Process for forming a foam product integral with surface cover element

Abstract

A process is provided for forming a foam product integral with a cover surface, which restricts emission of the carbon oxide during the step of preparing a carbon-oxide-mixed liquid by mixing carbon oxide into a first material containing polyol as a primary ingredient; under a pressure applied thereto. The process includes a first step wherein a carbon-oxide-mixed liquid material is prepared by mixing carbon oxide C into a first material containing polyol as a primary ingredient, under a pressure applied thereto, without effecting a forced stirring during said first step; a second step wherein said carbon-oxide-mixed liquid material and a second material containing isocyanate as a primary ingredient are impinged on and mixed with each other in a high-pressure foaming agent preparation device, thereby providing a resultant urethane material as a liquid urethane foaming agent; and a third step wherein said liquid urethane foaming agent produced at said second step is introduced toward an inside of a surface cover element under a pressure applied thereto.