Abstract: An aluminum-thermoplastic composite surface structure. A sheet of aluminum is formed to a single-sided mold by heating the sheet and applying a ramp of gas pressure. A thermoplastic resin is heated and microballons are added to the resin to lower the viscosity of the resin, which is applied through a nozzle in a hexagonal pattern on the formed aluminum sheet. Upon cooling, the composite resin forms a honeycomb pattern. The hexagonal pattern transitions to a columnar pattern and a backing layer of aluminum sheet is gas pressure formed to the resin composite. Gas forming of the aluminum sheet results in aspect ratios of up to 0.6, and the sheet maintains a clean surface that bonds to the applied resin.

Abstract: A self-adhesive reinforced foam gasket comprising a release liner having an upper surface which is a release surface, a layer of pressure sensitive adhesive applied to the release surface, a layer of flexible polymeric film, preferably polyester film, applied to the pressure sensitive adhesive layer, and a layer of flexible foam, preferably closed cell PVC flexible foam, thermally bonded to the flexible polymeric film layer. A length of material for die-cutting the gasket therefrom is provided, along with a method of making the length of material. The gasket may be used in automobiles and other applications.

Abstract: Disclosed is a protective foamed patch for a biaxially heat shrinkable, thermoplastic vacuum bag for protecting the bag from puncture by sharp protruding bones in the bone-in cuts of meat which are vacuum packaged within the bags. The patch is made from multi-layer film and comprises a layer of foamed polymer. The patch is biaxially heat shrinkable and shrinks with the bag. A method of making the patch is also disclosed.

Abstract: An integral sound absorber and water deflector door panel positionable in space defined between an inner wall and a passenger compartment door panel of an automobile vehicle door assembly. The integral panel is composed of a first polymeric layer made of a water impervious polymeric film having an essentially constant thickness. The first polymeric layer has a first face adapted to contact the interiorly oriented face on the inner wall of the vehicle door assembly and remain in overlying parallel orientation thereto. A second polymeric layer is composed of a polymeric foam integrally connected to the second face of the first polymeric layer in continuous overlying relationship thereto. The second polymeric layer has an outer face opposed to the first polymeric layer which, preferably, has at least one region adapted to directly contact a portion of the exteriorly oriented face of the passenger compartment door panel.

Abstract: A self-adhesive reinforced foam gasket comprising a release liner having an upper surface which is a release surface, a layer of pressure sensitive adhesive applied to the release surface, a layer of flexible polymeric film, preferably polyester film, applied to the pressure sensitive adhesive layer, and a layer of flexible foam, preferably closed cell PVC flexible foam, thermally bonded to the flexible polymeric film layer. A length of material for die-cutting the gasket therefrom is provided. The gasket may be used in automobiles and other applications.