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Method of molding skin-covered foamed plastic article

  • US 4,923,653 A
  • Filed: 12/13/1988
  • Issued: 05/08/1990
  • Est. Priority Date: 03/30/1988
  • Status: Expired due to Term
First Claim
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1. A method of molding a skin-covered foamed plastic article, comprising by steps:

  • (a) putting a bag-shaped outer skin member into a cavity of a lower mold, said skin member including an outer layer and a porous inner layer lining said outer layer;

    (b) putting a first upper mold on said lower mold to close said cavity with a portion of said porous inner layer exposed in said cavity;

    (c) fastening said lower and first upper molds together with a first fastening force;

    (d) pouring a foamable plastic material into said cavity and foaming and curing said material;

    (e) releasing an excessive pressure produced in said cavity during said foaming by discharging gas through said porous inner layer so that part of said material penetrates into said portion of said porous inner layer;

    (f) removing said first upper mold from said lower mold after the material is hardened to a certain degree;

    (g) putting a second upper mold on said lower mold to define a space therebetween with another portion of said porous inner layer exposed in said space;

    (h) fastening said lower and second upper molds together with a second fastening force of a magnitude different from said first fastening force;

    (i) pouring a foamable plastic material into said space and foaming and curing said material; and

    (j) releasing an excessive pressure produced in said space during said foaming by discharging gas through said porous inner layer so that part of said material penetrates into said another portion of said porous inner layer;

    said different fastening forces resulting in discharge of different amounts of gas and penetration of different amounts of material into said portions of said porous inner layer, thereby resulting in said article having certain portions which are different in resiliency.

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