PROCESS FOR MOULDING MULTIHARDNESS FOAM ARTICLE; DISPENSING TWO FOAMS SIMULTANEOUSLY INTO MOULD

摘要

The present invention concerns a process for preparing a multihardness foam article in a mould having the bottom surface flat or inclined up to 40 degrees to the horizontal plane. The process is characterized by the following steps: (a) arranging a dispensing means, comprising at least two outlets for dispensing at least two foam formulations, the outlets being arranged in a line, and the distance between adjacent outlets being less than the width of the mould, so that the outlets move across the mould either at or near one of the edges of the flat bottom surface or at or near the top of the incline of the inclined bottom surface along the line defined by the outlets; (b) effective relative motion of the outlets across the mould along the line defined by the outlets; and (c) dispensing from each outlet simultaneously a foam formulation whilst the outle is directly above the inside of the mould. The present process is particularly suitable for the preparation of a car seat comprising a layered foam seating area and single hardness or encapsulated foam side rolls in a single continous pouring operation.