Abstract: The invention relates to a process for the manufacture of thermally expandable thermoplastic microspheres. The process comprises, providing a mixture of monomeric materials suitable for polymerisation to form a thermoplastic polymer and at least one blowing agent, providing to the mixture a colloidal silica that is surface-modified with at least hydrophobic organosilane groups and forming an emulsion. A polymerisation is performed to form the thermally expandable thermoplastic microspheres. The invention further relates to thermally expandable thermoplastic micro spheres, expanded micro spheres and their use in the manufacture of products.

Abstract: Disclosed is a liquid, solvent free, moisture curable polyurethane adhesive composition comprising the reaction products of at least one polyoxypropylene polyol having a hydroxyl functionality of at least three and ethylene oxide end-capping with one or more polyisocyanates having a weight average isocyanate functionality of greater than 2.3. The adhesive composition has a long open time and rapid cure time compared to currently available adhesives. The polyoxypropylene polyol preferably has a number average molecular weight of from 3,000 to 8,000. The composition finds special use in panel lamination applications.

Abstract: The present invention provides a method for preparing a porous membrane of a fluorine-based resin having an improved shrinkage while maintaining excellent filtration efficiency and air permeability.

Abstract: The invention relates to a connection element, in particular a thermal adhesive bonding boss, to be introduced into at least one component, in particular a hollow chamber component, in particular a plate-shaped hollow chamber component which has hollow chambers, under the effect of pressure and rotation, comprising a main part which comprises a thermoplastic synthetic material. The connection element has a longitudinal axis and is designed to rotate about the longitudinal axis, and the connection element has an upper face with a tool placement point and a lower face which faces away from the upper face, wherein the connection element has an expanding portion made of a thermally activatable expandable material on the main part on a circumferential surface extending between the upper face and the lower face.

Abstract: The present invention relates to a multi-layered sheet suitable as floor or wall covering exhibiting a three-dimensional surface relief and a decorative image, comprising: i. a support layer having an upper surface and a lower surface; ii. a foamed layer having an upper surface and a lower surface, the lower surface of the foamed layer provided adjacent, and adherent to the upper surface of the support layer, the upper surface of the foamed layer comprising a discontinuous chemically embossed relief pattern, wherein the discontinuous chemically embossed relief pattern comprises indentations formed by single or stacked dots of a digitally printed material comprising a foam inhibiting agent; and optionally iii. a decorative layer adhered to the upper surface of the foamed layer; and optionally iv. at least one wear resistant layer provided adjacent and adhered to the decorative layer; and optionally v. a backing layer provided adjacent and adhered to the lower surface of the support layer.

Abstract: Methods of manufacturing composite workpieces that include positioning a heat-generating element proximate to an uncured composite workpiece, triggering the heat-generating element to produce an exothermic chemical reaction or exothermic physical reaction so that the temperature of the uncured composite workpiece is raised to a predetermined first temperature, and curing the composite workpiece while it is at a temperature that is at least the predetermined first temperature.

Abstract: A polymeric material for use in thermal insulation is provided. The polymeric material is formed from a thermoplastic composition containing a continuous phase that includes a matrix polymer and within which a microinclusion additive and nanoinclusion additive are dispersed in the form of discrete domains. A porous network is defined in the material that includes a plurality of nanopores having an average cross-sectional dimension of about 800 nanometers or less. The polymeric material exhibits a thermal conductivity of about 0.20 watts per meter-kelvin or less.

Abstract: This invention describes a 3-layer insulation material (10) comprising a first fabric layer (12), a second fabric layer (14) and a third fluted intermediate fabric layer (16) between the first and the second fabric layers (12, 14), the fluted intermediate fabric layer (16) being attached alternately to the first and the second fabric layer (12, 14) with longitudinal seams (18a-18n) forming longitudinal channels (20a-20n) for the insulation material (22) having individual insulation material (22) bundle in-side each longitudinal channel (20a-20n). Also disclosed are a method and an arrangement for producing the same.

