Abstract: A method of post manufacture processing of 3D printed parts involves a step of forming at least one treatment aperture through an exterior shell of a 3D printed part to provide access to a lattice of multiple layers of extruded thermo-plastic filaments within a hollow cavity of the part. The method involves a step of inserting a stabilizing substance that flows before it is set and then hardens when set through the at least one treatment aperture into the hollow cavity of the part. The method involves a step of coating the lattice with the stabilizing substance to fill spaces between the multiple layers and between individual thermo-plastic filaments, such that, when set, the stabilizing substance fixes the multiple layers of extruded thermo-plastic filaments of the lattice in position. The method reinforces and stabilizes the internal lattice structure of the part, without significantly adding material or increasing manufacturing cost.

Abstract: This composite structure is characterized in that: an internally inserted component, which is molded from a resin material having a tensile elongation of 10% or more, is placed inside a metal member having a hollow closed cross-section such that an external load can be received by both the internally inserted component and the metal member, and the outer shape of the internally inserted component occupies 50% or more relative to the hollow closed cross-section of the metal member as projection area ratio. By disposing the resin-made internally inserted component having a specific toughness at a specified state inside the metal member having a hollow closed cross-section, especially when a collision load occurs, the metal member undergoes ductile deformation and the internally inserted component also deforms correspondingly, and thus the waveform of the load-displacement curve can approach an ideal rectangular waveform, and excellent impact energy absorbing performance can be exhibited.

Abstract: Embodiments of the disclosure relate to an optical fiber cable having at least one optical fiber, a cable jacket and a foam layer. The cable jacket includes an inner surface and an outer surface in which the outer surface is an outermost surface of the optical fiber cable. The inner surface is disposed around the at least one optical fiber. The foam layer is disposed between the at least one optical fiber and the cable jacket. The foam layer is made of an extruded product of at least one thermoplastic elastomer (TPE), a chemical foaming agent, and a crosslinking agent. The foam layer has a closed-cell morphology having pores with an average effective circle diameter of less than 100 ?m. Further, the foam layer has a compression modulus of less than 1 MPa when measured at 50% strain.

Abstract: In one aspect, a material is disclosed, including: a periodic structure including a plurality of unit cells, the plurality of unit cells having a respective plurality of shared nodes, wherein each of the plurality of unit cells has a plurality of members forming an open cell volume; and a matrix material associated with the periodic structure. In another aspect, a method of forming a material is disclosed, including: forming a periodic structure including a plurality of unit cells, the plurality of unit cells having a respective plurality of shared nodes, wherein each of the plurality of unit cells has a plurality of members forming an open cell volume; and associating a matrix material with the periodic structure. Matrix material selection, composition, manufacturing, interfacial bonding modification, and post-treatments of the periodic structure-matrix material composites are disclosed.

Abstract: A method of producing a foamed composite molded product includes fixing an exposed part of an insert material on a fixing part provided in a mold, the insert material being inserted in an in-mold foamed molded product made of a thermoplastic resin; introducing a polyurethane liquid into the mold; and producing the foamed composite molded product by foaming the polyurethane liquid in the mold. The foamed composite molded product includes an in-mold foamed molded product unit including the insert material and the in-mold foamed molded product; and a polyurethane foam. At least part of the insert material is exposed to an outside of the in-mold foamed molded product, and the in-mold foamed molded product unit and the polyurethane foam are integrated.

Abstract: A method is provided in one example embodiment and may include positioning at least one nozzle within a hollow portion of a rotor blade at a distance associated with a span of the rotor blade and providing, via the at least one nozzle, a liquid foam mixture in the hollow portion, wherein the liquid foam expands and becomes a solid foam material that fills the hollow portion of the rotor blade. Another method is provided in another example embodiment and may include providing a plurality of openings for a rotor blade that are positioned proximate to a hollow portion of the rotor blade and providing a liquid foam mixture in the hollow portion of the rotor blade through at least one opening of the rotor blade, wherein the liquid foam mixture expands and becomes a solid foam material that fills the hollow portion of the rotor blade.

