Provision of a non-woven or woven sheet on a moulded part

Abstract

The invention is in the field of forming objects with a mould apparatus further comprising addition of at least one sheet to said object, in particular with a low or a high pressure mould apparatus, a method of forming a mould object including such at least one sheet, a mould piece obtained by said method or from said apparatus, wherein the object comprises a polymeric material.

Description

[0001] PROVISION OF A NON-WOVEN OR WOVEN SHEET ON A MOULDED PART

[0002] FIELD OF THE INVENTION

[0003] The invention is in the field of forming objects with a mould apparatus further comprising addition of a sheet to said object, in particular with a low or a high pressure mould apparatus, a method of forming a mould object including such a sheet, a mould piece obtained by said method or from said apparatus, wherein the object comprises a polymeric material.

[0004] RELATED APPLICATIONS

[0005] The present application claims the benefit of priority from Dutch Patent Application NL2038205, filed on July 11, 2024, in the name of HSV Technical Moulded Parts Group N.V., The Netherlands.

[0006] The entire contents of the above-referenced applications and of all priority documents referenced in the Application Data Sheet filed herewith are hereby incorporated by reference for all purposes.

[0007] BACKGROUND OF THE INVENTION

[0008] The present invention relates to an injection moulding in a thereto suitable apparatus. A mould is also referred to as a die. Injection moulding relates to a manufacturing process for producing large numbers of same parts by injecting a molten material into a mould, which mould is used over and over again. After injecting, the part is removed from the mould. Suitable materials for injection moulding include materials that melt at relatively low temperatures, such as metals, glasses, polymers, such as elastomers, thermoplastic polymers, and also alloys or blends. Materials are typically selected on the desired properties for the part formed, such as strength, elasticity, Youngs modulus, flexural strength, compressive strength, as well as costs. The material to be injected is melted before entering the mould, may be mixed thoroughly, and may be provided with further additives. When melted it is typically injected under force into a mould cavity. In the mould it cools down and solidifies. If injected properly the solidified material has the form of the internal of the cavity.

[0009] It is relatively important to design a mould properly, in order to obtain parts in a reproducible and easy, cost effective manner. Typically, a product part is designed for a given purpose or use. Then a mould is made, typically from metal, such as steel or aluminium. Mould making may be considered an art, and typically requires precision-machining to form the features of a desired part. Injection moulding is widely used for manufacturing a variety of parts.

[0010] Injection moulding typically is relatively complicated, such as in terms of equipment used. A typical injection moulding apparatus comprises an injection unit for injection the molten material, the mould itself into which the molten material is injected, and at least one clamp. The mould itself typically comprises two primary components, typically two plate-like elements, referred to as the injection mould (A plate) and the ejector mould (B plate). Further the mould comprises an injection opening, typically referred to as sprue or gate. The injection opening is designed to seal tightly against a nozzle or the like of an injection barrel of the moulding machine, the injection barrel providing molten material, and to allow molten material to flow from the barrel into the mould, the mould comprising a cavity. The injection opening bushing directs the molten material into the cavity, typically through channels. These channels are thereto typically machined into the faces of the A and B plates above. These channels provide fluid connection between the barrel and cavity, and are also referred to as runners. The molten material flows through the channel and may further enter one or more specialized gates and into the cavity to form the desired part.

[0011] Some typically precautions may be taken. For instance, trapped air in the mould and molten material can escape through air vents that are provided, typically ground into the parting line of the mould, or around ejector pins and slides that are slightly smaller than the holes retaining them. If the trapped air is not allowed to escape, it is compressed by the pressure of the incoming material and may be forced into the corners of the cavity. When trapped it prevents filling and can also cause other defects. The air can even become so compressed that it ignites and burns the surrounding plastic material. Further material is heated meticulously in order to provide a homogeneous molten material, before it enters the cavity. Typically, a mould may be cooled, in order to maintain at an acceptable temperature.

[0012] Injection moulding is typically performed in cycles, referred to as the injection moulding cycle. Arbitrarily, a cycle begins with the closing of the mould. The molten material is injected into the mould cavity. After filling the cavity, a holding pressure is typically maintained, such as to compensate for material shrinkage. The next amount of molten material (shot) may be fed to the front screw. And so on. Once the part formed in the mould is sufficiently cool, the mould can open and the part is ejected.

