Abstract: An acoustic baffle assembly for sealing or baffling a hollow body having a mass of heat activated expandable material that is capable of activating at a predetermined temperature. A substrate supports the mass. The substrate has a central portion and spaced apart projections extending outwardly from the central portion. The projections are configured to control expansion of the mass.

Abstract: A foam-fiber composite material is provided that is made up of a monolithic foam structure having a polymer material and a fiber web having a plurality of fibers disposed substantially throughout the foam structure.

Abstract: The present invention relates to a wheelchair having a back plate and a seat plate and a manufacturing method thereof, and more particularly, to a customized wheelchair having a back plate and a seat plate formed to fit a body shape and a manufacturing method thereof. In a method of manufacturing a customized wheelchair having a back plate and a seat plate which are designed to fit a body shape, the method includes steps of: forming a preliminary molding material which is directly formed to fit a back and a hip of a user; fixing the preliminary molding material to a molding frame; filling a foaming resin in the molding frame fixed with the preliminary molding material; hardening the foaming resin filled in the molding frame; and releasing a last molding material which is foamed and hardened to have a shape of the back and the hip of the user by the preliminary molding material.

Abstract: Provided is a method for reinforcing a foam material in which a working region is first prescribed. A gap that at least partially encloses the prescribed working region in a two-dimensional manner is created in the foam material. A strut is introduced into the foam material, extending from an entry surface of the foam material from outside the working region to at least the fibrous sheet-like material. From a further aspect, a sandwich component with a core which comprises a foam material is provided. A fibrous sheet-like material arranged in the foam material at least partially encloses a working region of the sandwich component in a sheet-like manner. At least one strut is incorporated in the foam material and extends from an entry surface of the foam material from outside the working region to at least the fibrous sheet-like material.

Abstract: An insulated frame member including first and second frame components held in a spaced relationship by a first, glazing unit facing connector component and by a second connector component, the first and second frame components together defining a void substantially filled with a foamed material, wherein the first connector component is of width greater than or equal to the thickness of the glazing unit.

Abstract: The panel-like laminate comprises a flexible skin (1), a rigid substrate (2) and an intermediate layer (3). The flexible skin (1) comprises a main part (8) which forms the front side of the laminate and at least one flange (9) which extends from the main part (8) of the skin towards the substrate (2) to form at least a portion of the lateral side of the laminate. In order to avoid foam leakage when molding the intermediate layer (3) between the skin (1) and the substrate (2), the flange (9) is extended by a border part (10) which comprises a flexible lip (11). The flexible lip is pressed against the rigid substrate (2) so that the flexible lip (11) forms a seal between the skin and the substrate. To prevent deformation of the skin, the border part (10) of the skin further comprises at least one continuous or discontinuous ridge (12) which extends along the flange (9) of the skin (1) and which prevents a sliding of this border part when closing the mold.

Abstract: A graphitizable carbon foam having enhanced directional thermal conductivity is provided. The mesophase portions of a mesophase pitch are aligned with each other to create an oriented mesophase pitch, which is then foamed to provide an oriented pitch foam. The pitch foam can be heated to carbonize the pitch thereby forming an oriented carbon foam. The carbon foam can be further heated to provide an oriented graphite foam.

Abstract: A method for forming a bond between a first and a second shell of a blade is provided. The method comprises the steps of forming a cavity between said first and second blade shells and filling an adhesive into said cavity to form a bond line between said first and second blade shells.

Abstract: A furniture composite board comprises different materials. The surface of a proper-shaped matrix is covered by thermosetting resin and then fibers. The fibers then are soaked in thermosetting resin. During the process of thermosetting, the fibers would be solidified and become hard and firm on the surface of the matrix. The composite board has strong strength and its weight would change according to the matrix. It is easy for the composite to form various shapes; easy to be produced and needs no complicated equipment.

Abstract: An interior finish panel for a vehicle may include a panel substrate, at least two pieces of skin disposed over the panel substrate, and a foam layer. The panel substrate may include an inclined portion disposed between a base portion and at least one sealing surface. The at least two pieces of skin may include an upper skin and a lower skin joined together at a seam, wherein the seam may be at least partially disposed over the inclined portion. The seam may be sealed to a vertex of the inclined portion between the inclined portion and the sealing surface. The foam layer may be disposed between the at least two pieces of skin and the panel substrate. The foam layer may taper from the base portion towards the vertex of the inclined portion and terminate along the inclined portion before the vertex of the inclined portion.

