Abstract: A mold tool (16) for forming a trim covered foam substrate of a seat assembly comprises an upper mold cast (18) defining an upper mold surface (19) and a lower mold cast (20) defining a lower mold surface (2). A split line (28) is defined adjacent to the upper and lower mold surfaces between the upper mold cast and the lower mold cast when the mold casts are in facing mating engagement forming a mold cavity (22) therebetween. A plurality of heat lines (24) extend through the upper (18) and lower (19) mold casts adjacent the respective upper and lower mold surfaces for heating the mold cavity (22). A cooling line (30) extends through at least one of the upper and lower mold casts adjacent the split line (28) for cooling the split line of the mold tool.

Abstract: A multi-layer sheet of the present invention comprises a thermoplastic resin foam sheet, a reinforcing sheet layered on integrated with at least one side of the thermoplastic resin foam sheet; the reinforcing sheet being formed by a non-woven fabric which comprises non-meltable fibers which are interwound with one another and which are bound together with a thermoplastic resin, the thermoplastic resin foam sheet having an aspect ratio Dz/Dxy of bubbles of 1.2 or more, and an expansion ratio of 5˜50 cc/g, and therefore the sheet is excellent in bending strength, compressive strength, thermo-forming property and dimensional stability as well as lightweight property, and so can ideally be used for an upholstery material for vehicles, a heat-insulation material, a buffer material and the like.

Abstract: A manufacturing method of a polyurethane foam injected with strand mats and a device for increasing the volume of the strand mats. The method comprises the steps of: increasing the volume of each of the strand mats to weaken the cohesion between glass fibers in each of the strand mats; continuously supplying and transferring the volume-increased strand mats; spraying a polyurethane foam solution on the continuously transferred strand mats; and foam molding the polyurethane foam solution in which the strand mats are immersed, into a polyurethane foam. Because the cohesion between the glass fibers in the strand mat is weakened and the volume of the strand mat is increased, the polyurethane foam solution uniformly permeates into the strand mats. As a result, the productivity of the polyurethane foam is improved and the variations in a variety of the mechanical properties are minimized.

Abstract: An impact absorbing composite structure (10), the impact absorbing composite structure including a plurality of impact absorbing members (18) and a flexible layer (16), each impact absorbing member (18) integral with the flexible layer (16).

Abstract: A method for forming a headliner assembly includes forming a main body blank having a periphery in a shape corresponding to a desired shape of the headliner assembly, the mold has a correspondingly shaped surface with a recess including an intermediate wall portion. The method includes introducing foam into the recess to simultaneously form at least one foam beam enclosing a selected component area, and join the at least one beam to the main body. The intermediate wall can be an accessory, and the beam may be formed to surround the component area. Additional foam application may be included to acoustically control the headliner's response to buzz, squeaks and rattles.

Abstract: The present invention relates to a method for producing a plastic composite element (1), in particular as an interior lining element for a motor vehicle, with an outer covering (2) being lined with a foamable plastic, characterized in that the outer covering (2) is lined at least partially with a flexible foam (3), that the flexible foam (3) is subsequently lined with a rigid foam (5) with a separating means being placed thereinbetween, and that a shaped part (4) which can be prefabricated is used as the separating means which by virtue of the mechanical properties of its material and/or its shape prevents the rigid foam (5) from penetrating the flexible foam (3) and/or prevents a deformation of the outer covering (2), and such a plastic composite element (2).

Abstract: The object of the present invention is to produce plural resin forms at one time with stability by dividing resin starting material continuously in a short time and with the same residence time into plural parts having desired amounts of resin and discharging to solidify them. The producing method is comprising, providing a liquid partition on the die land and/or die lip of a coat hanger shaped die along with the flow direction, introducing starting material for resin into said coat hanger shaped die and dividing it into plural parts and then discharging and solidifying on the adherent.

Abstract: An automotive vehicle sound absorption system. An expandable material, such as an polymer-based foam, is disposed on a surface of a wall. Upon activation, the foam transforms, preferably during an automobile assembly operation, and remains bonded to surface for sound absorption.

