Patent ID: 6030560
Filing Date: 2000-02-29
Classification: B29C,Y10S

Abstract:
A method of making a cushioned article, comprising the steps of:forming a base in a female base mold having an interior;forming a flexible skin by applying at least one carrier solvent free material to a form;assembling the base and flexible skin such that a cavity is formed therebetween; andinjecting a foam material into the cavity such that when the foam material cures, the foam material binds the base with the flexible skin to form the article, wherein the flexible skin forming step includes:applying a first carrier solvent free resin mixture on top of the form to form a first coating;applying a second carrier solvent free resin mixture on top of the first coating to form a second coating; andapplying a foamable resin mixture on top of the second coating to form a third coating.