A roof module for a motor vehicle comprises an RTM frame and a Class-A covering layer, which at least partially covers the frame and is made of polyurethane. A method for manufacturing a roof module comprises the following steps: Initially, a fiber mat is put into a first mold. Then, a reactive resin system is introduced into the closed mold and the resin cures, so that a blank is formed. The blank is put into a second mold, into which subsequently polyurethane is introduced in the open condition. The polyurethane expands, wherein it at least partially forms a Class-A surface.

A method of forming a plurality of fasteners includes extruding a continuous strip of material, the continuous strip defining a base portion, a tip portion, and a stem portion extending between the base portion and the tip portion. A portion of material is removed from the continuous strip of material along the tip portion such that a plurality of tip portions are separated from each other and spaced apart, each tip portion having at least one flexible tab. The continuous strip of material is then extruded through a foaming die, wherein the flexible tabs are elastically displaced away from the base portion during a foaming process such that a foam material fills a cavity of the foaming die to form a sealing element around the stem portion. Portions of the continuous strip between each of the tip portions are separated to produce a plurality of individual sealed fasteners.

A composite layer for use in a bedding product such as a mattress and a method of manufacture are disclosed. The composite layer generally includes an extruded three dimensional fibrous layer and a foam material, e.g., polyurethane, latex or the like, disposed within the fibrous layer and occupying at least a portion of the free volume in the layer. Also disclosed are processes for manufacturing a foam-fiber composite.

Composite materials having superior material properties useful as impact absorbing devices can be fabricated by embedding a lattice structure (e.g., polymer lattice structure) within a foam, so that the foam reinforces the lattice structure under impact. Materials and dimensions of the foam and the lattice structure may be selected to achieve composite materials having tailored impact absorbing elastic and/or viscoelastic responses over a wide range of temperatures.

A method of forming a plurality of fasteners includes extruding a continuous strip of material, the continuous strip defining a base portion, a tip portion, and a stem portion extending between the base portion and the tip portion. A portion of material is removed from the continuous strip of material along the tip portion such that a plurality of tip portions are separated from each other and spaced apart, each tip portion having at least one flexible tab. The continuous strip of material is then extruded through a foaming die, wherein the flexible tabs are elastically displaced away from the base portion during a foaming process such that a foam material fills a cavity of the foaming die to form a sealing element around the stem portion. Portions of the continuous strip between each of the tip portions are separated to produce a plurality of individual sealed fasteners.

A roof module for a motor vehicle comprises an RTM frame and a Class-A covering layer, which at least partially covers the frame and is made of polyurethane. A method for manufacturing a roof module comprises the following steps: Initially, a fiber mat is put into a first mold. Then, a reactive resin system is introduced into the closed mold and the resin cures, so that a blank is formed. The blank is put into a second mold, into which subsequently polyurethane is introduced in the open condition. The polyurethane expands, wherein it at least partially forms a Class-A surface.

Composite materials having superior material properties useful as impact absorbing devices can be fabricated by embedding a lattice structure (e.g., polymer lattice structure) within a foam, so that the foam reinforces the lattice structure under impact. Materials and dimensions of the foam and the lattice structure may be selected to achieve composite materials having tailored impact absorbing elastic and/or viscoelastic responses over a wide range of temperatures.

Polyurethane floor covering products are formed from a web layer containing at least 30% by weight fibers. A cooled polyurethane foam formulation which includes at least one polyisocyanate, water and at least one polyol having an equivalent weight of at least 500 is applied to the web layer. The wetted web layer is then compressed to mechanically wet out the fibers, gauged and heated to cure the foam formulation.