Abstract: The present invention concerns a method of producing a sandwich structure which is easy to produce and which has particular physical and/or chemical properties. To achieve that there is proposed a method of producing that sandwich structure which has the following steps: a) introducing a first cover layer (3) into an injection molding mold, b) introducing a second cover layer (3) into the injection molding mold, c) closing the injection molding mold, d) injecting a core material into the closed injection molding mold between the first and second cover layers (3) by means of injection molding, e) hardening of the core material so that a core layer (2) is formed between the two cover layers (3), and f) opening the injection molding mold and removing the sandwich structure (3) from the mold.

Abstract: The present invention relates to process for the manufacturing of mattresses characterized in that a liquid molding substance of the same material as the construction pieces (1, 3, 4, 6) is used in all the joints between the pieces. The process comprises steps wherein: the bottom piece (1) is laid out; the molding substance (2) is applied to the longitudinal edges (3) and cross edges (4) on one surface side of the bottom piece (1); the longitudinal pieces (3) and cross pieces (4) are lowered into a molding substance (2) and hardened; the molding substance (2) is applied on the same surface side of the bottom piece (1) between the longitudinal pieces (3) and cross pieces (4); a core (6) is lowered into the molding substance (2) and hardened; and the top piece (7) is provided with molding substance (2) and turned with the molding substance (2) facing the named upright longitudinal pieces (3) and cross pieces (4) and lowered onto the same and hardened.

Abstract: In one embodiment, a system and method for the production for a vehicle tray table employing foam in place sandwich structure, whereas the encapsulated foam is employed as a labor, cost and weight saving material to bond and affix the tray table assembly components.

Abstract: A process for attaching a wheel cover to a wheel in which a wheel cover and wheel are placed together and a foamable adhesive is injected into the gap defined between the wheel cover and wheel. After the foamable adhesive is injected into the gap defined between the wheel cover and wheel at an injection station, the cover/wheel assembly is transported to a station in which the cover/wheel assembly is heated to a temperature that is sufficient to effect the forming, expansion and curing of the foamable adhesive. The cover/wheel assemblies are supported and transported on carriers that are provided with clamping mechanisms.

Abstract: The present invention provides a method of manufacturing foam, including the steps of sealing a mold by providing a lower mold having an arbitrarily-shaped molding surface, and then sequentially placing a middle mold having at least one arbitrarily-shaped protrusion formed on one side thereof or both sides thereof and an upper mold having an arbitrarily-shaped molding surface on the lower mold; simultaneously forming an upper preform and a lower preform, which are prevented from foaming, by charging a foaming material in an inner molding space of each of the upper mold and the lower mold, which are divided by the middle mold; opening the mold and removing the middle mold from the mold; placing an interface material in grooves formed in the preform by the protrusion of the middle mold such that the upper preform and the lower preform are prevented from cross-linking with each other; and simultaneously cross-linking and foaming the upper preform and the lower preform by sealing the mold.

Abstract: An improved process for permanently attaching an overlay to a wheel disc, wherein the overlay is aligned and spaced apart from the wheel disc. A mold is created by a combination of the overlay, wheel disc and localized nests that engage at predetermined times during foam filling to close the mold. The mold is adequately sealed so that there is no foam leakage as the foam expands to fill the mold and, therefore, no final trimming of excess foam is required. The improved process is capable of accommodating a wheel having turbine openings therein.

Abstract: A back surface of an outer case is formed by mutually overlapping left and right back panels. The overlapping edges on the front side and backside of the panels may be bent toward the opposite side at a blunt angle. A joint between the back panels is established in which the overlapping edge of one back panel is pressed against the overlapping edge of the other back panel. Spacers are mounted between the outer and inner case such that the overlapping edges are put in close contact with each other. The bends are deformed in order to prevent leakage from the joint after the injection of foam liquid. Due to the pressure of the foam, both of the overlapping edges are placed in closer contact while deforming the bends to be substantially flat. Consequently, the sealing properties of the joint after the completion of the thermally insulated housing are secured.

