Abstract: A method for forming an armrest, wherein there are provided a three-dimensional box-like trim cover assembly having slit and hole formed therein, a frame and a shaft separate from the frame. In the method, the frame is inserted through the slit into the inside of the trim cover assembly, and then, the shaft is inserted through the hole into the same inside of trim cover assembly, so that the shaft is connected to the frame at a predetermined position within the trim cover assembly via a connecting element. Thereafter, such incomplete armrest unit is subject to foaming in a foaming die, to thereby form a complete armrest. The trim cover assembly includes a high-density foam layer and an impregnation preventive film having plural ventilation holes formed therein in order to prevent impregnation of liquid foaming material into a foam wadding layer of trim cover assembly and attain air permeability of armrest.

Abstract: A tandem motorcycle seat for attachment to the frame of an associated motorcycle has a unitary, rigid, elongated platform member configured to seat upon and be secured to the frame of the motorcycle, and an elongated tandem saddle on the platform member providing drive and passenger seat portions. A backrest for a person seated on one of the seat portions has a depending leg spaced inwardly from the side margins of the saddle which extends through a passage in the saddle into a receptacle on a bracket secured to the platform member. In making the seat, a first layer of a mixture of glass fibers and polyester resin is embedded on the lower element of a mold which is configured to form the platform member of the seat. Hardware is applied on the first layer and a second layer of glass fiber/resin is applied to the first layer and about the hardware so as to encapsulate at least a portion of the hardware in the layers which are then partially cured.

Abstract: A method for molding a plastic part comprises preforming a film laminate and insert molding a plastic substrate against the film laminate. According to one embodiment, the film laminate is preformed with re-entrant edge portions. The insert molding step involves positioning the film laminate in a mold cavity, closing the mold and injecting molten resin into the mold cavity against the film laminate. The force of the closing of the mold and the injection of the resin causes the re-entrant edge portions to curl up under the solidifying resin to ensure complete coverage of the longitudinal edges of the plastic substrate by the film laminate. According to another embodiment, a stencil of an image is made in the film laminate prior to the insert molding. The resin injected into the mold flows into the stencil so that the image is visible against the surrounding surface of the film laminate.

Abstract: A method for fabricating a composite article having a composite stiffening member co-cure bonded in integral combination therewith wherein the composite article comprises outer mold line (OML) and inner mold line (IML) composite skins and a modified honeycomb core interposed therebetween. The method includes a first set of steps for modifying the honeycomb core of the composite article and includes the steps of providing a detail mold that defines a detail cavity and a core engagement surface, aligning the honeycomb core with the detail mold by abuttingly engaging a first surface of the honeycomb core with the core engagement surface wherein a base segment of the honeycomb core is aligned with the detail cavity, to injecting a RIM foam to fill the detail cavity and the honeycomb cells of the base segment, and curing the injected RIM foam to form the modified honeycomb core that includes a densified base segment and a detail mandrel integral with the densified base segment.

Abstract: A body containing lengths of fiber embedded therein is formed by providing a winding fixture including a plurality of parallel support rods spaced apart in a Z-direction. A length of a fiber is wound over the rods such that a portion of the fiber extends in the Z-direction, to form a skeletal structure. The fiber may be coated, as with a resistive material to modify energy absorbtion, after winding. The skeletal structure is filled with foam, and the support structure is removed to leave a structure in which discrete lengths of fiber embedded in the foam lie parallel to the Z-direction. The fibers may be transferred to a sheet of uncured polymeric material by placing the foam piece in contact with the sheet of polymeric material and forcing the fibers into the sheet under an applied pressure.

Abstract: A method of producing a plastic pin, including a bowling pin, having a cellular and/or porous core that is surrounded by a solid-walled, noncellular and nonporous shell. The shell is initially produced as a whole body in a mold. While the material of the shell is not yet hardened and is still deformable, an insert is introduced into the narrowed neck portion of the shell, in a direction axial relative thereto, in such a way that the insert displaces an inner layer of the shell, dividing the hollow interior of the shell into an upper and a lower chamber and producing a fixed connection with the material of the shell. Material for the core, with such material being provided with an expanding agent, is then introduced into the shell, and after the shell and the core have set, the mold is removed.

