Method of producing skin-covered foamed plastic article

• US 4,959,184 A
• Filed: 10/20/1988
• Issued: 09/25/1990
• Est. Priority Date: 10/31/1987
• Status: Expired due to Fees

• Current Assignee: Ikeda Bussan Company Limited No 771 Kozono Ayase City Kanagawa Prefecture
• Original Assignee: Ikeda Bussan Co., Ltd. (Johnson Controls International plc)
• Inventors: Akai, Mikio, Mori, Masami
• Primary Examiner(s): Silverberg, Sam
• Assistant Examiner(s): Kuhns, Allan R.
• Application Number:
  US07/260,218
• Time in Patent Office: 705 Days
• Field of Search: 264/40.3, 264/46.6, 264/46.4
• US Class Current: 264/40.3
• CPC Class Codes: B29C 44/1209 by impregnating a preformed part, e.g. a porous lining
• CPC Class Codes: B29L 2031/58 Upholstery or cushions, e.g. vehicle upholstery or interior padding mattresses, cushions B29L2031/751
• CPC Class Codes: B29L 2031/751 Mattresses, cushions upholstery B29L2031/58

Abstract

A method of producing a skin-covered foamed plastic article, which includes preparing a lower mold which has a cavity formed therein; putting a bag-shaped outer skin member into the cavity, the skin member having a porous inner layer; pouring a foamable material for the foamed plastic article into the bag-shaped outer skin member; and controlling a pressure in the cavity in such a manner that the inner layer becomes saturated to a predetermined degree during curing of the material.

Claims

1. A method of producing a skin-covered foamed plastic article, comprising the steps of:

(a) preparing a lower mold which has a cavity formed therein;

(b) putting a bag-shaped outer skin member into said cavity, said skin member having a porous inner layer;

(c) sealingly closing said cavity;

(d) pouring a foamable material for the foamed plastic article into the bag-shaped outer skin member, said material being capable of impregnating said inner layer, said material foaming in said cavity and causing pressure in said cavity to gradually increase;

(e) curing said material to provide said article;

(f) allowing pressure in said cavity to increase to a first pressure;

(g) venting gas in said cavity after said first pressure is attained so that a second, lower pressure results; and

(h) allowing pressure in said cavity to return to said first pressure after venting, thereby controlling said pressure such that said curing is carried out under a certain pressure condition which will provide for even penetration of said material into said inner layer.

2. A method as claimed in claim 1, in which said first pressure is approximately 0.5 kg/cm².

3. A method as claimed in claim 2, in which said inner layer is a foamed material.

4. A method as claimed in claim 3, in which said foamable material is a liquid material for foamed polyurethane.

5. A method as claimed in claim 1 in which gas is vented after about 45 seconds after said foamable material is poured.

6. A method of producing a kin-covered foamed plastic article, comprising the steps of:

(a) preparing a lower mold which has a cavity formed therein;

(b) putting a bag-shaped outer skin member into said cavity, said skin member having a porous inner layer;

(c) sealingly closing said cavity;

(d) pouring a foamable material for the foamed plastic article into the bag-shaped outer skin member, said material being capable of impregnating said inner layer;

(e) curing said material to provide said article;

(f) allowing said foamable material to foam without an increase in pressure by venting gas from said cavity during an initial predetermined period of time; and

(g) then allowing pressure in said cavity to increase after said initial period of time such that said curing is carried out under a certain pressure condition which will provide for even penetration of said material into said inner layer.

7. A method as claimed in claim 6, in which said initial predetermined period of time is about 8 seconds.

8. A method as claimed in claim 6, wherein said foamable material is a liquid material for foamed polyurethane.

9. A method as claimed in claim 6, wherein said inner layer is a foamed material.