Method of making a composite panel of a foam material

Details Method of making a composite panel of a foam material Method of making a composite panel of a foam material

1988-06-07

1990-07-03

Thurlow, Jeffery

Adhesive bonding and miscellaneous chemical manufacture

Methods

Surface bonding and/or assembly therefor

264 462, 264 464, 264 48, 264 54, B29C 6720, B32B 518, B32B 520

Patent

active

049388193

ABSTRACT:
A method of making a foam product including the steps of reacting an isocyanate component with a polyol component and foaming with a foaming agent to form a self-supporting intermediate foam material. The isocyanate component is present in excess of a stoichiometric quantity needed to react with the polyol component. The self-supporting intermediate foam material is then contacted with water and the self-supporting, intermediate foam material is heated to form a foam product, the water reacting with the remaining unreacted isocyanate component. The self-supporting, intermediate foam material formed by the first foaming step is rigid or semi-rigid at room temperature but it can be softened by heating to enable it to be used for deep draw molding in a successive cure molding process without cracking, splitting or being destroyed. Once the self-supporting, intermediate foam material is contacted with water or steam in the final cure molding process to react the remaining isocyanate component, the material becomes a finally cured, rigid or semi-rigid foam material which will not soften on heating. The self-supporting, intermediate foam material can be laminated with facing materials or reinforced with glass fiber--non-woven cloth or the like to give a composite panel which exhibits stiffness, heat insulation, acoustic insulation, moisture resistance and is light in weight so that it can be used for a molded ceiling or door panel in an automobile or a partition or screen for interior use.

REFERENCES:
patent: 2850467 (1958-09-01), Livingood
patent: 3617594 (1971-11-01), Willy
patent: 3627603 (1971-12-01), Greig
patent: 3738895 (1973-06-01), Paymal
patent: 3874964 (1975-04-01), Cogliano et al.
patent: 3966521 (1976-06-01), Patton, Jr. et al.
patent: 4374934 (1983-02-01), Raynor
patent: 4451310 (1984-05-01), Lairloup

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