Abstract: Process for the manufacture of a shaped ski in a single step, which includes:in laying down, in the bottom of a mold, at least one lower reinforcing layer (13, 14);in positioning, on this lower assembly (10), an upper reinforcing layer (22) composed of mechanization elements;in placing, on this upper reinforcing layer (22), a protective and decorative layer (21);in closing the cover of the mold;in injecting, between the lower assembly (10) and upper assembly (22), a fluid intended to expand the various elements against the walls;wherein, in the region of the upper reinforcing layer (22), at least one additional element (30) is positioned, said additional element being intended to vary the relative position of the mechanization elements of said reinforcing layer (22) with respect to the faces of the ski.

Abstract: A doughnut plate type stop member is fixed to an opening edge of a stay hole formed on a skin. A concave groove is provided at a predetermined position of a stay of an insert. The stay extending from a base portion is disposed to protrude outward by inserting through the stay hole upon disposing the base portion of the insert in the skin. The stop member is engaged with the concave groove. Upon securing the foregoing condition, a foamed plastics material is poured into the skin, and a headrest is produced by providing a foamed plastic unit integrating the skin and the insert by means of a foam molding.

Abstract: An cut-resistant seat or seating material is disclosed together with methods of forming such a material. The material comprises at least one layer of flexible metal or non-metal matrix material embedded within a compressed flexible foam material. The foam material may be a fire retardant flame material.

Abstract: Methods and apparatus for molding a solid article incorporating one or more vulnerable inserts are disclosed. Centrifugal casting methods for producing a finished article composed of single or multiple curable fluid compounds utilize a self-releasing securing device for holding an insert stably and insulatedly protected within a mold.

Abstract: For use in rear turbine stabilized helicopters, a air foil blade comprising an integrally formed and readily replicated spar and blade in which the blade is created from compounded plastic having cellular structure and adherent to the spar. The air foil blade is produced by a unique adaptation of an injection molding process using a foamed polypropylene thermoplastic material.

Abstract: A passenger seat includes a frame element molded from relatively high density foam and, optionally, one or more pelvic support elements. The frame element and pelvic support elements are molded into a seat body of relatively lower density foam to which a trim cover is applied. In one embodiment, the frame element and the pelvic support elements are integrally molded and a vehicle anchorage means in embedded into the integral element and in a second embodiment the vehicle anchorage means is embedded in the frame element which may be molded separately from the pelvic support element to which it is connected prior to molding of the foam body.

Abstract: A lightweight contoured base for a seat cushion is produced by first forming a shaped lightweight foam core with a void corresponding to the ischial tuberosities of a user and then forming a sandwich assembly by placing a layer of foam or foamable material against both upper and lower surfaces of the shaped lightweight foam core to form a sandwich assembly. The sandwich assembly is then molded to produce the finished contoured base for a seat cushion.

Abstract: An automotive interior trim component is constructed by placing a cast polyvinyl chloride (PVC), vacuum formed or sprayed thermoplastic/thermoset cover stock, or a cloth/fabric outer shell in a closeable mold, spraying a coating of urethane foam forming materials onto a back surface of the shell, closing the mold with a lid so that an insert is held in spaced relation to the shell and clamping the lid shut while the foam forming material react to provide a shaped foam cushion that is between and bonded to the shell and the insert.

Abstract: A water heater comprising a tank for holding water, a jacket surrounding the tank, foam insulation between the tank and the jacket, a heating element for heating water in the tank, and a thermostat mounted on the tank for controlling the heating element in response to the temperature of water in the tank. The thermostat includes electrically active terminals, leadwires connected to the terminals, an electric circuit reset, and a temperature adjustment dial. The water heater also comprises a protective shield for covering the terminal and preventing foam contact with the terminal. The shield includes a face portion covering the thermostat in spaced relation to the tank. The face portion comprises a first access port for providing operator access to the circuit reset cutoff, and a second access port spaced from the first access port for providing operator access to the temperature adjustment dial. The shield also includes sidewall portions extending between the face portion and the tank.

