Abstract: An exemplary method for manufacturing and reinforcing a corner in an object made from a sandwich structure, having a thermoplastic core layer (18), which is arranged between two cover layers (16), at least one of which is a plastic cover layer, which method includes the steps of: producing an object including a corner between two object parts; positioning a thermoplastic core part (24) and an additional fiber-reinforced thermoplastic layer (26) in the corner, which thermoplastic core part has a shape adapted to the corner, in such a manner that the additional fiber-reinforced thermoplastic layer (26) substantially covers the exposed surface of the core part (24); and connecting a cover layer (16) of the sandwich structure to the additional fiber-reinforced thermoplastic layer (26).

Abstract: An apparatus for making a shingle, together with the shingle made thereby, is provided, in which one or more thermoplastic materials are extruded or co-extruded to form an extrudate, with the extrudate being cut into a preliminary shingle shape, which is allowed to dissipate heat, and then is delivered to a compression mold, wherein the preliminary shingle shape is compression molded to substantially its final dimensions and is then discharged from the mold and allowed to cool.

Abstract: A fabrication method of forming curved thermoplastic composite laminate parts with tailored and varying thickness in a continuous process. Automated equipment or hand lay-up are used to collate parts or components into a multi-layer stack. Each stack contains all plies, including ply build-up areas, tacked in the proper location to maintain orientation and location. Ply consolidation tooling contains all necessary part features and is coordinated to the customized multiple ply stacks to form a single integrated thermoplastic composite laminate potentially having areas of differing thickness from the multiple ply stacks.

Abstract: A method of manufacturing a foam having a negative Poisson's ratio comprising the steps: placing a pad 12 of open cell polyurethane foam on a moulding surface 4; placing a flexible membrane 18 over the exposed surface of the foam to create a sealed chamber 20 between the moulding surface 4 and the flexible membrane 18 in which the foam pad 12 is disposed; applying an isostatic pressure difference between the inside and the outside of the chamber 20 thereby collapsing the foam pad 12 between the flexible membrane 18 and the moulding surface 4; heating the foam pad 12 to a predetermined temperature, and subsequently cooling the foam pad 12 while collapsed.

Abstract: The invention relates to a packing material for biofilters, having a polyurethane polymer and starch. The packing material is resistant to compaction, can sorb pollutant organic compounds and reduces the start-up time of the biofilter. The packing material can be used as a substrate in the biofiltration of volatile and/or semi-volatile organic compounds present in gaseous or liquid effluents.

Abstract: A process for the preparation of thermoplastic auxetic foams comprising the steps of: a) taking conventional thermoplastic foam; b) subjecting said foam to at least one process cycle wherein the foam is biaxially compressed and heated; c) optionally subjecting the foam to at least one process cycle wherein the biaxial compression is removed and the foam mechanically agitated prior to reapplying biaxial compression and heating; d) cooling said foam to a temperature below the softening temperature of said foam; and e) removing said compression and heat.

Abstract: To provide a lactic acid polymer composition excellent in transparency, heat resistance and productivity, a molded article, a sheet and a multilayer sheet each of which comprises the composition, a thermoformed article obtained by secondary-forming the sheet or the multilayer sheet, and a process for producing the thermoformed article with excellent productivity. The lactic acid polymer composition of the invention comprises 100 parts by weight of a lactic acid polymer (A), 0.1 to 3 parts by weight of an organic crystal nucleating agent (B) comprising an aliphatic carboxylic acid amide having an amide bond, and 0.1 to 7 parts by weight of a crystallization accelerator (C). The thermoformed article of the invention is obtained with excellent production efficiency by thermoforming the sheet comprising the composition of the invention at a temperature of 60 to 130° C.

Abstract: A Styrofoam densification machine for melting used Expanded Polystyrene (Styrofoam) products. It includes a hopper for holding the disposed Styrofoam and a hopper discharge area for melting the used Styrofoam. The Hopper discharge area contains a heated tray compartment which holds a receiving tray for collection of melted Styrofoam. The compartment shall have two or less access area doors for the retrieval of the collection tray. The discharge and compartment tray areas have silicone heating pads on the outside of the panels for heat. The hopper is surrounded by a paneled cabinet which includes up to two inches of installation. The machine is loaded by way of mechanical hopper lid(s) which includes up to two lid panels, high temperature seals, hinges and handles for ease of opening. The machine sits on up to four (4) casters along with anchoring plates. The machine operates on 120 volts, 208 volts and 240 volts.

