Durable, energy-absorptive EPP/PUR structural composites
AssigneeLear Corporation
InventorJohn P. Slaven
Life of this patent
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Abstract
Structural composite parts having a light-weight expanded polyolefin core are rendered resistant to breakage under bending stress by molding an integral skin polyurethane flexible foam around the core. The resulting composite parts have excellent compressive strength and energy absorption properties while being resistant to breakage, and are well suited for light-weight and cost effective energy management structures in vehicle interiors.
Claims14
An energy management structural composite resistant to breakage under bending stress, comprising in major part an expanded polyolefin molded part surrounded on at least one surface by an effective breakage minimizing layer of an in situ-produced integral skin polyurethane flexible foam, said integral skin polyurethane foam directly abutting said expanded polyolefin molded part.
A process for the manufacture of an energy management structural composite resistant to breakage under bending stress, said process comprising:
- b) positioning an expanded polyolefin part into a mold spaced apart from at least one surface thereof;
- c) introducing a reactive, foamable integral skin polyurethane flexible foam formulation into said mold and allowing said formulation to foam and cure to form a structural composite having said integral skin foam surrounding at least one surface of said expanded polyolefin part;
- and
- d) removing said structural composite from said mold.
A process for decreasing the weight of an energy management interior part of a transportation vehicle while maintaining an acceptable degree of resistance-to-breakage under bending stress, said process comprising:
- constructing the major volumetric portion of said part from expanded polyolefin to form an expanded polyolefin interior;
- surrounding said expanded polyolefin interior with an integral skin polyurethane flexible foam integument,
- wherein a light weight breakage-resistant structural composite part results.
Dependencies are inferred from the claim text.