Abstract: A foam product includes a foam core, a soft skin covering the foam core, and a base structure on which the foam core is disposed. The foam core of expanded beads has an outer surface on which some outermost beads of the expanded beads are exposed and bulging outward with different heights to form a bubbly texture. The foam skin has an inner surface attached to the outer surface of the foam core, and has at its inner surface a plurality of concave cavities each matedly surrounding a respective one of the bulging, outermost beads on the outer surface of the foam core.

Abstract: An automated manufacturing method and system and in-mold coated plastic article produced thereby are provided. The system includes a compression mold and a plurality of program-controlled manipulators. An automatic sprayer supported on a first manipulator sprays at least a portion of a mold surface with an in-mold coating composition. An end effector supported on a second manipulator picks up a heated blank of moldable plastic sheet material from an oven and places the heated blank between upper and lower mold halves of the mold. An inner portion of the heated blank is forced into an article-defining cavity of the mold and into contact with at least a portion of the in-mold coating composition. The in-mold coating composition and the inner portion of the heated blank cure and bond to one another so as to form the coated plastic article.

Abstract: A sandwich-type, composite component having an injection molded backside protective covering including 3-D structures which provide at least one pattern at an outer surface of the component is provided. The component includes a first outer layer having an outer surface, a second outer layer and a core bonded to and positioned between the outer layers and having a plurality of cavities. The covering is integrally formed from at least one elastomeric material and includes the 3-D structures bonded to the outer surface by injection molding. The 3-D structures are sized, shaped and arranged in one or more patterns at the outer surface. The one or more patterns may form a textured surface finish, a logo or indicia such as instructions at the outer surface. The component may be a vehicle interior component such as a vehicle load floor component.

Abstract: A marine deck member and the process for forming the same are provided. The marine deck member comprises a sandwich-type composite panel made by a compression molding process. In such a process, the panel is made by subjecting a heated stack of layers of material to cold pressing in a mold. The cellular core has a 2-D array of cells, with end faces open to the respective layers or skins. The surface traction of this type of composite panel can be enhanced for marine deck applications by controlled debossing, or embossing, of the first skin while it cools in the compression mold. The debossing effect can be affected by applying pressurized gas, e.g., pressurized air, onto the outer surface of the first skin while in the compression mold. The embossing can be affected by applying vacuum pressure on the outer surface of the first skin while in the compression mold.

Abstract: A sandwich-type, composite component having a sprayed backside protective coating is provided. The component includes a first outer layer having an outer surface, a second outer layer and a core positioned between and bonded to the outer layers and having a plurality of cavities. The protective coating is integrally formed from an elastomeric material. The material is sprayed to form the coating and the coating is bonded to the outer surface by curing. The component may be a vehicle interior component such as a vehicle load floor component.

Abstract: An automated manufacturing method and system and in-mold coated plastic article produced thereby are provided. The system includes a compression mold and a plurality of program-controlled manipulators. An automatic sprayer supported on a first manipulator sprays at least a portion of a mold surface with an in-mold coating composition. An end effector supported on a second manipulator picks up a heated blank of moldable plastic sheet material from an oven and places the heated blank between upper and lower mold halves of the mold. An inner portion of the heated blank is forced into an article-defining cavity of the mold and into contact with at least a portion of the in-mold coating composition. The in-mold coating composition and the inner portion of the heated blank cure and bond to one another so as to form the coated plastic article.

Abstract: A marine deck member and the process for forming the same are provided. The marine deck member comprises a sandwich-type composite panel made by a compression molding process. In such a process, the panel is made by subjecting a heated stack of layers of material to cold pressing in a mold. The cellular core has a 2-D array of cells, with end faces open to the respective layers or skins. The surface traction of this type of composite panel can be enhanced for marine deck applications by controlled debossing, or embossing, of the first skin while it cools in the compression mold. The debossing effect can be affected by applying pressurized gas, e.g., pressurized air, onto the outer surface of the first skin while in the compression mold. The embossing can be affected by applying vacuum pressure on the outer surface of the first skin while in the compression mold.

Abstract: A marine deck member with enhanced surface traction and the process for forming the same. The marine deck member comprises a sandwich-type composite panel made by a compression molding process. In such a process, the panel is made by subjecting a heated stack of layers of material to cold-pressing in a mold. The cellular core has a 2-D array of cells, each of the cells having an axis substantially perpendicular to the outer surfaces, and extending in the space between the layers or skins, with end faces open to the respective layers or skins. The surface traction of this type of composite panel can be enhanced for marine deck applications by controlled debossing, or embossing, of the first skin while it cools in the compression mold. The debossing effect can be effected by applying pressurized gas, e.g., pressurized air, onto the outer surface of the first skin while in the compression mold.

Abstract: A marine deck member and the process for forming the same. The marine deck member comprises a sandwich-type composite panel made by a compression molding process. In such a process, the panel is made by subjecting a heated stack of layers of material to cold-pressing in a mold. The cellular core has a 2-D array of cells, with end faces open to the respective layers or skins. The surface traction of this type of composite panel can be enhanced for marine deck applications by controlled debossing, or embossing, of the first skin while it cools in the compression mold. The debossing effect can be affected by applying pressurized gas, e.g., pressurized air, onto the outer surface of the first skin while in the compression mold. The embossing can be affected by applying vacuum pressure on the outer surface of the first skin while in the compression mold.

Abstract: An automated manufacturing method and system and in-mold coated plastic article produced thereby are provided. The system includes a combination compression and injection mold and a plurality of program-controlled manipulators. An automatic sprayer supported on a first manipulator sprays at least a portion of a mold surface with an in-mold coating composition. An end effector supported on a second manipulator picks up a heated blank of moldable plastic sheet material from an oven and places the heated blank in the mold. An inner portion of the heated blank is forced into an article-defining cavity of the mold and into contact with at least a portion of the composition. The composition and the inner portion cure and bond to one another and a plastic compatible with the plastic of the sheet is injected into the mold so as to form the coated plastic article.