Abstract: The invention relates to a process for the production of a composite part with a multi-part outer layer and with a foam layer bonded on the reverse side to the outer layer, in particular internal cladding of a vehicle, and also to a composite part. The inventive process comprises the following steps: a) arrangement of a first skin and of a second skin with angled-off end regions on the surface of a mould in such a way that the angled-off end regions of the first and second skin have firstly been oriented away from the surface of the mould and secondly are adjacent to one another; b) application of a reduced pressure in the region of the position of the angled-off end regions, in such a way that the angled-off end regions are pressed two-dimensionally against one another; c) reverse-side foaming of the first and second skin with a foam composition. The inventive process permits the simple production of visually attractive composite parts with multi-part outer layer.

Abstract: A foam is disclosed that can be cured by heat having, for example, 10 to 80 vol. % of at least one gas and a compound that can be cured by heat. The foam can include at least one polyurethane polymer and at least one curing agent that can be activated by increased temperature. Foams that can be cured are suitable as flues, sealing compounds, or for the production of coatings, and can be cured by heat for structural adhesive bonds and for lining in vehicle construction.

Abstract: A projectile has filler material placed between an outer surface of its fuselage, and fins that are hingedly coupled to the fuselage. The filler material fills space that otherwise would be occupied by pressurized gases. Such pressurized gases could cause undesired outward force against the projectile fins during launch of the projectile from a launch tube or gun, such as when pressure outside the fins is suddenly removed, as in when the projectile passes a muzzle brake in the launch tube. The filler material may be any of a variety of lightweight solid materials, such as suitable plastics or closed cell foams. The filler material prevents pressurized gases from entering at least some of the space between the fins and the outer fuselage surface. When the fins deploy after the projectile emerges from the launch tube the filler material pieces fall away harmlessly.

Abstract: An object is to enhance the sound absorbing functions of an interior member, and furthermore, to increase ease of assembly of the interior member, and the interior member for the cab is integrally formed so as to have a laminated structure where a sound absorbing material is contained between an outer layer material and a foundation body panel, or inside a foundation body panel. In addition, such an interior member is formed in accordance with a reaction injection molding method.

Abstract: A decorative post includes an elongated outer polymer shell having at least one longitudinal groove extending a majority of a length of the elongated shell sized and shaped to hold a decorative fence panel. The decorative fence post also includes an elongated reinforcing member disposed in the outer polymer shell, and substantially extending a length of the fence post. A foam filler is disposed inside the outer polymer shell between the shell and the reinforcement member. An aperture is disposed in the outer polymer shell near an end of the reinforcing member, and a void extends from the aperture into the foam filler adjacent to and exposing an end of the reinforcing member. The void defines a slip zone at the end of the reinforcing member into which the reinforcing member extends as the outer shell shrinks longitudinally during post mold cooling.

Abstract: A method for making a coat for ear bud includes a step of preparing a male mold having insertions and a female mold having concavities, spreading a layer of non-foam Polyurethane material to outside of the insertions and an inside of the concavities; a step of filling foam material in the concavities; a step of inserting the insertions into the concavities, and then foaming the foam material, and a step of separating the male and female molds to pick up coats with the non-foam Polyurethane layer coated thereon. The coat for ear buds includes a body having pre-set shape and a layer of non-foam Polyurethane material is attached to outside of the body and a path axially defined through the body.

Abstract: A buoyant plant habitat and a process for manufacturing it. In one embodiment, the invention is a buoyant plant habitat comprising: a nonwoven matrix comprising fibers; and a plurality of buoyant foam units into said nonwoven matrix to produce a buoyant mass; wherein said buoyant foam units envelope a portion of said fibers. In another embodiment, the invention is a process for making a buoyant plant habitat comprising: providing a nonwoven matrix comprising fibers; and injecting a plurality of buoyant foam units into said nonwoven matrix. In another embodiment, the invention is a buoyant plant habitat comprising: a top layer of nonwoven matrix material; a bottom layer of nonwoven matrix material; a plurality of edge pieces of nonwoven matrix material that are attached by means of polymer plugs to said top layer and said bottom layer; and a plurality of closed-cell polymer foam pieces that are disposed between said layers.

Abstract: An article configured to distribute foam insulation between a water tank and an outer shell of a water heater is provided. The article comprises a body portion configured to extend between the water tank and the outer shell of the water heater. The body portion at least partially defines a flow passage for foam insulation. Opposed flap portions extend from an end of the body portion. Means are provided on the flap portions for attaching each of the flap portions to the water tank.