Abstract: Sound-absorbing material is provided which is more effective for the same volume. A sound-absorbing body is formed characteristically by hot-compression molding of a raw material (C) comprises a flexible polyurethane foam to a volume ratio ranging from 1/1.5 to 1/12. In the molding, metal molds (A·B) are heated in an electric furnace up to a set temperature of 180° C.; the flexible polyurethane foam of the cell number of 50 is held between the metal molds (A·B), and compressed and heated in the electric furnace in this state at 180° C. for 60 minutes; the fixing clamp is removed; and the hot-compressed urethane foam is taken out to obtain the intended sound-absorbing body.

Abstract: An integrated refrigerator car carriage structure is disclosed. The carriage structure has a protection layer (8) and an insulating layer. The insulating layer is composed of a left side plate (1), a right side plate (4), a head plate (2), a sole plate (5), a fore sealing plate (3) and a back sealing plate (6), that are injection molded with polyurethane material. The protection layer is adhered on the insulating layer. The plates of the insulating layer are connected with each other in a seamless manner, so as to form a unitary structure. It discloses a mounting method of the integrated refrigerator car carriage structure also. The structure is simple and easy to manufacture with improved space utilization rate and heat insulation performance.

Abstract: A method of moulding a plastics part provides mating pressure plates, at least one of which has a mould cavity. The pressure plates are maintained at a substantially constant cooling temperature. The plastics blank is pre-heated to a moulding temperature and thereafter placed between the pressure plates which are forced together to form the plastics part in the mould cavity.

Abstract: A plant for manufacturing a continuous latex foam layer (2) to form mattresses (6) provided with cells (5). The plant comprises a plurality of laying planes (7) provided with a plurality of separate tables (13) separately arranged side by side to form a surface for the foam deposit. Each table comprises protuberances (14) and the arrangement of the protuberances on a table can differ from that of the juxtaposed tables in order to create supporting areas for the different body parts of the user. Preferably the tables (13) with their protuberances (14) are slidably fitted onto the laying planes (7) and can be easily and quickly replaced with separately provided tables having protuberances (14) differently arranged in order to meet the support capacity values required by different users.

Abstract: A method of making an outer shell, the method comprising: (a) providing first and second sheets, each of the first and second sheets being made of a layer of high-density polyethylene, polypropylene, polyurethane or polycarbonate extruded with a layer of non-woven fabric; (b) providing a third sheet made of high-density polyethylene foam, polypropylene foam, polyurethane foam or polystyrene foam, the third sheet having top and bottom sides; (c) affixing a first layer of adhesive film on the top side of the third sheet; (d) affixing a second layer of adhesive film on the bottom side of the third sheet; (e) placing the third sheet between the first and second sheets such that the first layer of adhesive film of the third sheet contacts the layer of non-woven fabric of the first sheet and the second layer of adhesive film of the third sheet contacts the layer of non-woven fabric of the second sheet; (f) stitching together the first, second and third sheets in order to form a composite sheet; and (g) thermoformin

Abstract: Composites such as self-supporting rigid composites that include aerogel have low thermal conductivity and attractive mechanical properties. Methods for preparing such composites include, for example, combining an aerogel-containing material with a binder to form a slurry and allowing the slurry to harden. At least part of the hardening process in conducted under compression.

Abstract: A floating bed includes a body having four edges, including an upper edge, a lower edge, and two side edges. The body is optionally made from foam materials or foam rubber materials, such as polyethylene (PE) or ethylene vinyl acetate (EVA). The body has first and second surfaces that include a plurality of transverse concave and convex ridges that are optionally evenly distributed. Each concave ridge on the first surface optionally corresponds to a convex ridge on the second surface, and each convex ridge on the first surface optionally corresponds to a concave ridge on the second surface.

