Patent ID: 6352658
Filing Date: 2002-03-05
Classification: B29C

Abstract:
A method for forming a decorative component having an outer elastomeric layer that is integral with an inner foam layer, comprising the steps of:a) forming a polyurethane mixture free of any blowing agents by combining a flow of a polyisocyanate component with a flow of a polyol component, the polyurethane mixture having a first amount of the polyisocyanate component and a first amount of the polyol component; b) applying a layer of the polyurethane mixture onto a surface of a mold by flowing the polyurethane mixture through a spray nozzle directed toward the mold surface and forming an outer elastomeric layer on the mold surface; c) while continuing to apply the polyurethane mixture onto the surface of the mold introducing a flow of water into the flow of the polyurethane mixture, thereby forming a polyurethane mixture containing blowing agent, and changing the first amount of the polyisocyanate component to a second amount, wherein the second amount of the polyisocyanate component is greater than the first amount of the polyisocyanate component, while continuing to spray the polyurethane mixture onto the surface of the mold; d) continuing to direct the polyurethane mixture containing blowing agent toward the mold surface, thereby foaming the polyurethane mixture containing blowing agent and forming an inner foam layer that is integral with the outer elastomeric layer; and e) demolding the decorative component.