Blow mold and backfill manufacturing process

A method for manufacturing a foam product, the method comprising:

• sealing a tube of material in a cavity of a mold;
• blowing air into the tube of material through an aperture to form a skin comprising an interior surrounded by a wall that conforms to the shape of the cavity;
• cutting an incision forming a closeable slit in the skin wall;
• inserting a bracket through the incision and into the skin interior;
• filling the skin interior with foam through the aperture;
• and
• curing the foam;
• wherein the skin comprises a recessed region on an underside of the skin wall configured to mate with a mounting assembly, the recessed region having a length and a width;
• and
• wherein the incision slit is located on the underside of the skin wall but is separate from the recessed region, the incision slit has a width, the underside of the skin wall has a width, and the incision is wider than the recessed region but less than the width of the underside of the skin wall.

A method for forming a foam product, the method comprising:

• blow molding a tube of polymeric material by blowing air through an aperture to form a skin comprising a skin wall surrounding an interior;
• cutting an incision into an underside of the skin wall;
• inserting a bracket at least partially into the skin interior through the incision without removing any material from the skin wall;
• filling the skin interior with foam through the aperture;
• and
• curing the foam;
• wherein the skin comprises a recessed region in the underside of the skin wall configured to mate with a mounting assembly, the recessed region having a length and a width;
• wherein a portion of the bracket is wider than the width of the recessed region;
• wherein the incision is located entirely on the underside of the skin wall, has a width, and is separate from the recessed region;
• wherein the skin wall underside has a width, and the incision is wider than the recessed region but less than the width of the underside of the skin wall;
• and
• wherein the incision allows skin distortion to form an opening for inserting the bracket upon application of pressure, with the opening closing upon release of pressure.