A method for fabricating emulated wood with pores and fibers, comprising: immersing a plurality of synthetic fibers configured parallel in a plane into a resin so that the resin is coated on the surfaces of the plurality of synthetic fibers and in the gaps between the plurality of synthetic fibers; placing the plurality of synthetic fibers between two sheets, wherein the two sheets are planar sheets made from a uniform composition comprising a thermoplastic elastomer, a foaming agent, and a crosslinking agent; carrying out a heat-press process on the two sheets so that the foaming agent undergoes microcellular foaming and forms dense closed pores in the two sheets, and so that the composition on inner surfaces of the two sheets expands towards the plurality of synthetic fibers and penetrates through the gaps between the plurality of synthetic fibers; and cooling the two sheets to yield an emulated wood board.

The present invention relates to a method for producing a composite part, preferably an automotive trim composite part, comprising a textured skin and a rigid or foam substrate layer. The method comprises the steps of forming the skin by spraying or casting an aqueous thermoplastic dispersion which is derived from the melt blending of thermoplastic polymer, a dispersing agent, and water onto a textured mold and molding the rigid or form substrate onto the skin.

The invention relates to a sandwich component composed of at least two building material plates which are arranged essentially parallel to one another at a distance from one another and have a polyurethane foam core between the spaced building material plates, wherein the ratio of the greatest measured compressive modulus of the polyurethane foam core in a direction oriented parallel to the building material plates to the compressive modulus of the polyurethane foam core in a direction oriented perpendicular to the building material plates is less than 1.7. To produce the sandwich components, a mixture of (a) at least one polyisocyanate component, (b) at least one component which comprises at least one polyfunctional compound which is reactive toward isocyanates and (c) at least one blowing agent is introduced by the high-pressure injection method into a hollow space between spaced building material plates. The process makes it possible to produce sandwich components whose foam core has reduced anisotropy combined with good insulation values.

A method for manufacturing an interior lining part, includes producing a skin; placing the skin in a foaming mold with a support layer; foaming an intermediate layer; cutting out an area of the skin producing a cutout area of the skin; placing a piece of adhesive tape or film in the cutout area, the piece of adhesive tape or film being placed in between the skin and the intermediate foam layer; and placing an insert in the cut out area of the skin. A method for manufacturing an interior lining part, includes producing a skin by rotational molding; placing a piece of adhesive tape or film in the cutout area, the piece of adhesive tape or film being placed in between the skin and the intermediate foam layer; placing the skin in a foaming mold with a support layer; foaming an intermediate layer; cutting out an area of the skin producing a cutout area of the skin; and placing an insert in the cut out area of the skin.

A seat for vehicles including a seat cushion, a seat back, and a head rest has the following arrangement to ensure that a surface member can be relatively easily but positively removed from a urethane pad if a foam molding defect is found in the urethane pad in integral molding of the urethane pad and the surface member. In the seat for vehicles, any one of the seat cushion, seat back, and head rest has a configuration where a surface of the urethane pad is covered with the surface member. The urethane pad and the surface member are partially bonded together by integral molding.

A method for coating a pipe involves applying a coating material of cellular structured extruded thermoplastic material to the pipe and enclosing it on the outside by an outer covering layer of compact plastic. In an extrusion head, the annular opening for supplying coating material can be adjusted to a desired temperature by a region having coolant channels separated from the annular opening by an annular heat exchange surface. Before being applied to the pipe, the flowable coating material is guided along the heat exchange surface and cooled to a temperature just above the solidification temperature thereof. After the coating material leaves the annular opening, the coating material expands in a controlled manner, widening the outer covering layer depending on the adjusted temperature of the coating material, until the coating material begins to solidify. The outer covering layer surface condition can correspond to or be different from the pipe.

A method for manufacturing an interior lining part, includes producing a skin; placing the skin in a foaming mold with a support layer; foaming an intermediate layer; cutting out an area of the skin producing a cutout area of the skin; placing a piece of adhesive tape or film in the cutout area, the piece of adhesive tape or film being placed in between the skin and the intermediate foam layer; and placing an insert in the cut out area of the skin. A method for manufacturing an interior lining part, includes producing a skin by rotational molding; placing a piece of adhesive tape or film in the cutout area, the piece of adhesive tape or film being placed in between the skin and the intermediate foam layer; placing the skin in a foaming mold with a support layer; foaming an intermediate layer; cutting out an area of the skin producing a cutout area of the skin; and placing an insert in the cut out area of the skin.

The invention relates to a process for producing complex, mould-foamed rigid foam materials, more particularly of poly(meth)acrylimide (P(M)I) cores, preferably of polymethacrylimide (PMI) cores, which may be employed, for example, in carmaking or aircraft construction. A feature of the process is that through use of a particulate core during foam, it is possible to achieve an additional weight saving relative to foam materials or sandwich materials of the prior art.

A vehicle interior panel includes a decorative skin layer and a backing layer. The backing layer can include a barrier material that helps prevent outgassing of a plasticizer of the decorative skin layer in a direction toward an underlying substrate of the panel. The backing layer can be formed by vacuum coating and/or formed while a slush molded layer remains on a slush molding tool surface on which it was formed. In some cases, a slush molding tool thus finds new uses in a vacuum coating process or in some other process apart from slush molding.

A golf ball sub-assembly is provided that is formed from a core body and a foamed casing layer. The core body has a non-spherical profile due to the presence of centering elements, which can be provided in the form of protrusions or other types of structures on the outer surface of the core body. A foamed material is used for the casing layer. The core body can be plunged into a casting mold including the foamed material prior to the foamed material reaching a viscosity level that is typically required for the core body to be properly situated within the casting mold. A method of forming a golf ball using a core body having protrusions is also disclosed herein. The protrusions promote concentricity and therefore the method does not require targeting a specific viscosity of a foamed casing material when plunging the core body within the casting mold.