Abstract: The invention is directed to an article made from co-injection molding using gas-assist. The article has an inner material and an outer material. The inner material has a blowing agent uniformly distributed throughout the inner material. The outer material surrounds the inner material. The use of the blowing agent in the inner material produces a repeatable and consistent structure, as the blowing agent is uniformly activated through the product. The use of the gas-assist the heat and pressure associated with the blowing agent is allowed to out gas, thereby insuring that the finished molded chair or other item is aesthetically pleasing while providing increased strength and reduced weight compared to traditional plastic chairs formed with known methods.

Abstract: A seal assembly (10) is provided for sealing a core hole (52) formed in a concrete slab (54) having opposite first and second surfaces, with the core hole (52) extending between the first and second surfaces. The seal assembly (10) comprises a cover assembly (12) having a cover plate (14) that is configured for engaging the first surface of the concrete slab (54) and seating over and covering the core hole (52). The cover assembly (12) has a lower plate (16) that is configured for being received within the core hole (52). The lower plate (16) is coupled to the cover plate (14) through a support member (20) so that the lower plate (16) is spaced apart from the cover plate (14) when the cover plate (14) is seated over the core hole (52) to define a cavity between the lower plate (16) and the cover plate (14). A locking element carrier (26) is coupled to the cover assembly (12).

Abstract: A method for enabling a lining (14) to be applied to a pipe elbow or bend C comprises the steps of connecting a tie member (12) to an end of a flexible elongate mandrel (1), drawing the tie member through the elbow or bend so as to draw the mandrel therethrough and locate opposing ends of the mandrel adjacent to opposing respective ends of the elbow or bend, and securing the mandrel ends in relation to the respective ends of the elbow or bend. The mandrel can be adapted to the elbow or bend by locating the elbow or bend in a given orientation and deriving a profile S of the elbow or bend while in that orientation, removing the elbow or bend and then locating the mandrel in the given orientation, and adjusting the mandrel in relation to the profile of the elbow or bend to adapt it thereto.

Abstract: Provided is a sandwich component with a core which comprises a foam material. A fibrous sheet-like material arranged in the foam material at least partially encloses a working region of the sandwich component in a sheet-like manner. At least one strut is incorporated in the foam material and extends from an entry surface of the foam material from outside the working region to at least the fibrous sheet-like material.

Abstract: An internal stiffening member of varying configurations in which the stiffening elements support the skin using a compression-only load path is disclosed. A rib can be inserted into an assembled structural box beam, and a filler material can be used to fill any gaps between the slip-in rib and the interior surface of the structural box beam. The filler material is preferably an expandable material, such as an expandable foam-type material. However, in situations where a slip-in rib forms a primary structural rib, the filler material is preferably a structural adhesive or liquid shim material. A solid adhesive or filler would not crush under the clamping forces from fasteners or bolts at localized fitting attachments.

Abstract: A weatherseal adapted to be installed in a door or window opening includes a spine, a resilient foam core, an intumescent material, and a liner. The spine has first and second ends, the first end adapted for mounting the weatherseal to the door or window opening. The resilient foam core is attached to the spine, proximate the second end of the spine. The intumescent material is arranged proximate the foam core. The liner encloses the flexible foam core and the intumescent material. The weatherseal or a portion may be color-coded to identify the weatherseal for fire rated applications.

Abstract: A non-pneumatic wheel with reinforcement bands that provide structural support for the wheel and a method of manufacture of such a wheel are described. The reinforcement band forms part of an annular reinforcement structure that includes foam spacers positioned between the annular reinforcement band. The foam can be a reticulated foam into which a matrix material such as a polyurethane is introduced. The matrix material can also be used to form one or more features of the non-pneumatic wheel such as spokes, a mounting band, and a hub.

Abstract: The invention relates to a method for producing a composite part, in particular an internal paneling part for vehicles, having a multipart cover layer, and a composite part.

Abstract: A filter element, and filter apparatus, include a filter pack, a seal member, and a seal support frame operatively connecting the seal member to the filter pack. The seal support frame includes an annular extension, which is preferably canted at an oblique angle to a longitudinal axis, for supporting the seal member. The seal support frame also preferably includes a first end thereof including the annular extension, and a second end thereof spaced from the first end thereof along the longitudinal axis, with the first and second ends of the seal support frame joined by a hub of the outer peripheral sidewall of the seal support frame to define a cavity within the seal support frame for receiving the filter pack. The first and second ends of the seal support frame, and the filter pack are preferably joined and sealed to one another by a single bead of adhesive.

