Foam composite material comprising a first foam having an uncontoured surface, and a second, different foam fixed to the first foam at its uncontoured surface
AssigneeWoodbridge Foam Corporation
InventorsEdward T. Kuczynski, Ian L. Hughes, Charles R. Burchi
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Abstract
A foam composite material comprising a first isocyanate-based polymer foam comprising at least one uncontoured surface and a second, molded isocyanate-based polymer foam, the first isocyanate-based polymer foam and the second isocyanate-based polymer foam being: (i) of different composition, and (ii) fixed with respect to one another. A process for producing the foam composite material also disclosed. The foam composite material is useful in another of vehicular and non-vehicular applications.
Claims40
A foam composite material comprising a first isocyanate-based polymer foam comprising at least one uncontoured surface and a second, molded isocyanate-based polymer foam, the first isocyanate-based polymer foam and the second isocyanate-based polymer foam being:
- (i) of different composition, and (ii) fixed with respect to one another at the at least one uncontoured surface of the first isocyanate-based polymer foam.
A process for producing a foam composite material in a mold comprising a first mold half and a second mold half engageable to define a mold cavity, the process comprising the steps of:
- (i) providing a first isocyanate-based polymer foam having at least one uncontoured surface in the first mold half;
- (ii) dispensing a second foamable composition in at least one of the first mold half and the second mold half;
- (iii) closing the first mold half and the second mold half;
- (iv) expanding the second foamable polymeric composition to fill substantially the mold cavity to produce a second isocyanate-based molded polymer foam;
- (v) fixing the second isocyanate-based polymer foam with respect to the first isocyanate based foam to produce the foam composite.
Dependencies are inferred from the claim text.