PCT
`INTERNATIONAL APPLICATION PUBLISHED UNDER THE PATENT COOPERATION TREATY (PCT)
`WO 93/03910
`
`WORLD INTELLECTUAL PROPERTY ORGANIZATION
`International Bureau
`
`(51) International Patent Oassification 5 :
`B29C67/22
`
`(11) International Publication Number:
`
`Al
`
`(43) International Publication Date:
`
`4 March 1993 (04.03.93)
`
`(81) Designated States: AT, AU, BB, BG, BR, CA, CH, CS,
`DE, DK, ES, FI, GB, HU, JP, KP, KR, LK, LU, MG,
`MN, MW, NL, NO, RO, RU, SD, SE, European patent
`(AT, BE, CH, DE, DK, ES, FR, GB, GR, IE, IT, LU,
`MC, NL, SE), OAPI patent (BF, BJ, CF, CG, CI, CM,
`GA, GN, ML, MR, SN, TD, TG).
`
`Published
`With international search report.
`
`(21) International Application Number:
`
`PCT/CA92/00350
`
`(22) International Filing Date:
`
`12 August 1992 (12.08.92)
`
`(30) Priority data:
`744,331
`862,172
`
`13 August 1991 (13.08.91)
`2 April 1992 (02.04.92)
`
`us
`us
`
`(71) Applicant: WOODBRIDGE FOAM CORPORATION
`[CA/CA]; 4240 Sherwoodtowne Boulevard, Suite 300,
`Mississauga, Ontario L4Z 2G6 (CA).
`
`(72) Inventor: KERMAN, Michael, L. ; 136 Minot Street,
`Romeo, MI 48065 (US).
`
`(74) Agents: NASSIF, Omar, A. et al.; McCarthy Tetrault, Suite
`4700, Toronto Dominion Bank Tower, Toronto-Domin(cid:173)
`ion Centre, Toronto, Ontario M5K 1E6 (CA).
`
`(54)Title: PROCESS FOR PRODUCING A REINFORCED, FOAMED POLYURETHANE PANEL
`
`(57) Abstract
`
`A process for producing an energy absorbing panel having at least one energy absorbing surface in a mold comprising an
`upper mold and a lower mold. The process comprising placing a reinforcing layer in at least one of the upper mold and the lower
`mold. A liquid foamable polyurethane composition is then dispensed in the lower mold. The upper mold and lower mold are
`closed to define an enclosure corresponding substantially to the energy absorbing panel, the liquid foamable polyurethane com(cid:173)
`position is expanded to fill substantially the enclosure to produce a resilient polyurethane foam core which adheres to the reinfor(cid:173)
`cing layer thereby providing an energy absorbing surface. The reinforcing layer has a tensile strength greater than the tensile
`strength of the resilient polyurethane foam core. Upon compression of the panel at the energy absorbing surface to about 50 % by
`volume of the uncompressed panel in a direction substantially normal to the reinforcing layer, the panel recovers to at least about
`90 % of volume of the uncompressed panel in less than about 30 minutes. The panel has widespread utility and is particularly use(cid:173)
`ful in vehicular applications.
`
`EX1071
`Yita v. MacNeil
`IPR2020-01139
`
`

`

`FOR THE PURPOSES OF INFORMATION ONLY
`
`Codes used to identify States party to the Per on the front pages of pamphlets publishing international
`applications under the PCT.
`
`AT
`AU
`BB
`BE
`BF
`BC
`BJ
`BR
`CA
`CF
`cc
`CH
`Cl
`CM
`cs
`CZ
`OE
`DK
`ES
`
`Austria
`Australia
`Barbados
`Belgium
`Burkina Fa.,;o
`Bulgaria
`Benin
`Brazil
`Canada
`Central African Rcpublic
`Congo
`Swif.7.crland
`Cote d'b1oirc
`Cameroon
`(:ZCChoslovaki.1
`Czech Republic
`Germany
`Denmark
`Spain
`
`Fl
`FR
`GA
`GB
`GN
`GR
`HU
`IE
`IT
`JP
`KP
`
`KR
`LI
`LK
`LU
`MC
`MG
`Ml
`
`Finland
`France
`Gabon
`United Kingdom
`Guinea
`Greece
`Hungary
`Ireland
`Italy
`Japan
`Democratic People's Republic
`of Korea
`Republic of Korea
`I .icchlcnstein
`Sri Lanka
`I .uxemhourg
`Monaco
`Madagascar
`Mali
`
`MN
`MR
`MW
`NL
`NO
`NZ
`PL
`PT
`RO
`RU
`SD
`SE
`SK
`SN
`SU
`TD
`TG
`UA
`us
`
`Mongolia
`Maurit.inia
`Malawi
`Netherlands
`Norway
`New Zealand
`Poland
`Portugal
`Romania
`Russian Federation
`Sudan
`Sweden
`Slovak Republic
`Senegal
`Soviet Union
`Chad
`Togo
`Ukraine
`United Si.Hes of America
`
`!
`
`~
`
`

