A method for manufacturing three-dimensional items with flexible walls is provided, by method of a mold and counter mold between which a volume corresponding to that of the item to be obtained is delimited. The item is made up of laminar parts which are mounted on a template that is fixed to the inner surface of the mold. The laminar parts are joined to one another by means of a material which is injected in molten state through a network of conduits delimited between the counter mold, template and the facing edges of adjacent laminar parts. The template is made of an elastically deformable material and has a three-dimensional configuration.

The invention relates to a method for producing a support element for a means of transport, wherein the method comprises: providing a polypropylene/natural fiber mat (106), wherein the mat (106) has a basis weight of less than 1150 g/m.sup.2, wherein the polypropylene/natural fiber mat (106) comprises a first type of natural fibers, preheating the mat (106), placing the mat (106) in a mold (100), wherein the mold (100) has a rib-shaped cavity (112), pressing the mat (106) into a predefined form by the mold (100), so that the thickness of the mat (106) after the pressing is less than 1.5 mmimmediately and directly after the pressing, insert molding the mat (106) by injecting a polypropylene-containing material into the rib-shaped cavity, wherein the insert molding has the effect that the material forms stiffening ribs (200) that are integrally bonded with the mat (106), demolding the mat (106) comprising the stiffening ribs (200).

A method for forming a skin-foam architecture for a seat. The method includes loading a backing cover into a first portion of the tool. The method includes applying and curing a skin on a second portion of the tool, the skin including a first layer, and a second layer under the first layer. The method includes laminating a mesh under the skin. The method includes attaching and curing a foam layer under the mesh and the skin. The method includes mating the first and second portions of the tool. The method includes introducing foam between the mated first and second portions of the tool.

A method for producing a skin-covered foamed molded article including blow-molding a parison in a mold cavity to form a skin consisting of a hollow molded body, in which the parison is in a softened state by extruding a molten thermoplastic resin, filling expanded beads in the hollow molded body, and heating and fusion bonding the beads by supplying steam via a steam supply pipe inserted into the hollow molded body. The parison is in contact with a protruding portion, formed by protrusion from an inner surface of the mold cavity to an inside of the cavity, forming a recessed portion having a shape corresponding to the protruding portion in the inward direction of the hollow molded body. A steam hole is formed in the recessed portion, a steam supply pipe is inserted into the body, and the expanded beads are heated and fusion bonded by supplying steam.

The present disclosure provides a VR face mask and a manufacturing method thereof. The VR face mask includes a mask body, and a first PU covering layer arranged on a surface of the mask body to be attached close to a human face. The mask body includes a mask bottom layer arranged away from the first PU covering layer, and a filling layer arranged between the first PU covering layer and the mask bottom layer.

A method for manufacturing a seat cushion material, the seat cushion material including a front layer part and a back layer part having a back side surface, the method including: preparing for molding the seat cushion by attaching the back layer part to an upper die having an upper cavity surface; molding the seat cushion material by adding foamed resin raw material forming on a lower cavity surface of a lower die and then by closing the upper die to which the back layer part is attached, the lower cavity surface being provided with a plurality of protrusions which is configured to be brought into contact with a seating surface side of the back layer part and press the back layer part against the upper cavity surface when the upper die to which the back layer part is attached is closed; and demolding the molded seat cushion material.

A multifunctional fully integral panel system design, a unique material configuration, and a process for fabricating a net shape (or nearly net shape) panel in one production cycle. The panel may comprise a base facing with an outer perimeter, a decorative film applied to the exterior of the base facing, an aft facing having an outer perimeter fused to the base facing, and a reinforcement core disposed between the unfused portions of the base and aft facings, which reinforcement core also acts as acoustic insulation (i.e., a noise attenuator). Alternatively or additionally, a foam core or blanket having thermal and/or acoustic insulation properties is attached to the external surface of the aft facing. The fabrication process involves the application of different heat treatments to panel components having different forming temperature or rubbery/elastic plateaus.

The present invention is directed to a foam-injected slat and a method of manufacturing thereof used in building fencing, privacy screens, pergolas, louvers, wall claddings, and other similar types of structures. Use of foam-injected slats in the aforementioned structures provides noise reduction, heat insulation, and vibration absorption. In addition, they are lightweight, strong, durable in heavy weather conditions, environmentally friendly, easy to install, and cost effective. Lastly, the manufacturing process enables the forming of a special locking mechanism that further strengthens the foam-injected slats.

A composite foam cushion for a sound control device. The cushion includes a core formed of a polymeric foam material and a polymeric coating overlying at least a portion of the core of polymeric foam material. The polymeric coating includes an outer coating layer and an inner polymeric coating layer bonded to the core of polymeric foam material. The inner coating layer may provide the cushion with strength, while providing a high degree of flexibility and suppleness to closely conform around contours and obstructions. The outer coating layer may provide the cushion with enhanced abrasion resistance and/or chemical resistance while having an aesthetically pleasing feel and appearance.

An apparatus includes a first mold having an injection cavity at a side thereof, for molding of a substrate, a second mold having two injection cores and two skin shaping plugs, and a third mold having a foaming section where a foaming material is injected between a substrate and a skin, and a skin shaping section where embossing is carried out on a skin, wherein, under the condition that the first mold, second mold and third mold are simultaneously closed to one another, a substrate is molded by the injection cavity and a first injection core, embossing is carried out on a skin by one skin shaping plug and the skin shaping section, and, at a same time, the foaming material is injected between a previously molded substrate and a previously embossed skin by a second injection core and foaming section.