Abstract: The present invention relates to a refrigerator appliance including a wire harness fixing device and, more particularly, to a fixing device for fixing a wire harness crossing a space between an inner panel and an outer panel of a door, and where the wire harness is configured for electrical connection with a heater inside a partition unit. Embodiments also include a refrigerator appliance including the wire harness fixing device. The wire harness fixing device having a body part configured to have a hollow portion formed therein, thereby allowing a wire harness to be inserted therein, and an opening portion formed to be open partially at one surface thereof. The wire harness also having a fixing part, a cover part and a coupling part.

Abstract: A reinforcing device for reinforcing a structural element in a motor vehicle includes a support, a reinforcing element and an adhesive. The support has a first surface for orientation towards a first wall of the structural element and a second surface for orientation towards a second wall of the structural element. The reinforcing element is designed for arrangement between the support and the first wall of the structural element. The adhesive is designed to connect the support to the reinforcing element and to connect the support and the reinforcing element to the structural element.

Abstract: A door beam including an inner flange extending in a longitudinal direction, an outer flange extending in the longitudinal direction and facing the inner flange at a distance from the inner flange, and-a pair of webs connecting the inner flange and the outer flange. The inner flange has an end portion in the longitudinal direction which is made closer to an end portion of the outer flange such that the distance between the inner and outer flanges at the end portions is shorter than the distance at other portions of the inner and outer flanges.

Abstract: The present invention provides a method for manufacturing a fiber-reinforced resin substrate or a resin molded body, the method being capable of effectively performing impregnation of a reinforcing fiber material with a thermoplastic resin and having high productivity and economical efficiency, and an extruder for use in the manufacturing method. The manufacturing method of the invention is a method for manufacturing a fiber-reinforced resin substrate or resin molded body obtained by impregnating a reinforcing fiber material with a thermoplastic resin, including placing the reinforcing fiber material on a molten resin of the thermoplastic resin and pressurizing the same to impregnate the reinforcing fiber material with the molten thermoplastic resin, and subsequently, cooling and solidifying the reinforcing fiber material impregnated with the molten thermoplastic resin.

Abstract: A seating structure includes a body support member having laterally spaced opposite sides and longitudinally spaced ends. The body support member has a curvature in least one of the lateral and longitudinal directions, wherein the curvature is changeable between at least first and second configurations. The body support member includes a shape memory material extending in at least one of the lateral and longitudinal directions, wherein the shape memory material is attached to the body support member at two spaced apart locations. The shape memory material is contractible between at least a non-energized state and an energized state in response to an application of energy. The shape memory material biases the flexible body support member between the first and second configurations when the shape memory material is contracted to the energized state. Other office systems incorporating shape memory materials are also provided.

Abstract: A method for forming a perforated membrane includes providing a mold having at least a first set of a plurality of rods extending to at least a first height from a base of the mold, introducing a curable material into the mold in an amount such that a height of the curable material from the base of the mold is less than or equal to the first height so that the first set of the plurality of rods are within the curable material and extend to or past the height of the curable material in the mold, curing the curable material, dissolving the first set of the plurality of rods to thereby form perforations in the cured material and removing the cured material having the perforations from the mold.

Abstract: An armrest assembly with a cup holder includes an armrest frame with a cup holder frame. The assembly also includes a bezel with a bezel cup holder opening. The bezel cup holder opening is adjacent the cup holder frame. The bezel is retained on the armrest frame by a plurality of bracket latches. The assembly also includes a cup holder base. The cup holder base includes a base opening which is adapted to accommodate a beverage container. A base projection substantially surrounds the base opening. At least a portion of the base projection is located in the cup holder frame. The cup holder base is retained on the bezel by a plurality of base latches.

Abstract: A vehicle body side reinforcement assembly includes a first side reinforcement panel; an inner center pillar coupled to the first side reinforcement panel and to a floor support forming a lower portion of a vehicle body; and a second side reinforcement panel coupled to the first side reinforcement panel, the inner center pillar, and the floor support to form a closed structure at a lower portion of the side of the vehicle. This structure improves vehicle body performance during a side collision by transferring the collision load to the floor support, resulting in improved safety performance. In addition, the assembly minimizes the number of necessary parts and allows for low-cost assembly methods, such as spot welding, thereby reducing production costs and increasing marketability.

