Claims
- 1. A process for producing a multi-layered foam article which comprises:
(a) pouring a first elastomeric forming formulation into a mold to render a first elastomeric layer; (b) applying a release agent to the first elastomeric layer; (c) before the first elastomeric forming liquid formulation has fully cured, pouring a foam producing second formulation on top of the release agent; and (d) after the first elastomeric forming formulation and foam producing second formulations have cured, demolding the resulting product wherein the release agent is applied in an amount sufficient to prevent adherence of the foam producing second formulation, when cured, to the cured first elastomeric layer.
- 2. The process of claim 1, wherein the first elastomeric layer is a polyurethane, polyurea, polyacrylate, polyisoprene, polychloroprene, nitrile, polybutylene, silicone rubber, block copolymer of styrene and butadiene, or a combination thereof.
- 3. The process of claim 2, wherein the first elastomeric layer is a polyurethane.
- 4. The process of claim 3, wherein the first elastomeric layer is microcellular.
- 5. The process of claim 1, wherein the foam producing second formulation is an isocyanate and a hydrogen active compound.
- 6. The process of claim 5, wherein the isocyanate is an aromatic isocyanate.
- 7. The process of claim 1, wherein the release agent is a wax-based mold release agent.
- 8. The process of claim 1, wherein prior to step (a), an in-mold coating is applied to the mold.
- 9. The process of claim 8, wherein the in-mold coating contains a colorant or an UV absorbing or stabilizing material.
- 10. A seat produced by the process of claim 1.
- 11. The seat of claim 10, having a back portion and a seating portion.
- 12. The seat of claim 10, which is an automobile seat having a side support.
- 13. A process for preparing a multi-layered seat having at least one raised peripheral support and an inner zone which comprises:
(a) pouring a first elastomeric forming formulation into a mold having areas defining the inner zone and the at least one raised peripheral support for the resulting seat and forming an elastomeric layer; (b) applying onto the elastomeric layer in the areas corresponding to the raised peripheral support a release agent; (c) applying onto the elastomeric layer of the inner zone of step (a) and the mold release agent of step (b), before the first elastomeric forming formulation cures, a foam producing second formulation; and (d) after the first elastomeric forming formulation and the foam producing second formulation cure, demolding the seat wherein the release agent is applied in an amount sufficient to prevent adherence of the foam producing second formulation to the first elastomeric forming formulation.
- 14. The process of claim 13, wherein the first elastomeric forming liquid formulation and foam producing second formation render layers of different hardness.
- 15. The process of claim 14, wherein the foam producing second formulation is poured strip-wise over the inner zone.
- 16. The process of claim 13, wherein an in-mold coating is applied to the mold prior to step (a).
- 17. The process of claim 16, wherein the in-mold coating contains a colorant or stabilizing material.
- 18. A seat prepared by the process of claim 13.
- 19. The seat of claim 18, wherein the elastomeric layer has a thickness of from 0.1 to 30 millimeters.
- 20. The seating element of claim 18, wherein the cured layer resulting from the foam producing second formulation has an overall density of 15 to 80 kg/m3.
- 21. The process of claim 13, wherein the elastomeric layer is polyurethane, polyurea, polyacrylate, polyisoprene, polychloroprene, nitrile, polybutylene, silicone rubber, a block copolymer of styrene and butadiene, or a combination thereof.
- 22. The process of claim 13, wherein the release agent is a wax-based mold release agent.
- 23. A multi-layered seating element containing a raised support comprising an external elastomeric layer and an internal flexible foam layer having a release coating between the elastomeric and flexible foam layer in an amount sufficient to prevent the elastomeric layer from attaching to the flexible foam layer.
- 24. The seating element of claim 23, which is a seat for a transportation vehicle.
SPECIFICATION
[0001] This application claims priority from U.S. Provisional Application Ser. No. 60/298,709 filed Jun. 15, 2001.
Provisional Applications (1)
|
Number |
Date |
Country |
|
60298709 |
Jun 2001 |
US |