A mold component for forming a foamed part with a three-dimensional shape includes a magnetic block having a first face that defines a curved three-dimensional surface with a hook strip-receiving recess positioned above the magnetic block. The magnetic block is configured to be placed in a mold with a hook strip placed in the hook strip-receiving recess. The hook strip has a ferrous metal-containing component such that the magnetic block attracts and holds the hook strip with the hook strip conforming to the curved three-dimensional surface. Characteristically, the mold component is configured to be applied in a molding process to mold the three-dimensional shape in the foamed part wherein the hook strip attaches to a trim cover.

A mold component for forming a foamed part with a three-dimensional shape includes a magnetic block having a first face that defines a curved three-dimensional surface with a hook strip-receiving recess positioned above the magnetic block. The magnetic block is configured to be placed in a mold with a hook strip placed in the hook strip-receiving recess. The hook strip has a ferrous metal-containing component such that the magnetic block attracts and holds the hook strip with the hook strip conforming to the curved three-dimensional surface. Characteristically, the mold component is configured to be applied in a molding process to mold the three-dimensional shape in the foamed part wherein the hook strip attaches to a trim cover.

Provided is a fabric for producing a foam part, comprising: a non-woven fabric sheet comprising: a first metallic pattern printed on a first surface of the non-woven fabric sheet; wherein the first metallic pattern comprises a plurality of pattern elements having a predetermined optimal distance therebetween; wherein the metallic pattern comprises a print paste and a metallic powder; wherein the non-woven fabric sheet is structured to be positioned in a mold for producing the foam part such that the first metallic pattern of the non-woven fabric sheet is operatively coupled with a magnet element of a first mold half of the mold.

Provided is a fabric for producing a foam part, comprising: a non-woven fabric sheet comprising: a first metallic pattern printed on a first surface of the non-woven fabric sheet; wherein the first metallic pattern comprises a plurality of pattern elements having a predetermined optimal distance therebetween; wherein the metallic pattern comprises a print paste and a metallic powder; wherein the non-woven fabric sheet is structured to be positioned in a mold for producing the foam part such that the first metallic pattern of the non-woven fabric sheet is operatively coupled with a magnet element of a first mold half of the mold.

A method of producing a foamed composite molded product includes fixing an exposed part of an insert material on a fixing part provided in a mold, the insert material being inserted in an in-mold foamed molded product made of a thermoplastic resin; introducing a polyurethane liquid into the mold; and producing the foamed composite molded product by foaming the polyurethane liquid in the mold. The foamed composite molded product includes an in-mold foamed molded product unit including the insert material and the in-mold foamed molded product; and a polyurethane foam. At least part of the insert material is exposed to an outside of the in-mold foamed molded product, and the in-mold foamed molded product unit and the polyurethane foam are integrated.

A method of producing a foamed composite molded product includes fixing an exposed part of an insert material on a fixing part provided in a mold, the insert material being inserted in an in-mold foamed molded product made of a thermoplastic resin; introducing a polyurethane liquid into the mold; and producing the foamed composite molded product by foaming the polyurethane liquid in the mold. The foamed composite molded product includes an in-mold foamed molded product unit including the insert material and the in-mold foamed molded product; and a polyurethane foam. At least part of the insert material is exposed to an outside of the in-mold foamed molded product, and the in-mold foamed molded product unit and the polyurethane foam are integrated.

A fabric-like material for reinforcement in an urethane foam molding is obtained by impregnating a part of a surface of a nonwoven fabric of organic fibers with a hot melt magnetic material and immobilizing the hot melt magnetic material. The hot melt magnetic material satisfies compositions described below and has a softening point of 70 to 100° C. Ethylene-vinyl acetate copolymer (A): 10 to 95% by mass. Wax (B): 0 to 30% by mass. Magnetic powder (C): 5 to 70% by mass. (The total of (A), (B) and (C) is 100% by mass.).

A fabric-like material for reinforcement in an urethane foam molding is obtained by impregnating a part of a surface of a nonwoven fabric of organic fibers with a hot melt magnetic material and immobilizing the hot melt magnetic material. The hot melt magnetic material satisfies compositions described below and has a softening point of 70 to 100° C. Ethylene-vinyl acetate copolymer (A): 10 to 95% by mass. Wax (B): 0 to 30% by mass. Magnetic powder (C): 5 to 70% by mass. (The total of (A), (B) and (C) is 100% by mass.).

A method of manufacturing a composite component according to various aspects of the present disclosure includes disposing a fiber preform in a mold. The fiber preform includes a first portion having a first edge and a second portion having a second edge. The first edge and the second edge cooperate to at least partially define a gap. One of the first portion or the second portion includes a first ferromagnetic material and the other of the first portion or the second portion includes a first magnetic or magnetizable component. The method further includes closing the gap by generating a magnetic field from the first magnetic or magnetizable component. The method further includes injecting a polymer precursor into the mold. The method further includes forming the composite component by solidifying the polymer precursor to form a polymer. The composite component includes the fiber preform and the polymer.

A method of manufacturing a composite component according to various aspects of the present disclosure includes disposing a fiber preform in a mold. The fiber preform includes a first portion having a first edge and a second portion having a second edge. The first edge and the second edge cooperate to at least partially define a gap. One of the first portion or the second portion includes a first ferromagnetic material and the other of the first portion or the second portion includes a first magnetic or magnetizable component. The method further includes closing the gap by generating a magnetic field from the first magnetic or magnetizable component. The method further includes injecting a polymer precursor into the mold. The method further includes forming the composite component by solidifying the polymer precursor to form a polymer. The composite component includes the fiber preform and the polymer.