Biofoam door

A biofoam door made by a method comprising:

• a. creating a frame 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, the biofoam formulation consisting of:
• (i) a plant based polyol from 20 weight percent to 60 weight percent based on the total liquid hardenable flowable biofoam formulation consisting of 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, wherein the biomass content is selected from the group consisting of straw, ground pecan shells, cellulosic materials, silage, ground peanut shells, talc, and ground bagasse;
• and
• 2. a plant based oil content from 8 weight percent to 92 weight percent based on the total liquid hardenable flowable biofoam formulation, wherein the plant based oil is one of a plant based renewable source and a non-fossil fuel source;
• (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 based on the total liquid hardenable flowable biofoam formulation 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 based on the total liquid hardenable flowable biofoam formulation;
• (v) an isocyanate from 36 weight percent to 55 weight percent based on the total liquid hardenable flowable biofoam formulation;
• (vi) an antioxidant from 0.2 weight percent to 10 weight percent based on the total liquid hardenable flowable biofoam formulation;
• (vii) a filler from 0.2 weight percent to 10 weight percent based on the total liquid hardenable flowable biofoam formulation;
• and
• (viii) a crosslinking agent from 0.1 weight percent to 1.4 weight percent based on the total liquid hardenable flowable biofoam formulation;
• e. injecting the liquid hardenable flowable biofoam formulation 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 formulation expands within the frame and the polymer skins forming an expanded closed cell 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 closed cell biofoam forming a door with increased sound deadening properties and increased insulation properties that is produced without retaining a toluene, a pentane, or a styrene in the liquid hardenable flowable biofoam formulation to make the door;
• wherein the bond between the biofoam, the frame and the polymer skins has a tensile strength that withstands a hurricane category force wind.