[0013] However, for making a moulded object further comprising a sheet or the like, the provision of such a sheet in the method of making is complicated. For instance, the sheet is difficult to handle, handling is difficult to automate, and it is difficult to maintain the sheet in a required position. This is especially the case of injection moulding.

[0014] Incidentally reference can be made to KR 2003 0015155 A, US 2018 / 215085 A1, and WO 2023 / 274712 A1. KR 2003 0015155 A (or EP 1 284 182) recites a cover sheet comprising a thermoplastic film and a foam backing is heated to a specific temperature. The front and back molds between which the cover sheet is arranged, are moved relatively towards each other, so that the melted skin layer reproduces the front mold surface texture. The cover sheet is then cooled and the molds are separated. An Independent claim is also included for the apparatus for making a molded component. US 2018 / 215085 A1 recites a method for producing a part includes the steps of: positioning an insert in a mold via a gripping element, able to be actuated between an inactive configuration and an active configuration, of a gripping device comprising a shaping wall; shaping the insert in a reinforcing element against a surface; during positioning, maintaining a separation between the surface and the insert, and moving the shaping wall to apply the insert against the surface; and during the shaping, applying the shaping wall and the gripping element against the insert and the surface, the element being actuated in its inactive configuration before the application of the shaping wall. WO 2023 / 274712 A1 recites an injection moulding apparatus which is designed to produce an injection-moulded part provided with a decorative element, the decorative element comprising at least one design element, wherein the injection moulding apparatus comprises: a mould cavity in which the decorative element is situated; a mould comprising at least two mould elements, in particular a punch and a die, in order to open and close the mould; a filling apparatus which is designed to fill, when the mould is closed or partially closed, an injection-moulding compound into the mould cavity; at least one fixing apparatus which is designed to fix the decorative element in the mould cavity. According to the invention, the injection moulding apparatus also comprises a supply element which is designed to supply the decorative element into the open mould and to orient the decorative element relative to the mould in a target position (SP), wherein the supply element is designed to orient the decorative element according to a position and / or orientation and / or shape of the at least one design element. The invention also relates to a production method for an injection-moulded part using the injection moulding apparatus.

[0015] The present invention therefore relates to an improved method for injection moulding, and further aspects thereof, which overcomes one or more of the above disadvantages, without jeopardizing functionality and advantages.

[0016] SUMMARY OF THE INVENTION

[0017] The present invention relates in a first aspect to a method of providing a moulded polymeric foam with a woven or non-woven first sheet, comprising (i) providing the first sheet, wherein the first sheet may be provided as such, or may be treated into a required form, (ii) moving the first sheet with a gripper to an injection mould apparatus, (iii) positioning the first sheet with the gripper in the mould apparatus in a first mould, the sheet facing the first mould, (iv) controlling a constant distance between the first sheet and first mould, (v) releasing the gripper and removing the gripper from the mould apparatus, (vi) providing a second mould complementary to the first mould on the first mould forming an enclosed mould, and (vii) providing a polymeric foam on the first sheet. The woven or non-woven sheet, or likewise nonwoven fabric or non-woven fabric relates to a fabric-like material typically made from staple fibre, being relatively short, and long fibres, bonded together by chemical, mechanical, heat or solvent treatment. The sheet is a broad rectangular thin piece of e.g. cloth, such as linen or cotton, The term is used to denote fabrics, such as felt, which are neither woven nor knitted. Some non-woven materials lack sufficient strength unless densified or reinforced by a backing. In recent years, non-wovens have become an alternative to polyurethane foam. Woven fabric is typically a textile formed by weaving. Woven fabrics are often created on a loom, and made of many threads woven on a warp and a weft. Technically, a woven fabric is any fabric made by interlacing two or more threads at right angles to one another. Woven fabrics can be made of natural fibres, synthetic fibres, or a mixture of both, such as cotton and polyester. The present sheet is relatively thin, and therefore to some extent difficult to handle, in particular when it needs to be put in place, and maintained in place. The present invention in particular relates to a method of putting such a sheet in place, maintaining it in place, and, in addition, at more or less the precise location and position, such as in a mould apparatus. Thereto e.g. a gripper is used, which in an embodiment is specifically designed to move and manipulate the sheet accordingly. Not only is the sheet put in position, with reference to a mould, typically a first side thereof, that is, wherein the sheet faces a surface of the first mould such that substantially the full surface of the first mould is covered with the sheet, but the sheet is also maintained at a distance configured to provide a good adherence of the to be applied polymeric foam. If required, likewise a partial surface of the first mould is covered, and as a consequence of a product formed, in particular 10-90% thereof such as 30- 70% thereof. The distance is typically such that the first sheet and the first mould are in substantially full contact with one and another. Clearly, before providing the polymeric foam, the gripper is released and removed. Then the second mould complementary to the first mould is provided, that is, together forming an enclosed space representative of the mould object to be formed, on the first mould forming an enclosed mould. Through injection openings the polymeric foam is provided, such that it adheres to the first sheet. The polymeric foam may be provided as such, or may be generated inside the enclosed mould, such as by the provision of a blowing agent, a reactant, etc. In a typical example the first sheet is so to say fully impregnated with the polymeric foam, yet a surface of the formed object still has the looks and feel of the first sheet; in a further typical example a surface of the first sheet is partly impregnated, in particular 10-90% impregnated, such as 30-70% impregnated. Therewith drawbacks of prior art methods are overcome, reproducible foam objects comprising at least one sheet at at least one outer side thereof, can be produced in a reliable manner.