Abstract: A method of molding a composite structure of a polymeric preformed skin with tightly radiused features and a polymeric foam body is provided. The method includes providing a mold cavity having a first edge; placing the preformed skin in the mold cavity with a preformed first edge of the preformed skin adjacent to the first edge of the mold cavity; heating the preformed skin adjacent the first edge; exposing the first edge to a vacuum to reform the preformed skin first edge to be adjacent the mold cavity first edge and injecting a foam polymeric material into the mold.

Abstract: At least one embodiment of this invention relates to a cushioned dust control mat article wherein the mat comprises at least two distinct layers of rubber, one comprising foam rubber, the other comprising solid rubber. The solid rubber layer is present over the foam rubber layer on the side of the mat in which at least one integrated rubber protrusion is present to provide cushioning characteristics. The solid rubber layer acts as a cap or barrier for the foam rubber layer, particularly over the integrated protrusion or protrusions, in order to provide a mat which is resilient, will not easily degrade in its modulus strength after appreciable use and/or washing within industrial cleaning processes, and will not exhibit appreciable cracking or breaking, particularly within the integrated protrusion(s), after standard use for pedestrian traffic. A method of producing such an inventive cushioned floor mat article is also provided.

Abstract: A method is provided for molding an article (10) that includes a polymer (100) such as an epoxy resin, reinforced by fibrous material (102) such as fiberglass which is embedded in the polymer material, especially for a hollow article such as a shell. The method includes placing spacers (42, 44) in a mold cavity (30), where the spacers conform closely to the cavity surface and leave a free, or empty volume (64) within themselves. Foamable material (60A) is placed in the free volume and allowed to expand and push the spacers toward the cavity walls while forming a foam core (70) within the spacers. The mold is opened and the spacers and foam core are removed. Next, the foam core is covered with an impervious layer and the fibrous material (72) is wrapped around the foam core. The foam core is placed back in the mold, with the fibrous material spacing the foam core from the walls of the mold.

Abstract: A method for making a radome includes the steps of placing a first dry fiber preform into a female mold having a mold surface contoured as a negative image of a desired contour to be imparted to an exterior surface of the radome, and placing a polyetherimide foam core in the mold on top of the first dry fiber preform, the foam core having first been thermally formed to generally match the contour of the mold surface prior to being placed in the mold. Next, a second dry fiber preform is placed on top of the foam core so as to form a sandwich structure having the foam core sandwiched between the dry fiber preforms, and the dry fiber preforms are vacuum infused with a fluid heat-curable resin to impregnate the preforms with the resin. The sandwich structure is then heated to cure the resin.

Abstract: A helical corrugated coaxial cable possesses low cost of manufacture comparable to that of braided shield coaxial cable, electrical performance comparable to solid tubular shielded cable, flexibility of helical and annular corrugated cable, and fluid blockage comparable to annular shielded cable. The cable has an inner conductor surrounded by a foam dielectric insulator. A tubular shield surrounds the dielectric and has helical corrugations penetrating into and compressing the foam dielectric to effectively suppress the formation of fluid migration air gaps or passageways between the shield and the dielectric. The shield is preferably composed of aluminum or aluminum alloy. Alternatively, the shield may be annularly corrugated for improved water blocking performance. The manufacturing process employs high speed welding and multi-lead corrugating operations to reduce cost.

Abstract: An insulating paper container's body has a low m.p. thermoplastic synthetic resin film laminated on its outer wall surface and a compatibly expansile ink applied to the outer surface either as a primer or as indicia to provide stock material improved in its printability for bar codes or the like as well as in its insulating property. In addition there is provided a process for making such stock material.

Abstract: A process of molding a component on a substrate utilizes a substrate having a peripheral flange that projects into a parting line between mold segments defining a mold cavity, wherein the flange has a projecting, continuous circuitous ridge that forms a seal between the substrate and an upper mold segment. The process allows a substantially flash free molded component to be formed directly on a substrate, thus eliminating the need for a separate flash removal step.

