Patent ID: 8388875

Claim:
An insert molding method for molding an integrated skin and foam article in a single process for an article of manufacture comprising: placing a mold on a base member to be used as a part of a molded article of manufacture to form a closed mold cavity; injecting a reaction molding non-foaming polyurethane resin into the closed mold cavity along a surface of the base member under atmospheric pressure; and subsequently initiating injection of a reaction molding foaming polyurethane resin into the closed mold cavity along the surface of the base member under atmospheric pressure when a viscosity of the non-foaming polyurethane resin is between 400 cps and 700 cps; wherein upon injection of the non-foaming and foaming polyurethane resins into the closed mold cavity, the non-foaming polyurethane resin forms a non-foamed skin layer and the foaming polyurethane resin forms a foamed layer, opposed surfaces of the non-foamed skin layer and the foamed layer integrally connecting and fusing with one another to form a flexible layer, the flexible layer substantially uniform along the base member from an injection point to a point on the base member distant from the injection point; and, wherein the base member is a structural supporting member.