Abstract: A method of manufacturing a composite insert includes forming a polymer mold from a polymer sheet which may have a glass transition temperature of 70 to 160° C., the polymer mold either includes a cavity or may form a cavity disposed between the polymer mold and the carrier. The method proceeds by depositing a liquid reactive composite insert composition, which may be a two-component composition including a first part comprised of an isocyanate-epoxy blend and a second part comprised of an alcohol-epoxy blend, into the cavity under low pressure conditions of 0-10 bar and low temperature conditions of 15-100° C. The composition is then allowed to become dimensionally stable either within the polymer mold or between the polymer mold and the carrier.

Abstract: A method of manufacturing a composite insert includes forming a polymer mold from a polymer sheet which may have a glass transition temperature of 70 to 160° C., the polymer mold either includes a cavity or may form a cavity disposed between the polymer mold and the carrier. The method proceeds by depositing a liquid reactive composite insert composition, which may be a two-component composition including a first part comprised of an isocyanate-epoxy blend and a second part comprised of an alcohol-epoxy blend, into the cavity under low pressure conditions of 0-10 bar and low temperature conditions of 15-100° C. The composition is then allowed to become dimensionally stable either within the polymer mold or between the polymer mold and the carrier.

Abstract: A method of manufacturing a composite insert includes forming a polymer mold from a polymer sheet which may have a glass transition temperature of 70 to 160° C., the polymer mold either includes a cavity or may form a cavity disposed between the polymer mold and the carrier. The method proceeds by depositing a liquid reactive composite insert composition, which may be a two-component composition including a first part comprised of an isocyanate-epoxy blend and a second part comprised of an alcohol-epoxy blend, into the cavity under low pressure conditions of 0-10 bar and low temperature conditions of 15-100° C. The composition is then allowed to become dimensionally stable either within the polymer mold or between the polymer mold and the carrier.

Abstract: An insert for sealing and acoustic damping of a longitudinal cavity having an interior surface, comprising: a) one or more carrier plates made of a polymeric material (A) which does not deform when heated to a temperature not higher than 180° C. and which comprises a main polymer (A1) which gives mechanical strength to the carrier plate, and—at least one vibration-damping polymer (A2), and b) a thermally expandable material (B). The vibration-damping polymer (A2) is preferably selected from the group comprising: thermoplastic polyurethanes, styrene/butadiene block copolymers, hydrogenated styrene/butadiene block copolymers, styrene/isoprene block copolymers, hydrogenated styrene/isoprene block copolymers, styrene/isoprene/styrene tri-block copolymers, and hydrogenated styrene/isoprene/styrene tri-block copolymers.

Abstract: An insert for sealing and acoustic damping of a longitudinal cavity having an interior surface, comprising: a) one or more carrier plates made of a polymeric material (A) which does not deform when heated to a temperature not higher than 180° C. and which comprises a main polymer (A1) which gives mechanical strength to the carrier plate, and—at least one vibration-damping polymer (A2), and b) a thermally expandable material (B). The vibration-damping polymer (A2) is preferably selected from the group comprising: thermoplastic polyurethanes, styrene/butadiene block copolymers, hydrogenated styrene/butadiene block copolymers, styrene/isoprene block copolymers, hydrogenated styrene/isoprene block copolymers, styrene/isoprene/styrene tri-block copolymers, and hydrogenated styrene/isoprene/styrene tri-block copolymers.