pegs and springs facing upward; (4) pouring liquid foam around the pegs onto the mold board; (5) waiting for the liquid foam to mature; and (6) removing the mold from the mature foam with now embedded springs. The result is a mattress with dual support provided from the springs and foam. Embedding the springs into foam enhances the elasticity and durability of the spring itself, thereby extending the useful life of the mattress. Embedding the springs into the foam reduces the common coiling noises that are very common in the prior art.

A method for the manufacture of an interior cladding part with a visible side and a flat heating element includes arranging of the flat heating element as foam mat in a foaming tool such that the flat heating element abuts with a first flat side, which is facing the visible side of the interior cladding part to be manufactured, against an interior surface of the foaming tool, and introducing a first foam material into the foaming tool on a second flat side, opposite the first flat side, of the flat heating element such that the flat heating element is only back-foamed on the second flat side. The first foam material connects with the carrier element and the flat heating element.

A fixing member which ensures a surface pressure during toner fixation and which can achieve both an enhanced grip force of an elastic layer and cost efficiency; and a method for producing the fixing member are provided. The fixing member, as a press roll, has the elastic layer of a foamed elastic material on the outer peripheral surface of a core body. The elastic layer is an integrally shaped product of the foamed elastic material. When the specific gravity of the foamed elastic material in axially opposite end portions (grip portions) of the elastic layer is designated as d.sub.1, the specific gravity of the foamed elastic material in a portion (free portion) of the elastic layer other than the grip portions is designated as d.sub.2, and the specific gravity d.sub.2 is 0.7 or less, the proportion of the difference between d.sub.1 and d.sub.2 to the specific gravity d.sub.2 is 10-70%.

The invention relates to a steering wheel (1), especially a leather steering wheel, comprising a steering wheel skeleton (10), a foam padding (11) surrounding the steering wheel skeleton (10) at least partially and a wrapping (12) which encompasses the foam padding (11) at least in portions, wherein adjacent longitudinal edges (13) of the wrapping (12) are covered by a profile bead (20), in particular a decorative bead (24), the profile bead (20) including at least one anchoring element (21) which is fixed directly in the foam padding (11) for fastening the wrapping (12). Moreover the invention relates to a method of manufacturing such steering wheel.

Described are systems, methods, and apparatus for replacing the corrugated containers and dunnage to facilitate packaging of items in foam containers, referred to as polymer encapsulations, that can be used to protect and contain the item during shipment. When one or more items are ordered for delivery to a destination, the item(s) is picked from inventory and a rapidly setting polymer foam is injected around the bagged item to encapsulate and protect the item. For example, at packing, rather than placing the item in a corrugated container, temporary walls may be positioned around the bagged item and a pre-polymer injected into the space between the walls that surround the item such that a polymer forms that encases the item. After the polymer sets, the walls are retracted and the item is protected by the formed polymer encapsulation and available for transport to the destination.

An encapsulated electronic assembly comprises an electronic component and a foamed thermoplastic shell disposed about the electronic component. The foamed thermoplastic shell is formed from a thermoplastic encapsulant comprising a thermoplastic resin and a filler and is foamed with a foaming agent. A method of encapsulating the electronic component to form the encapsulated electronic assembly is also provided. The method includes the steps of melting the thermoplastic encapsulant, foaming the thermoplastic encapsulant, and injection molding the foamed thermoplastic encapsulant about the electronic component to form the foamed thermoplastic shell.