Abstract: An apparatus for manufacture of laminated panels having a foamed plastics core material includes an inclined press having a fixed platen surface and a movable platen surface hinged adjacent its lower edge. Panel thickness is adjustable by a mechanism which moves the hinge pivot relative to fixed platen surface. The platen surfaces are clamped at their upper edges by spaced clamps operable by lever and crank assemblies. A retractable seal spacer has liquid plastics injection nozzles and gas venting tubes in fluid communication with a hollow cavity in the press.

Abstract: A mold for skin covered foamed plastic molding capable of preventing penetration of the liquid foam resin to be poured on a skin cover without manual operation of target plate or use of double side adhesive tapes, and also capable of improving the efficiency of manufacturing process. The mold includes an element removably attached on the upper mold below the injection hole, for receiving the liquid foam resin before the liquid foam resin falls on the skin cover.

Abstract: A device for aiding in the assembly of a mold apparatus of the type including a mold cavity having a first side which is contoured to impart a shape to a component, a second side, and an aperture extending between the first and second sides, and of the type including an ejector pin positioned adjacent the second side, the ejector pin having an end positioned to move into the aperture to become a portion of a surface including the first side when the mold assembly is assembled, and positioned to effect movement of the component away from the mold cavity after the component is imparted with the shape, the device including an assembly pin having an end positioned to pass through the aperture, and a sleeve having a first portion positioned to slide onto the end of one of the ejector pins and to support itself on the end of the ejector pin and having a second portion protruding from the end of the ejector pin to receive therein the end of the assembly pin in axial alignment with the ejector pin in the sleeve.

Abstract: A mold for skin covered foamed plastic molding which utilizes a middle mold to be placed between an upper mold and a lower mold capable of preventing penetration of the liquid foam resin to be poured onto the skin cover, and also capable of improving the efficiency of the manufacturing process. The mold includes a middle mold configured for reducing pressure exerted by the liquid foam resin falling on the skin cover.

Abstract: A mold assembly for producing a skin-covered foamed plastic article includes a lower mold having a cavity formed therein, the lower mold including a bottom wall, an outer wall which extends around a periphery of the bottom wall to define the cavity, and an inner wall which extends inside of the outer wall with a given space defined therebetween, the inner wall being covered by an outside part of an outer skin member when the outer skin member is properly put in the cavity. The assembly further includes an upper mold which is to be put on the lower mold to close the cavity, the upper mold having a depressed given portion which is mated with the entire of a top of the inner wall of the lower mold when the upper mold is properly put on the lower mold; and a retaining member constructed of a resilient material. The retaining member has such a channel structure as to resiliently and detachably receive therein the inner wall with the outside part of the outer skin member sandwiched therebetween.

Abstract: The present invention relates to an improved apparatus for the production of a flowable mixture which reacts to form foam from flowable components stored in storage containers, wherein prior to metered introduction into a mixing zone, at least one of the components is charged with a defined quantity of gas, by (i) introducing said one component and gas separately into a gasification chamber equipped with a hollow stirrer, (ii) sucking gas into said component through the hollow shaft of the hollow stirrer, and (iii) stirring the gas into the component, until the desired value is attained, the improvement wherein (a) the component is circulated from the storage container through the gasification chamber and back into the storage container, (b) the gas sucked through the hollow shaft of the hollow stirrer being maintained at pressure at least equal to the pressure prevailing in the storage container, and (c) the component fraction remaining in the storage container is homogenized during those periods in which ga

Abstract: An apparatus for forming a seat comprising an upper die member, an intermediate die member, and a lower die member on which is placed a trim cover assembly. The intermediate die member has, formed at its inner lower area, a projection which is to close the recess of a valley or slope created in the retained area of the trim cover assembly where the upper die member is pressed against and collapses the peripheral end areas of the trim cover assembly placed on the lower die member. Further, a second projection is formed above such first one within the intermediate die member in order to from a recess in a resultant foam cushion member integral with the trim cover assembly so that a sewn jointed point and terminal end of the trim cover assembly are received in such recess, which permits a side wall portion of the trim cover assembly to be stretched neatly long the corresponding portion of the cushion member.

Abstract: A method of producing polyurethane foam slab by allowing a urethane foam stock solution in a tank to expand in a reduced pressure. The flatness of the top of the polyurethane foam is secured by providing a lifting jig or a plate within the tank, or by rotating the tank. An apparatus for carrying out the method is also provided.