Abstract: A combination fastener and foam sheet having enhanced fastener retention and methods of forming a foam sheet are provided so that the fastener is not easily removed from the foam sheet when an outward force is applied thereto. The combination preferably includes a foam sheet including a fibrous material and urethane foam material abuttingly contacting and substantially surrounding the fibrous material so that the fibrous material is substantially contained within and retained by the urethane foam material. The combination also, preferably includes a fastener having threaded portions positioned within the foam sheet so that the threaded portions are retained in the foam sheet and are not easily removed when an outward force is applied thereto. The foam sheet preferably also has a strengthening material such as glass also substantially surrounded by the urethane foam.

Abstract: A laminate structure for making a cushioned component for a vehicle interior, such as a seat cushion or head rest, has a high density foam bonded to an interior surface of a seat cover material. After the laminate structure is formed into a desired shape for the cushioned component, it is inserted into a vacuum mold having a mold surface with a shape corresponding with a desired exterior surface shape of the cushioned component. Liquid foam-forming material is injected into the laminate structure within the mold and allowed to cure to form the cushioned component. The high density foam of the laminate structure preferably has a density of at least 4 lbs/ft3 and an air permeability of 5 to 100 ft3/ft2 minute. This high density foam may be created by felting a polyurethane foam.

Abstract: A method of forming a polyurethane article wherein first and second components of a polyurethane system are sprayed into an unconfined space above a mold. The first and second components are sprayed together to mix initially in the space above the mold and then are deposited in the mold on an in-mold coating that was previously applied to the mold. The two components of the polyurethane system and in-mold coating are subsequently removed from the mold as a flexible polyurethane skin. The skin may then be placed in a second mold along with a reinforcement. Structural polyurethane foam may then be injected to the second mold where it bonds to the reinforcement and the skin to form a finished polyurethane article having a flexible skin adhered to its surface. A post-mix spray nozzle assembly is provided with a central nozzle forming a first hollow conical spray pattern and a coaxially aligned annular nozzle forming a second hollow conical spray pattern.

Abstract: A method of manufacturing a foamed plastic article includes disposing a release film on a mold surface of a mold cavity. At least a portion of a bushing is inserted through the release film to form an aperture in the release film. The bushing defines an inlet for foamable material. The mold cavity is then sealed. The foamable material is then injected into the mold cavity through the inlet, wherein the foamable material is conformed to the shape of the mold cavity.

Abstract: A fabric-less part and a method of making same are disclosed. The fabric-less part may include a flexible polyurethane foam body, a high-density polyurethane foam backing layer bonded to the foam body, and a polyurethane elastomer skin bonded to the backing layer. Alternatively, the backing layer may be eliminated and the polyurethane elastomer skin is directly bonded to the flexible polyurethane foam body. The fabric-less part may be an automotive interior part such as a pillar trim, headrest, trim panel, instrument panel, door panel, armrest, or part of an automotive seat such as a seat cushion.

Abstract: Methods are taught for manufacturing a press molded article (1) that comprises a profiled substrate layer (10) and a foamed layer (20). A substrate material (12) may be press molded with a foamable material (22) under pressure in order to join or attach the foamable material to the substrate material. In addition, a profile may be imparted to the substrate material during the press molding step, thereby forming the profiled substrate layer. After the press molding step has been completed, the foamable material is foamed and expanded, to thereby form the foamed layer. A skin material (32) optionally may be applied to the foamable layer before the press molding step. Optionally, embossed patterns may be imparted to the skin material during the press molding step, thereby forming an embossed skin layer (30) that is attached to the foamed layer.

Abstract: A method of making a sponge device is provided. This method includes introducing a curable liquid sponge forming material into a form, placing a handle into the material before it is fully cured, heating the form to cure the material, removing the cured material from the form, and rinsing the cured material. Another aspect of the present invention is the assembly for making this sponge device. This assembly includes a runner for joining a plurality of handles, plates that are spring-biased together to support the handles, a chase formed of heat conductive metal having a shelf where the plates can be set, and a silicone form having a plurality of cavities therein for receiving the sponge forming material.

