The invention relates to a method of making a thin construction element (10) in sandwich lightweight construction having a high-quality surface (26). Including the steps of deep drawing a substrate film, placing the deep-drawn film into a cavity of a die, introducing partially expanded particles onto the substrate, heating to completely expanded the particle foam, curing the expanded particle foam, and opening the die to remove the molded article.

A motor vehicle roof shell having a rigid composite component having an inner side facing a vehicle interior, and an acoustic insulation layer disposed on the inner side of the composite component. The panel-type rigid composite component has at least one tray-like recess on its inner side, said recess being filled with an open-pored foam material which forms the acoustic insulation layer and whose surface is flush with a surface of the composite component surrounding the recess. A motor vehicle roof shell motor vehicle having a panel-type rigid composite component having an inner side, which faces the vehicle interior, and an acoustic insulation layer disposed on the inner side of the composite component, wherein the acoustic insulation layer is formed by at least one rigid-foam or semi-rigid-foam plate which is bonded to the inner side of the composite component and compressed that its volume is reduced compared to preassembly state.

A decorative film structure includes a foamed resin layer and a protective resin layer. The protective resin layer is disposed on the foamed resin layer and has a stereoscopic patterned surface relatively far from the foamed resin layer. A manufacturing method of the decorative film structure is also provided.

A water resistant expansion joint system includes foam, which has been formed into a desired shape by at least one of stamping, cutting, molding and die-cutting; and a layer of an elastomer disposed on the foam. The layer of the elastomer facilitates compression of the water resistant expansion joint system when installed between substrates. The desired shape of the foam includes an angle, and the water resistant expansion joint system is angled around a corner and accommodates thermal and seismic movement in the system by expanding and contracting, and creates a waterproof seal around the corner upon expansion of the foam between the substrates.

A helmet and method for forming a helmet having a multi-density impact liner may include forming a puck with an interface surface and at least one side. The interface surface of the puck is placed in direct contact with a receiving surface of a cap located in an impact liner mold. Next, the interface surface of the puck is thermally fused directly to the receiving surface of the cap while contemporaneously an impact liner body is formed inside the mold. The impact liner body is fused to the at least one side of the puck, and to a majority of the receiving surface of the cap. The density of the puck may be greater than the density of the impact liner body. The puck and the impact liner body may be EPS, and the cap may be PC.

A film of plastic material for wrapping, obtained by cast co-extrusion in three layers, wherein an inner layer consists of elastomer-based propylene, containing ethylene, and metallocene polyethylene, while a central layer and an outer layer consist of metallocene polyethylene with different melt flow indexes, that of the metallocene polyethylene of the central layer being the lower one.

An eco-friendly buoy includes a foam including a cylindrical accommodation space in the interior of the foam, and coupling grooves at predetermined intervals at an outer surface circumference of the foam in order to fasten the foam to fixing members through wire; and a protective layer formed on an entire outer surface of the foam and protecting the foam from damage by waves or wind. The eco-friendly buoy is manufactured from eco-friendly expanded polypropylene and expanded styrene and has a protective layer on an outer surface thereof, thereby being protected from damage by waves or wind. In addition, the eco-friendly buoy may be used for a long time, thus reducing maintenance costs.

The present invention discloses a closed cell foam made of cross linked polyethylene and also discloses a method to produce the foam. The foam has an enhanced property of providing better thermal insulation and the same is achieved by incorporation of air gaps in the polyethylene foam.

The present invention provides a self-collapsing, moisture curable one component polyurethane foam (1K PU) composition from moisture curable polyurethane prepolymers and to methods of making weather resistant barriers and formed in place gaskets therefrom. The foam compositions are packed under pressure with a blowing agent. In the methods, the foams are applied to gaps in the exterior (sheathing) of a building under construction and collapse on cure to enable application an aqueous weather barrier coating thereover within an hour. The foams also cure when applied on or adjacent a structure to form a foam gasket that enables installation of additional structural elements over or adjacent the foam gasket without bowing or damage to the structure treated.

A weather seal includes an elongated micro-cellular foam bulb, and an elongated micro-cellular foam fin element attached to an extending along the length of the foam bulb. The fin elements includes a spine having opposed planar surfaces and at least one microcellular foam barb extending outwardly and at a downward angle from each surface and along the length of the spine. As an alternative to barbs, another option is to use a higher durometer foamed thermoplastic elastomer in a hollow circle shape that would push into a retention pocket. A t-slot version that has a foamed bulb and a polypropylene base is another option.