Vented mold and method for producing molded article

A mold for producing molded foamed polyurethane automotive seat cushions, the mold comprising:

• a first mold having a first inner surface for forming a B-surface of the automotive seat cushion and a second mold having a second inner surface for forming the A-surface of the automotive seat cushion, said first mold and said second mold being releasingly engageable between an open position and a closed position, the closed position defining a mold cavity for receiving a liquid foamable polyurethane composition for forming said seat cushion;
• and
• said first inner surface comprising multiple grooves connected to and in fluid communication with multiple vents for receiving air and carbon dioxide formed during polymerization of said polyurethane composition and siphoning said air and carbon dioxide away from said polyurethane composition to the exterior of the mold, thereby reducing the gaseous pressure within the mold during formation of said automotive seat cushion, each of said multiple grooves being configured to have a depth in the range of from about 3 mm to about 10 mm and a first width at the open end of the groove in the range of from about 0.5 mm to about 5 mm, the width at the closed end of the groove being less than said first width.

A polyurethane foam seat cushion made by a mold having a lid and a bowl releasingly engageable between an open position and a closed position, the closed position defining a mold cavity for receipt of a liquid foamable polyurethane composition that undergoes polymerization in said mold cavity to form said seat cushion, at least one of the lid and the bowl having an inner mold surface with (i) a plurality of vents, each vent having a passageway for gas and for carbon dioxide formed during the polymerization of said polyurethane composition to exit the mold cavity, and (ii) a plurality of interconnected grooves arranged to be in fluid communication with the plurality of vents, at least two of said vents being connected to each other through at least one of said plurality of grooves to permit said air and said carbon dioxide to exit the mold cavity through one or both of said vents, each groove configured to have:

• (i) a depth of up to about 10 mm and a width, the depth being greater than the width, and (ii) a cross-sectional shape comprising an open end having a first width of up to about 5 mm and an apex portion having a second width less than the first width.

A mold for producing polyurethane foam articles, the mold comprising:

• a first mold and a second mold releasingly engageable between an open position and a closed position, the closed position defining a mold cavity for receiving a foamable polyurethane composition that undergoes polymerization in said mold cavity to form said foam article;
• and
• a surface of the mold cavity comprising multiple grooves, each groove being connected to multiple vents, at least two of said vents being in fluid communication with each other through at least one of said grooves, each vent comprising a passageway for gas to escape from the mold cavity including carbon dioxide formed during the polymerization of said polyurethane composition, each groove configured to have a depth of up to about 10 mm and a width, the depth being greater than the width, and a cross-sectional shape with an open portion having a first width of up to about 5 mm and an apex portion having a second width less than the first width.

A mold for producing foamed polyurethane articles, the mold comprising:

• a first mold and a second mold releasingly engageable between an open position and a closed position, the closed position defining a mold cavity for receiving a foamable polyurethane composition that undergoes polymerization in said mold cavity to form said foamed article;
• and
• a surface of the mold cavity comprising a plurality of grooves, each of which is connected to a plurality of vents, the at least one vent comprising a passageway for gas to exit the mold cavity during polymerization of said polyurethane composition, said gas including carbon dioxide formed during the polymerization of said polyurethane composition, each groove is configured to have a depth in the range of from about 3 mm to about 10 mm and a first width in the range of from about 0.5 mm to about 5 mm, wherein the depth is greater than the width, and wherein each groove has an apex portion which has a width less than that of an open portion.

A mold for polyurethane seat cushions, the mold comprising:

• a lid and a bowl releasingly engageable to define a mold cavity for receiving a polyurethane composition that undergoes polymerization in said mold cavity to form said seat cushions, the lid comprising:
• (i) a plurality of vents, each vent having a passageway for gas to escape from the mold cavity during the polymerization of said polyurethane composition in said mold, thereby reducing the internal pressure in the mold during the polymerization process, and
• (ii) a plurality of grooves connected to each of the plurality of vents with at least two vents being in gaseous communication with each other through at least one of said plurality of grooves to permit said gas to exit the mold through either one or both of said at least two vents during the polymerization process, each groove configured to have a depth of about 3 mm to about 10 mm and a width, the depth being greater than the width, and a cross-sectional shape having an open portion with a first width of up to about 4 mm and an apex portion with a second width less than the first width.

A device for producing molded polymeric foam articles, the device comprising:

• a lid and a bowl releasingly engageable between an open position and a closed position, the closed position defining a mold cavity for receiving a liquid foamable polymeric composition, at least one interior surface of the lid and the bowl having a plurality of vents, each vent having a passageway for gas to escape from the mold cavity during the formation of said polymeric foam articles;
• and
• a plurality of interconnected grooves, the interconnected grooves being in fluid communication with the plurality of vents, at least two of said vents being connected to each other through at least one of said plurality of grooves to permit the escape of said gas from the mold cavity through either one or both of said at least two vents, each groove configured to have a depth of up to about 7 mm and a width, the depth being greater than or equal to the width, and a cross-sectional shape with an open portion having a first width of up to about 4 mm and an apex portion having a second width less than the first width.