MOLD AND METHOD FOR MANUFACTURE OF MOLDED ELEMENT

1 . A method for production of a cushion element in a mold having a mold cavity, the mold comprising a first region for receiving a fastener assembly having a fastening surface, the method comprising the steps of:

(i) placing the fastener assembly in the mold such that at least a portion of the fastening surface contacts a first surface of the mold an interface;

(ii) dispensing a liquid foamable composition in the mold;

(iii) removing gas from the interface; and

(iv) expanding the liquid foamable composition to fill substantially the mold cavity to produce the cushion element.

2 . The method defined in claim 1 , wherein Step (iii) comprises removing gas from the interface after gas pressure at the interface reaches a predetermined value.

3 . The method defined in claim 1 , wherein Step (iii) comprises removing gas from the interface after gas pressure at the interface is a value up to about 5 psi.

4 . The method defined in claim 1 , wherein Step (iii) comprises removing gas from the interface after gas pressure at the interface is a value in the range of from about 1 psi about 5 psi.

5 . The method defined in claim 1 , wherein Step (iii) comprises removing gas from the interface after gas pressure at the interface is a value in the range of from about 1.5 psi about 4 psi.

6 . The method defined in claim 1 , wherein Step (iii) comprises removing gas from the interface after gas pressure at the interface is about 2.5 psi.

7 . The method defined in claim 6 , wherein the interface comprises a trench portion in the mold for receiving at least a portion of the fastening surface.

8 . The method defined in claim 7 , wherein Step (iii) comprises removing gas from the trench portion.

9 . The method defined in claim 8 , wherein the fastener assembly further comprises a resilient element in a marginal portion thereof.

10 . The method defined in claim 8 , wherein the fastener assembly further comprises a resilient element in a peripheral portion thereof such that the fastening surface is disposed in a central region of the fastener assembly.

11 . The method defined in claim 10 , wherein the resilient element comprising a foam element.

12 . The method defined in claim 11 , wherein the foam element has an Indentation Force Deflection, when measured pursuant to ASTM D3574-95 in the range of from about 10 to about 1000 pounds·force.

13 . The method defined in claim 11 , wherein the foam element has an Indentation Force Deflection in the range of from about 10 to about 500 pounds·force.

14 . The method defined in claim 11 , wherein the foam element has an Indentation Force Deflection in the range of from about 10 to about 250 pounds·force.

15 . The method defined in claim 11 , wherein the foam element has an Indentation Force Deflection in the range of from about 30 to about 100 pounds·force.

16 . The method defined in claim 15 , wherein the foam element comprises a polyurethane foam.

17 . The method defined in claim 16 , comprising the further step of:

(v) partially impregnating the resilient element with the liquid foamable composition

18 . The method defined in claims 17 , wherein the mold comprises a bowl and a lid engageable to define the mold cavity, and Step (i) comprises placing the fastener assembly in the bowl.

19 . The method defined in claim 18 , wherein the bowl and the lid are disengaged during Step (ii).

20 . The method defined in claim 19 , wherein the bowl and the lid are engaged after Step (ii).

21 . The method defined in claim 20 , wherein the mold comprises a magnet disposed adjacent the interface and Step (i) further comprises magnetically securing the fastener assembly with respect to the trench.

22 . The method defined in claim 21 , wherein Step (i) comprises placing the fastener assembly on a raised platform disposed in the mold cavity.

23 . A mold for production of a molded element, the mold comprising:

a first mold element and second mold element reversibly engageable to define a mold cavity;

at least one mechanical fastener receiving area disposed in at least one of the first mold element and the second mold element; and

a valve element in fluid communication with the at least one mechanical fastener receiving are, the valve element being actuated at a prescribed pressure to remove gas from the mechanical fastener receiving area.

24 . The mold defined in claim 23 , wherein the at least one mechanical fastener receiving area comprises a trench portion for receiving a fastening surface of a mechanical fastener.

25 . The mold defined in claim 24 , wherein the valve element is actuated at a gas pressure of up to about 5 psi.

26 . The mold defined in claim 24 , wherein the valve element is actuated at a gas pressure in the range of from about 1 psi about 5 psi.

27 . The mold defined in claim 24 , wherein the valve element is actuated at a gas pressure in the range of from about 1.5 psi about 4 psi.

28 . The mold defined in claim 24 , wherein the valve element is actuated at a gas pressure of about 2.5 psi.

29 . The mold defined in claim 28 , comprising a plurality of mechanical fastener receiving areas.

30 . The mold defined in claim 29 , further comprising a raised platform in which is disposed the at least one mechanical fastener receiving area.

31 . The mold defined in claim 29 , further comprising a raised platform in which is disposed one mechanical fastener receiving area.

32 . The mold defined in claim 29 , further comprising a raised platform in which is disposed a plurality of mechanical fastener receiving areas.

33 . The mold defined in claim 29 , wherein a single valve element is provided for each mechanical fastener receiving area.

34 . The mold defined in claim 29 , wherein a single valve element is provided for a plurality of mechanical fastener receiving areas.