A pillow is provided that includes a foam core and a gel insert molded to each side of the foam core. Methods of producing a pillow are further provided and include a step of providing a foam molding system having a top mold defining a plurality of air ports and a bottom mold defining a plurality of air ports. A vacuum is applied to the plurality of air ports in both the top mold and bottom mold, and a gel insert is then positioned against each of the plurality of air ports. A foam precursor is subsequently dispensed into the bottom mold atop the gel insert, and the top mold is secured to the bottom mold. The foam precursor then expands within the foam molding system and bonds with the two gel inserts to produce a pillow having a gel insert molded to each side of the pillow.

The invention relates to a process for producing complex, mould-foamed rigid foam materials, more particularly of poly(meth)acrylimide (P(M)I) cores, preferably of polymethacrylimide (PMI) cores, which may be employed, for example, in carmaking or aircraft construction. A feature of the process is that through use of a particulate core during foam, it is possible to achieve an additional weight saving relative to foam materials or sandwich materials of the prior art.

A method for manufacturing a seat cushion material, the seat cushion material including a front layer part and a back layer part having a back side surface, the method including: preparing for molding the seat cushion by attaching the back layer part to an upper die having an upper cavity surface; molding the seat cushion material by adding foamed resin raw material forming on a lower cavity surface of a lower die and then by closing the upper die to which the back layer part is attached, the lower cavity surface being provided with a plurality of protrusions which is configured to be brought into contact with a seating surface side of the back layer part and press the back layer part against the upper cavity surface when the upper die to which the back layer part is attached is closed; and demolding the molded seat cushion material.

A method for selectively producing a first or a second variant of a multi-layer plastic component, where both variants have a substrate part, a decorative layer, and a foam layer between the substrate part and the decorative layer, includes producing the foam layer in a foaming mold which has a first mold half, into which the substrate part is inserted before the foaming process. To produce the first variant, the decorative layer is inserted into a second mold half of the foaming mold before the foaming process. To produce the second variant, a spacer layer is inserted into the second mold half before the foaming process where, after the foaming process, the spacer layer is removed from the foam layer and the decorative layer is applied to the foam layer. The foam layer includes at least one first portion having a higher contour stability than a second portion.

The present invention discloses the production of panels by a discontinuous process. The panels are produced by injecting a polyisocyanurate foam forming composition into the mold cavity at reduced pressure. The combination of certain polyisocyanurate foam forming formulation and the reduced pressure in the mold cavity allows production of and resulting sandwich panels in a discontinuous process where the produced panels are characterized by improved fire resistance.

A foaming apparatus for foaming a refrigerator cabinet includes a frame including a supporting structure, and first and second foaming jigs restrained to the supporting structure opposite to each other relative to the supporting structure. The first and second foaming jigs being respectively arranged in a lower position and in an upper position relative to a vertical direction of the foaming apparatus in an operating condition thereof. Each foaming jig includes a bottom wall, peripheral walls configured to enclose an outer shell of the refrigerator cabinet, a plug configured to engage an inner shell of the refrigerator cabinet, and at least one injection head configured to carry out injection of a foaming mixture into the refrigerator cabinet received therein. The peripheral walls and the plug are restrained to the supporting structure, whereas the bottom wall is removably mounted to the peripheral walls.

A method of making at least partially foam-filled sandwich panels includes providing a panel shell, moving at least one of a portion of a first and/or second panel facer or a side member away from the panel volume, thereby defining an opening between the volume and an exterior area. A dispenser proximate the opening moves across at least a portion of the opening while dispensing an amount of a foam agent into the volume through the opening. A press has three platens, a third platen of which is secured to at least one of a portion of the first and/or second facer and the at least one side member and is moveable with respect to the first platen and the second platen in response to a control system.

There is provided a seat pad 10 including a pad body 12 formed of a foam resin molding and a breathable cushion body 14 formed of a three-dimensional net structure made of linear bodies and provided in a pad surface side of the pad body 12. In the pad body 12, pulling-in grooves 22, 24 for pulling in a skin material 20 are provided on a pad surface, wires 26 are embedded along the pulling-in grooves, and locking holes 28 exposing part of the wires 26 are provided. The locking holes 28 are provided so as to pierce the pad to a pad reverse side and the breathable cushion body 14 is provided in a state where side surfaces thereof abut on the pulling-in grooves 22, 24 so as to communicate thereto.

A foaming die device for forming a headrest is provided, which comprises a lower die having a first protrusion and an upper die having a second protrusion. The lower and upper dies are used for accommodating a trim cover assembly with a headrest stay portion extending outwardly through a stay passage hole formed in the trim cover assembly. The first and second protrusions are adapted to press and turn over a projected area created about the stay passage hole into the inside of that trim cover assembly. Also, a foaming process for forming the headrest, using this foaming die device, is provided, in which the projected area is turned over by the first and second protrusions into the trim cover assembly when placing the trim cover assembly in the dies. Hence, conventional preliminary steps using cylindrical stick to turn over the projected area into the trim cover assembly are eliminated.

An apparatus includes a first mold having an injection cavity at a side thereof, for molding of a substrate, a second mold having two injection cores and two skin shaping plugs, and a third mold having a foaming section where a foaming material is injected between a substrate and a skin, and a skin shaping section where embossing is carried out on a skin, wherein, under the condition that the first mold, second mold and third mold are simultaneously closed to one another, a substrate is molded by the injection cavity and a first injection core, embossing is carried out on a skin by one skin shaping plug and the skin shaping section, and, at a same time, the foaming material is injected between a previously molded substrate and a previously embossed skin by a second injection core and foaming section.