Process for the production of a foamed article
First Claim
1. A process for the production of a foamed article comprising the steps of:
- providing at least a core layer (1) for said article, which core layer (1) comprises a flexible, open-cell foam having open voids forming at least 90% of the volume of the open-cell foam;
applying said core layer (1) between a lower (5) and an upper mold surface (9);
allowing a curable, foamable, isocyanate based liquid composition (7) to foam in the open voids of said open-cell foam to produce a further foam (4) filling these open voids while the core layer (1) is maintained between the upper (9) and lower mold surfaces (5); and
removing the produced article from between the upper (9) and lower mold surfaces (5),wherein the curable, foamable composition (7) is sprayed onto the core layer (1) and has a dynamic viscosity, measured at a shear rate of 1/s, of lower than 1000 mPa·
s when arriving onto the core layer (1), andwherein the core layer (1) is held in a lying position when spraying the foamable composition (7) thereon so that the sprayed foamable composition (7) is allowed to penetrate at least partially by gravity into the open-cell foam of the core layer (1).
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Accused Products
Abstract
The foamed article is produced starting from a core layer (1) which comprises a flexible, open-cell foam having voids forming at least 90% of the volume of the open-cell foam. The core layer (1) is applied in a mold (6, 8), optionally together with an upper (3) and/or a lower cover layer (2), between a lower (5) and an upper mold surface (9) thereof. The mold (6, 8) is closed and a curable, foamable composition (7) is allowed to foam in the mold to produce a further foam filling the voids of the open-cell foam. In order to enable to use less foamable composition (7) to fill the voids of the open-cell foam, the core layer (1) is laid onto the lower mold surface (5) and the foamable composition (7) is sprayed onto the core layer (1) lying onto the lower mold surface so that the foamable composition (7) can penetrate at least partially by gravity into the open-cell foam core layer (1). Moreover, the foamable composition (7) has a dynamic viscosity, measured at a shear rate of 1/s, of lower than 1000 mPa·s when arriving onto the core layer (1).
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Citations
25 Claims
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1. A process for the production of a foamed article comprising the steps of:
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providing at least a core layer (1) for said article, which core layer (1) comprises a flexible, open-cell foam having open voids forming at least 90% of the volume of the open-cell foam; applying said core layer (1) between a lower (5) and an upper mold surface (9); allowing a curable, foamable, isocyanate based liquid composition (7) to foam in the open voids of said open-cell foam to produce a further foam (4) filling these open voids while the core layer (1) is maintained between the upper (9) and lower mold surfaces (5); and removing the produced article from between the upper (9) and lower mold surfaces (5), wherein the curable, foamable composition (7) is sprayed onto the core layer (1) and has a dynamic viscosity, measured at a shear rate of 1/s, of lower than 1000 mPa·
s when arriving onto the core layer (1), andwherein the core layer (1) is held in a lying position when spraying the foamable composition (7) thereon so that the sprayed foamable composition (7) is allowed to penetrate at least partially by gravity into the open-cell foam of the core layer (1). - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25)
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Specification