The Dow Chemical Company

Michael J Brown

Werner A Lidy

Francois M Casati

Patrice Bocquel

A process for preparing a multilayered foam article such as an automotive seat is disclosed. A mold is arranged so that the bottom surface of the mold is flat or inclined up to 40 degrees to the horizontal plane. The first liquid foam formulation designed to produce a soft foam is poured into the mold from a mixing head outlet strip-wise across the seating zone of the mold along the line parallel to but near the external wall of the seating zone of the mold. Then, the second liquid foam formulation designed to produce a hard foam is poured into the mold from the same or different mixing head outlet strip-wise across the seating zone of the mold along the line parallel to but nearer to the external wall of the mold than the line of pouring of the first liquid foam formulation. The second liquid foam formulation is then allowed to spread on top of the first liquid foam formulation, the mold is closed and the foames are allowed to rise and cure in the mold. The process produces an article having excellent layered-foam seating area.

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Eysins/Vaud, Switzerland

Michael J Brown