Method for making a door with a biofoam

A method for making a door with a biofoam, the method comprising:

• a. creating a flame with a front side and a back side having a door shape;
• b. positioning a first polymer skin over the front side covering the front side;
• c. positioning a second polymer skin over the back side covering the back side, wherein the first and second polymer skins are spaced apart a width equivalent to a width of the frame;
• d. forming a liquid hardenable flowable biofoam formulation comprising:
• (i) a polyol from 20 weight percent to 60 weight percent with at least one of:
• 1. a biomass content from 8 weight percent to 48 weight percent based on the total liquid hardenable flowable biofoam formulation;
• and
• 2. a plant based oil content from 8 weight percent to 92 weight percent based on the total liquid hardenable flowable biofoam formulation;
• (ii) a catalyst from 0.75 weight percent to 1.2 weight percent based on the total liquid hardenable flowable biofoam formulation, wherein the catalyst is at least one of an amine catalyst or a metal catalyst;
• (iii) a blowing agent from 2.0 weight percent to 6.0 weight percent comprising at least one of:
• water, distilled water, oxygen, and atmospheric air;
• (iv) a surfactant from 1.1 weight percent to 1.4 weight percent;
• and
• (v) an isocyanate from 36 weight percent to 55 weight percent;
• e. injecting the liquid hardenable flowable biofoam between the first and second polymer skins and the frame for a period of time from 2 seconds to 60 seconds;
• and
• f. waiting from 1 minute to 10 minutes while the liquid hardenable flowable biofoam expands within the frame and the polymer skins forming an expanded biofoam that simultaneously eliminates the formation of cavities between the first and second polymer skins and the frame, bonding the frame and the polymer skins to the expanded biofoam forming a door with increased sound deadening properties and increased insulation properties that is produced without using a toluene, a pentane, or a styrene in the liquid hardenable flowable biofoam formulation to make the door.