This system and method provide for manufacturing a multi-material hybrid structure comprising a single- or multi-layer sheet or tube, which are made of metals, fabrics, polymer and their combinations, and at least one layer or body made of formed resin. The methods include a simultaneous forming-injection process that followed with an additional sequence to initiate the forming process along with curing and/or solidification and/or bonding processes. The additional sequence provides a pressure drop inside the cavity using tool movement and or additional deformation of one/or several layers of the sheet using any fluid pressure, suction and/or electromagnetic force. The injection process can be used for any kind of synthetic or bio-based resin with or without fiber reinforcement. It is also integrated with supercritical assisted technology.

The inventive fiber manufacturing process is particularly adapted for demanding applications such as sports racquets, including tennis racquets, badminton racquets and other sports applications. Because of the improved strength to weight ratio of components formed using the inventive method, a wide range of flexibility is achieved, allowing use of the inventive process to manufacture, for example, a fiber reinforced (for example, graphite) modular sports racquet, optionally provided with user-selectable weights and/or handle replacements. From the standpoint of the player, this allows a racquet frame featuring self customization. From the standpoint of a retailer, the benefit provided is reduction of inventory. The inventive fiber, for example graphite fiber) racquet frame is filled with a plastic foam and is formed using, for example, microencapsulation technology to time, generate and apply the pressure used to form the graphite composite material of which the racquet is comprised. Advantageously, inner and outer tubular members may be used to form the racquet frame, with the inner tubular member extending around the head of the racquet frame. This compares to the standard industry technique of air injection. The racquet is thus not hollow like conventional graphite racquets, and the walls therefore can be made thinner than those of existing graphite racquets still being of the same strength or being stronger, which gives the racquet exceptional performance. In addition, the overall dimensions of, for example the cross-section, of the racquet can also be reduced while still maintaining performance characteristics.

The inventive fiber manufacturing process is particularly adapted for demanding applications such as sports racquets, including tennis racquets, badminton racquets and other sports applications. Because of the improved strength to weight ratio of components formed using the inventive method, a wide range of flexibility is achieved, allowing use of the inventive process to manufacture, for example, a fiber reinforced (for example, graphite) modular sports racquet, optionally provided with user-selectable weights and/or handle replacements. From the standpoint of the player, this allows a racquet frame featuring self customization. From the standpoint of a retailer, the benefit provided is reduction of inventory. The inventive fiber, for example graphite fiber) racquet frame is filled with a plastic foam and is formed using, for example, microencapsulation technology to time, generate and apply the pressure used to form the graphite composite material of which the racquet is comprised. Advantageously, inner and outer tubular members may be used to form the racquet frame, with the inner tubular member extending around the head of the racquet frame. This compares to the standard industry technique of air injection. The racquet is thus not hollow like conventional graphite racquets, and the walls therefore can be made thinner than those of existing graphite racquets still being of the same strength or being stronger, which gives the racquet exceptional performance. In addition, the overall dimensions of, for example the cross-section, of the racquet can also be reduced while still maintaining performance characteristics.

A vehicle interior board which is thin, lightweight, has high strength, has less degradation, peeling and the like near an end portion of a metal plate, and has high quality and excellent productivity; and a method for manufacturing the same. The vehicle interior board includes a pair of metal plates and a foamed polyurethane layer formed between the pair of metal plates. A projecting ridge projecting outwardly and extending in a predetermined direction along the outer surface is formed on an outer surface of the metal plate. Thus, it is possible to obtain desired strength and rigidity even when the metal plates or the foamed polyurethane layer are thinned or when a lightweight aluminum plate or the like is adopted as the metal plates. Therefore, it is possible to reduce weight of a vehicle interior board.

A vehicle interior board which is thin, lightweight, has high strength, has less degradation, peeling and the like near an end portion of a metal plate, and has high quality and excellent productivity; and a method for manufacturing the same. The vehicle interior board includes a pair of metal plates and a foamed polyurethane layer formed between the pair of metal plates. A projecting ridge projecting outwardly and extending in a predetermined direction along the outer surface is formed on an outer surface of the metal plate. Thus, it is possible to obtain desired strength and rigidity even when the metal plates or the foamed polyurethane layer are thinned or when a lightweight aluminum plate or the like is adopted as the metal plates. Therefore, it is possible to reduce weight of a vehicle interior board.

Manufacturing systems for expandable components may include a controller, a heat and/or pressure source, and a transfer line. For example, the expandable components may be configured to transform from a compressed configuration to an expanded configuration upon application of heat and/or pressure. In addition, the controller may activate the heat and/or pressure source to release heat and/or gases that are directed to the expandable components via the transfer line. Further, the manufacturing system may also include an igniter, a manifold, and a valve to further control the release of heat and/or gases. Moreover, at least a portion of the heat and/or gases may be recaptured in a closed chamber and redirected to additional expandable components in other closed chambers. Furthermore, various post-processing may be performed on the components in their expanded configurations.

Fabrication system and associated methods of fabricating a sandwich panel. In one embodiment, a method includes holding a first skin and a second skin of the sandwich panel with a gap between opposing faces of the first skin and the second skin, and expanding a foamable material between the first skin and the second skin to form a foam core of the sandwich panel.

This system and method provide for manufacturing a multi-material hybrid structure comprising a single- or multi-layer sheet or tube, which are made of metals, fabrics, polymer and their combinations, and at least one layer or body made of formed resin. The methods include a simultaneous forming-injection process that followed with an additional sequence to initiate the forming process along with curing and/or solidification and/or bonding processes. The additional sequence provides a pressure drop inside the cavity using tool movement and or additional deformation of one/or several layers of the sheet using any fluid pressure, suction and/or electromagnetic force. The injection process can be used for any kind of synthetic or bio-based resin with or without fiber reinforcement. It is also integrated with supercritical assisted technology.

An upper shell panel may be placed between first and second sections of a mold. The first section may include one or more expansion cavities and the second section may include one or more pour cavities. A foam-producing chemical mixture may be delivered into the one or more pour cavities and the mold may be closed. The delivered foam-producing chemical mixture may be allowed to expand within the closed mold and to force regions of the upper shell panel into the one or more expansion cavities. The upper shell panel may then be removed from the mold subsequent to the expansion of the delivered mixture.

An upper shell panel may be placed between first and second sections of a mold. The first section may include one or more expansion cavities and the second section may include one or more pour cavities. A foam-producing chemical mixture may be delivered into the one or more pour cavities and the mold may be closed. The delivered foam-producing chemical mixture may be allowed to expand within the closed mold and to force regions of the upper shell panel into the one or more expansion cavities. The upper shell panel may then be removed from the mold subsequent to the expansion of the delivered mixture.