Patent ID: 6013213
Filing Date: 2000-01-11
Classification: B29C,B29K,B32B,B60R,B63B

Abstract:
A method of making a resilient composite structure having an exposed reinforcing fabric layer free of structural foam and curable resin, said method comprising the steps of:attaching a reinforcing fabric layer to a non-woven fabric layer on one side thereof;arranging said attached fabric layers in a configuration constrained against outward movement and with the non-woven fabric layer facing inwardly and defining a cavity between opposing surfaces thereof;dispensing a predetermined amount of a self-expanding, uncured resilient structural foam into said cavity, said foam expanding and curing in said cavity at a molding pressure determined by said predetermined amount of said foam and thereby attaching itself to said non-woven fabric layer to form said composite structure, said molding pressure causing said expanding foam to substantially fill only interstices of said non-woven fabric layer, without substantially penetrating the reinforcing fabric layer; and,freeing said cured composite structure from said constraint of said arranging step, said reinforcing fabric layer of said composite structure, upon being freed from said constraint, being substantially completely saturatable with a curable material for lamination to another structure in a subsequent processing step.