Abstract: A foam filled panel with decorative thread stitching is provided. In addition, the stitching can be sealed to prevent leakage of foam when it is injected between a substrate and a skin layer to provide a foam filled panel. The decorative thread stitching can be sewn into the skin layer of the foam filled panel before the panel is assembled and filled with injectable foam. In addition, the skin can be made via slush molding, which allows various features and details to be molded into the skin. In some instances, the stitching can be sealed by adhesively attaching an impermeable membrane along a length of the stitching, thereby covering all the openings. In other instances, the stitching is sealed by using an expandable thread. Also disclosed is a process for manufacturing a foam filled panel with decorative thread stitching.

Abstract: A self resonance-type sound-producing speaker that is waterproof and readily attachable. The self resonance-type sound-producing speaker includes an actuator speaker unit and a polymer foam arranged to cover the entire outer surface of this speaker unit and converts the vibrations from the speaker unit into plane waves to externally produce sound. The polymer foam preferably has the expansion ratio of 10 to 30 times and the closed pore structure. The thickness of the polymer foam is preferably not less than 2 mm and is more preferably not less than 3 mm.

Abstract: The present invention provides a method of manufacturing foam, including the steps of sealing a mold by providing a lower mold having an arbitrarily-shaped molding surface, and then sequentially placing a middle mold having at least one arbitrarily-shaped protrusion formed on one side thereof or both sides thereof and an upper mold having an arbitrarily-shaped molding surface on the lower mold; simultaneously forming an upper preform and a lower preform, which are prevented from foaming, by charging a foaming material in an inner molding space of each of the upper mold and the lower mold, which are divided by the middle mold; opening the mold and removing the middle mold from the mold; placing an interface material in grooves formed in the preform by the protrusion of the middle mold such that the upper preform and the lower preform are prevented from cross-linking with each other; and simultaneously cross-linking and foaming the upper preform and the lower preform by sealing the mold.

Abstract: A composite includes a first preform and a second preform spaced from and in overlying relationship to the first preform. The second preform defines at least one first opening extending therethrough along an axis transverse to the first preform. A first surface layer is disposed adjacent to the second preform and on an opposite side of the second preform from the first preform. A polymeric composition including the reaction product of an isocyanate component and an isocyanate-reactive component is disposed between the first preform and the second preform. The polymeric composition adheres the first surface layer to the second preform through the at least one first opening. The surface layer is adhered to the second preform during molding of the composite article and in the absence of additional adhesive, thereby reducing production time and cost of the composite article.

Abstract: A rigid insulating phenolic foam body (8) has at least one perforated facing (1). The facing (1) is preferably perforated before the facing (1) is adhered to the foam body. The facing (1) may be a gas impermeable material such as a metallic foil. The perforations (5) in the gas impermeable material reduce the drying and curing time, for phenolic foam bodies when compared with phenolic foam bodies with gas permeable facings.

Abstract: Continuous manufacture of at least a layer of latex foam with recesses of unlimited length to be divided in a plurality of blocks of latex foam by transverse cuts. The layer has a thickness between 10 and 20 cm and more. The process includes advancing along a predetermined longitudinal direction a metal laying surface provided with protuberances, gelating, curing. The process includes: a) Before depositing the latex foam inserting, by interference fit, supporting elements of resilient deformability having a predetermined thickness between pairs of protuberances of horizontal rows, the supporting elements of unlimited length; b) Carrying away the supporting elements with the advancing laying surface between an injection latex foam station and a layer extracting station; c) Embedding with latex foam the supporting elements. Advantageously the process forwards the blocks to a washing station and squeezes the blocks to a thickness reduction between 3% and 5% of their initial thickness.

Abstract: A method of making a composite material, the method comprising: providing a tile, wherein the tile comprises an inorganic material; and bonding the tile to a ductile backing material using heat-curable adhering material and catalyzed foamable exothermic material between the tile and the ductile backing material, wherein heat generated from the use of the catalyzed foamable exothermic material cures the heat-curable adhering material. In some embodiments, the exotherm from the foaming of the foamable exothermic material cures the heat-curable adhering material for a time sufficient to unite a solid foam body to the heat-curable adhering material of the tile and the ductile backing material. The method is particularly advantageous in bonding a tile composed of nano-particles to a ductile backing material, as it helps retain the nanoscale properties of the nano-particles in the tile.