Abstract: A method for manufacturing a physical security element with a spatially appearing pattern includes a carrier and at least one see-through transparent cover layer. Onto the carrier is applied a design layer deformable under pressure. Either the carrier has a lower dimensional stability under heat than the cover layer, or a cover layer has a lower dimensional stability under heat than the carrier. A see-through transparent structural layer forming the pattern is arranged between carrier and cover layer. The structural layer has a higher dimensional stability under heat than either the carrier or a cover layer. During lamination, the structural layer is pressed into the carrier or into the cover layer, whereby the design layer is deformed under the pattern formed by the structural layer and the structural layer in its edge regions is reshaped in such a way that its surfaces, in cross-section, converge tangentially.

Abstract: A reflector antenna, preferably a fixed mesh reflector antenna, and a process for manufacturing the reflector antenna, is disclosed that includes forming a support structure, placing a reflector surface on a mold, attaching the support structure to the reflector surface, measuring the geometry of the reflector surface, adjusting the surface geometry of the reflector if appropriate to obtain improved accuracy for the reflector surface, and fixedly connecting the support structure and the reflector surface. In an embodiment, the antenna reflector system includes a mesh reflector surface, a plurality of spline support elements, a plurality of splines connected to the reflector surface, and a plurality of adjustable spline supports attachable to the spline support elements and the splines, wherein the adjustable spline supports are adjustably repositionable with respect to the spline support elements, and also fixedly connectable to the spline support elements.

Abstract: A method for reinforcing, baffling or sealing a vehicle structure, comprising the steps of providing one or more materials having a horizontal axis, at least one terminating edge, and an initial length, forming openings in the one or more materials, and applying the one or more materials to a location requiring reinforcement, baffling, sealing or any combination thereof.

Abstract: Aspects are disclosed of a filler for occupying a volume. The filler includes an expandable filler positioned in the volume so that it occupies a percentage of the volume. The expandable filler can permanently expand from a first dimension to a second dimension upon the application of an expansion trigger. The filler also includes an acoustic filler made up of a plurality of acoustically active beads positioned with the expandable filler in the volume so that the acoustic filler can adsorb gas flowing into the volume. Other embodiments are disclosed and claimed.

Abstract: A vehicle seat back may include an integrated suspension structure including a suspension wire and suspension mounting guides coupled to both sides of the suspension wire; and a seat back pad foamed for integrating with the integrated suspension structure in a state in which the integrated suspension structure is inserted into a mold for seat back pad formation.

Abstract: A method for creating a three dimensional (3D) object from reactive components that form a thermoset product. In one embodiment, a method includes providing first and second reactive components that are effective to form the thermoset product. In one embodiment, the thermoset product includes a urethane and/or urea-containing polymer. In one embodiment, the first reactive component includes an isocyanate and the second reactive component includes a polyol having at least one terminal hydroxyl group, a polyamine having at least one amine that includes an isocyanate reactive hydrogen, or a combination of the polyol and the polyamine. In one embodiment, the first reactive component includes a prepolymer, and optionally the ratio of viscosity of the first and second reactive components is from 1:3 to 3:1. Also provided is a 3D object that includes a completely reacted thermoset product, and a thermoset system that includes a first and a second reactive component.

Abstract: Floor covering material, wherein this floor covering material comprises at least a foamed layer, a printed decor provided thereon, and preferably a transparent wear layer, wherein the printed decor represents a plurality of panel-shaped or tile-shaped elements, wherein at the edges of said represented elements, lowered edge regions are formed, which form at least a portion of the circumference of the respective element, wherein said lowered edge regions, seen in cross-section, are realized with at least two different geometries. The invention further also relates to a method for manufacturing such floor covering material.

Abstract: An absorbent core for an absorbent article, the absorbent core comprising at least two layers, each layer having a width w and a length l along a first plane and a thickness t extending perpendicular thereto, wherein the layers are arranged in facing relationship along the first plane, and wherein the layers comprise a polymeric foam having an open cell and interconnected porous structure. The first and second layers comprise an anisotropic cell structure having an axis of anisotropy extending substantially parallel to a longest length of a plurality of substantially neighbouring cells. The axis of anisotropy of the second layer extends substantially perpendicular to said thickness t and parallel to said first plane and the axis of anisotropy of the first layer is substantially perpendicular to the axis of anisotropy of the second layer.