`

`WO93/03910
`
`1
`
`PCT/CA92/00350
`
`PROCESS FOR PRODUCING A REINFORCED, FOAMED POLYURETHANE PANEL
`TECHNICAL FIELD
`The present invention relates to a process for producing an energy
`absorbing panel.
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`BACKGROUND ART
`Energy absorbing devices (also known as energy management devices)
`are known. Such devices can take one of a variety of shapes and forms.
`Currently, one of the major applications for energy absorbing panels is in use
`in vehicles, particularly automobiles. Such panels, when used in vehicles,
`would be of great convenience if they could be included in or substituted for
`trim panel and, indeed, are commonly referred to as trim panels. Current
`trim panels are particularly deficient as regards their ability to combine
`durability with energy absorbing capability.
`A common use for energy absorbing panels is in a vehicle instrument
`panel. An instrument panel typically includes a plastic substrate and a head
`impact zone.
`Pursuant to recent governmental guidelines for improved
`passenger safety, it is now a prerequisite that instrument panels and areas of
`the interior of the vehicle have an energy management capability.
`Heretofore, known instrument panels have comprised the use of a rigid
`substrate over which is placed a resilient, decorative foam. The foam has an
`indentation force deflection characteristic of about 1 to 2 pounds per square
`inch at 25 percent compression of the foam. This amounts to little or no
`energy absorbing capability for the foam. To make up for this, the substrate
`25 must be rigid, typically with a flexural modulus of at least 8,000 MPa. The
`rigid substrate is usually provided at a thickness of about Ya of an inch and is
`configured to have specific defined impact zones. This is deficient since the
`areas which are not impact zones are insufficient to absorb the energy of an
`impact. Rather, in such areas, the energy of impact tends to deflect away
`from the rigid substrate. In the case of an instrument panel, this can lead to
`severe or fatal consequences for a passenger of vehicle.
`The use of foam in an energy absorbing panel is known. Prior panels
`typically comprise the use of a friable, crushable foam (e.g. rigid polystyrene,
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`WO 93/03910
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`PCT/CA92/00350
`
`-2-
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`rigid polyurethane and the like). In use, this type of foam absorbs the energy
`from a single impact and, concurrently, crushes. Accordingly, after a single
`impact, the foam must be replaced.
`United States patent 4,508,774 discloses thermoforming compression
`of polyester-urethane foams.
`Specifically, this patent discloses cellular
`polyurethanes having a density of 15-400 kg/m3 and based on aromatic
`polyisocyanates and polyester polyols. The thermoforming takes place in a
`forming tool at a compression factor of 1-10 and at a temperature of 140° to
`200°C. This patent discloses the use of a starting polyurethane foam slab
`having a density of 15-40 kg/m3 which is cut to suitable dimensions of the
`:finished article. Thereafter, the cut slab is thermoformed using conventional
`techniques. The compression factor for closed molds is defined as the
`quotient of the density of the final polyurethane foam and the density of the
`initial polyurethane foam.
`
`The process disclosed in United States patent 4,508,774 is deficient for
`a number of reasons. Generally, the process is complicated by having to use
`pre-manufactured foam. This results in extra steps associated with making
`and shaping the pre-manufactured foam resulting in wastage of trimmed foam.
`Further, the use of a pre-manufactured foam necessitates the use of a
`specialized mold to provide the appropriate compression factor and to
`withstand the conditions of rapid mold closure and specialized temperature
`control required in the thermoforming operation. Third, the use of a pre(cid:173)
`manufactured foam necessitates the use of spray, laminating or hot-melt
`adhesives to adhere the reinforcing or decorative layer to the pre-formed foam
`while conducting the thermoforming operation. Fourth, when a fibrous
`reinforcing layer is used, the process of using an adhesive between the
`reinforcing layer and the polyurethane foam results in an inferior panel since
`the adhesive must serve the dual purpose of (i) adhering the reinforcing layer
`to the foam and (ii) forming a uniform matrix for inherent reinforcement of
`the fibrous reinforcing layer. Fifth, the requirement for a relatively high
`temperature during the thermoforming operation renders the overall process
`energy intensive.
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`WO 93/03910
`
`PCT/CA92/00350
`
`-3-
`
`In view of the above-mentioned deficiencies of the prior art, it would
`be desirable to have a relatively simple process for producing an energy
`absorbing panel which obviates or mitigates at one of the above-identified
`deficiencies of the prior art.
`
`DISCLOSURE OF THE INVENTION
`It is an object of the present invention to provide a novel process for
`producing an energy absorbing panel.
`Accordingly, the present invention provides a process for producing an
`energy absorbing panel having at least one energy absorbing surface in a mold
`comprising an upper mold and a lower mold, the process comprising the steps
`of:
`
`placing a reinforcing layer in at least one of the upper mold and
`(i)
`the lower mold;
`dispensing a liquid foamable polyurethane composition in the
`
`(ii)
`lower mold;
`
`closing the upper mold and the lower mold to define an
`(iii)
`enclosure corresponding to the shape of the energy absorbing panel; and
`(iv)
`expanding the foamable liquid polyurethane composition to fill
`substantially the enclosure to produce a resilient polyurethane foam core which
`adheres to the reinforcing layer thereby providing an energy absorbing
`surface;
`wherein the reinforcing layer has a tensile strength greater than the
`tensile strength of the resilient polyurethane foam core and upon compression
`of the panel at the energy absorbing surface to about 50% by volume of the
`uncompressed panel in a direction substantially normal to the reinforcing
`layer, the panel recovers to at least about 90 % of volume of the uncompressed
`panel in less than about 30 minutes.
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`BEST MODE FOR CARRYING OUT THE INVENTION
`It will be appreciated by those skilled in the art that the order of the
`process steps may be VcUied depending on the exact nature of the process.
`
`

