This paper describes the development of a process that will mold a urethane resin in the form of a laminate. The urethane resin is a most unusual material: it can be formulated to produce thermosetting foam of almost any density, and the formulation can also be made to produce either a flexible or rigid foam. It has excellent adhesive properties, which we have used to make the laminate.
The process produces a laminate of two skins, which are combined with a film of urethane resin in its liquid form. This combination, when placed in a heated mold, causes the resin to expand until both skins reach the confine of the mold. This then cures to the shape of the mold and the texture of its surface, making it possible to mold sculptured and formed shapes or panels, which can be used for interior trim for automobiles.