Molded parts for automobile interiors can be made from expanded thermoplastic polyurethane beads. Processes can be used to produce the molded parts from thermoplastic polyurethane.

A composition and method to form a composite core material for use as a panel, molded product, sheet, or reinforcing material. The composition generally includes a microsphere discontinuous portion disposed in a continuous encapsulating portion, such as an encapsulating resin. Final products made with the composition may also comprise a mesh assembly on one or both sides of a sheet or panel, and may comprise a scored panel or sheet such that a plurality of reinforcing blocks or sections are formed which allow the cured product to conform to, and reinforce, irregular shapes and surfaces.

A composition and method to form a composite core material for use as a panel, molded product, sheet, or reinforcing material. The composition generally includes a microsphere discontinuous portion disposed in a continuous encapsulating portion, such as an encapsulating resin. Final products made with the composition may also comprise a mesh assembly on one or both sides of a sheet or panel, and may comprise a scored panel or sheet such that a plurality of reinforcing blocks or sections are formed which allow the cured product to conform to, and reinforce, irregular shapes and surfaces.

The present invention relates to thermoplastic olefin elastomer expanded beads, having an average aspect ratio of 1.10 or less and an average circularity of 0.985 or more. The thermoplastic olefin elastomer expanded beads preferably have a crystal structure such that a melting peak inherent in the thermoplastic olefin elastomer (inherent peak) and one or more melting peaks on a higher temperature side than the inherent peak (high temperature peaks) appear on a DSC curve obtained when heating the expanded beads from 23° C. to 200° C. at a heating rate of 10° C./min.

A method of making molded foam articles and the articles produced. A molded foam article is produced by heating or preheating the mold to a temperature at or above the glass transition or melt temperature of the particles to be molded. Foamed particles are then introduced into the mold. The particle filled mold is then subjected to a vacuum to stabilize the molded article, without application of any additional heating or cooling. The molded article is then removed from the mold at a temperature at or below the glass transition temperature of the particles, and the cycle repeated to form multiple molded articles.

A method of making molded foam articles and the articles produced. A molded foam article is produced by heating or preheating the mold to a temperature at or above the glass transition or melt temperature of the particles to be molded. Foamed particles are then introduced into the mold. The particle filled mold is then subjected to a vacuum to stabilize the molded article, without application of any additional heating or cooling. The molded article is then removed from the mold at a temperature at or below the glass transition temperature of the particles, and the cycle repeated to form multiple molded articles.

A system for curing a composite part, includes a mandrel configured to receive and support the uncured composite part; a plurality of expandable pellets disposed on the uncured composite part; and a mold configured to hold the mandrel, the uncured composite part, and the plurality of expandable pellets, wherein the plurality of expandable pellets are configured to expand and apply a positive pressure to the uncured composite part according to a change in condition or triggering event, and wherein each of the plurality of expandable pellets includes a blowing agent, a polymer matrix configured to hold the blowing agent, and a flexible skin configured to encapsulate the polymer matrix and the blowing agent, wherein the flexible skin is at least partially permeable with respect to the blowing agent or a gas released by the blowing agent.

A system for curing a composite part, includes a mandrel configured to receive and support the uncured composite part; a plurality of expandable pellets disposed on the uncured composite part; and a mold configured to hold the mandrel, the uncured composite part, and the plurality of expandable pellets, wherein the plurality of expandable pellets are configured to expand and apply a positive pressure to the uncured composite part according to a change in condition or triggering event, and wherein each of the plurality of expandable pellets includes a blowing agent, a polymer matrix configured to hold the blowing agent, and a flexible skin configured to encapsulate the polymer matrix and the blowing agent, wherein the flexible skin is at least partially permeable with respect to the blowing agent or a gas released by the blowing agent.

The present disclosure relates to foam beads of an elastomeric composition comprising a propylene-based elastomer. The foam bead has a density of less than 0.5 g/cm.sup.3. The foam beads can be made from pellets of elastomeric compositions by expanding with supercritical fluid blowing agent. The foamed bead has reduced lightness while maintaining elasticity.

The present disclosure relates to foam beads of an elastomeric composition comprising a propylene-based elastomer. The foam bead has a density of less than 0.5 g/cm.sup.3. The foam beads can be made from pellets of elastomeric compositions by expanding with supercritical fluid blowing agent. The foamed bead has reduced lightness while maintaining elasticity.