Process for manufacturing a foamed resin article having a flocked three dimensional surface design

A process for producing a shaped foamed resin article having a simulated textile product surface decor comprising the steps of:

• a. providing a master mold, said mold having a plurality of matched sections, said sections having cavities therein that cooperate to define the contour of said shaped article;
• b. producing an exact reverse replica of a textile product, said replica being produced by casting a room temperature vulcanizable polymer over a textile product and removing the textile product;
• c. securing the reverse replica of said textile product within and along the contour of such of said cavities as are desired to impart the textile characteristics to predetermined areas of said molded article;
• d. casting a foamable polyurethane reaction mixture into certain of said mold cavities;
• e. bringing all of said mold sections into registry;
• f. permitting said reaction mixture to foam at ambient temperature whereby said foam expands into conformity with said contour and said textile product replica to produce said shaped article;
• g. removing said article from said mold;
• h. applying an adhesive over said simulated textile surface;
• and
• i. applying short textile fibers over said adhesive whereby said fibers are bonded to said simulated textile surface to further enhance the simulative

A process for producing a shaped foamed resin article having a three dimensional surface design along at least a portion of the surface of same comprising the steps of:

• a. providing a master mold, said mold having a plurality of matched sections, said section having cavities therein that cooperate to define the contour of said shaped article;
• b. producing an exact reverse replica of the surface of an item whose three dimensional surface characteristics are to be imparted to at least a portion of the surface of said shaped article, said surface replica being produced by casting a room temperature vulcanizable polymer over the surface of a model of said item, permitting the polymer to vulcanize and removing the model;
• c. securing the reverse surface replica within and along the contour of such of said cavities as are desired to impart the three dimensional surface characteristics of said item to the predetermined surface of said article;
• d. casting a frothed foam resin composition into certain of said mold sections;
• e. bringing all of said mold sections into registry;
• f. heating said frothed foam resin composition to cause said foam resin to become a unitary material in conformity with said cavities and said reverse replica to produce a unitary foam resin article;
• g. removing said shaped, unitary foam resin article from said mold;
• h. applying adhesive over said replica surface of said produced foam resin article;
• and
• i. applying flock fibers over said surface where said adhesive has been applied to bond said fibers to said article and simulate surface