Abstract: A method for manufacturing shoe components using EVA copolymer of film shape having a thickness of 0.01 to 2 mm, preferably 0.1 to 1.0 mm and a surface roughness variations which cannot be easily discriminated through touch or sight, and a shoe component manufactured by the method are provided. The method overcomes the drawbacks caused during the process of manufacturing a shoe component with different mechanical physical properties or colors. The method allows for ease of manufacture of a shoe component with two or more types of colors or physical properties, through a single foam molding process using a film with less variation and ease of processing, to thereby simplify manufacturing procedures and reduce manufacturing costs. In addition, a high quality shoe component with no additional seam-line is obtained.

Abstract: A system of manufacturing a molded article includes a mold having first and second parts engagable to one another to form a cavity. A first mold part is fixed to a mold station. The second part of the mold is movable between a spray station adjacent the mold station. An enclosure disposed between the mold station and the spray station contains emissions from the spray station so that the mold station is not contaminated. The molded article is fabricated by applying a surface coating at the spray station into, shuttling the movable part of the mold into alignment with the fixed part of the mold, and filling the mold with a settable mixture. The second part of the mold is released from the first part, and shuttled back to the spray station for demolding of the completed molded article.

Abstract: A method of manufacturing a vehicle body part embeds an insert piece into a foamed layer of the body part by holding the insert piece in a foaming tool using a magnetic force. The magnetic force holds the insert piece into position, eliminating the need for any additional holding structures in the foaming tool. A body part made by this method has improved visual quality, particularly at a transition area between the insert piece and a decorative part.

Abstract: A method for creating a hot melt foamed form for an air induction system. A block of thermal mastic elastomer is melted and blended with nitrogen gas to create a foamed material. The foamed material is applied by robotic techniques over a base material on the surface of a polypropylene glass lower shell. After the foamed material cures, a polypropylene glass cover is applied over the foamed material form to create an air tight dust/water seal. The cover does not adhere to the cured foamed material and is removable when service is necessary. The foam material can also be dispensed into a mold and then transferred to the base, allowing for changes in the shape and profile of the foamed material. This method can also be employed to create an isolation pad on an air induction system to absorb engine shock. The thermal mastic elastomer can also be employed to create a seal between the cover neck of an air induction assembly and a mass air flow sensor.

Abstract: A method of producing a vehicle steering wheel including a steering wheel rim comprises the following steps: A foaming mold with a top part and a bottom part is used; two different foam components, namely, a central carrier component as well as a soft component surrounding the latter, are injected into the bottom part which is not closed by the top part; the foaming mold is closed by closing the bottom part with the top part, and; the foaming mold is heated.

Abstract: A manufacturing method for a refrigerator door is disclosed. The method uses only a transparent plastic layer to make the refrigerator door. The present invention can simplify the manufacturing process, and reduce the number of parts required for the refrigerator door to reduce costs. Furthermore, an appearance pattern on the refrigerator door can be painted or printed onto the surface of the transparent plastic layer with different types, and a male mold of a vacuum forming machine can provide different shapes to make the refrigerator door into variety shapes. Moreover, because the appearance pattern can be painted or printed on the inner surface of the transparent plastic layer, the appearance pattern will not come off because of frequent touching.

Abstract: A foaming tool has a first mold part, a second mold part, and at least two cavities for producing at least two composite parts from a substrate. A compensation zone is disposed between the two cavities and is adapted to accommodate a relief zone formed on the substrate. The substrate has a first component section and a second component section adapted to be arranged in the cavities of the foaming tool. The first and second component sections receive a foamed backing of an expandable material to form the composite parts. The substrate has a relief zone between the first and second component sections to handle any stresses on the substrate and prevent surface defects in the substrate.

