Process for producing an energy absorbing panel

Plastic and nonmetallic article shaping or treating: processes – Pore forming in situ – Composite article making

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264 464, 264257, 264258, 2642791, 428246, 428226, B29C 6500

Patent

active

053893166

ABSTRACT:
A process for producing an energy absorbing panel having at least one energy absorbing surface in a mold comprising an upper mold and a lower mold. The process comprising placing a reinforcing layer in both of the upper mold and the lower mold. A liquid foamable polyurethane composition is then dispensed in the lower mold and allowed to expand to fill from 50-80% of the mold volume. The upper mold and lower mold are then closed to define an enclosure corresponding substantially to the energy absorbing panel and the liquid foamable polyurethane composition is expanded to fill the remainder of the enclosure to produce a resilient polyurethane foam core which adheres to the reinforcing layers thereby providing an energy absorbing surface. The reinforcing layer has a tensile strength greater than the tensile strength of the resilient polyurethane foam core. Upon compression of the panel at the energy absorbing surface to about 50% by volume of the uncompressed panel in a direction substantially normal to the reinforcing layer, the panel recovers to at least about 90% of volume of the uncompressed panel in less than about 30 minutes. The panel has widespread utility and is particularly useful in vehicular applications.

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