COMPOSITE ARTICLE

Abstract

A composite includes a first preform and a second preform spaced from and in overlying relationship to the first preform. The second preform defines at least one first opening extending therethrough along an axis transverse to the first preform. A first surface layer is disposed adjacent to the second preform and on an opposite side of the second preform from the first preform. A polymeric composition including the reaction product of an isocyanate component and an isocyanate-reactive component is disposed between the first preform and the second preform. The polymeric composition adheres the first surface layer to the second preform through the at least one first opening. The surface layer is adhered to the second preform during molding of the composite article and in the absence of additional adhesive, thereby reducing production time and cost of the composite article.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

Other advantages of the present invention will be readily appreciated, as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings wherein:

FIG. 1 is a cross-sectional side view of one embodiment of a composite article of the subject invention including a first surface layer adhered to a second preform;

FIG. 2 is an exploded perspective side view of the composite article of FIG. 1;

FIG. 3 is a cross-sectional side view of a mold having a mold surface defining a mold cavity with a first preform and the second preform spaced from the first preform and a composition being introduced between the first preform and the second preform and through first openings in the second preform for adhering the first surface layer to the second preform; and

FIG. 4 is a cross-sectional side view of another embodiment of the composite article of the subject invention including a second surface layer adhered to the first preform with the surface layers including a backing disposed between the surface layers and the respective preforms.

Claims

1. A composite article (20) comprising a first preform (24);a second preform (26) spaced from and in overlying relationship to said first preform (24) and defining at least one first opening (28) extending therethrough along an axis transverse to said first preform (24);a first surface layer (22) disposed adjacent to said second preform (26) and on an opposite side of said second preform (26) from said first preform (24); anda polymeric composition (32) comprising the reaction product of an isocyanate component and an isocyanate-reactive component disposed between said first preform (24) and said second preform (26) and adhering said first surface layer (22) to said second preform (26) through said at least one first opening (28).

2. A composite article (20) as set forth in claim 1 wherein said polymeric composition (32) is formed in the presence of a blowing agent.

3. A composite article (20) as set forth in claim 1 wherein said isocyanate-reactive component has an average nominal functionality of at least 3.

4. A composite article (20) as set forth in claim 3 wherein said isocyanate-reactive component is further defined as a glycerine-initiated polyol.

5. A composite article (20) as set forth in claim 1 wherein said isocyanate-reactive component has an average nominal functionality of less than 3.

6. A composite article (20) as set forth in claim 1 wherein said first surface layer (22) comprises a fibrous material (36).

7. A composite article (20) as set forth in claim 6 wherein said first surface layer (22) further comprises a backing (38) disposed between said fibrous material (36) and said second preform (26) with said fibrous material (36) adhered to said backing (38).

8. A composite article (20) as set forth in claim 7 wherein said backing (38) is further defined as a fibrous mat.

9. A composite article (20) as set forth in claim 7 wherein said backing (38) is further defined as a polymeric film.

10. A composite article (20) as set forth in claim 1 wherein said first surface layer is formed from a polymer.

11. A composite article (20) as set forth in claim 10 wherein said polymer exhibits adhesion with the polymeric composition (32) disposed between the first preform (24) and the second preform (26) with an adhesion strength of at least 5 psi.

12. A composite article (20) as set forth in claim 1 wherein at least one of said first preform (24) and said second preform (26) are formed from wood.

13. A composite article (20) as set forth in claim 1 wherein at least one of said first preform (24) and said second preform (26) are formed from a polymeric material.

14. A composite article (20) as set forth in claim 1 wherein said first preform (24) defines at least one second opening (30) extending therethrough along an axis transverse to said second preform (26).

15. A composite article (20) as set forth in claim 14 further comprising a second surface layer (34) disposed adjacent to said first preform (24) and on an opposite side of said first preform (24) from said second preform (26).

16. A composite article (20) as set forth in claim 15 wherein said second surface layer (34) is adhered to said first preform (24) through said at least one second opening (30).

17. 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);placing a first preform (24) and a second preform (26) in the mold cavity (46) with the preforms (24, 26) spaced from each other and the second preform (26) defining at least one first opening (28) extending therethrough along an axis transverse to the first preform (24);placing a first surface layer (22) in the mold cavity (46) between the second preform (26) and the mold surface (44);introducing a composition (40) comprising an isocyanate component and an isocyanate-reactive component between the first preform (24) and the second preform (26) and through the at least one first opening (28) for adhering the first surface layer (22) to the second preform (26) through the at least one first opening (28); anddemolding the composite article (20) from the mold cavity (46).

18. A method as set forth in claim 17 wherein the composition (40) further includes a blowing agent.

19. A method as set forth in claim 17 wherein the first surface layer (22) comprises a fibrous material (36).

20. A method as set forth in claim 19 wherein the first surface layer (22) further comprises a backing (38) disposed between the fibrous material (36) and the second preform (26) with the fibrous material (36) adhered to the backing (38).

21. A method as set forth in claim 20 wherein the backing (38) is further defined as a fibrous mat.

22. A method as set forth in claim 20 wherein the backing (38) is further defined as a polymeric film.

23. A method as set forth in claim 17 wherein the first preform (24) defines at least one second opening (30) extending therethrough along an axis transverse to the second preform (26).

24. A method as set forth in claim 17 wherein a second surface layer (34) is placed between the first preform (24) and the mold surface (44).

25. A method as set forth in claim 24 wherein the composition (40) is introduced through the at least one second opening (30) in the first preform (24) for adhering the second surface layer (34) to the first preform (24) through the at least one second opening (30).