Abstract: A molded multilayer plastics component (1) with continuously reinforced fiber plies (2, 2?), which has a sandwich structure made of an internal structure (3) made of a foam material, embedded between at least two outer plies of fiber composite plastic. Around the periphery of the embedded internal structure (3) the component (1) has a coherent edge made of the fiber composite plastic, formed through peripheral overdimensioning (2?) of at least one of the fiber plies (2, 2?) with respect to the internal structure (3). Two alternative production processes are also disclosed for producing the multilayer plastics component (1).

Abstract: A soft pad for a vehicle may include a soft foam layer stacked under a skin layer, a breathable film connected under the soft foam layer, to preserve thickness of the soft foam layer by protecting the soft foam layer from heat and pressure during a molding process and in which breathable holes may be formed to the breathable film at regular distances to let gas be released therethrough, and a pad resin injection-adhered under the breathable film.

Abstract: An annular reinforcement structure is provided having an inner reinforcement band, an outer reinforcement band positioned around and concentric with the inner reinforcement band, and a cast-in-place polymer foam spacer, which maintains the spatial orientation of the inner and outer reinforcement bands. The annular reinforcement structure may be embedded in an elastomeric matrix material to provide stability, such as for belt for power transmission.

Abstract: A component is produced according to the following steps: a) insertion at least of two skins into the second tool half of a tool having a cavity-forming first tool half and second tool half such that the skins overlap in their end regions; b) rear-foaming or rear-spraying of the skins with a foam material or spraying material, c) by exerting low pressure in the region of the overlap, the internally situated end region of the one skin being pressed against the externally situated end region of the other skin in a foam-tight or injection molding-tight manner.

Abstract: For a skin, a non-formed polyurethane resin layer at the surface side and a foamed polyurethane resin layer between the non-foamed polyurethane resin layer and a base member are configured to form an integral and uniform layer over and extent from an injection point to a distant point on a surface of the base member, so that an integral skin foam in which such skin layer and foamed layer are laminated can be molded, under an atmospheric pressure, in a single process, allowing for manufacture of a laminate article with a high degree of uniformity over an appreciable wide range of the article, as well as for provision of a laminate mold goods having the skin and foamed layers formed with a high uniformity along the base member, over the length in a flow direction of skin forming material.

Abstract: The present invention relates to a process for producing insulated pipes, the use of a polyurethane system comprising an isocyanate component (a), a polyol mixture (b) and at least one catalyst for producing insulated pipes, wherein the cream time for the polyurethane system is less than the time for introduction of the polyurethane system into the pipe, the use of specific amines as catalyst in a polyurethane system for producing insulated pipes and also an insulated pipe which can be obtained by the process of the invention.

Abstract: There is disclosed a baffle for inhibiting the passage of sound, debris or the like through a cavity of an automotive vehicle.

Abstract: Method for producing an SMC multi-layer component in a production process. The component has a sandwich structure. At least one foam material layer (3) is embedded between two SMC cover layers (2, 2?). An insert layer arrangement comprising at least one first and one second SMC semifinished product cover layer (2, 2?) is positioned in a press mold comprising a punch (1) and a die (1?). A first and a second SMC semifinished product cover layers (2, 2?) are shaped into two SMC cover layers (2, 2?) by applying pressure to the layer arrangement. Curing of the first and the second SMC semifinished product cover layers (2, 2?) is initiated. The punch (1) and the die (1?) are moved away from each other, until the distance provided therebetween corresponds to a thickness of the SMC multi-layer component to be produced. A foaming process of a material (3?) that can be foamed, which is provided between the two SMC cover layers (2, 2?) is initiated, producing the foam material layer (3).

Abstract: A prefabricated modular panel, comprising a framework that includes a plurality of lattices, with a lattice of the plurality of lattices comprising a first elongated member and a second elongated member that are spaced apart and juxtapose laterally parallel, forming an axial length of the lattice. Further included is a third member substantially transversally oriented at an angle along the axial length of the lattice, with the third member coupling the first elongated member with the second elongated member to form the lattice, with the plurality of lattices forming the framework. The plurality of lattices are coupled with one another in parallel by a solidified filler material forming a single piece, unitary modular panel.