Abstract: A foam laminate dressing includes a first distinct hydrophobic reticulated foam layer and an underlying second distinct hydrophilic layer bonded to the first layer and of substantially same length and width as the first distinct hydrophobic reticulated foam layer.

Abstract: 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.

Abstract: A motor vehicle roof shell having a rigid composite component having an inner side facing a vehicle interior, and an acoustic insulation layer disposed on the inner side of the composite component. The panel-type rigid composite component has at least one tray-like recess on its inner side, said recess being filled with an open-pored foam material which forms the acoustic insulation layer and whose surface is flush with a surface of the composite component surrounding the recess. A motor vehicle roof shell motor vehicle having a panel-type rigid composite component having an inner side, which faces the vehicle interior, and an acoustic insulation layer disposed on the inner side of the composite component, wherein the acoustic insulation layer is formed by at least one rigid-foam or semi-rigid-foam plate which is bonded to the inner side of the composite component and compressed that its volume is reduced compared to preassembly state.

Abstract: A vehicle seat includes a headrest, a seat back to which the headrest is attached, and a seat cushion connected to the seat back. The headrest includes pillar frames attached to the seat back, a core member that includes a pouring passage penetrating from one end to the other end, a cover that covers the core member and a part of the pillar frames, and a cushion member that is formed in a gap between the outer surface of the core member and the inner surface of the cover and inside the pouring passage. The pouring passage extends in a first direction from the one end of the core member to reach a predetermined position, extends in a second direction from the predetermined position to reach the other end, and includes a bent part at the predetermined position.

Abstract: A composite material for purifying air includes a porous foam material which is an open-cell polyurethane foam net; and a mixture sprayed on the interior and/or the surface of the porous foam material, the mixture including an absorbent material, a treating agent and an adhesive; wherein the adsorptive material is diatomite, and the treating agent is alkali solution.

Abstract: Soft touch fire retardant laminates with PVC middle layers, foamed or unfoamed, and multiblock copolymer or polyurethane or silicone top layers which meet FAA requirements are disclosed.

Abstract: A toilet seat includes a bottom plate, a top plate, and a bonding member. The top plate includes a sidewall part and a seating part. The sidewall part is provided on the bottom plate along a vertical direction. The seating part is supported by the sidewall part. The bonding member bonds the bottom plate and the sidewall part. The bonding member has an exposed surface exposed externally. The exposed surface is positioned below a central plane of the bottom plate and positioned outward of a central plane of the sidewall part.

Abstract: A sound absorbing mat comprising a first polyurethane open cell polyester layer, wherein the first polyurethane open cell polyester layer is at least one quarter of an inch thick, a polyvinyl chloride layer having a top surface and a bottom surface, wherein the polyvinyl chloride layer is at least a quarter inch thick and the bottom surface is fused to the first polyurethane open cell polyester, a second polyurethane open cell polyester layer having a top surface and a bottom surface, wherein the second polyurethane open cell polyester layer is at least three quarters of an inch and the bottom surface of the second polyurethane open cell polyester layer is fused with the top surface of the polyvinyl chloride layer, and a urethane layer, wherein the urethane layer is at least a quarter inch thick and is mated to the top surface of the second polyurethane open cell polyester layer.

Abstract: A method for manufacturing panels with at least a substrate and a top layer. The method having the steps of providing a granulate having thermoplastic material and having an average particle size of less than 1 millimeter, forming a substrate layer by strewing the granulate, consolidating the layer between the belts of a continuous press device, and providing the top layer on the substrate.

Abstract: A paper-based watercraft board (e.g., a surfboard) and a method of making a paper-based watercraft template (i.e., a blank or core) and watercraft board are described. The surfboard template composes paper-based materials to produce sustainable and recyclable alternative to traditional foam core surfboards.

