Patent ID: 8663514

Claim:
A method of making a chair comprising: co-injection molding a first portion of an outer material in a mold cavity; co-injection molding an inner material in a mold cavity, the inner material including a blowing agent uniformly distributed therein, the inner material cooperating with the outer material; co-injection molding a second portion of the outer material to encapsulate the inner material in a mold cavity; injecting pressurized gas into the inner material in the mold cavity, the pressurized gas having a temperature which is comparably low relative to a temperature of the co-injection molded inner material including the blowing agent; displacing the inner material including the blowing agent, to form a hollow channel inside the inner material; providing a pathway which allows gas generated by the expansion of the blowing agent to be vented outside of the outer material; removing the completed chair from the mold cavity; maintaining the pathway as the chair is removed from the mold cavity; wherein the introduction of the pressurized gas into the inner material displaces a portion of the inner material to help pressurize the internal material and provides additional cooling to the inner material; wherein providing the pathway allows heat and pressure associated with the blowing agent to out gas as the chair is in the mold cavity and after the chair is removed from the mold cavity, thereby preventing the gas generated by the blowing agent from being trapped and minimizing the effects of post blow of the blowing agent.