Abstract: A dunnage platform is in the general shape of a rectangular slab with legs extending form one side. The dunnage platform is made from an expanded polystyrene core. A chemical combination process is used to chemically combine portion of the core proximal to its surface with high impact polystyrene. In a first of two parts of the combination process, the core is placed in a forming mold with one of its two sides and two thirds of its thickness extending therefrom. A heated sheet of high impact polystyrene is brought into contact with the portion of the core extending from the mold. In a similar manner, the other of the two sides of the core is made to extend from the forming mold for contact with a heated sheet of high impact polystyrene.

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

Abstract: The present invention relates to a multi-layered structure (10; 20) comprising a first and a second continuous outer skin (11; 21), and an intermediate layer (12; 22) adhered to the first and second outer skin (11; 21), said intermediate layer (12; 22) comprises substantially spherical elements (13; 23) arranged between the first and the second outer skin (11; 21) The invention is characterised in that the spherical elements (13; 23) at their contact surfaces are bounded to the adjacent spherical element or elements. The present invention furthermore relates to a product comprising the claimed structure and a method for producing said structure.

Abstract: A water absorbing mat includes a base having an internal space open to a top; a squeezing unit disposed in the internal space and comprising a plurality of water bladders having a plurality of legs; and a water absorbing unit disposed on the water bladders and formed of a predetermined water absorbing material such as pile threads or foam.

Abstract: A flame retardant panel apparatus, and method, utilize a flame retardant panel, having an exterior and an interior face thereof, with the panel including a panel structure having a primary core encapsulated within a panel frame of reinforced phenolic material, and a layer of flame retardant material attached to the panel structure and extending outwardly therefrom to at least partially define an exterior face of the flame retardant panel. The flame retardant panel is suitable for use in mass transit conveyances, such as subway cars, high speed cars, rail cars, buses, rapid response vehicles, marine vessels, and elevators.

Abstract: A flame retardant panel apparatus, and method, utilize a flame retardant panel, having an exterior and an interior face thereof, with the panel including a panel structure having a primary core encapsulated within a panel frame of reinforced phenolic material, and a layer of flame retardant material attached to the panel structure and extending outwardly therefrom to at least partially define an exterior face of the flame retardant panel. The flame retardant panel is suitable for use in mass transit conveyances, such as subway cars, high speed cars, rail cars, buses, rapid response vehicles, marine vessels, and elevators.

Abstract: A molded foam article (100) comprises a foamed core (110) of an expanded non-thermoplastic foam material which is bonded to a skin (120) of an un-expanded or a minimally expanded non-thermoplastic material. Polyurethane is a suitable non-thermoplastic material. The skin (120) may be compressively molded of un-expanded polyurethane, and the foamed core (110) is formed using water as blowing agents.

Abstract: Disclosed is a mat or molded pre-form that may be used as a mounting mat to mount a fragile monolith within an outer housing of an exhaust gas treatment device, such as automotive catalytic converters and diesel particulate traps. The mat or pre-form may also be used as thermal insulation in the end cone regions of the exhaust gas treatment device. The mat and pre-form includes an inorganic microporous insulation component and a flexible fibrous material component. Exhaust gas treatment devices and methods for making exhaust gas treatment devices including the mat or pre-form are also disclosed.

Abstract: A cushion comprised of at least one chamber comprised of a barrier material, said barrier material comprised of an elastomer, said elastomer being at least semi-permeable to at least a first reactant compound, a second reactant compound disposed within said at least one chamber, wherein said first reactant compound and said second reactant compound react to form a resultant compound, and wherein a rate of diffusion of said resultant compound through said barrier material is less than a rate of diffusion of said first reactant compound through said barrier material. An article of footwear including a cushion, said cushion comprised of at least one chamber comprised of a barrier material, at least a first and a second solid or liquid reactant compounds disposed within said at least one chamber, wherein said first reactant compound and said second reactant compound react to form a resultant gaseous compound.

Abstract: A method of forming a panel is disclosed. The method includes forming a flexible skin (22); coupling a compressible material (24) to the skin (22); positioning the skin (22) and compressible material (24) in a mold; and forming a rigid substrate (20) around the skin (22) and compressible material (24) providing a first soft region (12) wherein the compressible material (24) is disposed between the skin (22) and the substrate (20) so that a first soft region (12) is defined by the compressible material (24).

