Abstract: An energy absorbing panel comprising a resilient polyurethane foam core having a density in the range of from about 1.5 to about 24 pounds per cubic foot and an indentation force deflection at 25%, when measured pursuant to ASTM 3574-B.sub.1, less than about 4000 pounds and at least one energy absorbing surface comprised of a flexible reinforcing layer covering the resilient polyurethane foam core. The panel is useful in a variety of applications where energy management is required. Upon impact, the panel is capable of absorbing at about 70% of the input energy. Futher, 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 the volume of the uncompressed panel in less than about 30 minutes. The panel is particularly advantageous for use in vehicular applications such as door panels, instrument panel topper pads, air bag doors and the like.

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 both of the upper mold and the lower mold. A liquid foamable polyurethane composition is then dispensed in the lower mold and allowed to expand to fill from 50-80% of the mold volume. The upper mold and lower mold are then closed to define an enclosure corresponding substantially to the energy absorbing panel and the liquid foamable polyurethane composition is expanded to fill the remainder of the enclosure to produce a resilient polyurethane foam core which adheres to the reinforcing layers thereby providing an energy absorbing surface. The reinforcing layer has a tensile strength greater than the tensile strength of the resilient polyurethane foam core.

Abstract: An acoustical barrier usable for sound deadening and vibration dampening in vehicles which includes a base layer of a flexible foam secured at the outer surface to an insulation layer of polyurethane elastomer molded to the shape of the area to be insulated such as an automobile fire wall area. The inner surface of the base layer will preferably be in contact with the area to be insulated. The polyurethane elastomer of the insulation layer will preferably include a natural mineral filler impregnated therein. The insulating layer provides the rigid form for holding of the flexible foam, which itself provides a stand-off to hold the insulating layer in spaced relation with respect to the vibrating surface. The polyurethane elastomer can vary in thickness in proportion to the level of acoustical activity of the area to be insulated.