[0018] The terms “first” and “second”, as in reference to a mould, a sheet, etc. are not limiting and can be interchanged. In a second aspect the present invention relates to a product obtainable by a method according to the invention, in particular for use as a support, more in particular a damping support, such as for damping impact. When the present product is used as a support, the polymeric foam provides damping of vibrations and the like. As a result e.g. noise is reduced. A mould piece obtained by a method according to the invention, in particular a mould piece selected from a mould piece with a volume of 0.1-100 dm3, in particular 0.2-50 dm3, more in particular 0.5-10 dm3, even more in particular 1-7 dm3,

[0019] In a third aspect the present invention relates to an injection mould apparatus, comprising a first mould, a second mould complementary to the first mould, characterized in that the first mould comprises at least one transit opening, wherein the at least one transit opening is configured for transition of a set of third moveable pointed rods, wherein the third moveable pointed rods are configured to maintain a first sheet into place and substantially in full contact with an inward surface of the mould, and wherein the second mould optionally comprises a set of ejector pins, the set of injector pins configured to support the place maintenance of the first sheet. At least one of the first and second mould further comprises injection openings, for providing a polymeric foam or the like.

[0020] Thereby the present invention provides a solution to one or more of the above-mentioned problems.

[0021] Advantages of the present invention are detailed throughout the description.

[0022] DETAILED DESCRIPTION OF THE INVENTION

[0023] The present invention relates in a first aspect to an injection moulding apparatus.

[0024] In an exemplary embodiment the present method further comprises before (vii) providing the polymeric foam, providing a second sheet in the second mould, and / or releasing the second mould and removing the polymeric foam-sheet from the mould apparatus. Therewith the present product is obtained.

[0025] In an exemplary embodiment of the present method the sheet is provided on a flat surface, such as a table, wherein the gripper comprises at least two sets of moveable pointed rods, such as needles, a first set of points of the pointed rods extending substantially perpendicular from a first gripper surface, and a second set of points of the pointed rods extending under an angle of 30-60 degrees with respect to the first gripper surface, in particular 40-50 degrees, and wherein an opposite end of the pointed rods extends from a second surface of the gripper opposite to the first surface of the gripper, and wherein the points of the pointed rods are provided through the sheet. The present gripper is especially suited for transferring a sheet e.g. from a location where it is formed in it’s required form to the injection mould apparatus, specifically to a first mould thereof. During transfer, and in particular when positioning the first sheet into the first mould, the form of the sheet is carefully maintained by the respective sets of pointed rods. Each set of pointed rods, including the third set, may have a plurality of rods, such as 2-100, depending e.g. on a size of the sheet, in particular 5-50 rods, more in particular 10-20 rods. Put different, typically about 0.2-10 rods per dm2of sheet is provided, in particular 1-8 rods per dm2, such as 2-6 rods per dm2.

