Patent ID: 11904512
Assignee: FORD GLOBAL TECHNOLOGIES, LLC
Field: Other special machines (Mechanical engineering)
Classification: CPC B | IPC B

Claim 12:
13. A method of making a vehicle headrest restraint comprising:
connecting first and second molds to form an enclosed mold cavity having an upper end and a lower end;
injecting a first material with a first density into the mold cavity through a first injection port inserted at a fixed location within the upper end such that the first material settles in the lower end of the mold cavity;
injecting a second material with a second density less than the first density into the mold cavity through a second injection port inserted at the fixed location within the upper end such that the second material settles over the first material and extends to the upper end of the mold cavity; and
subsequently allowing the first and second materials to cure together to develop an integrally formed headrest with:
a forward flexible foam portion defining opposite upper and lower edges; and
a rearward stiff foam portion being directly connected with the forward flexible foam portion along an integral parting line therebetween that extends uninterrupted from the upper edge of the forward flexible portion to the lower edge thereof.