An integral skin foam molded article includes: a skin formed by sewing a plurality of skin pieces in a hag shape; and a resin foam which is molded inside the skin integrally with the skin, wherein: at least one skin piece among the plurality of skin pieces has a surface material made of a natural leather, and includes a wadding material stacked on a back side of the surface material in a non-surface joined state and a lining material stacked on the wadding material; and in a shrinkage rate with respect to an in-plane compression load, a shrinkage rate of the liming material is smaller than a shrinkage rate of the wadding material.

A register box for an HVAC installation has a body with a plurality of side panels arranged in a generally rectangular or square configuration and a wall extending in generally transverse relation to the plurality of side panels, and an expandable polymeric material affixed to an inner side of the side panels and across the wall. The wall has a plurality of concentric circular areas cut into the wall. Each of the concentric areas is formed of a first partial circle having ends in spaced relation to a second partial circle. The circular area can be removed from the wall so as to allow a user to cut through the polymeric material at the wall so as to form a hole opening to an interior of the register box. This hole can receive a collar therein. The collar can be connected to the HVAC system.

A process for forming an insulated register box includes forming an insulation across the interior surface of a register box, placing a locating collar onto an outer surface of the register box, marking the outer surface of the register box so as to present a representation corresponding to an inner diameter of the collar, separating a portion of the outer surface of the register box from a remainder of the register box corresponding to the marked representation, penetrating the exposed insulation with the collar until an end of the collar opens to an interior of the insulated register box, and positioning the flange against the outer surface of the register box.

A process for forming a register box has a body formed with a plurality of side panels arranged in a generally square or rectangular configuration with a wall extending transverse to the side panels. A plurality of circular areas are cut into the wall. An expandable polymeric foam material is introduced into an interior of the body. The body is positioned in a fixture such that the wall is juxtaposed against a surface of the fixture. A plug is inserted into the interior of the body. The expandable polymeric foam material is expanded in the interior of the body such that the expandable polymeric foam material solidifies across the wall and around the plug. The plug is then removed from the body and the body is then removed from the fixture.

A heat transfer system for use within an avionics bay of an aircraft is provided by the present disclosure that includes, in one form, an aircraft panel comprising an upper skin, a lower skin, and a foam core disposed between the upper skin and the lower skin. At least one heat conducting array extends through the foam core and between the upper skin and the lower skin, the heat conducting array defining at least one upper cap, at least one lower cap, and a wall portion extending between the upper cap and the lower cap, the upper cap being disposed proximate avionics within the avionics bay. A heat conducting spreader is disposed between the lower cap of the heat conducting array and the lower skin of the aircraft panel.

A rigid composite panel 10 for insulating an installation such as a furnace or cooler (HVAC units). The panel 10 has a thermally insulating core 20, at least two laminate assemblies 30 which are bonded to the core 20 thus forming a sandwich, and an edge band 40 adhesively applied to the edges of the sandwich 50 so as to provide a smooth, continuous, and impermeable seal around said edges. There is also claimed a method for manufacturing a rigid composite panel 10 having an edge band 40, each laminate assembly being pretreated by plasma before the edge band 40 is bonded to the panel 10. Each laminate assembly 30 consists of a thin layer of polymer 38, as well as sheets 36 bonded to the surfaces of the layer 38.

The plurality of pieces of low density cellular material, such as foam plastics, form a core panel having opposite side surfaces and with adjacent pieces having opposing edge surfaces extending between the side surfaces. Sheets of flexible material, such as veils or mats or scrim, are adhesively attached to the side surfaces, and portions of one sheet extend between the opposing adjacent edge surfaces for limiting flexing of the panel. The pieces may be tapered, and portions of the one sheet may project between the edge surfaces either partially or fully to form double wall webs. The webs may have flanges adhesively attached to the other sheet on the opposite side. One sheet may also be stretchable in areas not adhesively attached to the pieces to provide for curving the panel from a planar position maintained by the sheet on the opposite side.

A method of manufacturing building panels includes assembling a frame of a building panel. The frame defines at least one cavity and at least one injection aperture in fluid communication with the at least one cavity. The method also includes positioning the frame on one of a base and a shelf of a multi-panel consolidation device having a plurality of shelves, with the shelves being in an expanded configuration, and at least substantially enclosing the at least one cavity. The method also includes forcing the shelves of the multi-panel consolidation device into a collapsed configuration, and injecting an expandable polymer through the at least one injection aperture into the at least one cavity. The method further includes forcing the shelves into an expanded configuration after a predetermined period of time selected to permit the expandable polymer to form a foam bonded to the frame.

A heat-insulating wall of the present invention includes: wall bodies (2 and 3) whose hollow portion is a heat-insulating space (10); gas circulation ports (5 and 6) which are disposed on the wall body and through which the heat-insulating space communicates with the outside; an open-cell urethane foam (4) of a thermosetting urethane resin with which the heat-insulating space is filled by integral foaming; and sealing materials (50, 51, 55, 60, 61 and 62) for sealing the gas circulation port.

The present invention relates to a process for producing composite profiles comprising at least two metal shells which are joined by struts comprising a thermoplastic material and a core comprising rigid polyurethane foam, which comprises introduction of the starting components of the rigid polyurethane foam into a hollow space formed by the metal shells, with the rigid polyurethane foam being formed, and subsequent application of a surface coating to the outer surface of the composite profile by means of a powder coating or baking enamel, where the rigid polyurethane foam is obtained by reaction of the following components: A) at least one polyisocyanate, B) at least one polyfunctional compound which is reactive toward isocyanates, C) one or more blowing agents comprising at least formic acid, D) optionally one or more flame retardants, E) optionally one or more catalysts and F) optionally further auxiliaries or additives,
wherein the starting components of the rigid polyurethane foam do not comprise any inorganic fillers.