Flexible gasketing device for foam control in crash pad pour molds

A method of forming a molded product comprising the steps of:

• placing a flexible gasket having a generally planar shape in an opening of a backing insert, thereby defining a space between the gasket and a portion of the insert to be protected from seepage of foam during molding;
• placing the backing insert and flexible gasket on a complementary surface of a first mold half adjacent a planar portion thereof;
• placing a continuous skin shell in a second mold half of complementary configuration to the first mold half and on a planar portion thereof so as to have a portion of the skin shell located adjacent the flexible gasket and in sealing engagement with portions of the flexible gasket when closing of the first mold half and the second mold half occurs;
• pouring an expandable foam formulation onto the skin shell in the second mold half;
• closing the mold halves so as to compress the flexible gasket between the first and second mold halves and the backing insert at the planar portions to prevent the expandable foam formulation from filling the space defined by the backing insert and the flexible gasket between the mold halves;
• expanding the foam formulation to adhere the skin shell to the backing insert;
• separating the mold halves;
• removing the adhered backing insert, foam, flexible gasket and skin combination comprising the product from the mold half;
• cutting and removing the skin shell over the flexible gasket from the remaining combination;
• and
• flexing and removing the flexible gasket from the backing insert and skin shell for reuse, creating an opening in the product.