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A method was adapted to measure the adhesion strength of polyurethane, semi-flexible foams to thermoplastic substrates. This method (lap-joint shear) was used to determine the effect of six (6) variables upon adhesion. These variables were: 1.) the type of substrate material, 2.) the type of polyurethane foam, 3.) the weight percentage of water in the polyurethane formulation (the degree to which the foam is blown and the chemical constituents), 4.) the chemical index of the polyurethane (the ratio of isocyanate to polyol resin), 5.) the surface roughness of the substrate, and 6.) the temperature of the polyurethane materials. Five (5) typical automotive interior thermoplastic substrates were studied: 1.) Polypropylene with preblended glass, 2.) Polycarbonate/ABS, 3.) PPO/HIPS with preblended glass, 4.) SMA with in-house dry blended glass, and 5.) SMA with preblended glass.

A new process has been developed at the Ford Motor Company Saline (Michigan) Plastics Plant using reclaimed glass reinforced S/MA (styrene maleic anhydride) resin in the production of composite foam instrument panels. This process involves granulating rejected panels and offal and introducing the ground material into a separator/aspirator systemwhich segregatesthe S/MA from other components. The reclaimed S/MA is then blended with virgin material and is suitable for reuse in the injection molding process with no significant adverse manufacturing or performance effects.