Polyurethane thermal insulating foam is made in the presence of a small amount of cis- and/or trans-1,1,1,4,4,4-hexafluorobut-2-ene and a hydrocarbon blowing agent. Very low lambda values are obtained.

A manufacturing method for a car safety seat includes the following steps: providing a mold and disposing a main body of the car safety seat into the mold, and injecting a foam material into a cavity of the mold and foaming the foam material so as to form a flexible layer integrated with the main body. A pressure in the cavity is between 1.5 bar and 5.0 bar. The manufacturing method disposes the main body into the mold and directly forms a flexible layer on the main body, so that the flexible layer ensures safety and comfort of the car safety seat while saves the necessity to dispose a seat pad or a cushion and fixing structures on the main body, and thereby reduces the cost and the work-hour of assembly, and the overall weight of the car safety seat can be reduced by omitting the fixing structures.

A manufacturing method for a child carrying device includes the following steps: providing a mold and disposing a main body of the child carrying device into the mold, and injecting a foam material into a cavity of the mold and foaming the foam material so as to form a flexible layer integrated with the main body. The manufacturing method disposes the main body into the mold and directly forms a flexible layer on the main body, so that the flexible layer ensures safety and comfort of the child carrying device while saves the necessity to dispose a seat pad or a cushion and fixing structures on the main body, and thereby reduces the cost and the work-hour of assembly, and the overall weight of the child carrying device can be reduced by omitting the fixing structures.

Method of forming an article from a molten plastic composition including a polymer and a blowing agent. The method provides that during an injecting step (c) and a packing step (d), the injection pressure and the packing pressure, respectively, are maintained above a minimum pressure threshold in at least one second region of the cavity to maintain the physical blowing agent as a gas dissolved in the polymer so that substantially no gas bubbles are formed in the at least one second region, during a mould opening step (e), at least some of the molten plastic composition is exposed to an external pressure lower than a minimum pressure threshold to form in the article at least one first portion having expanded cellular foam formed from the plastic composition, and prior to the opening step (e), the plastic composition in the at least one second region of the cavity has been cooled so as to be fully solidified to form in the article at least one second portion having a substantially homogeneous, solid phase, unexpanded plastic composition.

Method of forming an article from a molten plastic composition including a polymer and a blowing agent. The method provides that during an injecting step (c) and a packing step (d), the injection pressure and the packing pressure, respectively, are maintained above a minimum pressure threshold in at least one second region of the cavity to maintain the physical blowing agent as a gas dissolved in the polymer so that substantially no gas bubbles are formed in the at least one second region, during a mould opening step (e), at least some of the molten plastic composition is exposed to an external pressure lower than a minimum pressure threshold to form in the article at least one first portion having expanded cellular foam formed from the plastic composition, and prior to the opening step (e), the plastic composition in the at least one second region of the cavity has been cooled so as to be fully solidified to form in the article at least one second portion having a substantially homogeneous, solid phase, unexpanded plastic composition.

A vehicle interior component including a plurality of functional parts and a method of manufacturing the same are provided. A headliner which is a vehicle interior component includes a sheet-like core member formed of a urethane foam. The headliner has a plurality of functional parts with different functions set in a plane of the headliner. The core member has an in-plane distribution of a characteristic of the urethane foam varied corresponding to the plurality of functional parts.

A vehicle interior component including a plurality of functional parts and a method of manufacturing the same are provided. A headliner which is a vehicle interior component includes a sheet-like core member formed of a urethane foam. The headliner has a plurality of functional parts with different functions set in a plane of the headliner. The core member has an in-plane distribution of a characteristic of the urethane foam varied corresponding to the plurality of functional parts.

Provided is a material having an excellent sound-absorbing performance which can be easily applied to the desired area at the operation site and which can effectively prevent sound leakage.

The material includes an open-cell soft polyurethane foam prepared from a 2-part reactive urethane resin composition prepared from a polyisocyanate component and a polyol-containing component, wherein the polyol-containing component comprises a polyol component, catalysts, a foam stabilizer, an amine compound having primary or secondary amino groups, and carbon dioxide; wherein an average sound absorption coefficient of said polyurethane foam is 30% or more, measured in accordance with JIS A 1405-2:2007 for 63 hertz to 5000 hertz; and the length of liquid-dripping is within 300 mm.

A process for injection molded microcellular foaming various flexible foam compositions from biodegradable and industrially compostable bio-derived thermoplastic resins for use in, for example, footwear components, seating components, protective gear components, and watersport accessories wherein a process of manufacturing includes the steps of: producing a suitable thermoplastic biopolymer or biopolymer blend; injection molding the thermoplastic biopolymer or biopolymer blend into a suitable mold shape with inert nitrogen gas; controlling the polymer melt, pressure, temperature, and time such that a desirable flexible foam is formed; and utilizing gas counterpressure in the injection molding process to ensure the optimal foam structure with the least amount of cosmetic defects and little to no plastic skin on the outside of the foamed structure.

A process for injection molded microcellular foaming various flexible foam compositions from biodegradable and industrially compostable bio-derived thermoplastic resins for use in, for example, footwear components, seating components, protective gear components, and watersport accessories wherein a process of manufacturing includes the steps of: producing a suitable thermoplastic biopolymer or biopolymer blend; injection molding the thermoplastic biopolymer or biopolymer blend into a suitable mold shape with inert nitrogen gas; controlling the polymer melt, pressure, temperature, and time such that a desirable flexible foam is formed; and utilizing gas counterpressure in the injection molding process to ensure the optimal foam structure with the least amount of cosmetic defects and little to no plastic skin on the outside of the foamed structure.