Abstract: An automated manufacturing method and system and in-mold coated plastic article produced thereby are provided. The system includes a compression mold and a plurality of program-controlled manipulators. An automatic sprayer supported on a first manipulator sprays at least a portion of a mold surface with an in-mold coating composition. An end effector supported on a second manipulator picks up a heated blank of moldable plastic sheet material from an oven and places the heated blank between upper and lower mold halves of the mold. An inner portion of the heated blank is forced into an article-defining cavity of the mold and into contact with at least a portion of the in-mold coating composition. The in-mold coating composition and the inner portion of the heated blank cure and bond to one another so as to form the coated plastic article.

Abstract: An automated manufacturing method and system and in-mold coated plastic article produced thereby are provided. The system includes a combination compression and injection mold and a plurality of program-controlled manipulators. An automatic sprayer supported on a first manipulator sprays at least a portion of a mold surface with an in-mold coating composition. An end effector supported on a second manipulator picks up a heated blank of moldable plastic sheet material from an oven and places the heated blank in the mold. An inner portion of the heated blank is forced into an article-defining cavity of the mold and into contact with at least a portion of the composition. The composition and the inner portion cure and bond to one another and a plastic compatible with the plastic of the sheet is injected into the mold so as to form the coated plastic article.

Abstract: An automated manufacturing method and system and in-mold coated plastic article produced thereby are provided. The system includes a combination compression and injection mold and a plurality of program-controlled manipulators. An automatic sprayer supported on a first manipulator sprays at least a portion of a mold surface with an in-mold coating composition. An end effector supported on a second manipulator picks up a heated blank of moldable plastic sheet material from an oven and places the heated blank in the mold. An inner portion of the heated blank is forced into an article-defining cavity of the mold and into contact with at least a portion of the composition. The composition and the inner portion cure and bond to one another and a plastic compatible with the plastic of the sheet is injected into the mold so as to form the coated plastic article.

Abstract: An automated manufacturing method and system and in-mold coated plastic article produced thereby are provided. The system includes a compression mold and a plurality of program-controlled manipulators. An automatic sprayer supported on a first manipulator sprays at least a portion of a mold surface with an in-mold coating composition. An end effector supported on a second manipulator picks up a heated blank of moldable plastic sheet material from an oven and places the heated blank between upper and lower mold halves of the mold. An inner portion of the heated blank is forced into an article-defining cavity of the mold and into contact with at least a portion of the in-mold coating composition. The in-mold coating composition and the inner portion of the heated blank cure and bond to one another so as to form the coated plastic article.

Abstract: An automated method and system for making painted vehicle body panel skins and vehicle body panels, such as instrument panels, are provided wherein throughput and equipment utilization are greatly improved at a relatively low cost. The method includes transferring a mold having a mold surface from an entrance station to a paint station within a dispensing area. The method further includes applying paint on the mold surface to form a layer of paint on the mold surface at the paint station. The method still further includes spraying curable polyurethane elastomer on the painted surface at a spray station within the dispensing area. The paint and spray stations may be coincident.

Abstract: A water sports board includes a board body, a seat back and a pair of pedals. The seat back is arranged on a top surface of the board body for a user's back to lean on. The pair of pedals arranged on the top surface of the board body for the user's feet to step on the pair of pedals.

Abstract: A marine deck member and the process for forming the same. The marine deck member comprises a sandwich-type composite panel made by a compression molding process. In such a process, the panel is made by subjecting a heated stack of layers of material to cold-pressing in a mold. The cellular core has a 2-D array of cells, with end faces open to the respective layers or skins. The surface traction of this type of composite panel can be enhanced for marine deck applications by controlled debossing, or embossing, of the first skin while it cools in the compression mold. The debossing effect can be affected by applying pressurized gas, e.g., pressurized air, onto the outer surface of the first skin while in the compression mold. The embossing can be affected by applying vacuum pressure on the outer surface of the first skin while in the compression mold.

Abstract: A vehicle trim part having an injection molded, frontside protective covering is provided. The part includes a decorative layer having an outer surface which provides the appearance of a desirable material. An injection molded, light-transmissive protective layer is inter-bonded to the decorative layer and is integrally formed from a polymeric material which overlies and protects the decorative layer and provides a desired outer surface finish with little or no need for post-molding machining or polishing. The desired outer surface finish and the outer surface of the decorative layer at the interface between the layers form a reflected light pattern which is visible at the front of the part when lighting illuminates the outer surface finish and the outer surface of the decorative layer from the front of the part. The part may be a vehicle interior trim part.

Abstract: An anti-microbial partition divider assembly for a cart such as a golf cart is provided. The cart has a passenger seating area, including at least one seat, a roof and a floor. The assembly includes a flexible or beam-rigid partition divider having a substrate layer made of a material which prevents airborne liquid droplets from traveling therethrough.

Abstract: A carpeted automotive vehicle load floor including a composite panel having first and second reinforced thermoplastic skins and a thermoplastic cellular core disposed between and bonded to the skins is provided. The first skin as a top surface. A cover having top and bottom surfaces is spaced apart from the composite panel. A substantially continuous top covering layer is bonded to the top surface of the panel and the top surface of the cover to at least partially form a carpeted load floor having a carpeted cover. An intermediate portion of the top covering layer between the cover and the panel is not bonded to either the panel or the cover to form a living hinge which allows the carpeted cover to pivot between different use positions relative to the rest of the load floor.