Abstract: A ski having a composite structure. The ski includes a first element, a second element, an injected core positioned between the first element and the second element, with a polymer film positioned between the injected core and at least one of the first element and the second element, which is in contact with the film through a reinforcement component. The ski is produced by a process of providing on the internal surface of the first and/or second elements a solid compatibilizer film. The film forms an interface between an injected foam and the first and/or second elements to promote adherence.

Abstract: A method of forming a vehicle accessory embodying the present invention includes the provision of a fabric or other upholstery material in the shape of a container which when filled with an amorphous filler material defines an accessory such as a visor, introducing an amorphous material such as a mixture of expandable chemicals into the container so formed and allowing them to expand and cure while constraining the major sides of the container during curing thereby forming an accessory core and integral cover. Visors embodying a preferred embodiment of the present invention comprise an integral cover and structural core of an amorphous material introduced to fill the cover and which is bonded thereto. In a preferred embodiment, the cover is formed from a butterfly pattern which is folded and has edges joined with the exception of an opening at one corner and which is subsequently inverted to define the visor-shaped container.

Abstract: Process for the manufacture of a complex moulded structure, constituted by a foam core (16) made from plastic and on its periphery by two, respectively upper (11, 12) and lower (6, 8, 9), half-shells, includes the following steps:depositing in a mould (1, 2) a first element (6, 7, 8, 9) intended to form the lower half-shell,depositing on this first element (6, 8, 9) a deformable tubular element (13, 14, 17);depositing on top of this deformable tubular element (14) a second element (11, 12) intended to form the upper half-shell,closing the mould,injecting into the deformable tubular element (13, 14, 17) reactants intended to react in order to form a foam which expands in situ until pressing the element (11, 12) against the walls (3, 4, 10) of the mould,cooling the contents of the mould,and finally opening the mould in order to withdraw the complex moulded structure thus obtained, characterized in that at least the upper portion of the deformable tubular element (14) is rigid.

Abstract: An apparatus and method for fabricating accurate, numerically defined curved surfaces and volumes comprising a skeleton framework having a plurality of bulkheads fixed in spaced relationship with each other, each of the bulkheads having an equal number of boreholes passing through the outer perimeter thereof so as to provide a set of selected boreholes. A flexible spline having a memory is passed through each set of mating boreholes and is secured with the boreholes after the splines have reached their static states. The resultant framework is encased in a cured polymer and the polymer is trimmed and faired between the outer edges of the splines.

Abstract: A trim member for use as an interior furnishing in a motor vehicle includes a covering sheet including one surface having an embossed pattern, a first foamed body disposed on the other surface of the covering sheet, with a first component embedded partly in the first foamed body, and a second foamed body disposed on the other surface and/or the first foamed body, with a second component partly embedded in the second foamed body. The covering sheet, the first foamed body, and the second foamed body are integrally formed as a unitary construction. Since the trim member is constructed as an integral unitary assembly, it does not squeak while the motor vehicle is running, and does not have visible steps and joints on its outer surface.

Abstract: A ski and a process of forming a ski, including injecting foam within a tubular compartment constituted by a deformable and stretchable membrane made of polyurethane or copolyamide or ABS. During expansion the foam deforms the membrane and presses the elements against the peripheral walls of the ski maintained in the mold.

Abstract: A cut-resistant seat or seating material is disclosed together with methods of forming such a material. The material comprises at least one layer of flexible metal or non-metal matrix material embedded within a compressed flexible foam material. The foam material may be a fire retardant flame material.

Abstract: Improved process for producing a complex elastic molded structure of the sandwich type, consisting of a core of polyurethane foam (10) surrounded by a skin, of which at least a part is reinforced with a reinforcing textile sheet (5, 6) impregnated with a thermosetting resin adhering to said foam, which process consists in:firstly depositing on one of the faces (4) of a mold intended to be closed by a cover (2) an assembly comprising a stiffening element (12) and a semirigid reinforcing textile sheet (6), preimpregnated with a solventless, non-tacky epoxy resin,then closing the cover (2) of the mold (1) so as to define, together with said assembly, a volume corresponding to the volume of the core which is to be formed;then injecting into the volume thus defined the reactional mixture forming the polyurethane foam,and finally allowing the product to cool and opening the mold (1) to withdraw the resulting elastic complex molded structure.

