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Manufacturing a Double Density Foam Filled Panel

IP.com Disclosure Number: IPCOM000082858D
Original Publication Date: 1975-Feb-01
Included in the Prior Art Database: 2005-Feb-28
Document File: 2 page(s) / 44K

Publishing Venue

IBM

Related People

Ciancanelli, JM: AUTHOR

Abstract

This method can be used to manufacture a panel that is filled with foam of two different densities. The panel is both light in weight and highly resistant to dents. These features make it particularly useful as a door.

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Manufacturing a Double Density Foam Filled Panel

This method can be used to manufacture a panel that is filled with foam of two different densities. The panel is both light in weight and highly resistant to dents. These features make it particularly useful as a door.

The first step is to form the outer skin of the panel. This can be made of aluminum that is about 0.005-0.015 inch thick.

Next, the outer skin is backed with a high-density urethane foam. As shown in the figure, the thin metal outer skin 1 is placed in a stabilizing form 2 so that its shape will be maintained. A urethane foam mixture is poured on top of the outer skin 1. Enough of the mixture is introduced to produce a high-density foam lining 3 when its growth is confined to an area approximately 0.125 inch thick.

After the mixture is poured, an internal preform 4 is placed over it. The internal preform 4 rests on top of the stabilizing form 3 and is spaced from the outer skin 1 of the panel by approximately 0.125 inch. The internal preform 4 must be heavy enough, or enough pressure must be placed on top of it, to force the foam to grow to a high density within the confines of this space.

The internal preform 4 is then removed and another mixture of urethane foam is poured on top of the cured high-density foam 3. Enough of the mixture is introduced so that it will grow to fill the remainder of the door space at a low density. After the second pouring, an aluminum back skin (again about 0.005- 0.015...