Patent ID: 9097060
Filing Date: 2015-08-04
Classification: B29C,B29L,E04B,E04C,E06B,Y10T

Abstract:
1. 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: 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.