Abstract: A method facilitates fabricating a cellular cushion. The method comprises injecting material into a mold in an injection molding process to form a cushion first layer that includes a plurality of hollow cells that extend outward from the base and are each coupled together in flow communication, coupling a second layer to the first layer, and coupling an injection stem in flow communication to the plurality of hollow cells to enable an operating pressure within the cells to be changed.

Abstract: An insulating beverage or food container or sleeve is produced with a foam layer disposed on an inner surface of a paper stock. A polymer shrink film layer is arranged in a position along an inside surface of the beverage container. The foam layer is sandwiched between the polymer shrink film layer and the paper stock and decreases the energy transfer between the beverage and the user's hands allowing the user to hold onto the container for an extended period of time without causing user discomfort or pain. The polymer shrink film layer is produced from a shrink film polymer having a percent shrink in the range of 30% or less, and more particularly a percent shrink range of 5 to 10%.

Abstract: An expansion-molded article (foamed body) produced by using foamed and expanded beads, and having open voids has sound absorbing qualities, and can be used as a sound absorbing material. A sound absorbing material which is able to attain a high sound absorption coefficient in a wide acoustic frequency range is provided by a molded article produced by using resin particles, having through hole(s) and a porosity of 45 to 80% in a most densely packed state. The void content of the molded article is 10 to 60%, and the bulk density thereof is 0.01 to 0.6 g/cm3.

Abstract: There are provided methods for fabricating baby bottle nipples which mimic the function of the human breast nipple. In the human breast nipple, milk is delivered to the baby through 15-25 fluid-delivery capillaries called lactiferous ducts. These ducts are 2-4 centimeters in length and 500-900 microns in diameter. Baby bottle nipples fabricated in accordance with the methods of this invention have the common feature of at least one hydrophilic fluid delivery passage. In one embodiment, the fluid delivery passage is a microtube. In another embodiment, the fluid delivery passage is a microchannel. In yet another embodiment, the fluid delivery passage comprises a porous reticulated foam with interconnected pores. In each of these embodiments, the fluid delivery passage has at least one dimension in the range of 1-2000 microns.

Abstract: A vehicle headliner assembly (152) includes a headliner structural layer. A foam beam (174) is joined to the headliner structural layer. A washer fluid line (168) is embedded within the foam beam (174). A method of forming a headliner structure is provided. The method includes forming a headliner main body (170). The headliner main body (170) is positioned in a mold (220) that has a recess (224). The mold (220) is closed. Foam is introduced into the recess to form a foam beam (174) and to join the foam beam (174) to the headliner main body (170). A portion of a washer fluid line (168) is embedded in the foam.

Abstract: A vehicle headliner assembly (152) includes a headliner structural layer. A foam beam (174) is joined to the headliner structural layer. An NVH pad (156) is partially embedded within the foam beam (174). A method of forming a headliner structure is provided. The method includes forming a headliner main body (170). The headliner main body (170) is positioned in a mold (220) that has a recess (224). The mold (220) is closed. Foam is introduced into the recess (224) to form a foam beam (174) and to join the foam beam (174) to the headliner main body (170). A portion of an NVH pad (156) is embedded in the foam.

Abstract: A flexible polyimide foam having an apparent density of 13.5 to 900 kg/m3 and a glass transition temperature of 300° C. or higher can be prepared by mixing an aromatic tetracarboxylic acid comprising 2,3,3′,4′-biphenyltetracarboxylic dianhydride a portion of which is converted into its mono- or di-lower primary alcohol ester with an aromatic polyamine containing diaminodisiloxane in an amount of 0.1 to 10 mol. %, based on the amount of total amine compounds, to give a solid of polyimide precursor; heating the solid of polyimide precursor to a temperature of 300° C. to 500° C. to produce a polyimide foam; and compressing the polyimide foam.