Abstract: A method and apparatus for making a foam-in-place cushion in which a foam-forming composition is dispensed between two plastic film portions in a predetermined fashion to selectively control the distribution of the foam in the cushion. A foam dispenser can be moved in a transverse direction as foam is dispensed. A dispersion device can be employed to apply pressure on predetermined areas of the film portions towards each other so as to cause the composition to be redistributed in position in a predetermined manner while the composition is in a less than fully expanded state. The plastic film can then be sealed closed to form an expanding foam cushion that can be placed into a shipping carton where the cushion expands to fill void space, or into a mold where the cushion expands and is molded into a desired shape.

Abstract: An automated method and system for making painted vehicle body panel skins and vehicle body panels are provided. The method includes transferring a mold having a mold surface from an entrance station to a paint station within a dispensing area. The method further includes applying paint on the mold surface to form a layer of paint on the mold surface at the paint station. The method still further includes spraying curable polyurethane elastomer on the painted surface at a spray station within the dispensing area. The paint and spray stations may be coincident. The method still further includes, after the step of spraying and while the polyurethane elastomer is uncured, transferring the mold with the paint and the uncured polyurethane elastomer from the spray station to at least one accumulator station in a curing area to allow the polyurethane elastomer to completely cure in the mold and form the skin.

Abstract: The invention provides for a multi-layer automotive interior component and method of making the same. The multi-layer automotive interior component comprises a skin layer having an exterior portion and an underside portion, where the exterior portion is visible. The multi-layer automotive interior component further comprises a foam dam formed on the underside portion of the skin layer, a cantilevered skin portion extending from the foam dam, a substrate disposed opposite the underside portion of the skin layer, and a foam layer between the substrate and the underside portion of the skin layer. The foam layer is limited by the foam dam, and the foam layer is substantially uniform.

Abstract: A method and apparatus for making a foam-in-place cushion in which a foam-forming composition is dispensed between two plastic film portions in a predetermined fashion to selectively control the distribution of the foam in the cushion. A foam dispenser can be moved in a transverse direction as foam is dispensed. A dispersion device can be employed to apply pressure on predetermined areas of the film portions towards each other so as to cause the composition to be redistributed in position in a predetermined manner while the composition is in a less than fully expanded state. The plastic film can then be sealed closed to form an expanding foam cushion that can be placed into a shipping carton where the cushion expands to fill void space, or into a mold where the cushion expands and is molded into a desired shape.

Abstract: A structural member is reinforced with a thermoset polymer foam having (a) a density of 80-650 kg/m3, (b) a storage modulus, measured on a 12 mm wide×3.5 mm thick×17.5 single cantilever sample according to ASTM D 4065-01, under conditions of 1 Hz and a heating rate of 2° C./min, such that the ratio of the storage modulus at 0° C., expressed in MPa, divided by the density of the thermoset polymer foam, expressed in kg/m3, is at least 0.4, and (c) the ratio of the storage modulus of the thermoset polymer foam at 100° C. divided by the storage modulus of the thermoset polymer foam at 0° C. is at least 0.5. The foam is preferably a polyurethane-isocyanurate foam. The foam exhibits excellent resistance to cracking due to mechanical and thermal stresses.

Abstract: An instrument panel with a one piece body constructed of a thermoformed material and exhibiting first and second visually differentiable surface patterns. An associated process includes the creation of an instrument panel, such as through the use of a clamshell slush mold, and including the formation of a groove between the surface patterns which exhibits a visually appealing and rounded cross sectional profile.

Abstract: A method for armoring a vehicle by placing ballistic material inside a part of the vehicle and adding a foam material on the ballistic material that adheres to, and stabilizes, the ballistic material to form a lightweight armor, where the ballistic material and the foam material can absorb energy associated with projectile impact.

Abstract: A water heater and method of assembling the water heater are disclosed. The method includes the step of positioning an insulation member around a water tank. An expandable tube is positioned at an elevation between a top surface and a bottom surface of the insulation member. An outer shell is positioned over the water tank, the insulation member, and the expandable tube to at least partially encapsulate the water tank. The expandable tube is expanded to compress at least a portion of the insulation member against the water tank or the outer shell. Foam insulation is delivered into a space defined adjacent the top surface of the insulation member and between the water tank and the outer shell. The foam insulation is substantially limited from traveling past the expandable tube when the expandable tube is maintained in an expanded state.

