The present invention is related to a foam fabric and method of making it.

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 present invention provides means for improving bondability between a vehicle seat core and a cushion in a vehicle seat pad formed by integration of them without significantly impairing mechanical properties. A vehicle seat core is characterized in that it is a vehicle seat core for forming a vehicle seat pad by integration with a cushion, which comprises a foamed resin molded body obtained by filling a cavity of a mold with a plurality of foamed resin particles and performing in-mold foam molding, and that at least a partial region of a surface of the foamed resin molded body to which the cushion is bonded when forming the vehicle seat pad has a surface expansion rate of 40% to 85%, and the foamed resin molded body has a first fusion rate of 95% or more or a second fusion rate of 60% or more.

A method for manufacturing a foam molded body which can allow the foam resin sheet to follow the shape of the cavity of the mold with high accuracy even when the thickness of the foam resin sheet is thick. The method includes an arranging step to arrange one sheet of a foam resin sheet between first and second molds, the foam resin sheet being formed by extruding and dangling a molten foam resin from a slit; and an expanding step to expand the foam resin sheet by subjecting the foam resin sheet to a reduced pressure suction.

Low-density thermoplastic expandable microspheres are disclosed. Various low-density structures, in particular, sandwich panels, based on foam prepared from the low-density microspheres, are also disclosed. Process of preparing low-density polymeric microspheres, per se, and the corresponding low-density structures, based on the microsphere foam, are also disclosed.

A composite structure includes a foam core formed from a first polymer and between about 0.5 wt. % and about 2.5 wt. % graphene. The foam core has an average pore size between about 25 m and about 75 m, and a cell density between about 410.sup.6 cells/mm.sup.2 and about 610.sup.6 cells/mm.sup.2. Also, an overmolded skin formed from a second polymer and between about 0.25 wt. % and about 5.0 wt. % graphene is disposed on the foam core. A method of manufacturing a composite structure includes injection molding a foam core from a first polymer containing between about 0.25 wt. % and about 5.0 wt. % graphene, and injection molding an overmolded skin from a second polymer containing graphene between about 0.25 wt. % and about 5.0 wt. % graphene.

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.

A process for the production of composite materials at low temperatures, as well as a composite material obtained by the process and articles of manufacture comprising the composite material are provided.

This disclosure provides an article having a density of from 0.03 to 0.45 g/cc and including a plurality of anisotropic tubular particles that are randomly oriented in the article. The tubular particles include a thermoplastic elastomer foam and a polymer disposed on an exterior surface of the thermoplastic elastomer foam as an outermost layer of the particles. Each of the thermoplastic elastomer foam and the polymer independently has a softening temperature determined according to DIN ISO306. The softening temperature of the polymer is at least 5 C. lower than the softening temperature of the thermoplastic elastomer foam.

Low-density thermoplastic expandable microspheres are disclosed. Various low-density structures, in particular, sandwich panels, based on foam prepared from the low-density microspheres, are also disclosed. Process of preparing low-density polymeric microspheres, per se, and the corresponding low-density structures, based on the microsphere foam, are also disclosed.