Abstract: An improved composite metal-elastomer styled automotive-type wheel with a three-dimensionally contoured ornamental outboard face formed by a plastic overlay body permanently adhered or affixed to the outboard face, and an improved molding apparatus and method for constructing such a wheel. A plastic overlay body has an annular row of outboard pockets disposed in radially offset, axially overlapping relation with a annular row of inboard pockets which in turn register with vent openings in the disc to thereby provide air passages through the wheel for brake ventilation. The outboard pockets preferably are disposed radially remote from the center of the wheel close to the wheel rim, and a relatively thin cross-section of plastic material is molded so as to overlie the outboard rim flange to provide a full-face appearance to the wheel.

Abstract: Continuous molding apparatus includes a raw material supplying portion, a molding portion, a supporting portion, a mixing portion and a control portion. Each reservoir of the raw material supplying portion is connected independently with the mixing portion. The molding portion includes a plurality of spaced mold assemblies each with at least two separable mold sections. The supporting portion includes a plurality of the spaced mold assemblies each supported for independent rotation about more than one axis. The mixing portion includes an elongated mixing chamber disposed adjacent each mold assembly each with a plurality of deflector sections. A continuous method of molding a foamed product includes providing a plurality of raw material reservoirs and continuously moving raw material from each reservoir independently to a plurality of spaced mixing chambers each of which is located adjacent to an individual mold assembly including separable mold sections.

Abstract: An apparatus for producing foam-filled stud walls. The apparatus has a main frame, including a substantially vertical backplate against which the sheathing bears, a carrier unit moveable vertically on the main frame, and a dam carried on the carrier unit parallel to the backplate, moveable towards and away from the backplate. Hydraulic actuators are located between the carrier unit and main frame, and between the dam and the carrier unit, to hold the dam against the stud wall when the stud wall is positioned with its sheathing against the backplate, and to move the carrier unit and thus the dam vertically while it is so held against the stud wall.

Abstract: Continuous molding apparatus includes a raw material supplying portion, a mixing portion, a molding portion, a mixture delivery portion, a supporting portion and a control portion. Each reservoir of the raw material supplying portion is independently connected to an inlet of the mixing portion. The molding portion includes a plurality of spaced rotatable mold assemblies, each with at least two retractable mold sections. The mixture delivery portion is selectively alignable with each mold assembly sequentially in a preselected repeating cycle through an indexing mechanism.

Abstract: An apparatus for incorporating gas under pressure into a fused sugar mass, said vessel having an interior oriented to have top region and a bottom region an agitator in said interior and a bubble forming means for introducing compressed gas into said fused sugar mass as a curtain of gas bubbles, said bubble forming means being in the bottom of the pressure vessel below said agitator.

Abstract: Vents for molds can be improved if, in place of a single relatively large vent opening, there is used a vent which has a plurality of relatively smaller vent openings in which the cumulative cross-sectional area of the relatively smaller vent openings are approximately the same as that of the relatively larger vent opening it replaces. It was also found that the vents have a more efficient self-cleaning capability if the ratio of the depth of each vent opening to the cross-sectional diameter of the vent opening is about 1 or less.

Abstract: An injection molding method and nozzle for use therein wherein first and second variable pressures are applied to a piston of a valve mechanism of the nozzle so that a differential fluid pressure on the piston causes a tip portion of the valve mechanism to alternately open and close. In this way, the tip portion communicates the flow of resin from a nozzle body of the nozzle to an injection aperture of a mold. Differential pressure on the piston prevents a fluid which distributes the molten resin over the interior surfaces of the mold from entering the flow path of the molten resin in the nozzle body. The fluid preferably is a gas, such as nitrogen. Preferably, the piston is mounted for reciprocating movement within the nozzle body and the first pressure is provided by the resin during resin injection and the second pressure is partially applied by the nitrogen gas.

Abstract: This disclosure illustrates and describes a test mold for the quantitative measure of the effects of formulation and/or process variable changes on some kinds of surface problems of a molded part caused by different degrees of imperfection or voiding underneath the part surface. The molded part can be single component or composite, solid or foamed. One example of the surface problem is the so-called "measles or cellulite" problem observed on the vinyl surface of a vinyl/foam composite due to the voids or rattiness within the foam. To accomplish this result, the mold has various sized, spaced apart, aligned openings formed in each of the front and rear walls of the mold, but with the centers thereof at different elevations in the respective front and rear walls. Removable rods inserted through the aligned mold wall openings produce longitudinal openings through the part which is molded around the rods, permitting the effect thereof on the surface of the molded part to be evaluated.

