Disclosed are methods and systems for preparing open-celled polyurethane foams by a discontinuous box foam process in which (a) a polyurethane foam-forming composition is deposited into a container having a gas-permeable base and (b) the polyurethane-foam forming composition is allowed to form an open-celled polyurethane foam in the container. In these methods and systems, the gas-permeable base is heated before, during, and/or after step (a) and heating is continued during at least a portion of step (b).

Disclosed are methods and systems for preparing open-celled polyurethane foams by a discontinuous box foam process in which (a) a polyurethane foam-forming composition is deposited into a container having a gas-permeable base and (b) the polyurethane-foam forming composition is allowed to form an open-celled polyurethane foam in the container. In these methods and systems, the gas-permeable base is heated before, during, and/or after step (a) and heating is continued during at least a portion of step (b).

Disclosed are methods and systems for preparing open-celled polyurethane foams by a discontinuous box foam process in which (a) a polyurethane foam-forming composition is deposited into a container having a gas-permeable base and (b) the polyurethane-foam forming composition is allowed to form an open-celled polyurethane foam in the container. In these methods and systems, the gas-permeable base is heated before, during, and/or after step (a) and heating is continued during at least a portion of step (b).

Disclosed herein are a molding method and a mold capable of further reducing the distance between a base material and a seal member. A molding method includes: a preforming step of injecting a rubber material into a groove at a temperature where the rubber material is not vulcanized, in a cavity plate including the groove into which the rubber material is injected; and a vulcanization molding step of sandwiching a base material between the cavity plate and a mold, and molding the rubber material onto the base material as a seal member at a temperature where the rubber material is vulcanized. The cavity plate includes a gap forming portion between such portion and an inclined portion of the base material when a flat surface and a flat surface of the base material are pressed in the vulcanization molding, and a connecting groove connecting the groove and the gap forming portion.

Disclosed herein are a molding method and a mold capable of further reducing the distance between a base material and a seal member. A molding method includes: a preforming step of injecting a rubber material into a groove at a temperature where the rubber material is not vulcanized, in a cavity plate including the groove into which the rubber material is injected; and a vulcanization molding step of sandwiching a base material between the cavity plate and a mold, and molding the rubber material onto the base material as a seal member at a temperature where the rubber material is vulcanized. The cavity plate includes a gap forming portion between such portion and an inclined portion of the base material when a flat surface and a flat surface of the base material are pressed in the vulcanization molding, and a connecting groove connecting the groove and the gap forming portion.