Multilayer panel member

A process for manufacturing a multilayer foam panel member comprising the steps of:

• (A) providing at least a top sheet substrate;
• (B) providing at least a bottom sheet substrate
• (C) providing a flexible film fluid-dispensing device for dispensing a foam-forming reactive fluid mixture therefrom and that includes a flexible film liner and a rigid frame, the flexible film liner including a plurality of fluid inlet apertures, a plurality of fluid outlet apertures, and a plurality of flexible fluid flow path ducts, the rigid frame including arm members that extend parallel to each other, and the rigid frame being attached to edges of the flexible film liner and holding the flexible film liner in place to receive the foam-forming reactive fluid mixture;
• (D) dispensing the foam-forming reactive fluid mixture from the flexible film fluid-dispensing device onto a surface of the bottom sheet substrate, the foam-forming reactive fluid mixture entering the plurality of fluid inlet apertures, passing through the plurality of flexible fluid flow path ducts, and exiting the plurality of fluid outlet apertures onto the surface of the bottom sheet substrate distributing the foam-forming reactive fluid mixture exiting the flexible film fluid-dispensing device;
• (E) allowing the foam-forming reactive fluid mixture to react on the surface of the bottom sheet substrate, for a time sufficient to form a middle foam material substrate disposed inbetween, and integral with, the top sheet substrate and the bottom sheet substrate to form a multilayer panel structure;
• and
• (F) curing the panel structure to form a cured panel member.