摘要 |
A multi-density foam material and method of manufacturing thereof comprises combining in a mold a polyol mixture with an isocyanate mixture in a ratio of about 0.2 to 1.0 parts by weight of the polyol mixture, with expandable beads in an amount of about 0.1 to 1.5 parts per weight of the polyol mixture. The polyol mixture and the isocyanate mixture react exothermically to form a flexible foam, and heat generated from the reaction causes the expandable beads to at least partially expand, but the mold is at a temperature below that where significant expansion of the expandable beads occurs. The resulting foam material has a center with a first density, and an exterior edge with a second density different than the first density.
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