Abstract: The present invention relates to a process for producing shaped articles comprising, acting on a foam layer in a first region with a pressure of from 0 to 150 bar at a temperature of from 0° C. to less than or equal to 200° C., whereby the foam layer is compressed in the first region to greater than 12.5% to 100% of its original volume; acting on the foam layer in a second region with a pressure of from 50 to 150 bar at a temperature of from 100° C. to 200° C., whereby the foam layer is compressed in the second region from greater than 0% to 12.5% of its original volume; and wherein the foam layer comprises in the first region and the second region a polyurethane foam which is obtained by foaming and drying a composition comprising an aqueous, anionically hydrophilicized polyurethane dispersion.

Abstract: An air filter for a small internal combustion engine. The air filter includes a foam body having at least one flute which increases the outside area of the foam body. The fluid is formed in the foam body by compressing the foam body between two mold halves under pressure and heat until the foam body thermally sets with the formed flute.

Abstract: A method of forming a layered article, the method comprises thermoforming a substrate sheet to form a shaped substrate, wherein the shaped substrate is a fiber-reinforced plastic material having a void content sufficient to allow a vacuum to be applied through the shaped substrate; pulling a vacuum through the shaped substrate; and pulling a film layer onto a surface of the shaped substrate to form the layered article.

Abstract: A method of forming a layered article, the method comprises thermoforming a substrate sheet to form a shaped substrate, wherein the shaped substrate is a fiber-reinforced plastic material having a void content sufficient to allow a vacuum to be applied through the shaped substrate; pulling a vacuum through the shaped substrate; and pulling a film layer onto a surface of the shaped substrate to form the layered article.

Abstract: Load-bearing articles are manufactured from shape defining compressible cores and thermoplastic shells. The manufacture of these articles requires specific methods and tools. Articles that can be manufactured using these methods include relatively lightweight pallets with high load-bearing capacity.

Abstract: A method for processing a stamp material generally includes: heating one of a pressing member and a surface layer of the stamp material; pressing the surface layer of the stamp material using the pressing member; and cooling the stamp material to normal temperature.

Abstract: The present invention relates to process for the manufacturing of mattresses characterized in that a liquid molding substance of the same material as the construction pieces (1, 3, 4, 6) is used in all the joints between the pieces. The process comprises steps wherein: the bottom piece (1) is laid out; the molding substance (2) is applied to the longitudinal edges (3) and cross edges (4) on one surface side of the bottom piece (1); the longitudinal pieces (3) and cross pieces (4) are lowered into a molding substance (2) and hardened; the molding substance (2) is applied on the same surface side of the bottom piece (1) between the longitudinal pieces (3) and cross pieces (4); a core (6) is lowered into the molding substance (2) and hardened; and the top piece (7) is provided with molding substance (2) and turned with the molding substance (2) facing the named upright longitudinal pieces (3) and cross pieces (4) and lowered onto the same and hardened.

Abstract: The present invention relates to a method of making mounting mats for use in pollution control device.

Abstract: A sun visor for use in a vehicle is disclosed. The sun visor includes a first and second visor body shell. The shells define a retaining channel for a slider on a visor pivot rod and may be engaged and enclosed about the slider. It is also contemplated that the sun visor has a combination slider and detent slidably supported in channels molded into the first and second visor shells. A support arm may be provided and is readily offset from the combination slider and detent and is slidable relative thereto.

Abstract: A method and apparatus for the making of an impression of a person's foot in foam to be used in the manufacture of orthotics comprising in combination a box of foam that will be deformed by the person's foot during the making of a foot impression, placed in foam box receptacle that is supported on a base and which can adjustably swivel or rotate so that the person's knee, ankle and foot will be put in a neutral position and when in use the person is placed in a seated position and a box of foam is placed in the receptacle and a strap assembly is used to exert a downward force on the person's lower leg, the strap being secured to a lever arm used to exert a downward pressure and engage with a block arm which correspondingly exerts a downward force on a block situated above the box of foam and which pushes the foot down into the foam and wherein the block is slideable transversely to the box of foam to align with the arch of the person's foot and to insure that the block exerts its downward pressure evenly and

Abstract: The present invention relates to a process for producing ROHACELL® foams with a compacted surface. Markedly less adhesive then has to be applied during lamination and the good mechanical properties of the ROHACELL® foams are retained. The invention further permits the use of ROHACELL® foams as a removable core.

