System, method and composition for forming composite sprayed polyurethane skins having a low density expanded polyurethane layer

A sprayable expandable polyurethane composition for forming a sprayed skin, said composition comprising:

• polyol;
• isocyanate;
• blowing agent, and
• low fogging surfactant wherein the components are present in an amount such that a resulting layer of polyurethane, when cured, will have a density in the range of 0.05 to 0.2 g/cm3.

A system for making a composite polyurethane skin, said system comprising:

• a source of liquid polyol;
• a source of liquid isocyanate;
• a source of liquid low density foaming agent comprising blowing agent and low fogging surfactant;
• a spray mold tool having a mold surface;
• and
• a spraying device for spraying liquid material at the spray mold tool;
• the spraying device being able to receive polyol from the polyol source and isocyanate from the isocyanate source to form a polyurethane composition for spraying towards the spray mold tool to form a polyurethane skin layer on the spray mold tool;
• the spraying device being able to receive isocyanate from the isocyanate source, low density foaming agent from the low density foaming agent source, and polyol from the polyol source to form an expandable polyurethane composition for spraying onto the skin layer to form a resilient expanded polyurethane layer on the skin.