`

`WO 93/03910
`
`PCT /CA92/00350
`
`-4-
`
`For example, in certain cases, it may be possible to place the reinforcing layer
`in the lower mold ( or in the upper mold if secured by suitable fastening
`means), close the upper mold and the lower mold and thereafter inject the
`liquid foamable polyurethane composition - this is called a "closed mold"
`pouring technique. Alternatively, the upper mold and lower mold are not
`closed until the liquid polymeric composition has expanded to about 50,
`preferably from about 50 to about 90, more preferably from about 60 to about
`80, most preferably from about 70 to about 80, percent by volume of the
`enclosure defined by closing the upper mold and the lower mold - this is
`called an "open mold" pouring technique. To the Applicants knowledge, the
`"open mold" and "closed mold" pouring techniques work equally well and the
`choice of technique used is usually dictated by the nature of the article being
`produced. Generally, it has been found that the "open mold" pouring
`technique is most convenient since the mold has to be opened in any event to
`place therein the reinforcing layer which is preferably flexible.
`It has been surprisingly and unexpectedly discovered that the provision
`of the energy absorbing panel produced by the present process obviates the
`need for a rigid substrate in particular automotive applications such as
`passenger side air bag doors, knee bolsters, side impact bolsters, A, B and C
`pillars, sun visor cores and door panels. Many of these devices have
`heretofore had little or no energy management capability. The necessity of
`such capability has been recently mandated in the United States and other
`countries.
`It has also been discovered that the energy absorbing panel
`produced by the present process is capable of repeated impact since the core
`is comprised of a relatively resilient polyurethane foam core. These
`outstanding properties accrue from the energy absorbing panel produced by
`the present process due to its inherent relatively uniform energy absorbing
`capability when compared with known panels comprising high resiliency-low
`energy absorbing foams and low resiliency-high energy absorbing substrates.
`It is believed that the relative! y uniform energy absorbing capability of the
`energy absorbing panel produced by the present process is due substantially
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`WO93/03910
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`PCT/CA92/00350
`
`-5-
`
`to the interaction, upon impact, between the polyurethane foam core and the
`reinforcing layer.
`The energy absorbing panel produced according to the present process
`includes at least one energy absorbing surface having a reinforcing layer
`adhered to and covering at least a portion of the resilient polyurethane foam
`core. Preferably, the polyurethane core is disposed between a first energy
`absorbing surface and a second energy absorbing surface in a spaced,
`substantially parallel relationship to one another. The provision of two energy
`absorbing surfaces can lead to a dramatic increase in energy absorbing
`capability when compared to the use of a single energy absorbing surface as
`will be described hereinafter.
`The choice of reinforcing layer used in the present process is not
`particularly restricted provided that it has a greater tensile strength than the
`polyurethane foam core and may be a non-metal or a metal. Preferably, the
`reinforcing layer is flexible. The flexible reinforcing layer may be fibrous or
`non-fibrous. Non-limiting examples of fibrous reinforcing layers include at
`least one member selected from the group consisting essentially of glass fibres
`(e.g. in the form of a cloth or a mat, chopped or unchopped, such as Nico
`
`754 1 oz/ft2), polyester fibres, polyolefin fibres (e.g. polyethylene and
`polypropylene), Kevlar fibres, polyamides fibres (e.g. nylon), cellulose fibres
`(e.g. burlap), carbon fibres, cloth materials such spun bound polyesters (e.g.
`Lutravil 1DH7210B/LDVT222 and Freudenberg PTLD585G/PTLD600B) and
`paper (e.g. Kraft #60). It will be appreciated that the fibrous reinforcing layer
`may be woven or non-woven. Non-limiting examples of a non-fibrous
`reinforcing layer comprise at least one member selected from the group
`consisting essentially of thermosets (e.g. polyurethanes, polyesters and
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`epoxies), metals such as aluminum foil, polycarbonates (e.g. Lexan and Dow
`Calibre), polycarbonate/ABS alloys (e.g. Dow Pulse), ABS terpolymers (e.g.
`Royalite 59 and Dow Magnum), polyester terphthalate (PET), vinyl, styrene
`30 maleic anhydride (e.g. Arco Dylark), and fibreglass reinforced polypropylene
`(e.g. Az.del). It will be appreciated that many non-fibrous reinforcing layer
`materials may themselves be reinforced with fibrous materials and thus, the
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`