Abstract: The present invention relates to a process for thermoforming a foamed polyester sheet of low crystallinity to produce a heat-resistant molded foam article (13). The process comprises the steps of heating a foamed polyester sheet (10) to a preforming temperature by contact with at least one heating plate and molding the heated foamed polyester sheet onto a non-heated mold (30). The present invention further relates to a process for manufacturing a package by thermoforming a foamed polyester sheet of low crystallinity to produce a heat-resistant molded foam container, loading a product (51) into said container and sealing or welding a film of thermoplastic material (61) onto said container to close it. The heat-resistant molded foam articles and the packages thus obtained are excellent in heat resistance and are not thermally distorted even when heated in a microwave or conventional oven. They are particularly useful for the packaging of food products for dual ovenable applications.

Abstract: A solid state foaming process permits the use of up to 100% recycled pre- and post-consumer polymer for the manufacture of foamed polymer material and thermoformed foamed polymer articles. The process enables the optional formation of integral unfoamed skins of controllable depth and crystallinity on foamed polymeric materials suitable for a wide variety of applications. Because this process does not alter the underlying chemistry of the material all scrap from the manufacturing process may be reused without additive to form new foamed polymeric materials and articles.

Abstract: The invention is directed to a molded foam sports board made by steps: molding a foam core having a molded contour surface; laminating an extruded adhesive resin layer to a polyolefin foam sheet layer forming a film foam laminate; and thermoforming and heat laminating the film foam laminate to the molded foam core by pressing the molded foam core towards the film side of the film foam laminate and mating against the profile of a thermoforming bottom die surface. The board has a thermoformed polyolefin foam skin having an outer surface and an inner surface, a molded foam core having a molded contour surface, an extruded adhesive resin layer bonding the inner surface of polyolefin foam skin layer to the molded contour surface of the molded foam core. The molded foam core may comprise homopolymer or copolymer of expanded polystyrene foam, expanded polyethylene foam, expanded polypropylene foam and polyurethane foam.

Abstract: This invention discloses improvements that can be achieved in thermal or mechanical performance of aerogel composites via densification. Densified aerogels and aerogel composites can display higher compressive strength, modulus, flexural strength, and maintains or insubstantially increases the thermal conductivity relative to the pre-densified form. In the special case of fiber reinforced aerogel composites densification via mechanical compression can prove highly beneficial.

Abstract: An article of manufacture comprising a sag-resistant nucleus-forming monolithic composite capable of being located within a hollow interior portion of a structural material and being expanded therein. Also, articles of manufacture comprising open-cellular structural material containing within the open-cell or cell thereof, at least one sag-resistant nucleus-forming monolithic composite. The composite is desirably in the shape of a plug that is similar or close to similar to the shape of the hollow interior. In addition, there is described a process that comprises forming a pre-shaped sag-resistant nucleus-forming monolithic composite for use in reinforcing and stiffening a normally open-cellular structural material. Also described is a process for reinforcing or stiffening a normally open-cellular structure, any tubular structure, or any channel structure, by putting at least one sag-resistant nucleus-forming monolithic composite within a hollow interior portion of the structure.

Abstract: Load-bearing articles are manufactured from shape defining compressible cores and thermoplastic shells. The manufacture of these articles requires specific methods and tools. Articles that can be manufactured using these methods include relatively lightweight pallets with high load-bearing capacity.

Abstract: This invention provides method for placing indicia on a support for an imaging element comprising embossing indicia, such as a logo, on a roller; providing a support wherein said support comprises a closed cell foam core and adhered thereto at least one flange layer, wherein said closed cell foam core comprises a polymer that has been expanded through the use of a blowing agent; and pressing said support against said embossed roller.

Abstract: Load-bearing articles are manufactured from shape defining compressible cores and thermoplastic shells. The manufacture of these articles requires specific methods and tools. Articles that can be manufactured using these methods include relatively lightweight pallets with high load-bearing capacity.

Abstract: An improved neurosurgical sponge contains less than 0.45 EU/cm3 of bacterial endotoxins. A neurosurgical kit includes a plurality of sponges in a container, wherein the plurality of sponges contains less than 2.15 EU. Methods of producing the surgical sponge and using the surgical sponge in a surgical method are described. Rayon containing less than 0.45 EU of bacterial endotoxins per cm3 of rayon is also described.

