In a soundproof member 10 including a polyurethane foam 11 and disposed apart from an engine E on a vehicle interior side of a dash panel 50 partitioning a space into an engine room having the engine E as a sound source and a vehicle interior, the polyurethane foam 11 has a surface layer 12 on at least a part of the surface thereof, a one side surface of the polyurethane foam 11 directly facing the vehicle interior side of the dash panel 50 has at least a surface layer 12A in an open cell state or a core, and a surface layer 12B of the other side surface opposite to the one side surface is a surface layer in a closed cell state.

The present invention relates to methods of manufacturing moulded products, for example building panels, and in particular, but not exclusively, to manufacturing a panel comprising natural stone or rock set into a polymeric layer. The method of manufacturing a moulded product as described herein comprises at least one article being set into a polymeric layer, followed by placing the at least one article and particulate ferrous material in a container so that at least a portion of the or each article is embedded in the particulate ferrous material, introducing a polymeric material into the container to form the moulded product, and removing the moulded product from the container.

The present invention relates to methods of manufacturing moulded products, for example building panels, and in particular, but not exclusively, to manufacturing a panel comprising natural stone or rock set into a polymeric layer. The method of manufacturing a moulded product as described herein comprises at least one article being set into a polymeric layer, followed by placing the at least one article and particulate ferrous material in a container so that at least a portion of the or each article is embedded in the particulate ferrous material, introducing a polymeric material into the container to form the moulded product, and removing the moulded product from the container.

A method of making a vehicle seat includes molding a discontinuous layer of foam on a non-decorative side of a decorative layer of material to form a seat panel that subsequently forms part of an exterior surface of the seat. A portion of the decorative layer is positioned in a foam molding cavity, and another portion of the decorative layer is excluded from the molding cavity. The excluded portion can be temporarily folded into a loop and reside in a secondary cavity of the molding tool during molding. The discontinuous layer of foam can be wider than the molding tool with foam portions selectively positioned along the decorative layer.

A method of manufacturing a mold tool for manufacturing poured foam parts wherein the mold tool includes lower and upper molds and the method includes 3D printing a composite mold to form a mold cavity for forming the poured foam parts. The 3D printing of lower and/or upper molds decreases the time and expense required for producing a mold tool whether for prototype or full production foam parts.

A vehicle seat includes a headrest, a seat back to which the headrest is attached, and a seat cushion connected to the seat back. The headrest includes pillar frames attached to the seat back, a core member that includes a pouring passage penetrating from one end to the other end, a cover that covers the core member and a part of the pillar frames, and a cushion member that is formed in a gap between the outer surface of the core member and the inner surface of the cover and inside the pouring passage. The pouring passage extends in a first direction from the one end of the core member to reach a predetermined position, extends in a second direction from the predetermined position to reach the other end, and includes a bent part at the predetermined position.

A manufacturing method for forming highly filled foam through dual axis mixing of precursor chemicals and fillers to form end products and parts. The manufacturing method provides an improved highly filled foam material as well as improved methods for shaping such foam into various parts and end products. In this manufacturing method, a mixing container (33) may be used to mold highly filled foam directly into a cylindrical shape (40) for processing into parts and end products, or may be used to transport uncured highly filled foam to a separate molding station (50) to form molded end products (56) which incorporate well-mixed, highly filled foam therein

A toy includes an overall package that holds an A+B molding foam. The overall package includes both a transparent or translucent outer package that contains a first or A part of the molding foam, and an inner transparent or translucent package that contains a second or B part of the molding foam. The A and B parts having contrasting colors. The overall package therefore resembles an egg. The user manually bursts the inner package and mixes the two substances together within the outer package, then pours the resultant molding foam into a mold to create a toy figure. The egg-like package enhances the child's play experience of giving birth to or hatching the toy figure.

A toy includes an overall package that holds an A+B molding foam. The overall package includes both a transparent or translucent outer package that contains a first or A part of the molding foam, and an inner transparent or translucent package that contains a second or B part of the molding foam. The A and B parts having contrasting colors. The overall package therefore resembles an egg. The user manually bursts the inner package and mixes the two substances together within the outer package, then pours the resultant molding foam into a mold to create a toy figure. The egg-like package enhances the child's play experience of giving birth to or hatching the toy figure.

The invention relates to a foaming and punching tool for producing foamed products from structural foam, and to a method for producing such foamed products.