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`WO 93/03910
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`PCT /CA92/00350
`
`-6-
`
`flexible reinforcing layer may be a combination of fibrous and non-fibrous
`materials, either mixed or composite in construction.
`Preferably, the present process further comprises the step of utilizing
`a decorative layer to cover at least one surface of the energy absorbing
`surface. The specific choice of decorative layer is not particularly restricted
`and is usually dictated by application of the energy absorbing panel. A
`preferred decorative layer comprises a polyethylene or polyvinyl chloride
`(PVC) foam layer which is thermoformable, closed cell and permits one-step
`production of the entire decorative panel. In the case where a single flexible
`reinforcing layer is used, the decorative layer may be placed between the mold
`(upper or lower) and the flexible reinforcing layer or it may place in the other
`of the upper mold or lower which is not used to hold the flexible reinforcing
`layer.
`In the case where two flexible reinforcing layers are used, the
`decorative layer may place between the flexible reinforcing layer and either
`of the upper mold and lower mold, preferably the upper mold. When a
`decorative layer is disposed between the flexible reinforcing layer and one the
`molds, it is preferred to use a flexible reinforcing layer which at least
`somewhat permeable to the expanding foam mass in the mold. The allows for
`the expanding foam mass to pass through the flexible reinforcing layer thereby
`providing a resilient polyurethane foam core which is adhered to both the
`flexible reinforcing layer and the decorative cover.
`After expansion of the liquid foamable polyurethane composition, the
`polyurethane foam core produced therefrom preferably has a specific gravity
`of less than about 0.40, more preferably in the range of from about 0.10 to
`about 0.25. Preferably, the liquid foamable polyurethane composition has a
`free rise density of from about one to about twenty pounds per cubic foot,
`more preferably from about two to about eight pounds per cubic foot.
`In a
`preferred aspect of the present process the polymethane foam core has an
`indentation force deflection at 25 % deflection in the range of from about 150
`to about 4,000 pounds, more preferably from about 500 to about 2500 pounds,
`most preferably from about 900 to about 2000 pounds, when measured
`pursuant to ASTM 3574-Bl.
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`WO93/03910
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`PCT/CA92/00350
`
`-7-
`
`Upon compression of the energy absorbing panel produced according
`the present process at the energy absorbing surface to about 50%, preferably
`to about 65%, morepreferably to about 80%, by volume of the uncompressed
`panel in a direction substantially normal to the flexible reinforcing layer, the
`panel recovers to at least 90%, preferably at least 95%, by volume of the
`uncompressed panel in less than about 30 minutes. Preferably, the panel
`
`recovers to at least about 90% by volume of the uncompressed panel in less
`than about 10 minutes, more preferably less than about two minutes.
`A particularly preferred embodiment of the present process comprises
`the use of two flexible reinforcing layers. Ideally, in this embodiment of the
`present process, one flexible reinforcing layer will be placed in each of the
`upper mold and the lower mold. Thereafter, the liquid foamable polyurethane
`composition may be conveniently dispensed, via an "open pour" or a "closed
`pour" technique, directly on to the flexible reinforcing layer previously placed
`in the lower mold. After the liquid foamable polyurethane composition is
`expanded to provide the resilient polyurethane foam core adhered to each of
`the flexible reinforcing layer, an energy absorbing panel results having two
`energy absorbing surfaces (i.e. at each flexible reinforcing layer) disposed in
`a spaced, substantially parallel relationship with respect to one another. The
`energy absorbing ability of such a panel is dramatically increased when
`compared to an energy absorbing panel comprising a single energy absorbing
`surface (i.e. a single flexible reinforcing layer).
`The choice of liquid foamable polyurethane composition suitable for
`use in the present process is not particularly restricted. Non-limiting and