Abstract: A mask to improve the comfort and eye health of individuals suffering from dry eye syndrome including a substantially vapor impermeable shell with a unitary structure having a substantially planar portion and two eye recesses. Each eye recess forms a generally concave dome shaped region on one side of the substantially planar portion. The shell is adapted to be worn on the face of the dry eye subject. An absorbent material can be positioned in at least one of the eye recesses; so that the absorbent material extends less than the maximum depth of the eye recesses to present the absorbent material to the face in the vicinity of the eyes of the dry eye subject without extending beyond the edge of the substantially planar portion. The invention may also include securing member to secure the shell to the subjects head.

Abstract: An automobile trim has a trim body (a base layer) formed of a rubber composition and having a design surface, a decorating layer formed of a thermoplastic elastomer composition and thermally bonded integrally with the design surface of the trim body. A thermal bonding layer is formed of a thermoplastic resin composition and interposed between the decorating layer and the trim body so that the decorating layer is thermally bonded integrally with the trim body through the thermal bonding layer. The thermal bonding layer has a thickness to an extent not to prevent bending flexibility when the trim is attached to a vehicle body. In another example, a cushion layer is laminated on the trim body and formed of sponge rubber of EPDM, a decorating layer is laminated on the cushion layer and formed by foaming olefin thermoplastic elastomer, and an olefin bonding layer for bonding the cushion layer and the decorating layer.

Abstract: In a method for producing a trim article (1), the interspace between a sheet-like decorative material (5) and a carrier (3) is foam-filled. There is provision, during foaming, for the decorative material (5) to be pressed sealingingly onto the interior-side surface of the carrier (3) so as to run around the region to be foam-filled. In this case, the discharge of the air to be displaced during foaming can take place through the foam-tight, but, at least in regions, not gas-tight structure of the carrier (3). For this purpose, the carrier (3) can be gas-sealed in regions by the local compression of an intrinsically gas-permeable unprocessed part before introduction into the foaming die. Also disclosed is a trim article capable of being produced according to the method.

Abstract: An optional venting container comprises a base and a lid. The lid is releasably latched to the base. The lid comprises at least one ventable area formed therein. The at least one ventable area is adapted to form a vent only upon a user asserting pressure thereon. The lid is made from a polymeric foam.

Abstract: A method of deforming a component includes the step of forming the component from thermosetting, elastomeric microcellular polyurethane. The method further includes the step of heating at least a first portion of the component to a first temperature. The method further includes the step of compressing the first portion of the component while maintaining the first portion at the first temperature and while maintaining the second portion of the component at an undeformable state. The method of deforming the component shapes the first portion of the component. Preferably the method shapes the first portion of the component into a thin and/or complexly shape. The method of deforming the component also increases the first portion of the component relative to the second portion of the component, i.e. to densifying the component such that the component has varying density.

Abstract: A method for manufacturing environmental protection sponge comprises the steps of mixing material which are formed by predetermined ratios so as to form a mixing material; wherein the material contains PVA and starch; agitating and then boiling the mixing material; filling the mixing material into a mold so as to form a sponge; the sponge being taking out from the mold; washing the sponge; dewatering the sponge so as to form as environmental protection sponge; drying the environmental protection sponge; compressing the environmental protection sponge through at least one stage and then the compressed environmental protection sponge being cooled; rolling the environmental protection sponge by turning the environmental protection sponge through at least one roller so that the environmental protection sponge has a uniform structure; cutting and printing patterns on the environmental protection sponge; and packaging the shaped environmental protection sponge.

Abstract: The invention relates to a lasted footwear for enclosing a human foot having a heel, an ankle and medial and lateral sides. The footwear comprises an outer shell for receiving the foot and an inner lining mounted in the outer shell. The inner lining is less rigid than the outer shell and has an inner surface adapted to contact the foot in use and an outer surface being affixed to the outer shell. The outer shell is made of a multi-layer composite sheet that is thermoformed for defining a foot-receiving cavity having a three-dimensional geometry that conforms to the foot. The multi-layer composite sheet has a first layer of thermoformable foam having a core and first and second opposite surfaces and a second layer of fibers. One of the first and second opposite surfaces of the layer of thermoformable foam has a skin formed by exposing the surface to temperatures between 200° F. and 300° F. The invention also relates to a method of making a lasted skate boot comprising such an outer shell.

