Patent ID: 8501062

Claim:
A method of making a composite article ( 20 ) comprising the steps of: providing a mold ( 42 ) having a mold surface ( 44 ) defining a mold cavity ( 46 ); positioning a first preform ( 24 ) and a second preform ( 26 ) in the mold cavity ( 46 ) with the preforms ( 24 , 26 ) spaced from and opposing each other, wherein the second preform ( 26 ) comprises openings ( 28 ) extending therethrough along an axis transverse to the first preform ( 24 ); positioning a first surface layer ( 22 ) in the mold cavity ( 46 ) between the second preform ( 26 ) and the mold surface ( 44 ) on an opposite side of said second preform ( 26 ) from said first preform ( 24 ); introducing a composition ( 40 ) comprising an isocyanate component, an isocyanate-reactive component, and a blowing agent between the first preform ( 24 ) and the second preform ( 26 ) and through the openings ( 28 ); forming the composite article by curing the introduced composition ( 40 ) into a polymer composition ( 32 ) adhering the first preform ( 24 ) to the second preform ( 26 ) and adhering the first surface layer ( 22 ) to the second preform ( 26 ) through the openings ( 28 ); and demolding the resulting composite article ( 20 ) from the mold cavity ( 46 ).