In methods and apparatuses for producing auxetic foam from conventional foam, conventional foam is compressed into a mold before thermal, chemical or thermo-chemical treatment processes are performed. A segmented mold is accommodated in a compressing apparatus. After compressing the foam between the mold segments, the mold is fastened shut and removed from the compressing apparatus. The forces applied to any given volume of foam and the amounts by which the foam is compressed while being processed are controlled to impart desired mechanical properties to the produced foam. Poisson's ratio and density of discrete portions of finished foam shapes are reliably predicted and controlled to achieve uniform and non-uniform mechanical properties within a single continuous quantity of foam.

A method for producing a molded part, in particular a component of a sporting good, includes providing a mixture of a polymer melt and a foaming agent and injecting the mixture into a mold. The method includes solidifying at least a first portion of the molded part without foaming and at least a second portion of the molded part after foaming inside the mold, wherein the mixture includes a polymer having an average molecular mass corresponding to a viscosity number ≥130 ml/g, preferably ≥170 ml/g, more preferably ≥190 ml/g and most preferably ≥225 ml/g, wherein the viscosity number is determined via solution viscometry according to the ISO 307 standard.

A method for producing a molded part, in particular a component of a sporting good, includes providing a mixture of a polymer melt and a foaming agent and injecting the mixture into a mold. The method includes solidifying at least a first portion of the molded part without foaming and at least a second portion of the molded part after foaming inside the mold, wherein the mixture includes a polymer having an average molecular mass corresponding to a viscosity number ≥130 ml/g, preferably ≥170 ml/g, more preferably ≥190 ml/g and most preferably ≥225 ml/g, wherein the viscosity number is determined via solution viscometry according to the ISO 307 standard.

A trim article includes an outer casing having an inner surface defining an interior portion of the outer casing. The outer casing includes a front surface having a plurality of through apertures disposed thereon. A core portion is disposed within the interior portion of the outer casing and includes first and second portions having variated densities relative to one another. The first and second portions include lattice matrices having variated patterns of interconnected links and associated cells that provide variated force deflection parameters between the first and second portions of the core portion. The outer casing and the core portion are integrated to define a monolithic structure comprised of a common material.

This provides an improved process for making a flexible, porous, dissolvable solid sheet article with improved pore structures.

In methods and apparatuses for producing auxetic foam from conventional foam, conventional foam is compressed into a mold before thermal, chemical or thermo-chemical treatment processes are performed. A segmented mold is accommodated in a compressing apparatus. After compressing the foam between the mold segments, the mold is fastened shut and removed from the compressing apparatus. The forces applied to any given volume of foam and the amounts by which the foam is compressed while being processed are controlled to impart desired mechanical properties to the produced foam. Poisson's ratio and density of discrete portions of finished foam shapes are reliably predicted and controlled to achieve uniform and non-uniform mechanical properties within a single continuous quantity of foam.

The present invention provides means for improving bondability between a vehicle seat core and a cushion in a vehicle seat pad formed by integration of them without significantly impairing mechanical properties. A vehicle seat core is characterized in that it is a vehicle seat core for forming a vehicle seat pad by integration with a cushion, which comprises a foamed resin molded body obtained by filling a cavity of a mold with a plurality of foamed resin particles and performing in-mold foam molding, and that at least a partial region of a surface of the foamed resin molded body to which the cushion is bonded when forming the vehicle seat pad has a surface expansion rate of 40% to 85%, and the foamed resin molded body has a first fusion rate of 95% or more or a second fusion rate of 60% or more.

A trim article includes an outer casing having an inner surface defining an interior portion of the outer casing. The outer casing includes a front surface having a plurality of through apertures disposed thereon. A core portion is disposed within the interior portion of the outer casing and includes first and second portions having variated densities relative to one another. The first and second portions include lattice matrices having variated patterns of interconnected links and associated cells that provide variated force deflection parameters between the first and second portions of the core portion. The outer casing and the core portion are integrated to define a monolithic structure comprised of a common material.

The present invention provides means for improving bondability between a vehicle seat core and a cushion in a vehicle seat pad formed by integration of them without significantly impairing mechanical properties. A vehicle seat core is characterized in that it is a vehicle seat core for forming a vehicle seat pad by integration with a cushion, which comprises a foamed resin molded body obtained by filling a cavity of a mold with a plurality of foamed resin particles and performing in-mold foam molding, and that at least a partial region of a surface of the foamed resin molded body to which the cushion is bonded when forming the vehicle seat pad has a surface expansion rate of 40% to 85%, and the foamed resin molded body has a first fusion rate of 95% or more or a second fusion rate of 60% or more.

This provides an improved process for making a flexible, porous, dissolvable solid sheet article with improved pore structures.