Patent ID: 6841111

Claim:
A method for making a composite structure having a flexural modulus of at least 200,000 lb/in 2 wherein the composite structure includes at least one first-layer and at least one second-layer, said method comprising the steps of: (a) providing a mold substrate; (b) applying a first-layer of the composite structure to the mold substrate, said first-layer comprising the reaction product of a first-layer polyisocyanate component including an aliphatic polyisocyanate and a first-layer resin component including a polyamine and being substantially free of volatile organic compounds, wherein said first-layer is a show surface of the composite structure and has a Shore D hardness of at least 65; and (c) applying a second-layer of the composite structure to said first-layer, said second-layer comprising the reaction product of a second-layer polyisocyanate component and a second-layer resin component including a polyol having a theoretical functionality of at least three and being substantially free of volatile organic compounds (d) demolding the composite structure from the mold substrate.