Abstract: A vehicle body frame includes a longitudinally extending roof side rail. The roof side rail includes an outer panel, an inner panel fixed to the outer panel to define a cavity therebetween, and a reinforcement panel disposed between and fixedly secured to the outer and inner panels. The reinforcement panel separates the cavity into an inner cavity and an outer cavity. The roof rail has a forward end portion and a rearward end portion. An acoustic spray foam control bulkhead is secured within the cavity at the rearward end portion of the roof side rail. The bulkhead includes a first sidewall and a second sidewall spaced from and opposed to the first sidewall. The first and second sidewalls are configured to at least partially confine within the inner cavity between the first and second sidewalls an acoustic spray foam injected into an injection inlet aperture provided on the inner panel.

Abstract: Systems and methods for improving adhesion of an insulating foam to a molded polymeric insulating structure through use of ozone gas for functionalization of molded polymeric surfaces of an internal cavity of the insulating structure.

Abstract: A reinforcement includes a carrier having a plurality of exterior walls spaced from one another. The carrier defines a channel extending substantially parallel to a longitudinal axis defined by a cavity. A material layer is disposed on at least one of the exterior walls within the channel such that an electrocoating material is able to flow through the channel before the material layer is expanded and the channel is substantially filled after the material layer is expanded.

Abstract: The present invention relates to a continuous process for producing a profile comprising at least one core made of a polyurethane foam or a mixture comprising a polyurethane foam, at least one jacket made of at least one thermoplastic material, and optionally at least one foil between core and jacket, to a profile produced via said process, to the use of this profile for producing windowframes, doorframes, or in the fitting-out of interiors, or in apparatuses in which, during operation, temperature differences arise between interior space and exterior space, and also to an apparatus for carrying out the process of the invention.

Abstract: A propeller blade includes a foam core having a groove formed therein, a fibrous material filling at least a portion of the groove and a structural layer that surrounds the fibrous material and at least a portion of the foam core.

Abstract: A process is provided for producing a composite component having a first component element and a second component element, which are connected with one another by an adhesive connection. The process includes forming an adhesive cavity by applying thermally active plastic material to an adhesive connection side of the first component element and/or to an adhesive connection side of the second component element; arranging the first component element on the second component element, wherein a gap is formed between the adhesive connection side of the first component element and the adhesive connection side of the second component element, and supplying of heat in such a manner that the thermally active plastic material expands and forms a boundary in the gap between the first component element and the second one. The process further fills the formed adhesive cavity with an adhesive for the permanent connection of the first component element with the second component element.

Abstract: A foamed rigid bottom sanding block includes a sanding block formed of polyfoam material having a bottom portion with an integrally formed rigid member made of a material to lend weight as well as rigidity to said bottom portion, said rigid member nearly spanning a length and a width of said bottom portion and which encased within said polyfoam material, an upper portion of said sanding block having a handle which protrudes from said bottom portion and is made of said polyfoam material. A method and sanding block formed by the method are included.

Abstract: The present invention provides a method for manufacturing a metal/composite hybrid wheel for a vehicle by molding an inner rim of a composite material by compression and, at the same time, bonding an outer rim of a metal material to the inner rim to induce compressive residual stress in the bonding area by a difference in thermal expansion coefficient between the outer rim and the inner rim, thereby increasing the adhesive strength of the bonding area and the durability of the wheel. The present invention further provides a metal/composite hybrid wheel for a vehicle manufactured by the method.

Abstract: In one embodiment, a window spacer has an outer elongate strip with a first surface and a second surface. The window spacer also has first and second inner elongate strips that each has a first surface and a second surface. The inner elongate strips are arranged so that each of the first surfaces of the inner elongate strips is spaced from the second surface of the outer elongate strip. The inner elongate strips are also spaced from each other to form an elongate intermediate pane gap. Support legs extend between the outer elongate strip and the two inner elongate strips.

Abstract: In one embodiment, a lid structure with latches is configured for sealing use with container vessels of different materials having differing manufacturing dimensional tolerances, such plastic vessels and glass vessels. Another feature of a lid and vessel combination is the provision of a lid receptacle feature, configured to capture the base of a vessel in a stacking arrangement, without utilization of special features on the vessel base. Another feature of an embodiment of a lid is the capability of lid nesting of multiple lids with interference fit between adjacent lids to lock the lids together.

Abstract: A heat-insulating housing (21) includes: a wall body; and an open-cell resin body (4) of thermosetting resin with which a heat-insulating space formed by the wall body is filled by integral foaming, the open-cell resin body including: a plurality of cells (47); a cell film portion (42); a cell skeleton portion (43); a first through-hole (44) formed so as to extend through the cell film portion; and a second through-hole (45) formed so as to extend through the cell skeleton portion, wherein the plurality of cells communicate with one another through the first through-hole and the second through-hole.