Abstract: A method for production of a component in a tool having a cavity-forming first and a second tool half comprises the following steps: a) insertion at least of two skins with angled-over end regions into the second tool half such that the angled-over end regions of the skins are situated adjacently with the same orientation and angling; b) rear-foaming or rear-spraying of the skins with a foam material or injection moulding material, c) after insertion of the skins, the end regions of the skins being pressed together in a foam-tight or spray-fight manner at least in regions by pressing at least on one side of the end regions which are situated one above the other against a wall which determines the form and position of the pressed-together end regions.

Abstract: A method and apparatus for forming an improved pultruded and clinched Z-axis fiber reinforced composite laminate structure. The upper and lower skins and the core are pulled automatically through tooling where the skin material is wetted-out with resin and the entire composite laminate is preformed in nearly its final thickness. The preformed composite laminate continues to be pulled into an automatic 3-dimensional Z-axis fiber deposition machine that deposits “groupings of fiber filaments” at multiple locations normal to the plane of the composite laminate structure and cuts each individual grouping such that an extension of each “grouping of fiber filaments” remains above the upper skin and below the lower skin. The preformed composite laminate then continues to be pulled into a secondary wet-out station.

Abstract: An injection molded foam article including a structure and a projection projecting from the structure. The thickness of the projection is greater than 25% to 40% of the thickness of the structure, depending on the material of the article, and the front surface of the structure opposite the projection has a Class A surface.

Abstract: Partially expanded closed-cell unmatured polystyrene bead with a partial vacuum within the cells inside the bead, which may be coated with an air impervious coating to retain a partial vacuum inside cells for a prolonged period of time. The resulting bead has improved thermal insulating properties and may be used for insulation.

Abstract: The present invention is an article comprising a shaped rigid foam part; a heat activated foamable adhesive applied directly to at least a portion of the outer surface of the shaped foam part and an integral locating means. A second aspect of the invention is a method of forming a foam filled vehicle hollow member comprising, (a) inserting into a vehicular hollow member a rigid foam part comprised of a rigid foam having a heat activated foamable adhesive on at least a portion of the rigid foam insert and at least one integral locating means extending from a surface of the rigid foam, (b) engaging the locating means with the hollow member to locate the rigid foam part within the hollow member, and (c) heating the hollow member having the rigid foam part therein to a temperature and for a time sufficient to activate the heat activated expandable adhesive to form the foam filled vehicle hollow member.

Abstract: A furniture composite board comprises different materials. The surface of a proper-shaped matrix is covered by thermosetting resin and then fibers. The fibers then are soaked in thermosetting resin. During the process of thermosetting, the fibers would be solidified and become hard and firm on the surface of the matrix. The composite board has strong strength and its weight would change according to the matrix. It is easy for the composite to form various shapes; easy to be produced and needs no complicated equipment.

Abstract: An anti-skid exercise mat includes a foam member having a predetermined thickness, a fabric layer located on at least one side of the foam member, and at least one soft plastic material disposed on a predetermined area of a surface of the fabric layer and at least penetrating into the fabric layer for a predetermined depth for scarf joint and adhesive connection with fibers of the fabric layer. Accordingly, the anti-skid exercise mat has preferable anti-skid and perspiration-absorptive functions during the whole course of exercising.

Abstract: There is described a process for adhering a first elongate foam element having a first end portion to a second elongate foam element having a second end portion. The process comprises an initial step of melting a first surface portion of the first end portion to produce a first molten portion. Next the first end portion is abutted to the second end portion. Thereafter, the first molten portion is caused to solidify to create a seam bond between the first end portion and the second end portion. Thus, the present invention relates to adhering two elongate foam elements together at their end portions. The bond between the foam elements is created by melting at least a portion of the surface of one or both of the end portions of the two foam buns. This creates insitu a molten region which acts as an adhesive when the end portions of the two buns are abutted or otherwise contacted with each other.