Abstract: Example systems and methods are described including backing paper for use with uncured pre-impregnated material. An example system includes a backing paper having a first surface and a second surface. The system also includes a coating material positioned on the first surface of the backing paper. A blowing agent is encapsulated within the coating material.

Abstract: The present disclosure discloses a loudspeaker module and a manufacturing method thereof. The loudspeaker module comprises an outer casing; the outer casing accommodates a speaker unit; the speaker unit partitions an inner cavity of the whole module into two cavities: a front acoustic cavity and a rear acoustic cavity; the rear acoustic cavity is internally provided with a sound-absorbing material; the rear acoustic cavity is further provided with an isolating structure used for isolating the sound-absorbing material from the speaker unit; the isolating structure partitions the entire rear acoustic cavity into a filling area and a non-filling area; the sound-absorbing material is located in the filling area; the sound-absorbing material is a foaming material; the sound-absorbing material is formed by the foaming of the foaming material and then fills the filling area.

Abstract: The present invention is a variable-rocker surfboard, comprising: a tapered composite panel enveloped partially or entirely in a soft foam. The tapered composite panel is oriented horizontally partially or entirely within the soft foam, such that the length, width, and thickness of the panel correspond with the length, width, and thickness of the soft foam. The objective of this design is to provide a surfboard with desirable flex characteristics that result in variable rocker, wherein the tapered composite core attributes the flex characteristics, and the soft foam provides volume for the desired buoyancy. The present invention may be provided as a surfboard blank, wherein the soft foam needs to be worked into a surfboard shape. The present invention, may also be provided as a surfboard, wherein the soft foam has been shaped to the desired design and may be laminated with an exterior skin.

Abstract: A cellular structure may include a plurality of cells each cell of the plurality of cells having a sixteen-cornered cross section. The sixteen-cornered cross section may include sixteen sides and sixteen corners. Each cell may include a plurality of longitudinal walls extending between a top and a bottom of the cell, the longitudinal walls intersecting to create corners of the cell.

Abstract: A method for fabricating emulated wood with pores and fibers, comprising: immersing a plurality of synthetic fibers configured parallel in a plane into a resin so that the resin is coated on the surfaces of the plurality of synthetic fibers and in the gaps between the plurality of synthetic fibers; placing the plurality of synthetic fibers between two sheets, wherein the two sheets are planar sheets made from a uniform composition comprising a thermoplastic elastomer, a foaming agent, and a crosslinking agent; carrying out a heat-press process on the two sheets so that the foaming agent undergoes microcellular foaming and forms dense closed pores in the two sheets, and so that the composition on inner surfaces of the two sheets expands towards the plurality of synthetic fibers and penetrates through the gaps between the plurality of synthetic fibers; and cooling the two sheets to yield an emulated wood board.

Abstract: Interior panels for motor vehicles and methods for making such interior panels are provided. In one example, an interior panel includes a substrate and a skin covering that at least partially overlays the substrate. A foam is disposed between the skin covering and the substrate. A gas-receiving hollow structure is at least partially disposed in the foam. The gas-receiving hollow structure has an opening configured for receiving gas and includes a wall that at least partially surrounds a chamber that is in fluid communication with the opening.

Abstract: A structural reinforcement for an article including a carrier that includes: (i) a mass of polymeric material having an outer surface; and (ii) at least one consolidated fibrous insert (14) having an outer surface and including at least one elongated fiber arrangement having a plurality of ordered fibers arranged in a predetermined manner. The fibrous insert is envisioned to adjoin the mass of the polymeric material in a predetermined location for carrying a predetermined load that is subjected upon the predetermined location (thereby effectively providing localized reinforcement to that predetermined location). The fibrous insert and the mass of polymeric material are of compatible materials, structures or both, for allowing the fibrous insert to be at least partially joined to the mass of the polymeric material. Disposed upon at least a portion of the carrier may be a mass of activatable material.

Abstract: A padding assembly for a helmet includes a plurality of pads that is configured to couple to an external surface of the helmet, such as a football helmet. The pads are configured to absorb a force from an impact to the helmet when the helmet is positioned on a head of a user. The force of the impact to the head of the user is reduced.

