Patent ID: 8506866

Claim:
A method for producing a multilayered part comprising a moulded core ( 5 ) and a flexible polyurethane layer ( 4 ) formed by a flexible polyurethane skin layer or by a flexible integral skin polyurethane foam layer, the moulded core ( 5 ) comprising a moulded substrate layer ( 1 ) made of a substrate material having a Shore A hardness higher than 60 and the flexible polyurethane layer ( 4 ) having an average density higher than 400 kg/m 3 , which method comprises the steps of: providing a mould ( 11 , 12 ) having at least a first and a second mould section which are movable with respect to one another to open and close the mould; providing said core ( 5 ) inside said mould ( 11 , 12 ) so that a gap ( 14 ) exists between the surface of the core ( 5 ) and the internal wall of the mould when the mould is closed; introducing a polyurethane reaction mixture in said gap ( 14 ) between the surface of the core ( 5 ) and the internal wall of the mould ( 11 , 12 ) to overmould at least a first area of the core surface with the polyurethane reaction mixture; allowing said polyurethane reaction mixture to cure in said gap ( 14 ) to produce the flexible polyurethane layer ( 4 ) therein; and opening the mould ( 11 , 12 ) and removing the produced multilayered part, characterised in that the moulded core ( 5 ) which is provided in said mould ( 11 , 12 ) comprises said substrate layer ( 1 ) and at least one softer moulded part ( 2 , 3 ), which is moulded onto the substrate layer ( 1 ) or said substrate layer ( 1 ) is moulded onto the softer moulded part ( 2 , 3 ) or the substrate layer ( 1 ) and the softer moulded part ( 2 , 3 ) are moulded against one another, said softer moulded part ( 2 , 3 ) being made of a softer material with a Shore A hardness lower than 60 and forming a second area of the core surface.