Abstract: A process for making open-celled silicon carbide inserts (20) that allow metal infiltration to create metal-matrix composite part (100, 300) used for rubbing/wear components, such as an open-celled ceramic ring. The open-celled ceramic insert (20) is infiltrated by cast iron, and produces no negative effects to the iron casting process or the final metal-matrix composite product (100, 300) such as casting porosity or gas build-up inside the mold. Inserts (20) constructed in accordance with the invention enable manipulation and control over the density and weight of final metal-matrix composite products (100, 300). It is an advantageous characteristic of such inserts (20) that they enable manipulation and control over the dampening characteristics of final metal-matrix composite products (100, 300).

Abstract: Embodiments disclosed in the detailed description include a unitary or monolithic composite or hybrid cushioning structure(s) and profile(s) comprised of a cellular thermoplastic foam and a thermoset material. The thermoset material may also be provided as cellular foam as well. In one embodiment disclosed herein, the unitary composite cushioning structure is formed from a cellular thermoplastic foam and a thermoset material. The cellular thermoplastic foam provides support characteristics to the unitary composite cushioning structure. The thermoset material provides a resilient structure with cushioning characteristics to the cushioning structure. A stratum is disposed between at least a portion of the cellular thermoplastic foam and at least a portion of the thermoset material to secure the at least a portion of the thermoset material to the at least a portion of the cellular thermoplastic foam to provide a unitary composite cushioning structure.

Abstract: A game ball is disclosed that includes a polymer foam layer processed with an inert fluid blowing agent, such as nitrogen. The polymer foam may be a polyolefin material, such as polyethylene, polypropylene, and ethylvinylacetate, and the inert fluid blowing agent may have a relatively high-purity. The polymer foam may be manufactured with a process that includes impregnating a polymer with the inert fluid blowing agent and expanding the polymer by heating the polymer above a softening temperature of the polymer, reducing a fluid pressure surrounding the polymer, and cooling the polymer. The game ball may be a soccerball, football, or volleyball, for example, that includes the polymer foam.

Abstract: A method for fabricating an LCD device includes forming an alignment layer and an overcoat layer substantially simultaneously. The method includes, coating a mixture of an alignment layer material and an overcoat layer material on a substrate and at least partially separating the overcoat layer material and the alignment layer material by the curing the mixture.

Abstract: A method of continuously forming a multilayer panel includes making a gypsum slurry, then dividing the gypsum slurry into at least a primary gypsum slurry and a secondary gypsum slurry. An additive slurry having water and an intumescent material is created, then added to the secondary gypsum slurry to make an expandable layer slurry that is spread over at least a portion of a facing material. The primary gypsum slurry is distributed over the secondary gypsum slurry over the facing material and the expanding layer slurry to form a core. Optionally, another layer, an edge coating, is applied to the expanding layer for additional fire protection. The edge coating includes a second intumescent material. During a fire, the expanding layer expands to increase the thickness of the fire exposed gypsum panel and the edge coating expands to seal the gap between adjoining gypsum panels.

Abstract: A method for fabricating a door having a window, the door having a first door skin and a second door skin, the method including the following steps in the order named: forming a first door light opening perimeter having a first plurality of tabs arranged about the first door light opening perimeter, wherein the first door light opening perimeter defines a first door light portion; forming a second door light opening perimeter having a second plurality of tabs arranged about the second door light opening perimeter, wherein the second door light opening perimeter defines a second door light portion; positioning the first door skin on a first press; positioning an insert in aligned registration with the first plurality of tabs; positioning the second door skin over the insert, wherein the second plurality of tabs are in aligned registration with the insert, and the first door light opening perimeter is aligned with the second door light opening perimeter; applying pressure with the first press to secure the firs

Abstract: A surface-reinforced article includes a core assembly (12) comprising a foam core (20) with a surface region (22) that includes fine inner fibrous material intimately surround by foam that is integral with foam of the core, and an outer reinforcing covering (14) which includes an outer layer (32) of fibrous material and a resin (30) surrounding the outer layer of fibrous material and covering the primarily foam core assembly. The fine inner fibrous material (91-94) includes coupling fibers (100) with inner ends (102) embedded in the foam and outer ends (106) embedded in the resin, to better hold the resin to the foam. The primarily foam core assembly is molded within a first mold cavity (64) formed between spacers (60, 62) that lie within a second mold cavity (50).

