Patent ID: 7323126
Filing Date: 2008-01-29
Classification: B29C

Abstract:
1. A method for forming a foamed product integral with a three-dimensional, air-permeable trim cover utilizing a forming apparatus which comprises a first die, a second die housed within said first die and having air-ventilating holes, a core disposed within said first die, and a third die having an expandable resin pouring-hole and adapted to be combined with said first die, to thereby provide a forming cavity between said second die and said third die, said method comprising the steps of: a. preparing said three-dimensional, air-permeable trim cover, said trim cover having a two layer structure comprising a layer of foamed material and a sheet of covering material laminated with said foamed material layer; b. putting said trim cover on said second die such that said sheet of covering material faces said second die; c. applying vacuum to said trim cover through said air-ventilating holes of the second die, to thereby cause said trim cover to be drawn onto said second die; d. causing said third die to be combined with said first die to define said forming cavity in cooperation with said first die; e. thereafter stopping the applying of said vacuum to said trim cover; f. pouring an expandable resin into said forming cavity through said expandable resin-pouring hole of said third die and causing said expandable resin to foam up; g. closing said expandable resin-pouring hole, to thereby cause an interior of said first die to be kept in a hermetically sealed condition; and h. applying compressed-air to an annular space between said first die and said core in order that an inner pressure within said annular space is balanced with a gas pressure occurring within said forming cavity due to the foaming of said expandable resin, whereby a foamed product integral with said trim cover is produced, in which the degree to which the foamed resin is impregnated into said layer of foamed material is suppressed.