Abstract: A method of making a foam manikin with a stand is provided. The method includes sculpting a sculpture of the manikin and forming the sculpture around a mating portion. Then a mold is formed using the sculpture. The mold may include an opening that is formed around the mating portion. The mold may be made in a plurality of pieces and may be taken apart and put back together. To form the manikin, the mold is secured around the mating portion and the mold is filled with a foam. Once filled with foam, the manikin is formed with at least a portion of the mating portion embedded within. The mating portion may be releasably attached to a stand so that the manikin may stand in an upright position.

Abstract: The invention relates to a frame structure, such as a window sash or a frame for a window or door, comprising a core made from at least one core member made from expanded polystyrene (EPS) with a density of 80-200 kg/m3 and a shell of polyurethane (PUR) encasing the core. The core may include a plurality of core members, some of which may be made from a different material.

Abstract: A foam-filled panel is provided. The foam-filled panel can have a substrate layer with a padded area, an unpadded area, an opening within said unpadded area, and a bounding region between the padded area and the unpadded area. A skin can extend across the padded area of the substrate layer and a foam layer can be present between the padded area of the substrate layer and the skin. In addition, a disposable foam injection port is attached to the substrate layer at the bounding region of the padded area and can extend into and be an obstruction to the opening. The disposable foam injection port can be in fluid communication with the foam layer and unattaching the disposable foam injection port from the substrate layer can remove the obstruction to the opening.

Abstract: A porous polyimide film having a three-layer structure that comprises two surface layers (a) and (b) and a macrovoid layer sandwiched between the surfaces layers (a) and (b). The macrovoid layer has a partition wall bonding to the surface layers (a) and (b), and multiple macrovoids each surrounded by the partition wall and the surface layers (a) and (b) and having a mean pore size in the film plane direction of from 10 to 500 ?m. The partition wall of the macrovoid layer has a thickness of from 0.1 to 50 ?m and has multiple pores having a mean pore size of from 0.01 to 50 ?m. The surface layers (a) and (b) each have a thickness of from 0.1 to 50 ?m, at least one of the surface layers has multiple pores having a mean pore size of from more than 5 ?m to 200 ?m, and the other surface layer has multiple pores having a mean pore size of from 0.01 to 200 ?m.

Abstract: The plastic structural article includes an elongated tubular shell having opposed end sections, a middle section there between and an interior cavity. The interior cavity has a foam core situated therein. The foam core comprises steam expandable polymer beads which when expanded substantially fill the interior cavity. The bead and shell are of a similar plastic composition enabling the articles to be reground and recycled. An apparatus for forming the articles and an associated method of manufacture are also disclosed. A thermal management system includes a panel having a periphery, and a skin having a thermal bond to an in-situ foam core. The panel has a thermal transmittance u-value ranging from 0.1 to 0.17 W/m2° C.

Abstract: A supercharger system for a vehicle engine comprises a supercharger and a sound isolation unit at least partly surrounding the supercharger. The sound isolation unit comprises an inner layer facing the supercharger, a sound barrier layer facing away from the supercharger and a core there between. All three layers are made from polyurethane but with different densities. Furthermore, the core comprises an open cell structure for sound absorption.

Abstract: A method of making personal protective equipment, such as a push-in earplug, is disclosed. The method includes the steps of covering a substrate with an outer layer that includes an unactivated foaming agent, positioning at least a portion of the outer layer in a mold, and activating the foaming agent such that a portion of the outer layer expands.

Abstract: Methods for manufacturing a composite fan inlet housing are disclosed. The methods include inserting a first piece of composite material and a second piece of composite material into a molding tool, inserting an inflatable bladder between the first piece and the second piece, and pressurizing the inflatable bladder to a curing pressure for a length of time sufficient to allow the first piece and second piece to cure.

Abstract: A method facilitates fabricating a cellular cushion. The method comprises injecting material into a mold in an injection molding process to form a cushion first layer that includes a plurality of hollow cells that extend outward from the base and are each coupled together in flow communication, coupling a second layer to the first layer, and coupling an injection stem in flow communication to the plurality of hollow cells to enable an operating pressure within the cells to be changed.