Abstract: In a method and apparatus for manufacturing a flechette load, a series of operative steps are carried out to produce a matrix-supported load of flechettes held in a desired array. First, a load of flechettes are mounted by a die end cap in a desired array in which at least the trailing end portions thereof are exposed and disposed in closely spaced side-by-side relation. Next, the die end cap is assembled to a die body such that at least the exposed trailing end portions of the flechettes are placed in the mold cavity of the assembled die. A mixture of expandable thermoplastic beads and, preferably, a bond weakening agent is also placed in the mold cavity with the mixture surrounding the exposed trailing end portions of the fletchettes therein. Finally, the mixture is heated so as to produce in the mold cavity directly on and about the exposed trailing end portions of the flechettes a matrix in the form of a solid foam body of a thermoplastic foam material.

Abstract: Disclosed herein is a mold assembly for molding a plastic article having a recess formed therein. The mold assembly includes a lower mold having a cavity formed therein; an upper mold adapted to be put on the lower mold to close the cavity; a core adapted to be put in the cavity; positioning means including a first member connected to a given portion of the cavity of the lower mold and a second member connected to the core, the first and second members being coupled when mated; and guide means for guiding the core in a manner to facilitate the mating of the second member with the first member.

Abstract: A sintering device includes separable mould walls which together define a mould cavity and a mould core which is positioned within the cavity to define an undercut mould surface. The core includes a hollow frusto-pyramidal central support formed with guideways and a plurality of core segments mounted for slidable movement within the guideways whereby the core is radially expandable and contractable. The segments include a plurality of arc-surface segments alternating with trapezoidal segments. The mould walls and the core include passages for introducing steam and air into the cavity. The passages of the core place the hollow interior of the central support in communication with the mould cavity.

Abstract: A method of making a solid core locatable between a wheel rim and a tire fitted to the rim, includes introducing a foamable composition into a mould cavity having a substantially inflexible mould surface. The cavity is suitably shaped so that a core locatable between a wheel rim and a tire fitted to the rim can be moulded therein. The composition is allowed to foam, thereby to fill the mould cavity. Air and excess composition is allowed to vent from the cavity via an elongate vent slit extending along a major portion of the cavity. The foamed core thus moulded in the cavity is removed from the cavity on the composition having set at least partially.

Abstract: An insulated molded plastic structural unit includes spaced face portions, an intermediate portion and interlocking portions. The face portions each include an integrally formed stressed hard outer skin section and the intermediate portion includes an insulating core section. The interlocking portions include mateable sections along at least two edges of each unit, each mateable section including at least five alternating raised and recessed areas forming an asymmetrical pattern along the length thereof. The pattern is the same or a reverse thereof along each mateable section of the same unit and of adjacent units to which it will be joined. Particular mateable sections either extend beyond the face portions or are recessed below the face portions a substantially equal distance. Continuous molding apparatus includes a raw material supplying portion, a mixing portion, a molding portion and a control portion.

Abstract: A molding apparatus for producing a molding from multi-component plastic, especially polyurethane. The upper and lower parts of the mold are fastened, respectively, on mold holders of which at least one is movable relative to the other and can be propped in a closed position in which the upper mold part and lower mold part are still at a slight distance apart. Starting out from this closed position the upper and lower mold parts can be brought together and pressed against each other by a jacking device which is provided on at least one of the mold holders.

Abstract: A process which comprises (i) the generation of release surfaces by application to predetermined areas of a solid surface of a solution, suspension or dispersion of a release agent and a supercritical fluid that vaporizes from the release agent, (ii) the deposition of a mass onto the release surface containing the release agent, and (iii) the separation of the mass or a product derived from the mass from such surface covered by the release agent. Novel apparatus for carrying out the process are described.

Abstract: A manufacturing framework is used to manufacture a cosmetic puff for a liquid foundation. The cosmetic puff is manufactured by forming a latex film coating on one side of a crimp pattern plate by applying latex film compound thereon. The latex film coated plates are set in the manufacturing framework, and a foamed latex foam compound is injected into the manufacturing framework while coagulant and activator are added therein to thereby produce a gelled latex foam covered with latex films on both sides. The latex foam and the latex films are simultaneously vulcanized to thereby bond the latex films onto the latex foam.