Abstract: An innovative robotic foam application process that integrates system communications, non-contact vehicle insertion point locations, and applications controls to accurately dispense a two-component structural foam at a high volume and flow rate. The process begins by first inserting a baffle within the support structure. After an electrocoat application and bake, the baffles expand and are sealed within the support structure to form cavities having a fill hole. A hydraulic driven robotic dispensing system equipped with a high-pressure static mixer senses the respective fill hole, moves a robotic arm to a location sensed, and injects a high volume of mixed two-component viscous material within each of the respective located fill holes at a high fill rate. After dispensing, the viscous material undergoes an exothermic curing reaction to cure and is expanded to substantially fill each cavity.

Abstract: The invention provides in-mold decorated articles and methods to form the articles. The in-mold decorated articles include a polymeric portion having a substrate material adhered to a surface of the polymeric portion. The substrate material may be, for example, a film or a fabric. In some embodiments, the polymeric portion may be a foam and, particularly, a microcellular polymeric material. The articles are formed by injecting a mixture of blowing agent and polymeric material into a mold cavity in which the substrate material is disposed, so that the substrate material is forced against a wall of the mold cavity. The blowing agent, which in certain preferred cases is a supercritical fluid, decreases the viscosity of the polymeric material and, therefore, enables reductions in injection pressures and temperatures.

Abstract: A method of making a skin of an interior trim part and an interior trim part made according to the process. A male mold having a convex portion is used to form a skin having a uniform thickness that is sprayed on the surface of the mold. The surface of the mold has a grain pattern that is transferred to a skin. The skin is allowed to flash off or partially cure before being removed from the male mold. The skin is then turned inside out with the exterior surface being inverted to form a convex portion of the skin. The skin is placed into a female mold having a concave portion against which the convex portion of the skin is placed. Foam is injected into the inverted skin while in a female mold and is cured to form an interior trim part.

Abstract: The hollow bead of high quality are applied and molded into a shape corresponding to and following the shape of a applying position onto which the bead are to be applied. The bead-molding apparatus includes a discharging device 10 of a double nozzle structure 12 comprised of an inner nozzle 36 and an outer nozzle 38, a highly viscous material feed unit 16 for feeding a highly viscous material that is fluid in the form of a stream in a high speed flow region and can retain the shape into which it is applied and molded in a low speed flow region, a manipulator 60 disposed so as to transfer the discharging device 10 mounted thereon to a desired position, and a controller 22 for controlling the overall operations of the apparatus. The discharging device 10 is controlled so as to move along the applying position of a work 23 while feeding gases thereto from the inner nozzle 36 and discharging the highly viscous material thereto from the outer nozzle 38.

Abstract: A cellular molded article in a mold pattern having a surface skin, which has an excellent releasing property from a metal mold as well as an excellent printing property of a design formed on a surface of the metal mold, and a producing method thereof are provided. The cellular molded article in a mold pattern having the surface skin and a producing method thereof, in which, at least a face of the surface skin material, which contacts the metal mold, is an olefin thermoplastic elastomer sheet which is composed of an olefin resin without containing a polyethylene resin as its matrix, and pre-expanded beads, which are employed for an expansion molding in a mold pattern, are pre-expanded beads of an olefin resin.

Abstract: A process for producing a multi-layered article having a soft, leather-like feel comprising first introducing into a suitable mold a first liquid formulation designed to produce the top elastomeric layer on the finished article. A release agent is then applied on the elastomeric layer in the area where it is desired not to have adherence of the elastomer to the foam. Before the elastomeric layer is completely cured, a second liquid foam producing formulation, designed to produce a soft foam, is poured into the open mold. The elastomeric layer of the resulting article is integrally attached to the foam in the areas not containing the release agent.

Abstract: A method for making a multi-layer expanded shoe sole includes the steps of (a) molding a first foamable material to form a first unexpanded blank and cooling the first unexpanded blank to a low temperature to harden the first unexpanded blank, (b) molding a second foamable material to form a second unexpanded blank and maintaining the second unexpanded blank at a high temperature such that the second unexpanded blank is in a softened state, and (c) stacking and thermal molding the first and second unexpanded blanks in a mold at a molding temperature to permit the first and second unexpanded blanks to undergo a reaction for cross-linking and expansion.

