Patent ID: 7052634

Claim:
A method for making a foam sheet having ventilation holes, comprising the steps of: (a) preparing first and second molds, each of which includes lower and upper mold parts separably closed to each other so as to define first and second mold cavities for said first and second molds, respectively, and providing said second mold with a plurality of pins extending into said second mold cavity, said second mold cavity of said second mold being larger than said first mold cavity of said first mold; (b) placing a foamable blank into said first mold cavity of said first mold; (c) foaming said blank in said first mold cavity; (d) placing said blank foamed in step (c) into said second mold cavity, and piercing said blank through use of said pins; and (e) foaming said blank to form a foam product within said second mold cavity while being pierced by said pins.