Multidensity foam article and method of preparation

Abstract

A multidensity polyurethane foam article suitable for use as a seat cushion includes a supportive layer of firm foam and a comfortable layer of softer foam. The multidensity article has a sag factor of about 3.0 to about 4.5, and the two foam layers are bonded together without employing adhesives. The multidensity foam article is prepared by placing a first formulation capable of yielding a firm foam into a mold and permitting said formulation to start creaming, rising and foaming; introducing a second liquid formulation capable of forming a soft foam into the mold after the first formulation has completed 10 to 80% of its potential rise so that the second formulation passes through the rising first formulation and the first formulation floats upon the second formulation; and then permitting the two formulations to cream, foam, rise and cure into a single multidensity article having a firm supportive foam layer and a soft foam layer, which layers are bonded and knitted together at their common boundary during the curing process.

Dependencies are inferred from the claim text.