`preferred examples of suitable polyurethane foams for use in the present panel
`are available from Woodbridge Foam Corporation under the tradenames
`Enerflex 900, Enerflex II and Enerflex 400.
`Generally, the polyurethane foam suitable for use in the present panel
`and having the requisite characteristics may be pr~uced from the following
`general non-limiting formulation:
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`WO93/03910
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`PCT/CA92/00350
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`-8-
`
`Component
`Polymer Polyol
`Polyol
`Crosslinker
`
`Catalyst
`
`Silicone Surfactants
`
`Isocyanate
`
`Amount
`100 - 0 parts
`0 - 100 parts
`0 - 30 parts/ 100 parts total
`polyol
`0.05 to 3.5 parts/100 parts
`total polyol
`0 - 1.5 parts/100 parts tom.l
`polyol
`0.5 to 3.5 parts/100 parts
`total polyol
`Adequate quantity for an
`index of from about . 60
`to 1.30 ratio of NCO
`equivalents
`to
`the
`equivalents of NCO
`reactive sights.
`
`Suitable polymer polyols, polyols and isocyanates are described in
`United States patents 3,304,273, 3,383,351, 3,523,093, 3,939,106 and
`4,134,610 Belgian patent 788,115, Canadian Patent 785,835 and
`"Polymer/Polyols, a New Class of Polyurethane Intermediate", Kuryla, W.C.
`et al., J. Cellular Plastics, March (1966), the contents of which are hereby
`incorporated by reference.
`Suitable crosslinkers, catalysts and silicone surfactants are described
`in United States patents 4,107,106 and 4,190,712, the contents of which are
`
`hereby incorporated herein by reference.
`The preferred polyurethane foam suitable for use in the present panel
`may be produced from the following formulation:
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`WO93/03910
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`PCT /CA92/00350
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`-9-
`
`Component
`Polymer Polyol1
`Polyol2
`Crosslinker3
`
`Catalyst"
`
`Silicone Surfactants5
`
`Isocyanate6
`
`Amount
`30 - 70 parts
`70 - 30 parts
`5 - 15 parts/ 100 parts total
`polyol
`0.5 - 1.2 parts/ 100 parts
`total polyol
`0.3 - 1.1 parts/ 1()() parts
`total polyol
`1. 75 - 2. 75 parts/100 parts
`total polyol
`Adequate quantity for an
`index of from about 0.8
`to 1.1 ratio of NCO
`equivalents
`to
`the
`equivalents of NCO
`reactive sights.
`
`1 AC West Virginia Polyol Co. NIAX 31-28
`2 5000 MW propylene oxide adduct of glycerine with 75 % primary
`capping
`3 BASF 953
`4 DABCO R-8020
`5 Goldschmidt B-4113
`6 Dow Chemical Company PAPI 901
`
`It should be noted that the flexible reinforcing layer used in the energy
`absorbing surface is used on or just beneath (due to impregnation by the
`expanding foam) the surface of the panel only.
`In other words, the
`components of the reinforcing layer are not used as fillers throughout the
`polyurethane foam core. Using this reinforcement technique on this particular
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`WO 93/03910
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`-10-
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`type of resilient polyurethane foam provides surprising and unexpected
`stiffness and energy absorbing capabilities for the panel.
`The present process is advantageous over the prior art in that it permits
`relatively efficient production of a useful energy absorbing panel.
`Specifically, use of the present process obviates waste of foam materials, the
`use of adhesives and the use of specialized molds. Further the present
`
`process, in one of its preferred aspects, allows for a single-step production of
`
`an energy absorbing mold. By "single-step", it is meant that all constituents
`of the panel may be placed in a single mold to produce the finished article.
`The energy absorbing panel produced according to the present process
`
`is useful in a variety of applications. The energy absorbing panel has
`particular vehicular applications such as in door panels, instrument panel
`topper pads, air bag doors and the like.
`Further, the energy absorbing panel produced according to the present
`
`process can be used in heel blocker pads. As will be appreciated by those
`skilled in the art, heel blocker pads are located under the carpet and dash
`insulator in a vehicle against the sheet metal of the dash. These devices serve
`to protect the bones of the drivers leg from excess loading under the heel of
