Patent ID: 6451233
Filing Date: 2002-09-17
Classification: B29C,B29K,B29L,B60R,Y10T

Abstract:
A method of manufacturing a multiple foam substrate of predetermined shape with a mold having first and second mold cavities, the method comprising:injecting a first foam into the first mold cavity sufficiently to fill the first mold cavity; storing the first foam in the first mold cavity for a predetermined time sufficient to form a substantially non-mixing surface on the first foam, wherein the non-mixing surface has a notch formed thereon; loading a deployable airbag onto the non-mixing surface; injecting a second foam into the second mold cavity and onto the non-mixing surface on the first foam sufficiently to fill the second mold cavity after the step of loading the airbag; and storing the second foam in the second mold cavity for a predetermined time sufficient to bond the first foam to the second foam along the non-mixing surface, thereby defining the multiple foam substrate having the predetermined shape, and wherein the notch formed on the non-mixing surface allows for airbag deployment.