Abstract: A method of insulating a refrigeration appliance. The refrigeration appliance includes a case, a liner, and a five-sided, box like vacuum panel. The liner is formed to be inserted into the case forming a chamber between the liner and the case. The five sides of the vacuum panel define a cavity. The method includes in one embodiment, positioning the five-sided vacuum panel in the chamber between the case and the liner, injecting foam into the chamber, and curing the foam to attach the five sided vacuum panel to the case and the liner.

Abstract: An interior trim part for a passenger compartment of a vehicle has a shaped part which has a front side which forms a decorative wear layer of the interior trim part, and having at least one carrier layer which forms a rear side of the interior trim part, at least one part region of the interior trim part being provided with at least one supporting structure which provides a pleasant tactile sensation at the surface of the part region, the shaped part having at least one connecting element which is attached to the carrier layer of the rear side of the internal trim part, and the supporting structure being formed as a separate supporting element and being held by the connecting element of the shaped part. Moreover, a method for producing an interior trim part for a passenger compartment of a vehicle is also provided.

Abstract: Exemplary window covering component manufacturing systems, methods, and apparatuses are described herein. An exemplary window covering component manufacturing method includes 1) feeding two separate opposing surface sheets through a sizing channel space formed between opposing sizing elements, 2) depositing foam forming chemicals between the two separate opposing surface sheets before entry of the two separate opposing surface sheets into the sizing channel space, and 3) facilitating at least one reaction of the foam forming chemicals to form a foam material that expands in volume within the sizing channel space to press the two separate opposing surface sheets against the opposing sizing elements and then cures to form a rigid core disposed between and bonded to the two separate opposing surface sheets. Other exemplary window covering component manufacturing systems, methods, and apparatuses are also described herein.

Abstract: A disclosed method of manufacturing an image display element structure includes a coating step of coating a substrate surface including a plurality of recessed portions arranged at predetermined intervals, with a coating material that is plastic-deformable, in such a manner as to maintain spaces in the recessed portions; and an expanding step of forming gaps in the coating material coating the substrate surface by expanding gas in the spaces, wherein the gaps correspond to the recessed portions; and a peeling step of peeling off the coating material in which the gaps have been formed, from the substrate surface.

Abstract: A filter element (1), for example a cabin filter for a motor vehicle, includes a pleated fold pack (2), a plastic frame (4) that is molded at least in part to the fold pack (2) supporting pleat profiles (3), and a plastic foam seal (7) that is foamed at least in part onto the plastic frame (4). In a method for producing a corresponding filter element (1), a plastic frame (4) is generated at least in part around a fold pack (2) in a first injection molding process, and subsequently a plastic foam seal (7) is generated at least in part on the plastic frame (4) in a second injection molding process.

Abstract: A method of making a composite article includes providing an elastomeric composition with a blowing agent having an activation temperature and providing at least one structural member defining a fixed gap. The composition is formed below the blowing agent's activation temperature into a solid elastomeric member approximately the thickness of or larger than the gap. The elastomeric member is assembled into the gap, which may place the elastomeric member in a state of compression in the gap. The elastomeric member is then expanded by heating it above the activation temperature. During expansion, the escape of the gas produced is limited to increase the state of compression of the elastomer in the gap by means of confining any free surfaces or by including a platy filler such as nanoclay in the composition.

Abstract: A method for making a foam-in-place cushion in which a foam-forming composition is dispensed between two plastic film portions in a predetermined fashion to selectively control the distribution of the foam in the cushion. A foam dispenser can be moved in a transverse direction as foam is dispensed. A dispersion device can be employed to apply pressure on predetermined areas of the film portions towards each other so as to cause the composition to be redistributed in position in a predetermined manner while the composition is in a less than fully expanded state. The plastic film can then be sealed closed to form an expanding foam cushion that can be placed into a shipping carton where the cushion expands to fill void space, or into a mold where the cushion expands and is molded into a desired shape.

Abstract: A building panel for residential and commercial construction uses a plurality of insulating blocks connected together by adhesive. The insulation blocks are typically made of foam. A plurality of support members are disposed on opposite sides of the insulating blocks and offset with respect to the adjacent support member. The support member are typically made of metal and can have different shapes including “T” shape, “U” shape, and “L” shape. Each support member has a head portion in contact with a surface of the insulating block and a stem portion extending into the insulating block and having a length less than a width of the insulating block so that a thermal conduction path of the support member is discontinuous across the insulating block. The panel can be used as a curtain wall panel in high-rise construction, as well as bodies for aircraft, automotive, and marine applications.