Abstract: A method of continuously producing fiber-reinforced foamed resin structural composite materials is described. One embodiment of the method includes providing a foamable resin between fiber-reinforced layers within a cooled die. Another embodiment of the method includes providing elements through a fiber-reinforced foamed resin composite material for communicating information and/or fluids. Thus, for example, optical fibers, electrical conductors, or water or air ducts may be included through the composite material. The material is inexpensive to produce and can be recycled.

Abstract: The present invention provides for an improved armrest with a soft feel for use in a trim assembly, and to a continuous two-shot molding operation that may be continuously performed utilizing a single mold assembly. In an exemplary embodiment, a trim assembly includes an integrated armrest formed by injecting a first material into a first shot mold cavity in a first shot of a molding operation. An armrest cover is molded to at least a portion of the armrest by injecting into a mold chamber a second foamed material in a second shot of the molding operation to provide the armrest with a soft feel. The second foamed material includes a foamed material that produces a soft, outer skin and a light, cellular inner core such that when a force is applied to the cover, the skin will deform and compress the inner core, providing a soft-touch feel to the armrest.

Abstract: The present invention provides a method of making a foaming member with heterogeneous foaming layers. The first step is adding a foaming agent and an accelerator to a first material, which is a flexible material, and a second material, which is a non-flexible material, respectively, and then pressing and stirring the first material and the second material respectively for well mix. The second steps is pressing the first material and the second material respectively to form a first material piece and a second material piece. The third step is stacking the first material piece and the second material piece to form a stack. The fourth steps is vulcanizing the stack in a high pressure and high temperature environment to bond the first material piece and the second material piece together firmly; and the last step is releasing pressure on the stack to get a foaming member.

Abstract: A stringed musical instrument body is formed using injection molded high density polystyrene foam with a foaming agent. It is injection molded by itself or around a wooden core to make the body or to form two panels adhered together to sandwich a wooden core therebetween. The core provides good wood tone and the polystyrene with a foaming agent produces good sustain and a resonance of about twenty-eight seconds. A metal reinforced injection molded neck resists warping.

Abstract: The present invention relates to a process for the production of polyurethane molded articles in which the polyurethane-forming mixture applied to reinforcing fiber layer(s) or a reinforcing fiber mat includes a gas and a foam stabilizer. These molded articles are useful in automotive and construction applications and in furniture.

Abstract: A method for production of a component in a tool having a cavity-forming first and a second tool half comprises the following steps: a) insertion at least of two skins with angled-over end regions into the second tool half such that the angled-over end regions of the skins are situated adjacently with the same orientation and angling; b) rear-foaming or rear-spraying of the skins with a foam material or injection moulding material, c) after insertion of the skins, the end regions of the skins being pressed together in a foam-tight or spray-tight manner at least in regions by pressing at least on one side of the end regions which are situated one above the other against a wall which determines the form and position of the pressed-together end regions.

Abstract: A process of reinforcing a closed sectional portion of a vehicle body with a two-pack urethane foam composition. The process including the operations of injecting a two-pack urethane foam composition into the closed sectional portion of a vehicular body member; foaming and curing the two-pack urethane foam composition within said closed sectional portion; and then viewing the cured urethane foam-filling confirming opening to confirm whether the closed sectional portion has been sufficiently filled by the two-pack urethane foam composition. The closed sectional portion has a cured urethane foam-filling confirming opening, which is a hole extending through a wall of the closed sectional portion, The opening dimension of the cured urethane foam-filling confirming opening is 10 mm or less in order to assure rigidity of the vehicular body member.

Abstract: An injection moulding process for making a completely recyclable, multilayered article which contains: i) a rigid layer formed of a thermoplastic polymer and ii) a foamed skin layer formed of a thermoplastic polymer compatible with the material of the rigid layer, by injection moulding of the rigid layer into a mould composed of two sides, lifting one side of the mould, or change one side of the mould to obtain a small gap of between 3 to 4 mm between the rigid layer and the side of the mould lifted or changed and injecting the foamed skin layer into the gap formed in step b).

Abstract: The invention provides for a sandwich-type layered structure including at least one first core layer made of cellular material, a first reinforcing layer connected to a first surface of the first core layer, and a second reinforcing layer on the side connected to the second surface of the core layer, the layered structure including, between the first core layer and the first reinforcing layer, at least one compressed foam layer connected to these two layers.