Abstract: A method and apparatus for manufacturing a composite stringer. A composite material and foam are laid up onto a tool in the form of a stringer. The foam has a plurality of structural members within the foam. The plurality of structural members has a number of orientations to resist a number of loads. The composite material, the foam in the form of the stringer, and the plurality of structural members are cured to form the composite stringer.

Abstract: A foam product includes a foam core, at least one elastic buffer and a foam skin. The foam core defines an area on a surface thereof. The elastic buffer has a bottom surface bonded to the area of the surface of the foam core. The foam skin has a bottom surface bonded to a top surface of the elastic buffer and other areas of the surface of the foam core. The elastic buffer is made of foam materials and is elastic than the foam core. Additionally, the elastic buffer causes a bulge in the first foam skin.

Abstract: A support surface includes a foam base layer including a foam bottom layer and a pair of foam side edges disposed adjacent sides of the foam bottom layer. The foam side edges are firmer than the foam bottom layer. A honeycomb material layer is disposed over the foam base layer, and a cover surrounds the foam base layer and the honeycomb material layer. The combination of foam and honeycomb material provides an effective support surface resulting in superior pressure relieving characteristics, resistance to bottoming out, good edge support, and reduced manufacturing costs.

Abstract: A game ball is disclosed that includes a polymer foam layer processed with an inert fluid blowing agent, such as nitrogen. The polymer foam may be a polyolefin material, such as polyethylene, polypropylene, and ethylvinylacetate, and the inert fluid blowing agent may have a relatively high-purity. The polymer foam may be manufactured with a process that includes impregnating a polymer with the inert fluid blowing agent and expanding the polymer by heating the polymer above a softening temperature of the polymer, reducing a fluid pressure surrounding the polymer, and cooling the polymer. The game ball may be a soccerball, football, or volleyball, for example, that includes the polymer foam.

Abstract: A method and apparatus are disclosed for fabricating an anti-fatigue mat that employs a layer of resilient gel material that exhibits a first durometer. The method employs a frame assembly that receives a flexible support sheet. The frame assembly includes an aperture that receives a layer of heated liquid gel which cools to form the layer of resilient gel material exhibiting the first durometer. In one embodiment, a barrier layer exhibiting a second durometer is situated on the gel layer that exhibits the first durometer. In one embodiment, the barrier layer prevents the flow of oils from the gel layer to a flexible base sheet disposed on the barrier layer. In another embodiment, the flexible base sheet may exhibit a second durometer. In either embodiment, the layers exhibiting the first and second durometer cooperate to influence the feel of the mat to the user.

Abstract: A low cost, easy to manufacture scent-dispersing mat apparatus has a flexible closed cell foam mat containing a plurality of blind holes extending from its upper surface. These blind holes are partially filled with a fragrant liquid scent, creating air spaces thereabove. The upper surface of the flexible closed cell foam mat is sealed with a polymeric sheet that entraps the air spaces in the blind holes, causing entrapped air to become saturated with fragrant scent vapor. The polymeric sheet is perforated by one or more fine needles at the blind hole locations. The perforations permit escape of fragrant scent-saturated air to the ambient when pressure is applied to the top surface of the mat. Upon release of pressure, the foam mat and the blind holes recover their shape; the entrapped air pressure decreases, drawing fresh ambient air into the entrapped air spaces.

Abstract: A mattress, mattress foundation, upholstered furniture article, filled furnishing article or other similar composite article for use in institutional (non-residential) occupancies made with a fluid proof outer cover, a fire barrier material and a mattress core, wherein all materials used are free of halogens are presented.

Abstract: Precompressed sealing tape for sealing a joint has a foam strip and a foil-type wrapping, which completely surrounds the foam strip and thus holds it in a precompressed state. A first transverse surface of the foam strip is pressed against a strip-like element, which is arranged inside the wrapping and has a certain resistance to bending in the transverse direction of the foam strip. A second transverse surface of the foam strip, which is arranged opposite to the first transverse surface, is firmly connected to the foil-type wrapping.