Abstract: The invention concerns a method for making an interior covering element, and an interior covering element with no central defect. The invention concerns a method which consists in providing a soft skin (14) and a support (10), placing the skin (14) and the support (10) on parts of the mould, closing the parts of the mould for completely delimiting a moulding cavity (16) between the skin and the support, and introducing a fluid material designed to form a foam. The making of the support (10) includes placing a catching member (24) proximate the orifice, and the method includes, prior to closing the mould, causing the catching members (26, 24) of the mould and the support to co-operate, such that the support (10) is not spaced apart from the mould. The invention is applicable to motor vehicle interior covering.

Abstract: An insulating panel 1 comprises a first sheet 2, a second sheet 4, and a body of insulating foam 5 between the sheets 2, 4. The foam 5 has a plurality of longitudinally extending conduits 7 through which a heat exchange medium such as air is circulated. A barrier 10 is used to create an enlarged void space for air circulation. The barrier is located below profile crowns 3 to prevent foam from entering the crowns 3 and to create additional foam-free voids below the crown. Heat transfer efficiency is increased.

Abstract: It is an object of the present invention to provide a panel capable of obtaining sufficient strength, weight reduction and sound absorbing performance. A space is formed by an inner thin plate fixed to the inner surface of an outer thin plate, and a foam material is filled in the space. The foam material is preferably a highly foamable rubber sound absorbing material. In the inner thin plate, a perimetrical side part and perimetrical edge part for forming the space, and a concave part for enhancing the strength of the panel are drawn to the side of the outer thin plate. The bottom faces of the perimetrical edge part and concave part of the inner thin plate are bonded to the outer thin plate using a thermosetting adhesive.

Abstract: A composite air and foam protective packaging product comprises a packaging cushion having, in cross-section, at least three plies of plastic film, foam between a first ply and a second ply of the three plies of plastic film, and air between the second ply and a third ply of the three plies of plastic film.

Abstract: A resin panel for an automobile includes a skin layer formed on sides of a package tray along the direction of the thickness of the package tray and both surfaces of the package tray substantially orthogonal to the sides. An expanded layer is formed in an inner part of the package tray surrounded by the skin layer having voids by enlarging the volume of the cavity of a mold assembly during molding of the package tray to expand a thermoplastic resin in the cavity. Hollow ribs are formed of solid layers in the expanded layer to extend along the surfaces, each have a hollow formed inside over the entire length so that ends of the hollow rib continue out to the skin layer at the opposed sides of the panel. Openings in communication with the hollow rib are formed through the skin layer at the opposed sides, respectively.

Abstract: The invention provides a holding jig for supporting and fixing a solid material capable of being foamed by application of heat in a cavity of a hollow structure. The holding jig may be provided with a plate-like base body made smaller in diameter than the cavity of the hollow structure, a holding part that is provided in a predetermined width in the form of a ring on the periphery of one side of said base body and supports one side of the foamable material, a step part with predetermined height, which is projected in the form of a ring at the inner peripheral end of said holding part and supports the inner peripheral surface of the foamable material, and an attaching means with which the base body can be freely attached to or detached from the hollow structure. The holding part can be provided with a plurality of small holes that open from one side to the other side of the base body, preferably in a net or lattice pattern.

Abstract: A panel structure and a method of forming the panel structure are disclosed. The panel structure typically includes at least one panel associated with a material. The panel structure has been found particularly advantageous for use as an interior panel of an airplane.

Abstract: A sandwich panel for a vehicle is provided. The sandwich panel includes a first panel defining a plurality of apertures, and a second panel attached to the first panel. The second panel and the first panel define a cavity between the first panel and the second panel. Foam is disposed between the first panel and the second panel. The plurality of apertures of the first panel are operatively configured to receive a tool for pumping expandable foam in between the first panel and the second panel.