Abstract: A catalyst precursor suitable for the Fischer Tropsch reaction is described comprising cobalt oxide supported on a porous support wherein the porous support is a ceramic foam comprising a closed cell structure.

Abstract: The present disclosure discloses a loudspeaker module and relates to the technical field of electroacoustic products. The loudspeaker module comprises an outer casing; the outer casing accommodates a speaker unit; the speaker unit comprises a vibration system and a magnetic circuit system; the speaker unit partitions an inner cavity of the whole module into two cavities: a front acoustic cavity and a rear acoustic cavity; the rear acoustic cavity is internally provided with a sound-absorbing material; the rear acoustic cavity is further provided with an isolating structure used for isolating the sound-absorbing material from the speaker unit; the isolating structure partitions the entire rear acoustic cavity into a filling area and a non-filling area; the sound-absorbing material is located in the filling area; the sound-absorbing material is a foaming material; the sound-absorbing material is formed by the foaming of the foaming material and then fills the filling area.

Abstract: A multi-layered composite material suitable for use in orthopedics includes a foam core layer bonded between two layers of thermoformable polymer material. The thermoformable material is heat formable within a target temperature range allowing for rapid heating and application to a patient such as in the form of a splint. While within the target temperature range, the composite material includes a dwell time sufficiently long to enable proper fitment and adjustment, yet not overly long requiring extended periods of holding the composite material in place. The composite material is very light yet extremely rigid and easily conformable to patients.

Abstract: A rivetable adhesive for use in a joint between dissimilar materials, comprising a liquid epoxy resin, an expoxidized polysulfide, a flexibilizer, a solid epoxy CTBN adduct based upon bisphenol A, a phenoxy resin, an impact modifier including methacrylate-butadiene-styrene, a curing agent; and a blowing agent. The adhesive finds particular suitability for use in riveting aluminum panels to steel structures, such as for forming automotive vehicle roof structures.

Abstract: A panel assembly is formed by a plurality of bonds between two sheet materials in a face to face relationship to form a preform. The plurality of bonds define a closed perimeter region between the two sheet materials and an open perimeter region between the two sheet materials. The preform may be formed into a predefined shape. Pressurized fluid is applied through an inlet into the open perimeter region to expand the preform. The pressurized fluid expands the open perimeter region such that the two sheet materials expand in an opposing direction, thereby defining an expanded open perimeter region. The closed perimeter region between the two sheet materials remains vacant of the pressurized fluid such that the closed perimeter region is not expanded. The expanded open perimeter region is filled with a filler material for improving a performance characteristic of the panel assembly, e.g., strength, sound absorption, or stiffness.

Abstract: Techniques and mechanisms to form a semi-rigid structure from a flexible sheet. In an embodiment, a portion of the flexible sheet includes layer portions and one or more compartments each disposed between said layer portions. The one or more compartments each having disposed therein a first fluid compound that is reactive—e.g., when exposed to oxygen, heat, ultraviolet (or other) light, or a different fluid compound—to form a solid. In another embodiment, a graphic printed on the flexible sheet indicates a location of the one or more compartments. Activation of the one or more compartments and bending of the flexible sheet portion at the activated one or more compartments aids in the formation of a shelter or other semi-rigid structure.

Abstract: The present disclosure provides a headliner assembly for a vehicle. The headliner assembly includes a base panel and a cover layer disposed below the base panel. The base panel includes an edge in a length direction of the vehicle and a portion adjacent to the edge and having a plurality of notches. The cover layer has an edge extending beyond the edge of the base panel.

Abstract: A biomimetic skin for an animatronic figure and other applications is provided. The biomimetic skin may include an outer layer having a surface texture, and an inner layer attached to the outer layer. The inner layer may include a compressible cellular material. The outer layer may move correspondingly with the inner layer such that as the inner layer is moved the outer layer moves.

