A mat and a method for manufacturing the same are provided. The mat includes a first foam layer, a second foam layer and a third foam layer. The first foam layer has a first hardness and a first porosity. The second foam layer is connected with the first foam layer and has a second hardness and a second porosity larger than the first porosity. The third foam layer is connected with the second foam layer and has a third hardness and a third porosity smaller than the first porosity. The second foam layer includes a first connecting surface facing the first foam layer and a second connecting surface facing the third foam layer. The contact area between the first connecting surface and the first foam layer is different from the contact area between the second connecting surface and the third foam layer.

In an expanding device for expanding an expandable particle foam material with an expansion furnace which has an interior space for receiving the expandable particle foam material, a radiator is formed which is arranged in the interior space of the expansion furnace, and a conveying device with a conveying surface is formed, which serves to guide a particle foam material received on the conveying surface in a conveying direction through the interior space of the expansion furnace.

In an expanding device for expanding an expandable particle foam material with an expansion furnace which has an interior space for receiving the expandable particle foam material, a radiator is formed which is arranged in the interior space of the expansion furnace, and a conveying device with a conveying surface is formed, which serves to guide a particle foam material received on the conveying surface in a conveying direction through the interior space of the expansion furnace.

Methods of forming a lightweight reinforced thermoplastic core layer and articles including the core layer are described. In some examples, the methods use a combination of thermoplastic material, reinforcing fibers and bicomponent fibers to enhance retention of lofting agents in the core layer. The processes permit the use of less material while still providing sufficient lofting capacity in the final formed core layer.

An insulated panel includes a first layer defining an inner surface; a corrugated medium defining a plurality of peaks, the plurality of peaks attached to the inner surface, a plurality of flutes defined between the corrugated medium and the inner surface; and an insulation material at least partially filling a flute of the plurality of flutes.