Abstract: A method of fabricating a mold includes 3D printing a first shell using a first material, the first shell having a first interior surface and a first exterior surface, and 3D printing a second shell using a second material different from the first material, the second shell having a second interior surface and a second exterior surface wherein the second interior surface generally conforms to the first exterior surface. The first material may be thermally conductive and the second material may be thermally insulative, and the first and/or second shell may include at least one thermal regulation element formed therein.

Abstract: A vehicle seat for a vehicle. The vehicle seat includes a first foam and a second foam. The first foam has a rate sensitivity as measured in accordance with a modified ISO 3886/1 standard which can accommodate a slow speed test with a static strain rate of about 0.001 second?1 and a high speed test with a dynamic strain rate of about 100 second?1 such that the dynamic versus static strain rate increases by at least 200%, and the first foam is temperature stable such that the glass transition temperature of the first foam is less than or equal to zero degrees Celsius and a change in tan delta of less than or equal to 35% from a median value measured over a temperature range of from about negative 20 degrees Celsius to about 60 degrees Celsius.

Abstract: A seat cushion is provided. The seat cushion includes a first cushion comprising a top side and a bottom side. The bottom side or the top side includes a contoured area and the contoured area has a convex or a concave shape.

Abstract: A seat cushion is provided. The seat cushion includes a first cushion comprising a top side and a bottom side. The bottom side or the top side includes a contoured area and the contoured area has a convex or a concave shape.

Abstract: A composite structure comprising a core portion having a pair of generally opposed surfaces. A first fibrous layer is disposed on a first surface of the core portion and has a plurality of fibres disposed substantially parallel to the first surface. A second fibrous layer disposed on a second surface of the core portion and has a plurality of fibres disposed substantially parallel to the second surface. A first polymer layer is disposed over the first fibrous layer and a second polymer layer is disposed over the second fibrous layer. The first fibrous layer is partially embedded in both the core portion and the first polymer layer. The second fibrous layer is partially embedded in the core portion and the second polymer layer. The present composite structure may be used in structural and/or non-resilient components of the vehicle. Such components include exterior body panels (e.g., TONNEAU covers), door panels, beds for pickup trucks and the like.

Abstract: An improved energy management device comprises a substrate body and at least one permeable insert sheet disposed in the substrate body. The shape and orientation of the sheet may be varied. In the various embodiments, the insert sheet has a wall substantially transverse to the energy absorbing surface of the energy management device. The substrate body and the at least one energy absorbing insert sheet are engaged with respect to one another. This may be achieved by having at least a portion of the substrate body disposed in the permeable portion of the insert sheet thereby “locking” in place the insert sheet. It has been discovered that such a combination of a substrate body and an insert sheet surprisingly and unexpected results in improved energy management properties when compared to the independent energy management properties of the substrate body and the insert sheet. The energy management device is useful, for example, in the construction of a vehicular bumper.

Abstract: An improved energy management device comprises a substrate body and at least one permeable insert sheet disposed in the substrate body. The shape and orientation of the sheet may be varied. In the various embodiments, the insert sheet has a wall substantially transverse to the energy absorbing surface of the energy management device. The substrate body and the at least one energy absorbing insert sheet are engaged with respect to one another. This may be achieved by having at least a portion of the substrate body disposed in the permeable portion of the insert sheet thereby "locking" in place the insert sheet. It has been discovered that such a combination of a substrate body and an insert sheet surprisingly and unexpected results in improved energy management properties when compared to the independent energy management properties of the substrate body and the insert sheet. The energy management device is useful, for example, in the construction of a vehicular bumper.

Abstract: A foam composite material comprising a first isocyanate-based polymer foam comprising at least one uncontoured surface and a second, molded isocyanate-based polymer foam, the first isocyanate-based polymer foam and the second isocyanate-based polymer foam being: (i) of different composition, and (ii) fixed with respect to one another. A process for producing the foam composite material also disclosed. The foam composite material is useful in another of vehicular and non-vehicular applications.

Abstract: A polyurethane foam essentially free of organic carbon-based blowing agent, the polyurethane foam comprising a foam core having a density of from about 5 to about 45 pounds per cubic foot and an integral skin consisting of substantially non-cellular, non-porous polyurethane. The presence of the integral skin is characterized by a compression force deflection index of at least about 1.20, the compression force deflection index being defined as the ratio of (i) the compression force deflection orthogonal to a cross-section of the foam to (ii) the compression force deflection of the foam core, the compression force deflection measured according to ASTM 3574C. In a preferred embodiment, the present polyurethane foam is further characterized by a flexural modulus index of at about 1.60. In another preferred embodiment, the present invention is characterized by a density index of at least about 1.60.

Abstract: A process for producing a polyurethane foam includes the steps of (a) providing a substantially uniform mixture having an isocyanate, an active hydrogen-containing compound, a blowing agent, and a catalyst to form a reaction mixture, and (b) expanding the reaction mixture to produce the polyurethane foam. The active hydrogen-containing compound has from about 50 to 100 parts-by-weight of a first active hydrogen-containing compound having an equivalent weight of from about 200 to about 800 and from 0 to about 50 parts-by-weight of a second active hydrogen-containing compound. The average equivalent weight of the active-hydrogen containing compound is in the range of from about 150 to about 700.