Abstract: A method of producing a breast cup having a pattern includes the steps of: (a) preparing a substrate having inner and outer fabric layers that sandwich a foam layer; (b) placing a patterning plate over a surface of the substrate; and (c) forming the substrate into a cup and simultaneously providing the surface of the substrate with a pattern corresponding to the patterning plate by hot-pressing the substrate in the presence of the patterning plate.

Abstract: A pair of form keys and a method for forming reverse drafts in foam parts are disclosed. A male form key is reciprocally mounted in a first mold half in a retracted position. A female form key is rotatably mounted in a second mold half in a neutral position. The first mold half includes a first drive pin that when engaged, moves the male form key into engagement with a foam sheet to form an undercut as the first and second mold halves are closed. The first mold half also includes a second drive pin that engages the female form key as the first and second mold halves close rotating the female form key into engagement with the foam sheet and the male form key. After closure of the mold and the product is formed, the mold is opened. As this occurs, the drive pins are disengaged and the male form key retracts and the female form key rotates to their neutral positions. The formed product may then be stripped from the mold while maintaining the reverse draft or undercut.

Abstract: A method and device for forming a cross-linked foam and a cross-linked foam are provided. The method includes the steps of preparing at least one foaming material for cross-linked foaming, the foaming material processed to have a plane or three-dimensional shape; forming at least one interfacing pattern on a surface of at least one of the foaming material using at least one interfacing material that prevents chemical and physical interaction between the foaming materials; and forming a cross-linked foam by foaming the foaming material having the interfacing pattern thereon, the cross-linked foam having a foam body and an internally-formed surface.

Abstract: A method of making a sponge device is provided. This method includes introducing a curable liquid sponge forming material into a form, placing a handle into the material before it is fully cured, heating the form to cure the material, removing the cured material from the form, and rinsing the cured material. Another aspect of the present invention is the assembly for making this sponge device. This assembly includes a runner for joining a plurality of handles, plates that are spring-biased together to support the handles, a chase formed of heat conductive metal having a shelf where the plates can be set, and a silicone form having a plurality of cavities therein for receiving the sponge forming material.

Abstract: Methods for fabricating foam cored items in which the foam core is tightly encased by an outer shell. The foam core is compressed, reducing a characteristic dimension, thereby facilitating installation and/or removal of the foam. The foam is then allowed to expand to the desired size. The methods are particularly suited for fabricating foam collars that are located above the chine of a boat and extend longitudinally along the sides of the boat to provide stabilization for the boat during high performance maneuvering and/or provide a fendering system.

Abstract: A method of manufacturing a mattress including providing a foam block, convoluting the foam to form a tongue extending longitudinally along the foam block, and removing at least a portion of the tongue, to thereby form a channel within the foam block.

Abstract: Elastomeric sealing elements such as gaskets, O-rings and diaphragms suitable for use as seals in ultra-pure water systems are fabricated from foamed PVDF by compressing foam blanks up to a 5:1 to 7:1 ratio in a heat environment of about 300° F. to about 350° F. The compressed and heated blank is held for a time period sufficient to displace substantially all air from the foam pores and released.

Abstract: A method for producing an alkenyl aromatic polymer foam structure that comprises melting at least one alkenyl aromatic polymer resin. An effective amount of blowing agent mixture is dissolved in the at least one alkenyl aromatic polymer. The blowing agent mixture comprises at least one VOC blowing agent and acetone. The majority by mole percent of the VOC blowing agent is selected from n-butane, iso-butane, propane and combinations thereof. An extrudate is formed comprising the at least one alkenyl aromatic polymer resin, the at least one VOC blowing agent, and acetone. The extrudate comprises less than about 2.7 wt. % of the at least one VOC blowing agent. The extrudate is transferred to an expansion zone and permitted to expand to produce the foam structure. The foam structure has an extruded density less than about 7 lbs/ft3 and a basis weight of less than about 20 grams per 100 in2.