Abstract: A method and apparatus for producing foam elastomer tires for various uses including bicycle and wheel chair tires with a minimum amount of wasted material. The method involves spin casting the tires wherein a mold with suitably designed tapers on the exterior surface is placed between press plates with corresponding annular tapers which cause the mold to be accurately centered within the press plates when the press is closed. The preblended liquid foamable materials are either poured directly into the mold or onto a surface immediately adjacent to the mold gate. One or more tension members are located within the mold such that either the incoming stream of preblended liquid foamable materials wet the tension member(s), or the tension member(s) lie more or less in the path of the expanding foamable material as it fills and forces its way out of the mold, or (preferably) both.

Abstract: A method of manufacturing rotors having helical lands and intermediate grooves wherein a multi-layer rotor body (2) is moulded or otherwise formed on a shaft (1) to only a small degree of accuracy, whereafter an outer layer (3) of polymer-based material is moulded on the rotor body to a high degree of accuracy. For the purpose of eliminating shrinkage-induced distortion of the lands of the rotor body (2) subsequent to applying the outer layer, the rotor body is produced in a multiple of layers (21, 22), by casting or like moulding processes, with each of the body layers having a thickness which is greater than that of the high accuracy outer layer (3).

Abstract: A method for producing a foam base material product composed of a composite sheet having a surface layer and a foam base layer with a securing device fixed on the form base layer. The method includes the steps of preparing an insert part with the securing device integrally fixed thereto, the insert part being made of a beads foam derived from a resin, placing the insert part within a mold, placing the foam base material layer of the hot molten composite sheet on the mold so that it faces the insert part, and closing the mold whereby the composite sheet is formed and the composite sheet is integrally heat fused with the insert part. This method produces a foam base material product that is more durable and easier to assemble with an auto body than is the prior art.

Abstract: A structural part, such as a kinetic energy-absorbing beam for vehicle construction, formed of a hollow metal member produced from profiled members connected by application of heat and a prefabricated reinforcing core of light-weight material is produced by first providing the core with a shell of heat-foamable material, then completing the hollow member by welding, and finally subjecting the assembly to an immersion-coating operation with heat. The hollow member has local inward projections for positioning of the core, leaving open spaces which provide thermal insulation during the welding process and which are permeated by hot coating material during the immersion-coating, so that the shell is foamed and a positive, force-transmitting connection is provided between the core and the hollow member.

Abstract: A method of molding a skin-covered foamed article includes the steps of (a) putting an outer skin member having an opening to a mold; (b) putting a frame in the outer skin member; (c) setting a pair of wires at the end portion of the outer skin member so that the opening is tightly closed; (d) pouring a liquid foamable material in the outer skin member upon opening the opening; (e) closing the opening and the mold and curing the liquid foamable material; and (f) removing the wires from the outer skin member.

Abstract: A golf club includes a straight shaft and a metallic member having a first end connected to the lower end of the shaft. The other end of the metallic member is bent to define an obtuse angle with the first end. In a preferred form, a flat metallic stiffener plate is welded or otherwise affixed to one side of the metallic member. These portions are placed in a suitable mold into which polyurethane is admitted, and heat is differentially applied to or removed from the various surfaces of the mold in order that the polyurethane solidifies to form a substantially flat striking layer of dense integral-skin polyurethane juxtaposed against the stiffener plate remote from the metallic member, and a back cushion enclosing the stiffener plate and all of the metallic member. The back cushion is thicker than the striking layer, and is of polyurethane less dense than that of the striking layer.

Abstract: As structural plastic pipe has an outer diameter of at least 10 inches and is suitable for use as a plastic piling. The pipe is at least 10 feet long and comprises an inner pipe core of no more than 6 inches in diameter. There is an outer, extruded, continuous, substantially homogeneous plastic layer at least two inches thick on substantially the entire length of the steel core. The plastic layer comprises low density polyethylene, high density polyethylene, polypropylene, foaming agent, and antioxidant, as well as a synergist for the antioxidant. The plastic layer is extruded directly onto the pipe core in a single extruding operation. A die head can be used for imparting rotational motion to an extruded plastic composition before it is introduced into a mold used for forming the plastic pipe to make certain that the entire mold is filled with the plastic composition.