Abstract: In a molded product, at least an opening end, forming a window frame of a window formed as a part of a molded subassembly, is fastened integrally to a skin of the molded subassembly. Alternatively, a decorative component part is disposed on an outer periphery of the window so that a parting line between the decorative component part and the skin is visible as being joined closely in a decorative surface of the completed molded product. Processes for manufacturing the same are disclosed as well.

Abstract: There is disclosed a baffle for inhibiting the passage of sound, debris or the like through a cavity of an automotive vehicle.

Abstract: In one advantageous embodiment of the claimed invention, an integral cushioned trim panel (14a-14c) for a vehicle passenger cabin (10) is provided. The integral cushioned trim panel (14a-14c) includes a substrate (22) for attachment to a predetermined portion (12a-12c) of the vehicle. The substrate (22) has a cover member (24) coupled thereto for substantially covering the substrate (22). In addition, the substrate (22) and the cover member (24) have a cushioning member (16) disposed therebetween. The cushioning member (16) is injection molded between the substrate (22) and the cover member (24) for forming an integral construction, minimizing the manufacturing cycle time, and decreasing the costs associated therewith.

Abstract: An automobile interior component including a support layer formed of a foam material and being generally covered by a cover layer, and a film layer generally disposed between the support and cover layers to prevent a selected portion of the foam material from directly contacting the cover layer during manufacture of the interior component, and/or allow placement of the cover layer on a selected portion of the support layer upon application of a vacuum within the film layer. The support, film and/or cover layers may be formed of biodegradable and/or renewable materials. The invention also provides a method of manufacturing the aforementioned automobile interior component.

Abstract: The invention relates to a method for production of a composite chassis piece (16, 28) for a motor vehicle, in particular, for production of a roof module in a tool (10), comprising a first (14) and a second tool part (12) which may be adjusted relative to each other. An outer skin (16) is laid in the first tool part, at least one part (24) of the circumferential region (22) of the side of the outer skin facing the first tool part is tightly inserted in a sealing arrangement (18) provided on the first tool part, plastic material (28) is applied to the side of the outer skin facing away from the first tool part, whereby a shaping of the plastic material is performed by the second tool part and the composite chassis piece is released from the seal arrangement and removed from the tool. The invention further relates to a corresponding tool.

Abstract: Provided is a method for reinforcing a foam material in which a working region is first prescribed. A gap that at least partially encloses the prescribed working region in a two-dimensional manner is created in the foam material. A strut is introduced into the foam material, extending from an entry surface of the foam material from outside the working region to at least the fibrous sheet-like material. From a further aspect, a sandwich component with a core which comprises a foam material is provided. A fibrous sheet-like material arranged in the foam material at least partially encloses a working region of the sandwich component in a sheet-like manner. At least one strut is incorporated in the foam material and extends from an entry surface of the foam material from outside the working region to at least the fibrous sheet-like material.

Abstract: The present invention relates to a wheelchair having a back plate and a seat plate and a manufacturing method thereof, and more particularly, to a customized wheelchair having a back plate and a seat plate formed to fit a body shape and a manufacturing method thereof. In a method of manufacturing a customized wheelchair having a back plate and a seat plate which are designed to fit a body shape, the method includes steps of: forming a preliminary molding material which is directly formed to fit a back and a hip of a user; fixing the preliminary molding material to a molding frame; filling a foaming resin in the molding frame fixed with the preliminary molding material; hardening the foaming resin filled in the molding frame; and releasing a last molding material which is foamed and hardened to have a shape of the back and the hip of the user by the preliminary molding material.

Abstract: A method and an apparatus for manufacturing an envelope style bus seat back cushion includes the steps of opening a hinged mold and then spraying the cavity of the mold with an elastomeric skin. The hinged mold includes first and second sides having a cavity in each of the sides. The cavities of the mold combine to form a mold cavity. The sides of the mold include interengaging faces, ridges and recesses. The faces, ridges and recesses interengage to seal the mold. Once the first and second sides of the hinged mold are closed and intermate, the steps of injecting a urethane foam into the mold cavity of the closed hinged mold are inserting, quickly, a center core insert into the mold cavity of the closed hinged mold; curing the urethane foam; removing the center core insert from the mold cavity; opening the first and second sides of the mold cavity; and, removing and demolding the envelope style bus seat back cushion from the mold.