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`the drivers foot during a front end crash.
`The energy absorbing panel produced according to the present process
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`may also be used in knee bolsters used in vehicles. Typically, knee bolsters
`are used as blockers to prevent the knees of the driver and passenger in the
`
`front seat of a vehicle from sliding forward and underneath the instrument
`panel structure during an impact.
`The energy absorbing panel produced according to the present process
`may be used as an anti-submarining device in vehicle seats. Generally such
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`devices are incorporated underneath the seat cushion and serve the purpose of
`preventing the occupant from sliding forward and under the seat restraint
`
`during impact.
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`WO93/03910
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`PCT/CA92/00350
`
`What is claimed is:
`
`-11-
`
`A process for producing an energy absorbing panel having at least one
`1.
`energy absorbing surface in a mold comprising an upper mold and a lower
`5 mold, the process comprising the steps of:
`(i)
`placing a reinforcing layer in at least one of the upper mold and
`the lower mold;
`dispensing a liquid foamable polyurethane composition in the
`
`(ii)
`lower mold;
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`closing the upper mold and the lower mold to define an
`(iii)
`enclosure corresponding to the shape of the energy absorbing panel; and
`(iv)
`expanding the foamable liquid polyurethane composition to fill
`substantially the enclosure to produce a resilient polyurethane foam core which
`adheres to the reinforcing layer thereby providing an energy absorbing
`surface;
`wherein the reinforcing layer has a tensile strength greater than the
`tensile strength of the resilient polyurethane foam core and upon compression
`of the panel at the energy absorbing surface to about 50% by volume of the
`uncompressed panel in a direction substantially normal to the reinforcing
`layer, the panel recovers to at least about 90% of volume of the uncompressed
`panel in less than about 30 minutes.
`
`The process defined in claim 1, wherein said energy absorbing surface
`2.
`is comprised of a flexible fibrous reinforcing layer.
`
`The process defined in claim 2, wherein said fibrous reinforcing layer
`3.
`comprises at least one member selected from the group consisting essentially
`of glass fibres, polyester fibres, polyolefin fibres, Kevlar fibres, polycunide
`fibres, cellulose fibres and carbon fibres.
`
`The process defined in claim 1, wherein said energy absorbing layer
`4.
`is comprised of a non-fibrous reinforcing layer.
`
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`WO 93/03910
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`PCT/CA92/00350
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`-12-
`
`The process defined in claim 4, wherein said non-fibrous reinforcing
`5.
`layer comprises at least one member selected from the group consisting
`essentially of thermosets, aluminum foil, polycarbonates, polycarbonate/ ABS
`alloys, ABS terpolymers, polyester terphthalate (PET), vinyl, styrene maleic
`anhydride, polyvinyl chloride and fibreglass reinforced polypropylene.
`
`The process defined in claim 1, wherein Step (i) further comprises
`6.
`placing a decorative layer between the reinforcing layer and the at least one
`of the upper mold and the lower mold.
`
`The process defined in claim 1, wherein Step (i) comprises placing a
`7.
`reinforcing layer in each of the upper mold and the lower mold.
`
`5
`
`10
`
`The process defined in claim 7, wherein the same reinforcing layer is
`8.
`placed in each of the upper mold and the lower mold.
`
`15
`
`The process defined in claim 7, wherein Step (i) further comprises
`9.
`placing a decorative layer between the reinforcing layer and at least one of the
`upper mold and the lower.
`
`The process defined in claim 7, wherein the reinforcing layer is
`10.
`flexible and fibrous.
`
`The process defined in claim 10, wherein the reinforcing layer
`11.
`comprises at least one member selected from the group consisting essentially
`of glass fibres, polyester fibres, polyolefin fibres, Kevlar fibres, polyamide
`fibres, cellulose fibres and carbon fibres.
`
`20
`
`25
`
`The process defined in claim 7, wherein the reinforcing layer is non-
`12.
`fibrous.
`
`30
`
`

