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.

A method for producing an automotive equipment part includes the following steps: arranging a porous layer in a foaming mold; injection, on one side of the porous layer, of a foam precursor; expansion of the precursor material to form a foam base layer bonded to the porous layer; and extraction from the mold of the equipment part including the porous layer and the foam base layer bonded to the porous layer. The method further includes a step for injecting a pressurized fluid on a second side of the porous layer to form a counter-pressure to the expansion of the precursor material.

A molded foam member manufacturing method including: a first process of placing a foam molded first portion (11) (first molded body) and a rigid member (3) (rigid plate) in a second portion forming mold (20) (forming mold); and a second process of pouring a second portion-forming synthetic resin raw material (U) (foamable material) into the second portion forming mold (20) (forming mold) and foam molding a second portion (12) (second molded body) so as to surround a portion of the rigid member (3) (rigid plate) and form an integral unit with the first portion (11) (first molded body).

The invention relates to a panel with a porous shell and a spring layer, part of which enters the shell and produces an integrated sealed barrier. The foam of the shell is an integral skinned foam and the shell has a core with a substantially homogenous density and a porous skin. The overall density of the shell is between 150 and 350 kg/m3. The skin thickness is between 0.3 and 2 mm and has a permeability such that a 2 mm thick foam strip cut into the shell and integrating the skin exhibits air flow resistance of between 250 and 2000 N.s.m−3.

A process for manufacturing products made of foamed polymeric material, comprising the following steps: generating, via software, a virtual model (M) of a product to be manufactured in a solid foamable polymeric material; performing a topological optimization via software of the virtual model (M) in order to obtain an optimized virtual model (MO) with areas of differentiated relative density; preparing the foamable polymeric material and inserting it in a mold (1); solubilizing, under pressure, at least one foaming agent in the foamable polymeric material placed in the mold (1) with a pressure profile of the foaming agent variable over time and/or space as a function of the topological optimization; releasing the pressure in order to obtain a product (S) made of foamed polymeric material provided with the above-mentioned areas of differentiated relative density; removing the product (S) made of foamed polymeric material from the mold (1).

A method of manufacturing a hybrid insulating panel includes providing a mold of a frame, dispensing a first foam material in a liquid phase in the mold, and placing a beam in the mold. The method includes curing the first foam material to form an integrated frame, in which the integrated frame includes the beam at least partially surrounded by the first foam. Further, the method includes dispensing a second foam material into a panel cavity to form a panel body. The panel cavity is at least partially defined by a side of the integrated frame. The method includes curing the second foam material to form a panel body, wherein the panel body is secured to the integrated frame.

The invention relates to a method for creating a motor vehicle seat cushion. The inventive method provides for a cover having a format of a complex comprising a layer of covering material and a sublayer of elastically compressible foam, and for arranging on the sublayer a film based on thermoplastic polyurethane. The film has a melting point and a melt mass-flow index that breaks down under the action of the heat released during the formation of the foam. The film is provided with a reinforcing thin-film to form a two-layer barrier against the penetration of foam. The reinforcing thin-film is based on a thermoplastic polyurethane with a melting point higher than that of the film and has a melt mass-flow index lower than that of the film, to have greater strength than the film so that the reinforcing thin-film breakdown under the action of heat is delayed.

A composite structural panel for use in bridge structures, and method of manufacturing same, comprises a top panel and a bottom panel separated by and attached to at least one, but preferably a plurality, of structural composite preforms which may be fabricated by a continuous manufacturing process and may be saturated by resin using a continuous wetting process. The composite preforms may take any cross-sectional shape but are preferably trapezoidal. The top and bottom panels may be fabricated from a plurality of layers of woven fabric layers and non-woven fabric layers which are saturated with a resin that is subsequently cured using cure processes known in the art. The composite structural panel of the invention is usable as a flat structural member for use as bridge decking, ramps, trestles, and any application requiring a structural panel.

The invention relates to a method for creating a motor vehicle seat cushion. The inventive method provides for a cover having a format of a complex comprising a layer of covering material and a sublayer of elastically compressible foam, and for arranging on the sublayer a film based on thermoplastic polyurethane. The film has a melting point and a melt mass-flow index that breaks down under the action of the heat released during the formation of the foam. The film is provided with a reinforcing thin-film to form a two-layer barrier against the penetration of foam. The reinforcing thin-film is based on a thermoplastic polyurethane with a melting point higher than that of the film and has a melt mass-flow index lower than that of the film, to have greater strength than the film so that the reinforcing thin-film breakdown under the action of heat is delayed.

A method for manufacturing a foam mat having a printed layer on its surface includes the steps of: stacking a plurality of foam sheets in a foaming mold; forming a printed layer by printing a layer of ink on a top surface of an uppermost one of the foam sheets or a bottom surface of a lowermost one of the foam sheets or both; and heating the mold for foaming the foam sheets at a same foaming rate of 2 to 3.5 times. The ink of the printed layer does not fall off. The printed layer can beautify the surface of the foam mat and prevent dust and dirt from accumulating on the surface of the foam mat.