PROCESS FOR MANUFACTURING A PADDED ELEMENT

摘要

A process for manufacturing a padded element using a mold having a mold cavity and including an upper mold having an interior surface complimentary to the upper surface of the padded element and a lower mold having an interior surface complimentary to the lower surface of the padded element. The process includes placing a trim cover on the upper mold, with the trim cover comprising an inner surface and a finished outer surface in contact with substantially the entire interior surface of the upper mold, placing a liquid foamable polymeric composition on the interior surface of the lower mold and closing the upper mold and the lower mold after the liquid foamable polymeric composition expands to fill from about 50 to about 90 volume % of the mold cavity and prior to expansion of the liquid foamable polymeric composition to a point corresponding to the interior surface of the upper mold in a closed position. The liquid foamable polymeric composition expands in a direction substantially away from the lower mold and adheres to the inner surface of the trim cover. A substantial amount of expansion gases produced during expansion of the liquid foamable polymeric composition are vented prior to closing of the upper mold and the lower mold.