Method of molding articles of polymeric foam substantially free from flashing

Claim 1

A process for molding an article of polymer foam substantially free from flashing using a polymer foam forming mix comprising ingredients which undergo chemical interaction with simultaneous blowing in situ, said process being characterized by the steps of: providing a two piece mold, one of said mold pieces being substantially rigid and the other of said mold pieces being relatively flexible; providing a jig comprising two facing jig members held in permanent, spaced apart, relationship one of said jig members having disposed thereon an inflatable hollow flexible bag; providing an opening in said jig to permit insertion of said assembled two piece mold between said facing jig members without disassembly, in whole or in part, of said jig; charging polymer foam forming mix to the cavity of said two piece mold; inserting said charged mold, after assembly thereof, between the said two facing jig members via said opening in said jig; inflating said hollow flexible bag to a pressure such that the two mold pieces are held in sealing engagement one with the other and said mold is held in clamped engagement with said jig solely by means of said inflated bag; permitting said foam mix to expand and set in said mold so disposed in said jig; thereafter deflating said flexible bag and removing said mold and contents from said jig via said opening without disassembly of said jig in whole or in part, and demolding said article of polymer foam.