A process for manufacturing a thermoset polyester foam includes the following successive steps: (a) providing an expandable and thermosetting composition containing a polyol component including at least one element selected from glycerol, diglycerol and glycerol oligomers; a polyacid component including citric acid; a surfactant selected from alkyl polyglycosides and mixtures of an anionic surfactant and a cationic surfactant, and an esterification catalyst; (b) introducing the expandable and thermosetting composition into a mold or applying the expandable composition to a support; and (c) heating the expandable and thermosetting composition at a temperature at least equal to 135 C. so as to react the polyol component with the polyacid component and form a block of thermoset polyester foam.

A resin foamed body 1 is a resin foamed body made of flexible resin, the resin foamed body entirely includes a skeleton part 2, the skeleton part includes a plurality of bone parts 2B and a plurality of connection parts 2J connecting end parts of a plurality of bone parts, and an average value AV(A0/A1) of a ratio A0/A1 of cross-sectional area A0 of a bone change part of each bone part at an edge 2B22 on a bone constant part side relative to cross-sectional area A1 of the bone change part at an edge 2B21 on the connection part side satisfies
0.15?AV(A0/A1)<0.5.

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.

A 2-step processing method to form a partly cross-linked polyurethane (PU) comprising foam having densities below 600 kg/m.sup.3, preferably in the range 20-300 kg/m.sup.3, said method comprising: A first processing which comprises at least following steps: a) providing a reactive mixture comprising an isocyanate composition comprising at least one isocyanate compound, an isocyanate-reactive composition comprising at least one isocyanate reactive compound, a crosslinking agent and a blowing agent composition comprising at least a heat activatable blowing agent which is heat activatable to achieve blowing at an activation temperature T.sub.activate, and b) allowing the reactive mixture to polymerize, optionally using a shape or mold, at a process temperature T.sub.process wherein T.sub.process<T.sub.activate and T.sub.process<T.sub.melt to form a polyurethane comprising material having a melting temperature T.sub.melt and which is solid at room temperature, and then A second processing which comprises at least following steps: c) placing the polyurethane comprising material in an autoclave, pressure vessel or pressurizable mold, d) subjecting the polyurethane comprising material to a temperature sufficient to soften the polymer material (T.sub.softening) wherein T.sub.softening?T.sub.activate in combination with an elevated pressure P.sub.1 wherein P.sub.1 is higher than atmospheric pressure (P.sub.atm), and then subsequently e) subjecting the polyurethane comprising material to a pressure reduction which is sufficient to achieve expansion (foaming) and to obtain the partly cross-linked polyurethane comprising foam

Disclosed herein are composite building materials having at least one textured surface. The textured surface includes at least a plurality of particles. The textured surface closely mimics conventional building materials. The building materials can contain an image printed using ink jet printing methods with inks optimized for enhanced color stability.

Lightweight and strong components may be manufactured using self-skinning foam material compositions by the processes described herein. One or more mandrels may be inserted into a molding tool, and a self-skinning foam material composition may be injected into the molding tool. After closing the molding tool, the self-skinning foam material composition may expand and cure to form a component, and one or more skins may be formed on exterior and/or interior surfaces of the component. For example, an external skin may be formed on an exterior surface of the component in contact with surfaces of the molding tool, and one or more internal skins may be formed on one or more interior surfaces of negative space spars of the component in contact with surfaces of the one or more mandrels.

Lightweight and strong components may be manufactured using foam material compositions and resin coating materials by the processes described herein. One or more mandrels and/or a molding tool may be coated with resin coatings, the one or more mandrels may be inserted into the molding tool, and a foam material composition may be injected into the molding tool. After closing the molding tool, the foam material composition may expand and cure to form a component, and heat may be applied to cure the resin coatings into skins. For example, an external skin may be formed by the resin coatings on an exterior surface of the component in contact with surfaces of the molding tool, and one or more internal skins may be formed by the resin coatings on one or more interior surfaces of negative space spars of the component in contact with surfaces of the one or more mandrels.

A method of manufacturing a protection film includes performing a first foaming of a first part of a base material on a substrate to form a bumper layer having first bubbles foamed with a first foaming ratio, and performing a second foaming of a second part of the base material to form a light blocking layer having second bubbles foamed with a second foaming ratio.

In order to provide a structural component (100) for a vehicle (102), in particular a bulkhead (104) for a road vehicle, for example for a passenger car (106), which can be produced simply and cost-effectively and preferably simultaneously meets requirements relating to weight reduction and structural integrity, according to the invention the structural component (100), in particular the bulkhead (104), comprises the following: a main body (108), which comprises one or more foamed portions (124) and one or more compact portions (130), the structural component (100) preferably also comprising one or more cover elements (126) which cover the main body (108) in one or more foamed portions (124) and/or in one or more compact portions (130).

Components for articles of footwear and athletic equipment including a foam are provided. The foam portion of the components and articles include a composition which includes a thermoplastic copolyester, the composition having a foam structure. A polymer layer is provided on at least on surface of the foam portion. The polymer layer can control or reduce the water uptake of the foam portion. Methods of making the compositions, foams, and components are provided, as well as methods of making an article of footwear including one of the foam components. In some aspects, the foams and foam components can be made by injection molding, or injection molding followed by compression molding.