Abstract: A sandwich structure based on a composite panel made of a thermoplastic core layer connected to at least one fiber-reinforced thermoplastic layer, in particular in-situ manufactured sandwich panels, comprises a thermoplastic core, which is arranged between two cover layers, in which the core is reinforced with fiber-reinforced thermoplastic reinforcing ribs which extend between the cover layers. Preferred methods for the manufacture are also described.

Abstract: A fiber composite component is at least partially produced by braiding. It comprises a core element which has at least one concavely constructed face that is adjoined by a passage opening. Respective opposite transverse or longitudinal sides of the core element and the side of the passage opening not bounded by the core element are enclosed by a braided fiber composite loop element.

Abstract: A lightweight, reinforced composite structural element is disclosed, which includes a hollow housing, interior reinforcement, a filling of polyurethane foam, and a substantially uniform outer coating of a high-solid protective coating. The reinforced composite structural element can be used as a railroad tie and for other construction uses. The structural element is formed with a housing having end caps or ends sealed by flaps that are connected with and bendable from the housing material to create a sealed container with openings for injection of the foam into cavities of the housing formed by the interior reinforcement.

Abstract: An airframe includes a mass barrier layer mounted to a multitude of frame members and adjacent to each of a multitude of foam portions to provide a contiguous layer to seal the foam portions within the respective multitude of frame voids.

Abstract: The present invention provides a viscoelastic support structure having improved energy absorption properties. The support structure generally comprises a frame, at least one resilient filler layer, a flexible covering, and at least one gel insert interposed between the covering and the frame. The support structure finds particular use in vehicles, such as bicycles and motorcycles.

Abstract: A fabric sheet member includes a cover cloth layer, an inner cloth layer, and two or more longitudinal fabric elements disposed between the cover cloth layer and the inner cloth layer, and secured to the cover cloth layer and the inner cloth layer for forming one or more air circulating spaces between the longitudinal fabric elements and the cover cloth layer and the inner cloth layer. The longitudinal fabric elements may be secured to the cover cloth layer and the inner cloth layer with such as stitches. The longitudinal fabric elements may be made of resilient cotton materials or filament materials. The fabric sheet member may be attached to a pillow, a bed cushion, a seat cushion or the like.

Abstract: A method of making foamed articles that includes providing a copolymer composition, combining the copolymer composition and cellulosic fibers, applying heat, mixing energy and pressure to the copolymer composition and cellulosic fibers mixture to form a foamable mixture, and forming the foamed article by placing the foamable mixture in a molding or extruding operation. The copolymer composition includes a copolymer of 51% to 99.9% of primary monomers, 0.1% to 49% of anhydride containing monomers, and 0% to 25% of other monomers and 0% to 30% of elastomeric polymers. This is combined at 30% to 99.99% copolymer composition with 0.01% to 70% by cellulosic fibers such that the copolymer anhydride groups react with the cellulosic fiber hydroxyl groups to produce a blowing agent byproduct to form a foamable mixture. The foamed article has a density of not more than 1.3 g/cm3.

Abstract: The invention is related to a material for horse protect gear which is mainly purposed to protect the material and products used for manufacturing protect gears, whereof a rubber or plastic foam body is used as the base material whose surface is bonded with a cloth; and the foam body and cloth combination is further made with a lot of through holes which pierce through the cloth and foam body, so that multiple small holes are visible on the cloth surface of the material to achieve a ventilation effect, thereby to enhance the conforming effect to the horse wearing the said protect gear without feeling sultriness.

Abstract: The present invention relates to an irregularly shaped grain for providing ingrowth and growth of connective tissue as well as growth of other cell types leading to cluster of cells, tissues and parts of organs. Said grain includes multiple pores that are continuous through said grain, and openings of said multiple pores and ducts or passages interconnecting at least a portion of said multiple pores have a width of greater than about 10 ?m. Said grain is preferably a metal or metal alloy. The invention also relates to different applications of the grains.

