Patent ID: 7029610

Claim:
A process for producing a polyurethane-foam product molded integrally with an insert, wherein a molded body, including a substrate and a polyurethane-foam molded body being molded integrally with the substrate, is produced, the substrate being disposed in an expansion-molding mold as the insert, the process comprising the steps of: forming a fine groove-shaped polyurethane-foam relief groove and a polyurethane-foam adjuster in at least one of an end of the substrate and a mold surface of the expansion-molding mold which contacts with the substrate, the polyurethane-foam relief groove communicating with a cavity of the expansion-molding mold, the polyurethane-foam adjuster being in communicating with the polyurethane-foam relief groove and having a volume larger than that of the polyurethane-foam relief groove; and adjusting the leakage of polyurethane foam, which is foamed in the cavity, with the polyurethane-foam adjuster, and removing polyurethane foam, which is formed by the polyurethane-foam relief groove and the polyurethane-foam adjuster, from the expansion-molding mold in such a state that it is bonded integrally with said molded product; wherein the substrate is a plate-like cover and has a decorative first side and a polyurethane-foam molded body molded on a second side.