| abstract |
An integral foam product consisting of a substantially closed three-layer laminate skin formed to a final desired shape, and a foam body which is formed by injecting an expandable mixture, for example, a raw liquid of reactive polyurethane in the form of a liquid or cream and combined unitarily with the inner surface of the skin without permeating into the skin. The three-layer laminate skin consists of an outermost layer composed of a gas-permeable cloth, such as a knitted cloth or a woven cloth, an intermediate layer composed of thin foam, such as thin urethane foam and combined with the inner surface of the outermost layer, and a screening film combined with the inner surface of the intermediate layer and composed, for example, of a polyvinyl chloride film or a polyurethane film having therein a plurality of fine pores capable of passing a gas therethrough but incapable of passing an expandable mixture therethrough. The screening film ensures the excellent fluidity of the expandable mixture owing to the excellent smoothness thereof, prevents any permeation of the expandable mixture into the intermediate layer of the foam film and the outermost layer, and enables the formation of a generally soft and homogeneous foam body. |