Abstract: A molded resin laminate in which the dimensional accuracy and the strength are excellent at a bent portion and a method for producing the same are provided. One, in which an average diameter of small cells existing in a region on a side of a resin cover to be formed into a surface layer is smaller than an average diameter of large cells existing in a region on a side of a base resin component to be formed into a base layer, is used as a foamed resin component to be formed into an intermediate layer of the molded resin laminate. After the base resin component is molded with a molding machine, the base resin component is held on a male mold of a forming machine different from the molding machine described above. A sheet-shaped laminate, which is obtained by joining the foamed resin component and the resin cover, is arranged between the base resin component and a female mold. Subsequently, the forming machine is subjected to mold clamping.

Abstract: Injection molding encapsulation processes for packaging an object or objects in microcellular foamed material, comprising the steps of providing a mold having a mold cavity, positioning at least one object in the mold cavity, providing a packaging material, introducing a fluid into the packaging material under conditions sufficient to produce a supercritical fluid-packaging material solution, introducing the solution into the mold cavity, and converting the solution into a microcellular foamed material. Such processes are advantageously employed in encapsulation of electronic or electrical components. Packaged objects produced therefrom may be completely or partially encapsulated.

Abstract: A roof module comprises an outer shell and a foamed inner shell. The outer shell has a rim including an edge of cut and the inner shell extends as far as on the edge of cut. There is also proposed a method of producing such a roof module.

Abstract: A method for making an expanded shoe sole includes the steps of (a) molding a first foamable material to form an unexpanded sole blank, and cooling the unexpanded sole blank to harden the unexpanded sole blank, (b) positioning the hardened unexpanded sole blank on a first mold, (c) heating a second mold to a molding temperature, (d) positioning assembly of the hardened unexpanded sole blank and the first mold in the second mold, (d) filling a second foamable material in the second mold prior to expansion and cross-linking of the hardened unexpanded sole blank, and (e) thermally molding the second foamable material and the hardened unexpanded sole blank in the second mold.

Abstract: The present invention relates to a multiple foam substrate of predetermined shape and a method of manufacturing the substrate. The substrate is a multiple foam substrate which may be manufactured by the method with a mold having first and second mold cavities. The method includes injecting a first foam into the first mold cavity sufficiently to fill the first mold cavity and storing the first foam in the first mold cavity for a predetermined time sufficient to form a substantially non-mixing surface on the first foam. The method further includes injecting a second foam into the second mold cavity and onto the non-mixing surface on the first foam sufficiently to fill the second mold cavity. The method further includes storing the second foam in the second mold cavity for a predetermined time sufficient to bond the first foam to the second foam along the non-mixing surface.

Abstract: A method for dehydrating a porous cross-linked polymer conveniently to a low final water content is provided. A porous cross-linked polymer sheet is produced by a method which comprises causing a porous cross-linked polymer obtained by forming and polymerizing a water-in-oil type higher internal phase emulsion to be dehydrated by the use of non-woven fabric rolls furnished with an aspiration mechanism. Properly in this case, the porous cross-linked polymer is subjected to preliminary squeezing. In accordance with the present invention, a porous cross-linked polymer abounding in a water absorbing property to be dehydrated to a low final water content with a small number of rolls.

Abstract: A method and apparatus for making a composite article that includes a soft trim component employs a pair of mold halves, wherein a suitable skin material is sprayed onto a first mold cavity surface to obtain an in-mold coating, and a substrate is positioned between the mold halves such that a first area of one side of the substrate is located in opposition with the in-mold coating. A sprue defined in the second mold half, in opposition with the other side of the substrate, directs injected foam through an aperture in the substrate and into a gap defined between the one side of the substrate and the in-mold coating. A portion of the first mold half includes a layer of a sealing material that is harder than the substrate material to thereby eliminate the need to otherwise trim the overmolded soft trim component upon release from the mold.