Abstract: A walk-in refrigeration room system effective for providing and defining an interior chilled air space includes an outer wall layer, a framing layer defining a series of spaces having a depth of at least 6? inside the outer wall layer, an outer layer of insulation that has been sprayed into the framing layer spaces, a middle wall layer, an inner foamboard insulation layer, a vapor barrier layer, an optional inner wall layer, a door to permit walk-in access to the interior chilled air space, and one or more functional openings to permit electrical connections and/or chilled air to enter or exit the chilled air space. The inner wall layer forms an air-tight envelope when any doors or windows in the inner wall layer are closed. The outer insulation layer and the inner insulation layer overlap in a manner that does not contain any insulation gaps or thermal bridges.

Abstract: Foamable polystyrene compositions with enhanced blowing agent solubility and methods of making such polystyrene compositions by incorporating a polar additive in styrenic polymer or copolymers.

Abstract: A spray foam formulation used to form a spray foam insulation layer in a wall structure is described. The formulation may include the reaction product of a polyisocyanate compound and a polyol compound; a fire retardant chosen from at least one of a non-halogenated fire retardant; and a reactive halogen-containing fire retardant, and a carbohydrate. The spray foam insulation layer has an insulative R value of 3.0 to 7.2 per inch, and a density of between about 0.3 to about 4.5 pcf. Further, spray foam insulation made from the spray foam formulation may have fire retardant characteristics that are equivalent to or better than a similar spray insulation foam insulation using non-reactive halogenated fire retardants such as tris(1-chloro-2-propyl)phosphate (TCPP).

Abstract: A method of fabricating a formed structure with expandable polymeric shell microspheres. A first plurality of polymeric shell microspheres are heated from an unexpanded state to an expanded state to form a plurality of expanded microspheres. The plurality of expanded microspheres are mixed with an epoxy resin and a second plurality of unexpanded polymeric shell microspheres. The mixture is formed in a shape to create a preform. The preform is wrapped with fiber tape to create a wrapped preform. The wrapped preform is placed in a mold. The mold is heated and the second plurality of unexpanded microspheres expand from an unexpanded state to an expanded state. The mold is cooled and the formed structure is removed from the mold.

Abstract: A continuous process for preparing insulation panels having thick (0.2 mm to 1 mm) metal facing panels and a fiber-reinforced polymer foam core is disclosed. In the process, a bottom metal facing panel (2) is continuously supplied. A mat (10) of reinforcing fibers and a foamable resin composition (19) are applied to the bottom facing panel. A flexible barrier layer (5) is applied atop the foamable resin composition, and the assembly is passed through nip rolls (12,13) to compress the assembly and force the resin composition into the fiber mat. An adhesive layer (4) and top metallic facing layer (1) are then applied on top of the flexible barrier layer, and the resulting assembly is gauged and cured by passing it through a double band laminator (11).

Abstract: An asymmetric tape and a system and method for impregnating at least one fiber roving with a polymer resin to form an asymmetric tape are provided. The asymmetric tape includes a polymer resin, and a plurality of fibers embedded in the polymer resin to form a fiber reinforced polymer material. The fiber reinforced polymer material includes a first surface and an opposing second surface. The fibers are disposed in the fiber reinforced polymer material to form a resin rich portion and a fiber rich portion. The resin rich portion includes the first surface and the fiber rich portion includes the second surface.

Abstract: An improved adhesive composition having increased insulative properties is provided. The adhesive composition having improved insulative properties includes a starch component; an alkaline component; sodium tetraborate; water; and a plurality of expandable microspheres. Products having improved insulation capabilities and methods of making the products having improved insulation capabilities are also provided. The present adhesive and products including the adhesive is environmentally friendly.

Abstract: A wind turbine tower is made of reinforced concrete with fiber rovings as reinforcements, wherein the fiber rovings are basalt fiber rovings. In one embodiment, the basalt fiber rovings may include, for example, a bundle of multiple parallel oriented basalt fibers forming a thin rope. In one embodiment, the tower is produced in a slip forming process or slip molding process, wherein the basalt fiber rovings are embedded in the concrete during the slip forming process.