Soft molded composites and a process for their production

A process for the production of a soft composite in a closed mold comprising:

• a) applying a composition which forms a soft elastomer that includes a prepolymer of diphenylmethane diisocyanate having an NCO content of from about 8 to about 17% by weight and at least one isocyanate-reactive compound with at least two isocyanate-reactive groups to the interior walls of the open mold;
• b) introducing a composition which is made up of
• 1) a mixture of diphenylmethane diisocyanates and/or polyisocyanates having an NCO content of from about 32.0 to about 32.8 which isocyanates are not prepolymers,
• 2) a polyol mixture having a functionality of at least two and molecular weight of from about 400 to about 8,000,
• 3) a blowing agent,
• 4) an amine catalyst, and
• 5) an amine crosslinking agent and will react to form a low density, high resiliency, flexible foam under molding conditions in an amount such that the formed foam will fill the mold into the mold in a manner such that this composition will be substantially completely within the elastomer-forming composition present on the mold walls;
• c) closing the mold and
• d) allowing the composition introduced in b) to form a foam.