Methods of manufacturing of aerospace structures are disclosed. More specifically, methods of manufacturing relatively lightweight yet strong aerospace structures. In one embodiment, the method includes the addition of a volume of a rigid and flexible polyurethane mixture into a mold to create a composite structure. In one aspect, the method includes the integration of special structures within a larger structure to remove traditionally structurally weak or vulnerable areas.

The present invention is related to a foam fabric comprised of foam particles, a foaming agent, an antibacterial agent, a filler and a glue and methods of making it. The foaming agent is comprised eg of azodicarbonamide, triazinyl triazine, ethanolamine and aluminum potassium sulfate; the antibacterial agent is comprised eg of 2,4,4-trichloro-2-hydroxydiphenyl ether and ethylene oxide; the filler is chosen eg from titanium dioxide, iron oxide, mica powder and combinations thereof; and the glue is comprised of eg a rosin resin and an epoxy composite resin, wherein the epoxy composite resin is comprised of an epoxy resin, a terpene resin, aluminum oxide, polybutene and an emulsifier and a solvent.

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 450000 (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)).

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.

Methods of manufacturing wall structures having high racking strength are described in this specification. The methods include spray applying a foam-forming composition into a cavity of a wall structure, wherein the wall structure is disposed in a climate-controlled spray application station and allowing the foam-forming material to expand within at least a portion of the cavity to form a foam layer deposited in the cavity. In the methods, the foam layer is formed in-situ during the manufacturing method, and the density of the foam layer is selected and the relative humidity and dew point of the air in the climate-controlled spray application station throughout the spray applying is selected so that the wall structure has a racking strength of at least 500 pounds per linear foot.

The invention relates to a film laminate, including at least one compact decorative layer with a lacquer layer on the upper side and with a foam layer on the underside, where the density of the foam layer is more than 500 kg/m.sup.3. The invention further relates to the use of said film laminate for the coating of components for the interior trim of motor vehicles and to interior trim parts of motor vehicles provided with said film laminate. The foam layer is based on a composition which includes from 15 to 60 parts by weight of at least one thermoplastic vulcanizate, from 15 to 35 parts by weight of at least one high melt strength polyolefin, and from 30 to 60 parts by weight of at least one low density polyethylene (LDPE).

A structural panel and method of fabricating and 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 method for producing a reinforcing component from different materials, wherein, in a first step, the component is produced in a first mould by plastics injection-moulding with foaming of the plastics material used and by reducing large cross sections of the component by insert parts of the same plastics material, wherein, in a second step, at least one type of fibre is wound around the component, and wherein, in the third method step, the component as a whole is overmoulded with plastic of a second plastics material in a second mould.

A method for making a foam component is provided and includes inserting a foam material into a cavity of a mold having a top plate and a bottom plate, heating the foam material to cause the foam material to expand, and moving one of the top plate and the bottom plate relative to the other of the top plate and the bottom plate as the foam material expands and contacts the one of the top plate and the bottom plate to cause the foam material to fold over on itself within the cavity.

Methods of manufacturing wall structures having high racking strength are described in this specification. The methods include spray applying a foam-forming composition into a cavity of a wall structure, wherein the wall structure is disposed in a climate-controlled spray application station and allowing the foam-forming material to expand within at least a portion of the cavity to form a foam layer deposited in the cavity. In the methods, the foam layer is formed in-situ during the manufacturing method, and the density of the foam layer is selected and the relative humidity and dew point of the air in the climate-controlled spray application station throughout the spray applying is selected so that the wall structure has a racking strength of at least 500 pounds per linear foot.