Abstract: Methods and tools for assembling an article are provided. The method includes providing a mold having a cavity configured as a desired shape, positioning a base within the mold so that a surface of the base material is exposed, applying a coating material, e.g., urethane or polyurethane, to substantially cover both the exposed surface of the base and an inner surface of the cavity, depositing a cushion material into the cavity and sealing the cavity with the exposed surface of the base so that the coating material forms a skin around the cushion material and adheres the cushion material to the base.

Abstract: A rotational angle sensor has a molded body made of a resin and having a substantial cylinder shape with a center axis, and a conversion IC buried in the molded body and having a magnetic sensing portion, a computing portion and leads connecting the magnetic sensing portion with the computing portion. The magnetic sensing portion is disposed nearly perpendicular to the center axis of the molded body. The leads are bent such that the computing portion is disposed parallel to the center axis of the molded body and that a connection between one of the lead and the computing portion is positioned closer to the center axis of the molded body than a radially outer end of the lead.

Abstract: A lightweight composite fairing bar (14) for use in fabricating a composite component (16) of an aircraft. The fairing bar (14) includes a core (18) and an elongated outer shell (20) surrounding the core (18). The outer shell (20) is comprised of a laminate material, and the core (18) is comprised of epoxy syntactic foam having a lower density than that of the laminate material. The outer shell (20) is configured for supporting the composite component (16) during the manufacture of the same.

Abstract: A back surface of an outer case is formed by mutually overlapping left and right back panels. The overlapping edges on the front side and backside of the panels may be bent toward the opposite side at a blunt angle. A joint between the back panels is established in which the overlapping edge of one back panel is pressed against the overlapping edge of the other back panel. Spacers are mounted between the outer and inner case such that the overlapping edges are put in close contact with each other. The bends are deformed in order to prevent leakage from the joint after the injection of foam liquid. Due to the pressure of the foam, both of the overlapping edges are placed in closer contact while deforming the bends to be substantially flat. Consequently, the sealing properties of the joint after the completion of the thermally insulated housing are secured.

Abstract: A method of making a composite support structure and sander includes the steps of providing a rigid plate adjacent a mold such that a polyfoam layer can be formed to a front surface thereof which includes a wall defining a contained surface, the plate having a back surface for connection to a handle and introducing into the mold fluid components which react to form a polyfoam which is reaction bonded to the front surface of the rigid plate such that a back surface of the polyfoam layer forms within the contained surface and about the wall in a complementary manner thereto and a front surface of the polyfoam layer extends outward from the front surface of the rigid plate and is formed to have a relatively planar surface thereby rendering the composite support structure for removably connecting sandpaper to the relatively planar surface of the polyfoam layer.

Abstract: An insulating panel comprises sheets (1, 2) with a body (3) of insulating foam between the sheets. The insulating material has a vacuum insulated panel (4) embedded therein. The panel is substantially thinner than corresponding panels without a vacuum insulated panel (4).

Abstract: A process for assembling a composite piece for use in the interior of an automobile. An outward facing skin of the composite piece is connected to a substrate by a foaming material, and at least one switch item is integrated seamlessly into the composite piece. Part of the process includes wrapping a visible portion of each switch item with the outward facing skin. A spare piece is placed against the surface of the visible area of each item opposite the surface located on the visible surface of the composite piece. A foaming material is injected between the skin and the substrate, and then each spare piece is removed. A control component is placed at each cavity left where the removed spare pieces blocked expansion of the foaming material.

Abstract: Method of encapsulating optoelectronic components, by embedding the components to be encapsulated between a first transparent polymer layer and a second polymer layer, which is filled with unactivated foaming agent, and then activating the foaming agent, so that the two polymer layers join to one another, in particular weld to one another, and the components are enclosed between the two polymer layers.

Abstract: Continuous manufacture of at least a layer of latex foam with recesses of unlimited length to be divided in a plurality of blocks of latex foam by transverse cuts. The layer has a thickness between 10 and 20 cm and more. The process includes advancing along a predetermined longitudinal direction a metal laying surface provided with protuberances, gelating, curing. The process includes: a) Before depositing the latex foam inserting, by interference fit, supporting elements of resilient deformability having a predetermined thickness between pairs of protuberances of horizontal rows, the supporting elements of unlimited length; b) Carrying away the supporting elements with the advancing laying surface between an injection latex foam station and a layer extracting station; c) Embedding with latex foam the supporting elements. Advantageously the process forwards the blocks to a washing station and squeezes the blocks to a thickness reduction between 3% and 5% of their initial thickness.