Abstract: An insulation panel (1, 601) is used as exterior wall insulation cladding affixed to the external walls of a building via fitting section or fastening flange (8, 608) of the panel (1, 601) which includes screw slots to allow simple installation. The panel (1, 601) consists of an outer layer or front surface (2, 602) of thermoplastic or other suitable material that provides weatherproofing, is durable with low conductivity and an efficient inner insulation material (7) consisting of a closed cell thermal insulation material in a cavity (6, 606). The panels (1, 601) are aligned and attached together by tessellation. The panel (1, 601) is extruded or injection moulded or formed by any other process suitable for this application. Internal features (15, 615) can include connecting bridges for added rigidity. A rear surface (3, 603) of the panel (1, 601) may feature air and moisture vents to disperse trapped moisture and gas between the wall face and the rear (3, 603) of the panel (1, 601).

Abstract: A composite profile comprises: a foam core (1) with opposing frontal faces (2) and a plurality of side faces (3); and a reinforcement fabric (4) which is at least partially in direct contact with at least two adjacent side faces (3). The reinforcement fabric (4) is a woven textile or an at least bidirectionally oriented non-woven textile; the foam core (1) does not or not completely penetrate into the reinforcement fabric (4); and at least on one side face (3) the foam core (1) is exposed. A method of manufacturing comprises the steps of: (I) providing a reinforcement fabric (4), the reinforcement fabric (4) being provided in such a shape as to define at least one upwardly open cavity (1?) adapted to receive a foam (4); and (H) providing a solid or spreadable foam (1) into the at least one cavity (1?) of the reinforcement fabric (4).

Abstract: A pillow, mattress pad, mattress pad and pillow system, and mattress are provided having a plurality of zones for providing a selected distribution of pressure across different parts of a sleeper's body. The pillow has a first zone of elasticity for supporting the head of a sleeper and an integral second zone of elasticity for supporting the neck and upper thoracic spine, said pillow comprising a firm high resistance foam lower portion and a viscoelastic foam upper portion matingly contoured to the lower portion and internally sealed to the lower portion along a surface of predetermined curvature.

Abstract: An energy management system for use with a vehicle having an interior includes an elongated plastic member having a wall defining a cavity. Disposed within the cavity is an elongated first in-situ foam core member, which has a first thermal bond to the wall. The wall having a first portion facing towards the vehicle interior and a second portion opposed to the first portion. A second in-situ foam core member is connected to at least a portion of the elongated plastic member forming the energy management system. The energy management system is capable of passing a 5-mph crash test passing Federal Motor Vehicle Safety Standard 215 (FMVSS 215) Phase II.

Abstract: A cavity between inner and outer walls of an open-box-shaped mould is filled with a polyurethane reaction mixture, containing an isocyanate and an emulsion of an isocyanate-reactive composition with three polyols and a blowing agent, which is cured to a polyurethane containing polymer. The inner and outer wall are a fixed distance from one another and each wall comprises a bottom and sides. The mixture is fed through an inlet in the bottom of the outer wall. Before filling the cavity, the mould is turned downwards so that the mixture foams upwards, filling the cavity. The three polyols are polyether polyol obtained by adding an epoxy to carbohydrates or difunctional or higher-functional alcohols; polyether polyol obtained by adding an epoxy to an aromatic amine; and polyester polyether polyol obtained by adding an epoxy to the esterification product of an aromatic dicarboxylic acid derivative and a difunctional or higher-functional alcohol.

Abstract: A composite structure, such as a structural member (12), is formed by the steps of knitting a three dimensional pre-form (17) from one or more selected fibers such as natural fibers selected from hemp, cotton, flax, jute and synthetic fibers such as boron aramide fibers, carbon fibers, glass fibers and polymer based fibers, using a three dimensional knitting machine (16). The pre-form (17) has a shape commensurate with that of the structure (12) to be formed. The pre-form (17) is caused to take its three dimensional shape by inflating or otherwise expanding the pre-form such as by injecting a foamable synthetic plastics material into the interior of the pre-form, and thereafter fixing the shape of the shaped fibers to form the composite structure.

