A skin covered foamed plastic article capable of providing improved softness, feel and comfortableness by reducing the amount of penetration of the liquid foam resin into the skin cover with a thin wadding. The article includes a wadding to be attached on a back side of the surface skin and to make a direct contact with the pad member, having a soft layer contacting the surface skin and a hard layer contacting the pad member which has a constant thickness and is made to be harder than both the soft layer and the pad member.
A porous sheet material is inserted into a back side of a foam base material at a convex section and forces a mat-shaped fiber reinforcing material set in a mold toward a facing material during molding. Alternatively, an impregnated sheet material is inserted between the facing material and the fiber reinforcing material at the convex section so that a molding material for the foam base material is impregnated into the impregnated sheet material during molding. Further, a concave section is molded on the back side of the foam base material at the convex portion by a mold projecting section of the mold. That is, the fiber reinforcing material set in the mold is forced toward the facing material by the mold projecting section during molding.
A seat cushion is disclosed, in particular for an aircraft seat, with a supporting body of a foamed plastic with a spring core embedded therein, and a flameproofing layer of flame-retardant plastics foam, to which a covering material is secured, preferably detachably. The supporting body is formed from a lower supporting part of foamed plastic having the spring core embedded therein and a sitting part, also of foamed plastic, preferably of a different density.
An aircraft seat cushion comprises a foamed plastic supporting body consisting of a lower supporting part, an upper sitting part, the lower sitting part being detachable from the supper surface of the supporting part, and a detachable flameproofing layer covering the upper surface of the sitting part and the edges of the sitting and supporting parts, and a flameproof layer covering the entire lower surface of the supporting part so that the cushion is encapsulated in the flameproof layers.
A laminate structure for making a cushioned component for a vehicle interior, such as a seat cushion or head rest, has a high density foam bonded to an interior surface of a seat cover material. After the laminate structure is formed into a desired shape for the cushioned component, it is inserted into a vacuum mold having a mold surface with a shape corresponding with a desired exterior surface shape of the cushioned component. Liquid foam-forming material is injected into the laminate structure within the mold and allowed to cure to form the cushioned component. The high density foam of the laminate structure preferably has a density of at least 4 lbs/ft.sup.3 and an air permeability of 5 to 100 ft.sup.3 /ft.sup.2 minute. This high density foam may be created by felting a polyurethane foam.
A mold gate insert includes a mold gate insert body, which is comprised of a material having a high thermal conductivity, and a thermal insulation element, which is nested in the mold gate insert body. The thermal insulation element is provided to abut a nozzle seal and align the nozzle with a mold gate. The amount of heat transferred from the nozzle to the mold gate insert is reduced by the thermal insulation element.
