Abstract: A mask is used to make an article having two or more layers. The layers are formed from either a paint or polyurethane elastomer composition. The article is made in a mold including a surface defining a mold cavity and having a first and second effect region. For the method, a mask is placed into the mold cavity adjacent the first effect region. Pressure is applied to the mask to retain the mask adjacent the first effect region. A first composition is applied into the mold cavity to form a first layer adjacent the second effect region. The mask is removed from the first effect region. A second composition is applied into the mold cavity to form a second layer adjacent the first effect region. Benefits of pressure applied to a mask are also realized when making the article from a preformed part using the mask outside of a mold.

Abstract: The subject invention provides a resin component, a sprayable elastomer composition that includes an isocyanate component and the resin component, and a method of making a composite structure. The resin component is reactive with the isocyanate component and includes a first polyol and a second polyol that is different from the first polyol. The resin component further includes a moisture scavenger and an anti-settling agent to prevent the moisture scavenger from settling out of the resin component. For the method, a first layer is applied to a mold cavity. The first layer is a show surface of the composite structure. The sprayable elastomer composition is sprayed on the first layer to form a support layer. The composite structure is then cured in the mold cavity. After curing, the composite structure is demolded from the mold cavity.

Abstract: The method of the present invention is particularly suited for making decorative objects in a mold cavity. The method enables one to form a decorative component having an outer elastomeric layer that is integral with an inner layer of foam. Because the chemical formulation for the outer layer and the inner layer is identical, other than the inner layer includes a foaming agent, the decorative component does not suffer from the drawbacks of the previous methods such as, for example, poor adhesion between the elastomeric layer and the foam layer causing delamination of the two layers, sinks or holes in the foam layer leading to imperfections in the elastomeric layer, and bleed through to the elastomeric layer from the foam layer. The method permits the mold to be pre-coated with an in-mold paint prior to the molding process. Coatings can also be applied after demolding the resulting part.