Abstract: A method for manufacturing a soft foamed assembly includes a first step of providing a mold having an interior formed with a predetermined die cavity, a second step of fixing a polyurethane (PU) synthetic skin in the die cavity of the mold, a third step of filling a polyurethane (PU) liquid substance into the die cavity of the mold, a fourth step of closing the die cavity of the mold, and a fifth step of foaming the PU liquid substance in the die cavity of the mold to form a soft foamed body which is combined with the PU synthetic skin so as to form a soft foamed assembly consisting of the soft foamed body and the PU synthetic skin. Thus, the soft foamed assembly is made easily and quickly.

Abstract: A method for producing a cushion element for a vehicle seat, in which a component suitable for forming a three-dimensional separation zone is inserted in a tool, subsequently at least one first foamable mass is introduced into a first space of the tool. On foaming the mass, the component forms a three-dimensional separating element between a first foamed cushion region and a further space within the tool. The component is pressed against a counter-support in the tool during the forming to give a three-dimensional separating element. A suitable tool comprises an upper tool, a lower tool and a counter support for contacting a component taking on a three-dimensional shape. By introducing the three-dimensional mouldable shape into the tool and the subsequent forming thereof to give a three-dimensional separating element, complex formed regions with differing properties, in particular, differing degrees of hardness can be economically generated in a foamed cushion element.

Abstract: A method for molding composite material is revealed. A hollow air bag with high toughness is made from elastic material by a first mold, and then injects a filler such as foaming material or filling material into the air bag to form core material that connects to the air bag. The air bag with the core material matches the size and shape of the mold where the air bag with the core material has a feature of smooth surface so that it is covered with composite material such as fiber fabric easily. Next, the air bag with the core material covered by the composite material is set into a third mold to be inflated and heated. Thus a composite material product that matches the size of the mold is obtained wherein the air bag and the core material are released easily. The method simplifies the procedures and saves energy.

Abstract: Embodiments of the present invention relate to a method of dispensing a porous material and to a method of making a porous material insert for various plant grow pots, plant bowls, and plant baskets, the porous material insert including a growth enhancing element integrated with and dispersed throughout the insert.

Abstract: A process for forming plastic articles is described which uses a machine (10) having a pair of hingedly-connected female molds (12, 14), which can be heated and cooled and which can be clamped together. The process involves placing a plastic particulate material in each mold (12, 14) when they are in an open position and heating the molds (12, 14) to form a plastic skin (58, 60) lining each mold (12, 14). An expandable filler material (62) is then placed in one mold and the two molds clamped closed to form a completely closed cavity. The plastic skins in the two molds bond together to form a continuous plastic shell (66) completely encasing the filler material (62).

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: A cavity filler for use in a hollow pillar of a vehicle. The cavity filler includes a carrier having a generally planar upper surface, an expandable foam mounted to the carrier wherein the expandable foam is mounted to the carrier around a peripheral edge of the carrier. The invention further includes a flange connected to the expandable foam (also made of the expandable foam) wherein the flange extends away from and generally parallel with the planar upper surface of the carrier. The extension and flange of the expandable foam are operable to extend the expandable foam to ensure a full filling of the expandable foam after the heat treating process. The fully occupied hollow cavity of the pillar with the expandable foam blocks the transmission of noise from the engine, wind and/or road noise through the pillars to the interior vehicle cabin.

Abstract: A method and an apparatus for manufacturing an envelope style bus seat back cushion includes the steps of opening a hinged mold and then spraying the cavity of the mold with an elastomeric skin. The hinged mold includes first and second sides having a cavity in each of the sides. The cavities of the mold combine to form a mold cavity. The sides of the mold include interengaging faces, ridges and recesses. The faces, ridges and recesses interengage to seal the mold. Once the first and second sides of the hinged mold are closed and intermate, the steps of injecting a urethane foam into the mold cavity of the closed hinged mold are inserting, quickly, a center core insert into the mold cavity of the closed hinged mold; curing the urethane foam; removing the center core insert from the mold cavity; opening the first and second sides of the mold cavity; and, removing and demolding the envelope style bus seat back cushion from the mold.

Abstract: Frame kits and frames are disclosed herein. In an example, a frame kit includes at least two frame legs. Each frame leg has two edges, where one of the two edges of each frame leg is to abut another of the two edges of an adjacent frame leg when a frame is constructed with the frame legs. Each frame leg includes a non-foamed polymer exterior wall; a hollow space defined by the non-foamed polymer exterior wall; and an expanded foam material positioned within the hollow space.

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.