Abstract: A process for the production of a foam-backed cushion portion with a cover covering same on all sides includes turning the cover inside out and applying the cover over a first mold portion of blade-like configuration with its outward surface over the first mold portion, arranged two second mold portions at respective sides of the first mold portion at a spacing therefrom, thereby forming at least one mold cavity between the first mold portion and the second mold portions. A reaction mixture is then introduced into the mold cavity to fill same with foam forming foam backing portions on the cover. The mold is then opened and the foam-backed cover is removed from the first mold portion and turned inside out to provide a foam-backed cushion portion, the cover which was disposed on the inward side of the foam material coming to lie on the outward side of the foam-backed cushion portion.

Abstract: A method of making an upholstered element wherein a cover is introduced into a mold to which it tightly adheres. The mold is closed by means of a first lid, following which a soft-foam reaction mixture is introduced into a first hollow chamber of the mold closed off by the first lid. At the end of the reaction, the soft-foam reaction mixture fills the first hollow chamber and forms a soft-foam body. Subsequently, the first lid is removed from the mold and replaced by a second lid, the soft-foam body remaining in the mold. Between the soft-foam body in the mold and the second lid, a second hollow space is formed. Subsequently, a rigid-foam reaction mixture is introduced into the second hollow chamber, which at the end of the reaction fills the second hollow chamber and forms a rigid-foam body.

Abstract: Process of providing on the internal surface of the first and/or second elements of a ski a solid compatibilizer film made of polyurethane or acrylonitrile butadiene styrene or copolyamide. The film forms an interface between foam injected into the internal space of the first and second elements of the ski to promote adherence.

Abstract: A method for forming a 360 degree integral skin handle in a thermoplastic part for use in automotive trim products includes the steps of forming a mold with a partial recess closed by a removable plug and thereafter selectively directing heat from a first source through the mold and from a second source through the plug to form a completely closed, curved, heated tube surface and thereafter casting thermoplastic material against the curved, heated tube surface to fuse and cure a layer of material thereon in the form of a tube skin segment which is releasable from the mold when the plug is removed. Apparatus for practicing the method includes a mold with a recess therein and a plug is supported on the mold for movement into a position for closing the tube surface and into a demolding position for releasing the molded part.

Abstract: A composite insulator is formed having evacuated hollow plastic enclosures arranged in a closely packed configuration with a foamed plastic resin filling the interstice between the plastic enclosures. According to a preferred aspect of the invention, hollow evacuated spheres are embedded into a matrix of polyurethane foam. The composite insulator can be formed directly within an insulating cavity of an appliance or can be formed into customized panels which can be inserted into an appliance. Also, disclosed is a method of manufacturing the composite insulator by forming a seamless continuous plastic wall on a molding chamber that has been at least partially evacuated, incorporating the resulting hollow plastic enclosure into a plastic resin which is capable of being foamed in place, introducing the composite into an enclosed cavity that is to be filled with insulation, and causing the plastic resin to foam in place.

Abstract: A method of manufacturing an article having a substructure with a wall having a wall surface and a foam layer along the wall surface, including the steps of: placing the substructure in a tool having a die surface being spaced apart from the wall surface; injecting a foamable material between the die surface and the wall; applying a clamp load between the die surface and the foamable material; allowing the foamable material to expand and exert a force on the wall; and reducing the clamp load on the foamable material to reduce the force exerted on the wall by the expanding material whereby the force exerted on the wall does not deform the article.

Abstract: A water heater comprising a tank including an outer surface, and including an inner surface defining a water chamber, an electrical component extending outwardly of the outer surface of the tank, an outer jacket surrounding the tank and having therein an opening affording access to the electrical component, a door which is mounted on the outer jacket and which covers the opening, a dam which is located within the opening and surrounds the electrical component, which extends between the tank and the outer jacket, and which includes a portion extending between the door and the outer jacket, and insulating material located between the tank and the outer jacket and outside of the dam.

