Patent ID: 8328972

Claim:
A process for the production of a foamed article comprising the steps of: providing at least a core layer ( 1 ) for said article, which core layer ( 1 ) comprises a flexible, open-cell foam having open voids forming at least 90% of the volume of the open-cell foam; applying said core layer ( 1 ) between a lower ( 5 ) and an upper mold surface ( 9 ); allowing a curable, foamable, isocyanate based liquid composition ( 7 ) to foam in the open voids of said open-cell foam to produce a further foam ( 4 ) filling these open voids while the core layer ( 1 ) is maintained between the upper ( 9 ) and lower mold surfaces ( 5 ); and removing the produced article from between the upper ( 9 ) and lower mold surfaces ( 5 ), wherein the curable, foamable composition ( 7 ) is sprayed onto the core layer ( 1 ) and has a dynamic viscosity, measured at a shear rate of 1/s, of lower than 1000 mPa·s when arriving onto the core layer ( 1 ), and wherein the core layer ( 1 ) is held in a lying position when spraying the foamable composition ( 7 ) thereon so that the sprayed foamable composition ( 7 ) is allowed to penetrate at least partially by gravity into the open-cell foam of the core layer ( 1 ).