Method for producing a multilayered part

A method for producing a multilayered part comprising a moulded core (5) and a flexible polyurethane layer (4) formed by a flexible polyurethane skin layer or by a flexible integral skin polyurethane foam layer, the moulded core (5) comprising a moulded substrate layer (1) made of a substrate material having a Shore A hardness higher than 60 and the flexible polyurethane layer (4) having an average density higher than 400 kg/m3, which method comprises the steps of:

• providing a mould (11, 12) having at least a first and a second mould section which are movable with respect to one another to open and close the mould;
• providing said core (5) inside said mould (11, 12) so that a gap (14) exists between the surface of the core (5) and the internal wall of the mould when the mould is closed;
• introducing a polyurethane reaction mixture in said gap (14) between the surface of the core (5) and the internal wall of the mould (11, 12) to overmould at least a first area of the core surface with the polyurethane reaction mixture;
• allowing said polyurethane reaction mixture to cure in said gap (14) to produce the flexible polyurethane layer (4) therein;
• and
• opening the mould (11, 12) and removing the produced multilayered part,
• characterised in that
• the moulded core (5) which is provided in said mould (11, 12) comprises said substrate layer (1) and at least one softer moulded part (2, 3), which is moulded onto the substrate layer (1) or said substrate layer (1) is moulded onto the softer moulded part (2, 3) or the substrate layer (1) and the softer moulded part (2, 3) are moulded against one another, said softer moulded part (2, 3) being made of a softer material with a Shore A hardness lower than 60 and forming a second area of the core surface.