Patent ID: 6902694

Claim:
A method of forming a urethane foam sheet having enhanced fastener retention so that a threaded fastener is retained within the urethane foam sheet and is not easily removed from the urethane foam sheet when an outward force is applied thereto, the method comprising: positioning at least one layer of a polyolefin blend and at least one layer of a glass material in a mold; supplying a non-polyolefin urethane foam material to the layers of the polyolefin blend and the glass material at a velocity so that the non-polyolefin urethane foam material is dispersed throughout the layers of the polyolefin blend and the glass material in the mold; pressing the layers of the polyolefin blend and the glass material and the non-polyolefin urethane foam material in the mold so that the materials are compacted to thereby increase the density of the materials and to enhance imbedding of the layers of the polyolefin blend and the glass material within the non-polyolefin urethane foam material; and controlling a temperature in a press during expansion of the non-polyolefin urethane foam material throughout the mold so that the layers of the polyolefin blend and the glass material are substantially contained within and retained by the non-polyolefin urethane foam material.