In one embodiment, a method of forming an extruded board includes mixing a resin and a foaming agent, melting the mixed resin and foaming agent to form a uniformly colored extrudate, differentially expanding voids formed from the foaming agent within the uniformly colored extrudate by passing the uniformly colored extrudate through a breaker plate, forming a board with the differentially expanded voids and uniformly colored extrudate, and forming lightened portions on an outermost surface of the formed board.

A push-in earplug is provided. The push-in earplug comprises an elongate core comprising a core material. The push-in earplug also comprises an outer layer comprising a foam material, the outer layer covering at least a portion of an outer surface of the elongate core. The push-in earplug also comprises a channel extending through the elongate core from a first end of the elongate core to the second end of the elongate core.

A push-in earplug is provided. The push-in earplug comprises an elongate core comprising a core material. The push-in earplug also comprises an outer layer comprising a foam material, the outer layer covering at least a portion of an outer surface of the elongate core. The push-in earplug also comprises a channel extending through the elongate core from a first end of the elongate core to the second end of the elongate core.

In one embodiment, a method of forming an extruded board includes mixing a resin and a foaming agent, melting the mixed resin and foaming agent to form a uniformly colored extrudate, differentially expanding voids formed from the foaming agent within the uniformly colored extrudate by passing the uniformly colored extrudate through a breaker plate, forming a board with the differentially expanded voids and uniformly colored extrudate, and forming lightened portions on an outermost surface of the formed board.

Processes, systems, and methods described herein can be used for manufacturing reinforced carbon fiber structures. For example, processes can include forming a plurality of foam substructures. The foam substructures can be made of heat expanding foam that further expands when heated to a first threshold temperature. Processes can also include positioning carbon fiber on at least a portion of surfaces of the foam substructures, assembling the plurality of foam substructures with the carbon fiber into a superstructure, wrapping an outer surface of the superstructure with additional carbon fiber to form a wrapped superstructure, and curing the wrapped superstructure within a mold to form a reinforced carbon fiber structure. The reinforced carbon fiber structures can include internal truss structures within the foam. The reinforced carbon fiber structures can be used to form reinforced carbon fiber bicycle frame components.

In one embodiment, a method of forming an extruded board includes mixing a resin and a foaming agent, melting the mixed resin and foaming agent to form a uniformly colored extrudate, differentially expanding voids formed from the foaming agent within the uniformly colored extrudate by passing the uniformly colored extrudate through a breaker plate, forming a board with the differentially expanded voids and uniformly colored extrudate, and forming lightened portions on an outermost surface of the formed board.

The present invention relates to a method for manufacturing a shower tray trough, from a composite panel of the sandwich type, to which a mask is applied corresponding to a pattern cavity making it possible to imprint, in the thickness of the foam reinforcing slab of said composite panel, the desired recesses to form said shower tray trough. To that end, the top plate of the composite panel is heated locally, only at the zones corresponding to the recesses to be imprinted, so as to allow the deformation of said top plate and the arrangement of said recesses in the thickness of the foam slab.

In one embodiment, a method of forming an extruded board includes mixing a resin and a foaming agent, melting the mixed resin and foaming agent to form a uniformly colored extrudate, differentially expanding voids formed from the foaming agent within the uniformly colored extrudate by passing the uniformly colored extrudate through a breaker plate, forming a board with the differentially expanded voids and uniformly colored extrudate, and forming lightened portions on an outermost surface of the formed board.