A foam sheet core, including a plurality of foam sheet walls defining an array of hollow cells, wherein the plurality of foam sheet walls are bonded together to form the array of hollow cells, each of the plurality of foam sheet walls has a thickness from about 0.002 inches to about 0.08 inches, and each of the plurality of foam sheet walls has an average height from about 0.05 inches to about 5 inches.

The present invention relates to multi-layered composite structures and to methods for the preparation thereof. The present multi-layered composite structures are light weight and capable of high load bearing making the present multi-layered composite structures especially suitable to be used as load bearing structures in, for example, automotive. Specifically, the present invention relates to methods comprising the steps of a) providing a mould for said multi-layered composite structure; b) layering said mould with two or more layers forming the outer surface of said multi-layered composite; c) filling said layered mould with a mixture comprised of non-expanded heat-expandable microspheres and closing said mould; and d) subjecting said closed mould to a temperature of 80° C. to 140° C. during 1 to 230 minutes thereby providing a relative pressure in said closed mould of 0.1 to 20 bar through expansion of said heat-expandable microspheres thereby forming a multi-layered composite structure in said mould with a foam enforced inner core and a multi-layered outer surface; and e) separating the multi-layered composite structure from said mould.

A block copolymer including a polymer block (A) containing more than 70 mol % of a unit derived from an aromatic vinyl compound, and a polymer block (B) containing 30 mol % or more of a unit derived from a conjugated diene compound is provided. The block copolymer satisfies the conditions: (1): a content of the polymer block (A) in the block copolymer is 1 to 70% by mass; (2): a maximum width of a series of temperature regions where tan δ measured in accordance with JIS K7244-10 (2005), under conditions including a strain amount of 0.1%, a frequency of 1 a measurement temperature of −70 to 100° C., and a temperature rise rate of 3° C./min, is 1.0 or more is less than 16° C.; (3): a temperature at a peak position of tan δ in the condition (2) is 0° C. to +50° C.; and (4): a mobility parameter M indicating a mobility of the polymer block (B) is 0.01 to 0.25 sec.

A structural member including a lightweight core, one or more skins, and a crosslinking nanolayer interposed therebetween that results in significant mechanical strength in the structure. The core is a polymer of reduced density by way of included voids, such as an open or closed cell foam, honeycomb, or corrugated structure. The core polymer has a lower density and may have a higher softening or melting temperature than the polymer skin materials. The core may be discontinuous at the interface with the skin such that only a small percentage of the core surface is actually in contact with the skin compared to the overall area of the interface. The skin may be a thermoplastic layer that attaches to the core material. The skin may be a composite material including non-thermoplastic reinforcements. The crosslinking nanolayer is covalently bonded to the surface of the core material and provides molecular compatibility with the skin material.

In an embodiment, an adhesive sheet has an expandable adhesive layer 2 on one side or both sides of a base 1, wherein the expandable adhesive layer 2 contains an epoxy resin including a polyfunctional epoxy resin, a phenol resin as a curing agent, an imidazole-based compound as a curing catalyst, and a temperature-sensitive foaming agent. The adhesive sheet has properties in good balance, such as fast curability, heat resistance, and adhesiveness, and also excellent properties such as thermal conductivity attributed to a good filling property.

A structural member including a lightweight core, one or more skins, and a crosslinking nanolayer interposed therebetween that results in significant mechanical strength in the structure. The core is a polymer of reduced density by way of included voids, such as an open or closed cell foam, honeycomb, or corrugated structure. The core polymer has a lower density and may have a higher softening or melting temperature than the polymer skin materials. The core may be discontinuous at the interface with the skin such that only a small percentage of the core surface is actually in contact with the skin compared to the overall area of the interface. The skin may be a thermoplastic layer that attaches to the core material. The skin may be a composite material including non-thermoplastic reinforcements. The crosslinking nanolayer is covalently bonded to the surface of the core material and provides molecular compatibility with the skin material.

A system and method for dielectric bonding including a dielectric heater having a pair of opposing electrode plates, a nest removably coupled to a first electrode plate of the pair of electrode plates, and an interchangeable electrode assembly removably coupled to a second electrode plate of the pair of electrode plates. The nest having a plurality of cooling channels defined in a body thereof in which a cooling fluid circulates to cool a material assembly that is supported by the nest. The interchangeable electrode assembly having a plurality of concentrator members that are configured to concentrate energy from a voltage source in predetermined locations on the material assembly.

In order to provide a manufacturing method of an elongated foam sheet capable of manufacturing the elongated foam sheet with highly-precise thickness without being limited by the material and thickness of foam material, a method of manufacturing an elongated foam sheet includes performing a slice process in which a foam sheet is created by slicing a foam block and a sheet pasting process in which a large number of foam sheets are arranged and pasted onto one side of an elongated base material sheet to manufacture the elongated foam sheet where the large number of foam sheets are lined up in a longitudinal direction of the base material sheet.

A multilayer material, including a compressible polymer foam layer, wherein the compressible polymer foam layer has a density of less than 400 kg/m.sup.3, a compression force deflection of 5 to 1,035 kPa at 25% deflection determined in accordance with ASTM D3574-17, and a thickness of less than 3.5 millimeters; and a solid, polymeric flame retardant layer disposed on a first side of the compressible polymer foam layer, wherein the flame retardant layer has a thickness of less than 0.3 millimeters, wherein the thickness of the compressible polymer foam layer is at least two times greater than the thickness of the flame retardant layer; wherein each of the compressible polymer foam layer and the flame retardant layer includes a flame retardant composition, and wherein the multilayer material has a thickness of 3.5 millimeters or less, and a UL-94 rating of V1, preferably V0, HF1, or a combination thereof.

A reinforcing vibration-damping material that includes a reinforcing material and a vibration-damping material disposed on the reinforcing material in a thickness direction of the reinforcing material. The vibration-damping material has a first portion that overlaps the reinforcing material in the thickness direction and a second portion that does not overlap the reinforcing material in the thickness direction. When the reinforcing vibration-damping material is attached to the object, the reinforcing material is adhered to the object and the second portion of the vibration-damping material is also adhered to the object so that the vibration-damping material suppresses the downward displacement of the reinforcing material.