Patent ID: 8133419

Claim:
A process comprising a) applying a foamable polyurethane composition onto a mat of at least one reinforcing fiber to form an impregnated mat; b) molding the impregnated mat at an elevated temperature sufficient to cure the polyurethane composition, to form a molded, fiber-reinforced polyurethane foam, and c) demolding the fiber-reinforced polyurethane foam, wherein the foamable polyurethane composition comprises a polyol or mixture of polyols, a polyisocyanate and about 3.0 to about 5.5 parts of water per 100 parts by weight of polyol(s), the polyol or mixture of polyols having an average of 3.8 to about 8 hydroxyl groups/molecule and a hydroxyl equivalent weight of about 100 to about 135, wherein at least 70% of the hydroxyl groups contained in the polyol or mixture of polyols are secondary hydroxyl groups and the polyol or polyol mixture is substantially devoid of primary or secondary amino groups, and further wherein the polyisocyanate index is from 90 to 130, wherein step c) is performed within 60 seconds of the beginning of step b).