Abstract: A method of assembling a vehicle seat by bonding adhesively a trim cover assembly to a preformed foam cushion member. In the assemblage, a location board having a serrated part on its side is sewn to the trim cover assembly such that the serrated part projects from the reverse surface of cover assembly, and such assembly is turned over and placed on a lower die having a location groove which includes a vertically curved part. The location board is fitted and bent vertically along such location groove, which permits bonding of the cover assembly neatly over the uneven surface of cushion member, without slack and wrinkles, when pressing the cushion member against the cover assembly by means of an upper die.

Abstract: A method and structure for manufacture of a foam cushion article. The method of constructing the cushion article does not require the use of a conventional mold and is performed by placing a frame within the space to be filled with foam. Fabric is then disposed around the frame in a step toward the formation of a preselected geometric shape for the cushion article. Subsequently, a skeletal assembly is positioned externally against the fabric in a final step to achieve the preselected geometric shape. The method allows production of a structure which includes selected areas of fabric bonded and unbonded to foam material. The method also allows substantial degrees of freedom in generating and positioning regions of preformed cushions or of different density foam cushions and in controlling overall strength and bonding between the different cushions and the fabric.

Abstract: A process for the production of a headrest with an articulated insert, comprises casting in situ polyurethane foam (7) within an external cover in which is disposed an insert (5) having articulated legs (4) that protrude from the cover, then hollowing out, by means of heating elements (2), swinging spaces (3) for the articulated legs (4) of the insert (5) by hot fusion of the external cover (6) and of the polyurethane foam (7) at the corresponding locations (8) of the headrest (1), and simultaneously heat sealing the external cover (6) and the surface of the polyurethane foam (7) bordering the swinging spaces (3).

Abstract: A method of molding a foamed product is carried out by using a front and a rear mold for molding a front and a rear portion of the foamed product and a core interposed between the front and rear molds. The method includes steps of pouring or spraying one of foaming stock solutions onto a molding surface of the one mold, arranging the core in the one mold and pouring or spraying the other foaming stock solution onto the core or a molding surface of the other mold. The front and rear molds are closed at a moment when a lapse of time arrives at 30-100% of a rise time of the foaming stock solution later applied. Thereafter the closed molds are maintained in a position where an angle of the closed molds relative to a horizontal plane is within a range between 90.degree. and an angle more than 0.degree.. The front and rear molds are pivotally connected to each other with their one ends by means of a pivot shaft. The core is pivotally supported with its one end by a shaft arranged in parallel to the pivot shaft.

Abstract: A composite style wheel, and method and apparatus for making the same, including a metal wheel mounting disc and a rim secured thereto adapted to receive a tire thereon, and a composite plastic ornamental overlay covering at least part of the outboard face of the disc and/or rim. The overlay includes a molded in-situ body of relatively high density resilient urethane plastic material permanently affixed to the disc and/or rim and a plastic insert having a weight-to-volume ratio much less than that of the body plastic material. At least the major portion of the insert is disposed radially outwardly from the overlay, aperture wheel mounting and the overlay body plastic material covers the insert so as to completely embed the same in the composite overlay to thereby hide the insert from view and assist in securement thereof to the wheel. The overlay body is cast and cured against the wheel metal with the insert pre-secured thereto.

Abstract: A plastic element with an outer surface defining a running surface, particularly for a belt or chain, arranged at the outer circumference of a metallic insert designed as a rolling or sliding bearing, consisting of a polymeric plastic material hardened after polymerization produced in a mold comprising adding an expanding agent to the polymeric plastic material by mixing, inserting the metallic insert into the mold, filling the mold with polymeric plastic material containing an expanding agent at a low pressure compared to injection molding pressures, allowing the polymeric plastic material to expand by action of the expanding agent to the outer surface of the metallic insert and to the mold to form the running surface and hardening the polymer plastic material.

