A method for making a foam component is provided and includes inserting a foam material into a cavity of a mold having a top plate and a bottom plate, heating the foam material to cause the foam material to expand, and moving one of the top plate and the bottom plate relative to the other of the top plate and the bottom plate as the foam material expands and contacts the one of the top plate and the bottom plate to cause the foam material to fold over on itself within the cavity.

A resin foamed body 1 is a resin foamed body made of flexible resin, the resin foamed body entirely includes a skeleton part 2, the skeleton part includes a plurality of bone parts 2B and a plurality of connection parts 2J connecting end parts of a plurality of bone parts, and an average value AV(A0/A1) of a ratio A0/A1 of cross-sectional area A0 of a bone change part of each bone part at an edge 2B22 on a bone constant part side relative to cross-sectional area A1 of the bone change part at an edge 2B21 on the connection part side satisfies

0.15≤AV(A0/A1)<0.5.

A recorded matter having a three-dimensional image is produced by a method comprising the steps of: applying, to a recording medium including a substrate and a foaming layer provided thereon, a foam-promoting liquid containing water and a foam-promoting component; and heating the foaming layer. The foaming layer contains a binder resin and a foaming particle which foams as heated, while the foam-promoting component lowers a foaming start temperature of the foaming particle. The foaming particle includes a shell layer containing a thermoplastic resin and a volatile material encapsulated in the shell layer. The binder resin contains a water-insoluble resin, while the foam-promoting component contains a compound having no hydroxyl group.

Flooring material has an anti-slip, noise reducing pad directly self-adhered to a bottom surface. The pad is formed by applying a foamable PVC material is directly on the bottom surface of the flooring and heating the PVC material to foam the PVC material. The PVC material may then be cooled to form the pad with a definite formed shape having a resilient outer surface layer and a spongy foamy inner structure.

A method of microcellular foam molding an article is provided with filling a mold with a polyolefin compound; forming crosslinks in the mold to obtain a crosslinked mold; dissolving a supercritical fluid into the crosslinked mold under a predetermined pressure and at a predetermined temperature for a predetermined period of time to obtain a second mold configured to allow the supercritical fluid to effuse through; and heating the second mold at a second predetermine temperature for a predetermined foaming time until a foamed article is finished in the second mold. A second embodiment involves using elastomers as foaming materials is also provided.

Methods of making molded polystyrene articles are described. The methods include introducing steam into a mold simultaneous to filling the mold with foam particles, and cooling the mold without the use of cooling water. The method can be performed faster and with a lower temperature differential than conventional molding processes, permitting faster turn-around to the production of subsequent molded articles. The molded articles produced by the method can have thicker side walls, improved foam particle fusion, and improved compression properties as compared to conventional EPS molding processes.

In at least one embodiment, the present disclosure provides a vehicle seat assembly comprising a cushion having an “A” surface and a “B” surface, a central portion, and two bolster areas, with each bolster area being adjacent the central portion, with the cushion having a plurality of intrusions extending from the “A” surface towards the “B” surface to form a hardness gradient between at least one of the bolster areas and the central portion of between 5% to 25%, the plurality of intrusions comprising a plurality of pairs of patterns, each pair of patterns comprising a first pattern spaced apart and opposingly and inversely facing a second pattern.

Lightweight and strong components may be manufactured using self-skinning foam material compositions by the processes described herein. One or more mandrels may be inserted into a molding tool, and a self-skinning foam material composition may be injected into the molding tool. After closing the molding tool, the self-skinning foam material composition may expand and cure to form a component, and one or more skins may be formed on exterior and/or interior surfaces of the component. For example, an external skin may be formed on an exterior surface of the component in contact with surfaces of the molding tool, and one or more internal skins may be formed on one or more interior surfaces of negative space spars of the component in contact with surfaces of the one or more mandrels.

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.