Abstract: A flexible core element having a large bonding surface area suitable for sandwich type construction comprising a plurality of first hexagonal nodes defining a first surface, a plurality of second hexagonal nodes defining a second surface spaced apart from and parallel to the first surface, and a plurality of rectangular wall members which interconnect said first hexagonal nodes to said second hexagonal nodes and define the depth of the core element. Each hexagonal node corresponds to an open hexagonal cell on its obverse surface and serves as a bonding surface. The core element is fabricated from a continuous sheet of material that has been die-cut with a repeating geometrical design, creased and folded, concertina style, in upon itself to make a double-sided core material that is flexible, able to vent, exhibits good bend and shear strength, and has a large surface bonding area rendering it suitable in the construction of lightweight sandwich panels and offering a wide array of other applications.

Abstract: The present invention relates to a composite part, and a method for producing a composite part, having a first body with at least one zone forming a depression and being separated from the front face of the first body by a projection forming one or more lateral walls. The depression receives a second foam body that is covered by a covering or finishing element. At least one lateral end portion of the covering element forms an edge held between the foam body and a corresponding lateral wall.

Abstract: An anti-skid exercise mat includes a foam member having a predetermined thickness, a fabric layer located on at least one side of the foam member, and at least one soft plastic material disposed on a predetermined area of a surface of the fabric layer. Accordingly, the anti-skid exercise mat has preferable anti-skid and perspiration-absorptive functions during the whole course of exercising.

Abstract: The present embodiment 10 provides a safety device for use with rodeo type bucking chutes as a means of reducing serious injuries to the participant, (which are common to the sport of bull riding and bronc riding) while preparing to mount livestock during exhibitions and competitions. The device comprises of a pad 42 filled with shock absorbing material 46 and covered with an encasement 42 made of vinyl, leather or other material strong enough to withstand substantial impact by individuals and/or livestock. The embodiment 10 is designed to fit over the top of the chute gate slider frame 18, extending slightly below the attachment area and attached at both ends of the chute frame 18. Attachment is accomplished with the use of nylon straps 30 (or other suitable material) to hold the embodiment 10 in place. Velcro strips 38 may also be used to attach the embodiment 10 to the chute frame 18. The embodiment 10 as shown 10 FIGS.

Abstract: A laminated support for pressure-relief comprising an upper layer of visco-elastic foam, a middle layer of visco-elastic foam having a greater hardness, and a bottom layer of highly resilient polyurethane foam. These layers are sandwiched between two layers of reticulated filter polyurethane foam.

Abstract: Cell walls (16) made of wood form a plurality of cells in which a filler material 18 (e.g. foam insulation) is received. Facing members (12, 14) are glued to the sides of the core structure (10). The grain of the wood cell walls (16) extend sideways of the core (10), such that in grain is directed towards the facing members (12, 14). This construction may be used to form logs (L) used for making log cabins, beams, columns, etc. It may also be used for constructing panels used to form furniture elements, such as desks, cabinets, etc., and for making doors.

Abstract: A long life scent dispersing mat apparatus uses an outer housing with apertures appointed to disperse a scent or fragrance. The fragrance is provided in a fragrant body which is a springy spongy rubber or polymeric sponge soaked with essential oils that have high vapor pressure at ambient temperatures. The fragrant body is inserted into an inner pouch which has small apertures and the stagnant air within the inner pouch attains saturation of fragrance vapor, thereby stopping further evaporation of the essential oils. When the scent-dispersing mat is stepped on, the inner pouch releases the saturated fragrant vapor into the interior of the outer housing and it is released to room air through apertures provided in the outer housing. When force on the mat is released, the fragrant body recovers its original shape and the inner pouch draws fresh make up air and essential oils volatilize until saturation is reached.

Abstract: The invention relates to a method of manufacturing a sandwich panel (10). Such a sandwich panel consists of a foamed core layer (12) and at least one thermoplastic cover layer (14). The sandwich panel is made by in situ foaming. In a first assembling step a core web, comprising at least one sheet of a thermoplastic material (12) containing an amount of a suitable physical blowing agent is positioned between two cover layers (14). The assembly of core web and cover layers is arranged between two press plates. Due to heat and pressure applied in a subsequent foaming step, foaming of the core web and effective bonding thereof to the cover layers is achieved. Subsequently the foamed assembly is allowed to cool down. Remaining physical blowing agent is removed during a subsequent drying step at elevated temperature while the outflow of physical blowing agent via the peripheral edges of the panel (10) is restricted, e.g. by taping (24) or clamping by clamps (16, 20).