Method of producing skin-covered foamed plastic article

• US 4,976,414 A
• Filed: 10/20/1988
• Issued: 12/11/1990
• Est. Priority Date: 10/31/1987
• Status: Expired due to Fees

• Current Assignee: Ikeda Bussan Co., Ltd. (Johnson Controls International plc)
• Original Assignee: Ikeda Bussan Co., Ltd. (Johnson Controls International plc)
• Inventors: Yanagishita, Norio
• Primary Examiner(s): Silverberg, Sam
• Assistant Examiner(s): Kuhns, Allan R.
• Application Number:
  US07/260,420
• Time in Patent Office: 782 Days
• Field of Search: 264/46.4, 264/46.6, 264/40.3
• US Class Current: 264/40.3
• CPC Class Codes: B29C 44/0415 by regulating the pressure of the material during or after filling of the mould, e.g. by local venting
• CPC Class Codes: B29C 44/1209 by impregnating a preformed part, e.g. a porous lining
• CPC Class Codes: B29C 44/14 the preformed part being a lining B29C44/1209 takes precedence
• CPC Class Codes: B29C 44/5618 Impregnating foam articles
• 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 adjusting a pressure which is created in the cavity due to foaming of the foamable material.

Claims

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

(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 a portion of 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; and

(f) activating pressure control means when said pressure increases to a predetermined value and thereby adjusting said pressure such that said curing is carried out under a certain pressure which will provide said inner layer with a material-impregnated part of a desired thickness therethroughout.

2. A method as claimed in claim 1, in which said inner layer is a foamed material.

3. A method as claimed in claim 2, in which said foamable material is a liquid material for foamed polyurethane.

4. A method as claimed in claim 2, in which said pressure control means is an enclosed clearance between an outer surface of said outer skin member and an inner wall of said cavity which communicates with the atmosphere when the pressure in said clearance increases to a given degree.