Abstract: In a process for producing a hollow body with a wall which partially comprises foamed thermoplastic material by an extrusion blow molding procedure, a preform which comprises at least first and second layers of which at least one comprises foamable plastics material is first extruded, the layer of foamable material is foamed, and then the preform is expanded in a blow molding mold by the application of an internal pressure. The hollow body may have a welded seam at a region of the hollow body at which an operation of squeezing off excess material has been carried out, the seam being in the form of an outwardly projecting flange web portion and the thickness thereof being such that the layer of foamable material is compressed at least to such an extent that it is not thicker than in the unfoamed condition.

Abstract: A pour hole closure for use with an injection foam molding system including a mold assembly having a pour bushing leading to a reaction chamber. A cylinder having a slightly oversized plastic plug extending downwardly therefrom is normally positioned above the pour bushing in the mold assembly. The cylinder is pivotally movable away from its normal position against the force of resilient means. A pour head and nozzle assembly is adapted to move into engagement with the cylinder to move the latter while attaining a position wherein the nozzle is positioned above the pour bushing. The nozzle is lowered to engage the top edge of the pour bushing for injection of foam material into the reaction chamber.

Abstract: The foam slush molding apparatus of this invention comprises a mold and a hot air jacket, and an optional heat retaining hood. The hot air jacket and the optional heat retaining hood are provided along and a certain distance apart from the molding surface on which a resin is heated and fused. The molding surface and the jacket form a first hot air chamber for heating, and the jacket and the optional heat retaining hood form an optional second hot air chamber for heat retention. The apparatus permits uniform heating and foaming at an efficient molding cycle.

Abstract: An apparatus is provided for molding an article of footwear having an outer sole, a lateral sole and an inner sole, the outer and lateral soles being of an elastomer, and the inner sole being of a thermoplastic or a mixture of isocyanate and a polyol reacting into polyurethane. The outer sole and the inner sole are each injection molded from an elastomer and bonded at their common contact zone by full vulcanization. The outer sole and the lateral sole may each be of different elastomers. The outer sole and the inner sole are bonded together in the area of their contact zone via chemical bonds between the isocyanate and reactive end-groups of substances added to the elastomer.

Abstract: A flow molding process and associated molding apparatus for making plastic parts employing a radio-frequency heating field. In a two-piece mold, a diaphragm is supported thereacross and over a foam plastic compound that is disposed in the bottom half of the mold. A fluid is adapted to be introduced into the mold against the diaphragm. The introduction of this fluid is controlled to initially inject the fluid into the mold to cause deflection of the diaphragm to thus expel substantially all air from the mold and to thereafter extract the fluid from the mold during the heating cycle as the material expands, the extraction causing a vacuum that assists in the plastic foam compound expansion.

Abstract: A pour mold includes two parts one of which forms a mold cavity and the other of which forms the lid for the mold cavity; the lid includes a retractable pilot pin and vacuum cups for positioning a mold insert within the mold cavity automatically upon lid closure. The pilot pin loosely pilots the insert in the mold as it closes and as the vacuum cups pull the insert toward the lid during such closure. The vacuum cups hold the insert against the lid continuously during foam injection, foam reaction and cure and as the lid is separated from the mold cavity part so as to automatically remove the finished part from the mold when the lid is separated therefrom.

Abstract: The present invention relates to a new process for gasifying confection by means of incorporation of a gas enclosed in the head space of a container and recirculation of the gas through a fused sugar mass, equalization of the size of the bubbles and their homogenization. The incorporation of the gases is affected at the lower part of the pressure vessel, just below an agitator. The gas enters the container as a fine vaporous curtain directed toward the lower surface of an agitator, gas is fractured by the agitator and dispersed into the sugar mass. Large size bubbles and the presence of a undesirable quantity of candy dust in the finished product having a diameter inferior to 1 millimeter is avoided.Thus, the quantity of waste product produced by the present method ranges only between about 15 to 20% instead of the prior art typical 30 to 35%.Moreover, this technique allows operation at a most convenient pressure. The candy thus obtained mainly shows fragments or pieces with a mesh size between 1-4.

Abstract: An improved rotational molding method for making a laminated plastic structure of the type in which successive charges of particulate plastics are released in a mold cavity rotating in an oven to coalesce successively along the mold cavity wall after which the mold is removed from the oven for cooling. By removing the rotating mold from the oven prior to completion of the formation of the inside layer, cooling of the outside of the mold will be concurrent with coalescence of the inside layer. This shortens the time of the molding cycle and reduces warping problems.

