Multi=layer product

摘要

A multi-layer product comprises an outer layer of natural leather(48) and a CO2(carbon dioxide) blown foam core which is moulded directly onto the leather layer in a closed mould. Also claimed is a process for manufacturing part or all of the product which employs a multi-part, sealable, heated tool consisting of a fixed lower tool (110) with bores (114) in the base connected to a vacuum source, an intermediate ring with an inner contour corresponding to the component and an upper tool (130) with an insert which fits into the intermediate ring. The process stages involve: (i) placing and drawing the leather layer (48) onto the base of the lower tool (110) using vacuum; (ii) positioning the intermediate ring onto the edge(49) of the leather layer and forming a seal against the lower tool; (iii) metering a PU(polyurethane) foam mixture into the cavity formed within the intermediate ring; (iv) lowering and locking the upper tool (130) onto the lower tool before the foam expands to fill the cavity; and (v) opening the tool after foam setting and demoulding the product.