`

`WO93/03910
`
`PCT/CA92/00350
`
`-13-
`
`The process defined in claim 12, wherein said non-fibrous reinforcing
`13.
`layer comprises at least one member selected from the group consisting
`essentially of thermosets~ aluminum foil, polycarbonates, polycarbonate/ ABS
`alloys, ABS terpolymers, polyester terphthalate (PET), vinyl, styrene maleic
`anhydride, polyvinyl chloride and :fibreglass reinforced polypropylene.
`
`The process defined in claim 1, wherein said polyurethane foam core
`14.
`has a free rise density of from about 1 to about 20 pounds per cubic foot.
`
`The process defined in claim 1, wherein said panel recovers to at least
`15.
`about 90% by volume of the uncompressed panel in less than about 10
`minutes.
`
`5
`
`10
`
`The process defined in claim 1, wherein said panel recovers to at least
`16.
`about 90% by volume of the uncompressed panel in less than about 2 minutes.
`
`15
`
`

`

`1NTERNATIONAL SEARCH REPORT
`lnt«natlonal .Application No
`
`PCT/CA 92/00350
`
`I, a.ASSIFICATION OF SUBJEC'C MATTER
`(If several classiflc:atlon symbols apply, Indicate all)'
`According to International Patent Classification (IPC) or to both National Classification and IPC
`Int.Cl. 5 B29C67/22
`
`D, FIELDS SEARCHED
`
`Classification System
`
`Int.Cl. 5
`
`B29C
`
`Minimum Documentation Sarcb-7
`
`Classification Symbols
`
`Documentation Searched other than Minimum Docummtation
`to the Extent that such Documents are Included in the Fields Searched1
`
`m. DOCUMENTS CONSIDERED TO BE RELEVANT9
`Category"
`Citation of Doc:ument, 11 with indication, where appropriate, of the relevant passages 12
`
`ltelevant to Claim No,13
`
`X
`
`X
`
`X
`
`FR,A,2 545 039 (BASF)
`2 November 1984
`
`see the whole document ---
`
`WO,A,8 500 755 (TM)
`28 February 1985
`see page 5, line 17 - page 6, line 18;
`claims 1,5-9,11,12,17-22,24; figures 1,2
`---
`WO,A,8 001 892 (INTERNATIONAL HARVESTER)
`18 September 1980
`see page 2, line 19 - page 3, line 16
`see page 3, line 30
`see page 3, line 36 - page 4, line 9;
`figure 1
`---
`
`1-3,6,
`14-16
`
`1-16
`
`1-5,7,8,
`10,11
`
`-/--
`
`•
`
`T
`
`" Special categories of cited documents : lO
`"A" document defining th:.Ceral state of the art which is not
`considered to be of p cular relevance
`earlier document but published on or after the international
`filing date
`"L" document which may throw doubts on priority claim(s) or
`which is cited to establish the publication date of another
`citation or other special reason (as specified)
`•o• document refening to an oral disclosure, use, exhibition or
`other means
`"P" document published prior to the International filing date but
`later than the priority date daimed
`1 IV, CEI.TIFICATION
`Date of the Actual Completion of the International Sarcb
`25 NOVEMBER 1992
`
`T
`