Abstract: A method is disclosed of making in a mould cavity objects having an outer wall from a micro-cellular or non-cellular elastomer (7) and a core consisting at least partly of a synthetic foam (9), including the following steps: in a first step, a layer (7) of the elastomer is applied by spraying onto the surface (1) defining the mould cavity, and then, in a second step, before the elastomer is completely cured, a reaction mixture for obtaining a synthetic foam (9) is injected in the thus by the formed elastomer layer (7) defined space (8) of the mould cavity and wherein, in a third step, after the synthetic foam (9) has been cured substantially completely and forms a whole with the elastomer layer (7), the thus obtained object is demoulded.

Abstract: A process for producing a seat element from a portion of an outfit (1) including a relatively compact plastic covering layer, a network formed by a continuous sheet of metal springs (5), the intermingled turns of which, on one side, come substantially flush against the lower face of the covering (1), and an intermediate connecting layer (3) made of a plastic foam which partially encases the turns of the sheet of springs (5).According to the invention, the peripheral edge (7) of the said outfit portion is gripped in an injection mold (11), this mold having a cavity (9) into which the said edge (7) penetrates, a thermoplastic to which an expanding agent has been added is injected into the said cavity at low pressure, and this thermoplastic is allowed to harden there.

Abstract: In a process and apparatus for the production of a component including a support element and foam portions adhering to the top and bottom surfaces thereof, the support element is arranged with its bottom surface over a first mold cavity of a mold. A cover is then sealingly fixed on the mold in such a way that a second mold cavity is defined between the cover and the support element. A first reaction mixture is introduced into the second mold cavity and reacts to form a first foam portion on the top surface of the support element. The cover with support element and first foam portion are then removed from the first mold cavity. Thereupon a second reaction mixture is introduced into the first mold cavity which is then immediately sealingly closed again by the unit consisting of the cover and the support element with its first foam portion.

Abstract: A longitudinal multi-component frame element is formed by positioning at least one longitudinal member to form a first component of the frame element within a longitudinal mold. A second component of the frame element is formed by introducing into the mold a foamable and curable material such as polyurethane which cures to form a rigid plastic component connected to the longitudinal member. Before formation of the rigid plastic component, the longitudinal mold is bent in a direction opposite to a direction of anticipated warping of the frame element that would be caused by internal stresses therein. Thus, the frame element initially is formed within the mold to be of a bent configuration, and after removal of the frame element from the mold, the internal stresses transform such initial bent configuration into a straight or rectilinear configuration.

Abstract: A method for making an armrest or the like used in vehicles where the armrest is affixed to the vehicle door and also serves as a grab-handle to enable the passenger to pull the door closed. The method is an injection molded vinyl process that utilizes a two-piece insert in the main body of the armrest which allows foam to be introduced into the upper portion and inboard side where the user's arm rest. This method produces a more comfortable armrest that also is more visually pleasing and one that can be produced at a lower cost than known armrests of this type.

Abstract: A process for manufacturing a padded element in a mold having an upper mold and a lower mold. The process includes providing in the lower mold a cushion member with a first portion having an open recess therein, with that recess having a lower portion. The cushion member is enveloped by a trim cover having a finished upper outer surface and an inner surface. The trim cover has at least one aperture therein, and the open recess and trim cover define a cavity. The upper mold and lower mold are closed so that the upper mold is in contact with the upper outer surface of the trim cover. A liquid foamable polymeric composition is dispensed in the cavity and onto the lower surface of the open recess via the aperture in the trim cover. The polymeric composition is allowed to expand to fill substantially the cavity, and the composition comes into contact with the inner surface of the trim cover such that the first portion corresponds proportionally to the finished surface of the padded element.

Abstract: A motor-vehicle steering wheel which is made of plastics material but looks like a wooden steering wheel is produced from a die having ribs such as to form in the moulded part indentations having a typical wood-grain pattern and arrangement. In the moulded part, the plastics material used for the moulding assumes a density of the same order of magnitude as that of a typical wooden steering wheel. A dark-colored ink is applied to the surface of the moulded part and penetrates the indentations to give them the wood-grain appearance, the ink subsequently being removed from the rest of the surface of the part and the part then undergoing a final varnishing step.