Method of molding a laminated foamable sheet

Stock material or miscellaneous articles – Structurally defined web or sheet – Discontinuous or differential coating – impregnation or bond

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264 453, 264 54, 264257, 264DIG5, 4283175, 4283179, B29C 3910, B29C, C08J 908

Patent

active

047987634

ABSTRACT:
A method of molding and forming a laminated foamable sheet which contains a solid catalyst that is activated at the molding temperature of the laminate. A laminated foamable sheet is first provided by saturating a glass fiber mat with a urethane foam composition containing a solid catalyst of stearate salt and then sandwich it between two layers of cover sheet. The solid catalyst contained in the urethane composition cannot be activated until it is heated to the molding temperature of the laminated sheet. The laminated foamable sheet is then positioned into a mold having two heated platens and a cavity defined therein with the mold temperature set at a temperature of at least that of the melting point of the solid catalyst contained in the urethane composition. The solid catalyst in the composition melts and causes the urethane precursors to start the foaming reaction such that the laminate expands and fills the cavity of the mold. After a sufficient length of time during which the foamed sheet is cured under heat and pressure, a completed part in the shape of the cavity is removed from the mold.

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Becker, Walter E., Edt., Reaction Injection Molding, New York, Van Nostrand Reinhold, .COPYRGT.1979, pp. 17-33.

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