`later document published after the international filing date
`or priority date and not In mnfllct with the aizlicadon but
`cited to understand the principle or theory 11D erlying the
`inYlllltion
`"X" docummt of particular relevance; the claimed invention
`cannot be considered novel or cannot be considn to
`Involve an Inventive step
`"Y" docummt of particular relevuce; the claimed invention
`cannot be considered to Involve an Inventive step wbea the
`document Is combined with one or more other such docu-
`ments, such combination being obvious to a person sldlld
`in the art.
`•&• docu.ment member of the same patent family
`
`Date of Malling of this International Search Report
`'!? (':"
`.. 1£., •..
`
`lf f:.
`
`International Sarcbing .Authority
`
`EUROPEAN PATENT OFFICE
`
`Signature of .Authorized Officer
`PHILPOTT G.R.
`
`F- PCT/ISA/210 (.....& Ulltl (J.-y 1915)
`
`

`

`DL DOCUMENTS CONSIDERED TO BE .REI.EV ANT
`Category 0
`
`(CONTINUED FROM lHE SECOND SHEET)
`Ctation of DUC11ment, with indication, where appropriate, of the relevant passages
`
`Relev.uit to CbJm No.
`
`International Application No
`
`PCT/CA 92/00350
`
`P,X
`
`EP,A,0 448 063 (HOOVER UNIVERSAL)
`25 September 1991
`
`see page 5, line 1 - line 5
`see page 8, line 51 - line 58
`see page 9, line 14 - line 19; claims 1,2;
`figures 1,5-8
`
`WORLD PATENTS INDEX LATEST
`Derwent Publications Ltd, London, GB
`AN 92-085227 [11], DW9211
`& JP-A-4028511 (TOYO RUBBER)
`US,A,4 508 774 (GRABHOEFER ET AL)
`2 April 1985
`cited in the application
`see column 3, line 54 - column 4, line 25
`
`31 Jan 1992
`
`P,X
`
`A
`
`1-3,
`6-11,
`14-16
`
`1-3
`
`2-13
`
`

`

`ANNEX TO THE INTERNATIONAL SEARCH REPORT
`ON INTERNATIONAL PATENT APPLICATION NO. SCAA 9200350
`63401
`
`'Ibis IIDllex lists the patent family members relating to the patent documents cited in the above-mentioned international sean:b report.
`The members are as contained in the European Patent Office EDP file on
`The European Patent Office is in no way liable for these particulars which are merely given for the purpose of information. 25/ 11/92
`
`~
`
`Publication
`Publication
`Patent document
`Patent family
`cited in Rlll"Ch report
`date
`dace
`mmiber(s)
`FR-A-2545039
`31-10-84
`3315804
`DE-A-
`02-11-84
`----------------------------------------------------------------------
`WO-A-8500755
`3329230
`28-02-85
`28-02-85
`DE-A-
`CA-A-
`11-04-89
`1252341
`03-03-88
`DE-A-
`3468983
`27-01-88
`EP-A,B
`0152440
`JP-T-
`60501991
`21-11-85
`US-A-
`21-02-89
`4806302
`US-A-
`4713032
`15-12-87
`----------------------------------------------------------------------
`WO-A-8001892
`18-09-80
`AU-A(cid:173)
`5620780
`11-09-80
`EP-A-
`0025065
`18-03-81
`----------------------------------------------------------------------
`EP-A-0448063
`25-09-91
`None
`---------------