Foaming mould an intermediate component made therein

摘要

The two part(10,12) tool has two or more molding cavities(16,18). A compensating area(20) between both cavities accommodates a relaxation section(28) created in a substrate(22) during component molding in the tool. The compensating area(20) comprises a groove extending the full breadth of the foaming tool into which the substrate(22) extends during molding. Groove cross-section can be a U or V shape or is rectangular. Foamed plastic extends to a point just before the relaxation section(28) to form a composite component with the substrate. Independent claims are included for: (1) a substrate, in particular an outer skin for a composite component, having two component sections(24,26) for aligning with the tool cavities and a relaxation section between the component sections; and (2) a process for manufacturing a composite product in which: i) a substrate is formed with two or more component sections and a relaxation section between them; ii) foam is introduced to the tool behind the component sections; and iii) the relaxation section is cut away from the back-foamed components.