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.

The invention relates to a process for producing a motor vehicle seat cushion comprising the following steps: providing a cover with an insert, the insert having a layer of coating material and a foam sublayer; placing the cover in a mold; positioning a thermoplastic film on the sublayer; injecting a foam precursor mixture to produce a block of padding. The film used is based on polyurethane with a melting point between 40 C. and 60 C. and a melt-mass flow rate greater than 15 g/10 min. The film degrades under the action of the heat released during the formation of the foam of the block to enable an overmolding of the sublayer by the block substantially without penetration of the foam of the block into the thickness of the sublayer.

A reinforced composite structure that includes multiple regions of different geometric configurations connected together by a transition region. The reinforced composite structure includes reinforcement fibers on at least a portion of the transition region.

A method of manufacturing a slim foam pad for vehicle seats, may include injecting a first foam solution into a first mold to manufacture an upper pad; inserting the manufactured upper pad into a second mold; and injecting a second foam solution to a first surface of the upper pad inserted into the second mold to manufacture a lower pad integrally coupled to the upper pad, wherein the second foam solution is foamed in a state of being in direct contact with the first surface of the upper pad, wherein no additional border separation member is provided at a border between the upper pad and the lower pad.

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.

A molded foam member manufacturing method including: a first process of placing a foam molded first portion and a rigid member in a second portion forming mold, and pressing and fixing the rigid member against the second portion forming mold; and a second process of pouring a second portion-forming synthetic resin raw material into the second portion forming mold and foam molding a second portion so as to surround at least a portion of the rigid member and to form an integral unit with the first portion.

A flat lightweight member that is favorable in appearance quality and also excellent in productivity while being excellent in mechanical property at the ends and adhesiveness between a core and a skin includes: skin layers disposed on both surfaces of the flat lightweight member; end reinforcing layers disposed to have contact with both inner surfaces of the skin layers on the both surfaces at the ends of the flat lightweight member; and a core layer disposed in the space surrounded by the skin layers and the end reinforcing layers to have contact with the inner surfaces of the skin layers.

A method of manufacturing a wrapped object, having a first segment and a second segment connected to each other by a curved transition segment having a common tangent with the first segment and a common tangent with the second segment, respectively. The method includes providing a mandrel with a surface structure to define at least part of the shape of the first segment, of the shape of the second segment and of the shape of the transition segment in between, and wrapping, one or more elongate elements over the mandrel and bonding the elongate element(s) to itself and/or each other so as to provide the first segment, the second segment and the transition segment as a continuous structure. The mandrel is provided with a fortification to support the element(s) forming the transition segment against inward-directed forces while wrapping and/or bonding the element(s) to form the transition segment.

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 foam molding article includes an outer-shell-configuring part, an insert that is at least partially embedded in the outer-shell-configuring part, and a fitting member. The outer-shell-configuring part includes a body side foam member. The body side foam member includes a foam and a missing part where a part of the foam is missing. The missing part is located in an intermediate part of the body side foam member, and the fitting member is mounted in the missing part.