A process for making a three dimensional foam article of non-uniform shape employs a two-stage nitrogen autoclave process and a pre-form which has a non-uniform cross-section in at least one dimension.

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.

An article has a density of from 0.03 to 0.45 g/cc. The article includes a plurality of anisotropic tubular particles that are randomly oriented in the article. The tubular particles include a thermoplastic elastomer foam and a non-foamed polymer disposed on an exterior surface of the thermoplastic elastomer foam as an outermost layer of the tubular particles. Each of the thermoplastic elastomer foam and the non-foamed polymer independently has a softening temperature determined according to DIN ISO 306. Moreover, the non-foamed polymer includes an additive that is responsive to non-heat energy to selectively heat the non-foamed polymer to its softening temperature prior to the thermoplastic elastomer foam reaching its softening temperature.

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.

Multi-step method for producing a soundproof composite cover for internal combustion engines and product thus obtained, producing a cover made of thermoplastic material and insulating foam. The method uses a multiple mold with first and second cells, having male and female elements, the cells taking a first closed configuration and a second open configuration; the method including: closing the multiple mold and injecting the thermoplastic material through a channel from a hot chamber to the first cell; the thermoplastic material solidifies and the multiple mold is opened to move the solidified thermoplastic material from the first cell to the second cell; closing the multiple mold and, while a new injection occurs in the first cell, an insulating foam is injected into the second cell; and opening the double mold and, while the finished product is extracted from the second cell, a new transfer occurs from the first cell.

Among other things, the invention relates to a method of making a thin construction element (10) in sandwich lightweight construction having a high-quality surface (26).

A cavity-containing polyester film is disclosed, including a layer (layer A) which has therein cavities, and layers (layers B) which each include a polyester resin containing inorganic particles and which are laminated, respectively, over both surfaces of the layer A. The layer A includes a composition including a polyester resin and a polypropylene resin. The polypropylene resin satisfies requirements of: (1) the melt flow rate (MFR) ranges from 1.0 to 10 g/10-minutes (at a temperature of 230 C. under a load of 2.16 kg); (2) the deflection temperature is 85 C. or higher under load (at a bending stress of 0.45 MPa); and (3) the weight-average molecular weight Mw ranges from 200,000 to 450,000 (measured by gel permeation chromatography (GPC)); and the molecular weight distribution ranges from 2 to 6 (being represented as the ratio of the weight-average molecular weight Mw to the number-average molecular weight Mn of the polypropylene resin (Mw/Mn)).

The present invention provides a method for manufacturing a foam molded body, including: a setting step of inputting a foam matrix material into a mold that is not affected by microwaves, wherein the foam matrix material includes a plurality of half-foamed granules of thermoplastic polyurethanes (TPU) and at least an embedded component, and the embedded component is of a material or its product that is not affected by microwaves; and a foaming step of heating the mold by microwaves, wherein the half-foamed granules in the mold are affected by microwaves such that the temperature thereof are raised to effect foaming and the granules are squeezed with each other, and the embedded component is therefore squeezed and fixed, so as to form a foam molded body embedded with an embedded component after cooling and demolding.

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.

The present invention is directed to a device for at least partially covering a vehicle floor pan of a motor vehicle, comprises a carrier element made at least by a hard foam material, a vibration decoupling element made at least by a soft foam material, a surface layer to visually cover the device from the top, wherein the device has a shield element, which is made at least by a plastic material and is configured for accepting, absorbing and distributing the energy of a localized impact stress, which is applied on the device from above against the shield element. The present invention is also directed to a method for producing the device.