Abstract: A retainer mold for forming foamed automotive articles, particularly instrument panels, after a thin vinyl skin shell has been mounted in the mold. The mold includes a plurality of die block assemblies mounted in recesses formed in a surface of the mold cavity. Each die block assembly includes a plate member secured in the recess, and a die block slidably mounted within controlled limits on the plate member, and adapted to be covered by the shell and to be moved as required to prevent wrinkling or bridging of the portion of the shell extending between adjacent die blocks.

Abstract: The invention provides a process and apparatus for producing an injection moulding of plastics material.

Abstract: A method for manufacturing a plastic foam, wherein a plastic compound with chemical foaming agent is charged in molding cavity which is defined by a pair of upper and lower die cavities and wherein the plastic compound is subject to a dielectric heating, so that the chemical foaming agent decomposes. One of the cavity surfaces is movable to vary the volume of the molding cavity in accordance with the expansion of the plastic compound, so that the movable cavity surface is kept in contact with the plastic compound which expands during heating.

Abstract: A device for executing a method of molding expandable thermoplastic polymer beads in a mold to form articles of foamed material comprising: pulsing steam through at least one of the cavities to contact and expand the beads in the cavity for a finite period of time and drawing the steam amongst the beads by providing reduced pressure to at least one of the cavities for the same period of time; and pulsing mist through the expanded beads by providing mist to at least one of the cavities and drawing the mist through the expanded beads by providing reduced pressure to at least one of the cavities for the finite period of time of predetermined duration to form articles of foamed material.

Abstract: The present invention is directed to an apparatus for the production of foam cushions having a textile cover in which the cover is inserted into a mold cavity and adapted to the contour of the mold cavity by the application of a vacuum wherein movable gates assist in improving the adaptation of the cover to the contour of the mold cavity.

Abstract: A composite plastic product is formed by a process which includes formation of a preform of high strength plastic having openings formed therethrough which are covered by a film barrier that is formed during molding of the preform; and wherein the preform is configured to be placed as a unit in a foam station at which material is foamed onto the insert without escape to its backside.

Abstract: A process and an apparatus obtain plastic molded objects according to a technique which consists of introducing the plastic into a silicone elastomer mold, then inserting this mold into a high frequency device comprising a turntable "carrousel", a series of high frequency heating presses and a cooling device.The process is characterized by the introduction of plastic into one end of the mold in the form of liquid plastisol under low pressure, i.e., less than 1 Magapascal. The apparatus employs a carrousel, a mold having two male inserts and resting on the carrousel, vacuum-creating means and plastisol injection means.

Abstract: The apparatus includes a first female mold member defining a mold cavity for receiving a plastisol skin or layer. A second mold member or slide is positioned with a surface thereon contiguous with the surface of the mold cavity. The surface of the second mold member receives and holds thereon a portion of the plastisol skin extending from the mold cavity. A third mold member, such as a mold core, positions a rigid insert in the mold cavity with an insert surface or edge adjacent the portion of the plastisol skin on the second mold member. The second mold member includes passages for directing fluid pressure against the portion of skin thereon to fold it over the adjacent insert edge. A fourth mold member, such as a mold lid, is movable toward the second and third mold members for pressing the folded-over skin against the insert during foam formation between the skin and insert.

Abstract: The apparatus includes a first female mold member defining a shaped mold cavity for receiving a plastisol layer or skin. A second mold member is pivotally disposed on the female mold member between an open and closed position. In the open position, the second mold member receives and holds thereon a portion of the plastisol skin extending from the mold cavity. An insert is positioned in the mold cavity by a third mold member such as a mold lid on which the insert is releasably retained. After the insert is positioned in the mold cavity, the second mold member is pivoted toward the mold lid to fold the skin portion thereon over and against an edge of the insert. The skin is folded adjacent the pivot axis of the second mold member. Foam can then be introduced and cured between the skin and insert.

Abstract: A forming die for forming a vehicle seat foam cushion member integrally on its surface with a pile-type fastener adapted to be engageable with a mating pile-type fastener provided on the back surface of a top cover member associated with the seat. In the forming die, there is formed a recessed groove, in which resiliently and frictionally secured is a base plate with an engageable member fixed thereto. The engageable member is capable of removable engagement with the pile-type fastener which is to be integrally provided on the cushion member.

Abstract: An injection molding apparatus for making a molding of fiber-reinforced synthetic resin which comprises a mold assembly having a molding cavity defined therein, into which a liquid molding material of synthetic resin containing reinforcing fibers is injected. The mold assembly has a gate defined therein, which gate has a thickness within the range of 0.2 to 0.4 times the thickness of a portion of the molding adjacent the gate, and also has a gate land of a length within the range of 10 to 20 times the thickness of the gate.

Abstract: Apparatus for molding a composite metal-elastomer styled wheel in which a middle mold part consists of a metal wheel disc and rim subassembly. A base mold part seats against the outboard face of the metal wheel in the closed condition of the mold and has a mold cavity surface to provide an ornamental configuration for the outboard face of the plastic body of the composite wheel. A clamp seats against the inboard face of the middle mold part to urge the middle part into sealing engagement with the base mold part. The mold parts are axially separable from one another to open the molding apparatus to clear the middle mold part from said clamp and base mold parts. The clamp includes a funnel adapted for registry with a liquid reaction mixture injection nozzle coupled with injecting mixing apparatus. The funnel has a nozzle passage registering with a pour opening in the disc in the closed condition of the mold.

Abstract: An improved mold assembly which has a cavity mold part and a cover which form a space into which foam precursors are poured and the cover carries a mold insert which is bonded to the foam formed in the mold space; the cover carries a pour spout and a seal for preventing foam leakage from the space wherein the improvement comprises: means including a pour hole and a rotatable tube extending through said pour hole for defining a pour spout having an inboard end located within the space when the mold assembly is closed; seal means in surrounding sealing relationship with said inboard end of said rotatable tube; and means operative when the cover is closed and when the tube is located in the pour space for holding the insert within a desired variation of a designed location in said space and for holding the insert against said seal means to prevent foam leakage through the pour hole.

Abstract: A nozzle for the injection molding of thermoplastic materials includes a nozzle body having a first bore for establishing a flow path for a molten thermoplastic. A first end of the nozzle body is adapted for fluid connection with a sprue of an associated mold body, and a second end thereof is adapted for fluid connection with an end of an associated injection molding machine. The nozzle body also includes a second bore. A first valve assembly, which is adapted for reciprocating movement in the nozzle body second bore, is provided to control the flow of plastic through the nozzle body. The first valve member includes a body having a tip portion and a fluid passage formed in the body and open at one end through the tip portion. A connection member is provided for communicating the valve body fluid passage with an associated source of pressurized fluid.

Abstract: A process for producing molded articles, especially molded polyurethane foam articles, wherein the mold is treated with an aqueous release agent or a concentrate of one or more release-active substances in organic solvent. The release agent is preheated, e.g. by an atomizer supplied with hot pressurized air, prior to being applied to the mold. The process enables the efficient use of water-base release agents and thus reduces the emission of harmful organic solvents into the atmosphere.

Abstract: A decorative speaker cover and a method for fabricating a speaker cover for use in a ceiling or wall comprising panels, the speaker cover having an appearance which blends with other panels so that it conceals the presence of a speaker system while providing satisfactory transmission of sound from the speaker system. The decorative speaker cover is fabricated by first forming a mold liner suitable for generating a facsimile of a ceiling or wall panel. Next, the mold liner is placed in a molding container and a closed cell expandable foam system is uniformly spread over the mold liner so that the foam rises vertically. The thickness of the resulting cast is reduced to a dimension below which acoustic transmission loss is not discernable by human ears.

Abstract: A composite molded article and a method of fabricating such an article is disclosed, which is especially well-suited for forming one-piece interior vehicle panels, by way of a single molding operation, wherein the one-piece interior panel can be easily installed as a unit within the vehicle. In the fabrication of the one-piece molded composite article, a deformable sheet material, such as vinyl, is positioned on a female molding surface and drawn into conformity with the female molding surface of the mold cavity, either with or without preheating or vacuum forming. The mold apparatus is closed and a first moldable material is introduced into the mold assembly, with certain predetermined portions thereof being blocked off. Subsequently, a second moldable material is introduced at least into the predetermined areas previously blocked off during the introduction of the first moldable material.

Abstract: A method for making a foamed article having a laminated structure comprises providing a mold having a cavity therein and a rib vertically mounted from a bottom of the cavity and having a predetermined height to establish at least two blocks on the bottom, and pouring a foamable liquid compositions into the respective blocks in amounts which permit one of the foamable liquid composition to cover the other foamable liquid composition upon foaming whereby the resulting foam has a laminated structure whose boundary between the foamed layers made of the respective foamable liquid compositions is smooth and agreeable to the touch.