[0026] In an exemplary embodiment of the present method first the points of the second set of pointed rods are provided through the sheet, and then the points of the first set of pointed rods. In an exemplary embodiment of the present method the gripper is provided with at least one moveable plunger, wherein movement of the at least one plunger is perpendicular to a / the first surface of the gripper, and wherein the at least one plunger provides (iv) controlling of the constant distance.

[0027] In an exemplary embodiment of the present method the movement of the at least plunger is controlled by at least one piston, in particular at least one releasable piston. Therewith the plunger can easily be released.

[0028] In an exemplary embodiment of the present method before (vii) providing the polymeric foam the / a second set of pointed rods is retracted from the sheet. Once the sheet is in position the rods can be retracted, one by one, or set by set.

[0029] In an exemplary embodiment of the present method the first mould is provided with mould release rods, in particular pointed mould release rods, also referred to as a set of third moveable pointed rods, such as needles, wherein the mould release rods are configured to extend through the first mould, and are configured to release the gripper from the formed polymeric foam / sheet from the first mould.

[0030] In an exemplary embodiment of the present method the mould release rods are retracted after providing the polymeric foam.

[0031] In an exemplary embodiment the present method comprises providing the injection moulded product with or without the sheet, moving the moulded product with a second gripper, such as s robot gripper, to a flat surface, such as a second table, melting a top surface of the moulded product, such as with an infrared source, moving the moulded product with the melted top surface to a first table, the first table comprising a second sheet of woven or non-woven material, and adhering the top surface to the sheet. As such a further sheet, that is second sheet, can be provided on the moulded product of the invention.

[0032] In an exemplary embodiment of the present method adhering is performed under pressure, such as a pressure of 50-500 kPa.

[0033] In an exemplary embodiment of the present method the pointed rods have a diameter of 1- 10 mm, in particular wherein the first set pointed rods have a diameter of 7-9 mm, and wherein the second set pointed rods have a diameter of 1-4 mm, and wherein the third set pointed rods have a diameter of 1-4 mm.

[0034] In an exemplary embodiment of the present method the form of the points of the pointed rods is selected from symmetrical with respect to a longitudinal axis of the rod, and one sided acute angle, such as 50-80 degrees at a longest side of the rod with respect to a longitudinal axis of the rod.

[0035] In an exemplary embodiment of the present method the rod is selected from a hollow rod, and a solid rod., and / or wherein the rod is made from a material selected from a metal, and an alloy.

[0036] In an exemplary embodiment of the present method the polymer of the foam and of the melted top surface each individually are selected from thermoplastic polymers, more in particular from poly acrylates, poly alkadienes, poly amides, poly carboxylic acids, poly ethers, poly esters, poly imidazoles, poly sulfones, poly oxyalkylenes, poly ketones, poly imides, poly alkylenes, poly chlorides, poly phenylene oxides and sulphides, poly vinylidene fluoride, poly tetra fluoro ethylene, poly urethanes, and copolymers thereof, and combinations thereof, in particular from Low Density Poly-Ethylene, High Density Poly-Ethylene, Poly-Propylene, Poly-Styrene, Acrylonitrile Butadiene Styrene, Poly-Amide, Poly-Carbonate, Acrylonitrile Styrene Acrylate, and optionally comprising at least one of a 1-20 wt.% filler, such as Talcum, Glass fibre, and Glass beads, 0.1-5 wt.% Flame retardant, 0.01-5 wt.% UV-Stabilizer, 0.1-5 wt.% Color Masterbatch, 0.1-5 wt.% Physical Blowing Agent, and 0.1-5 wt.% Chemical Blowing Agent, and / or wherein the foam has a specific density of 0.8-2 kg / dm3, in particular 0.9-1.5 kg / dm3. A large variety of foams may be used, providing less or more dense foams.

[0037] In an exemplary embodiment of the present method the material of the first and second sheet each independently is selected from natural materials, semi-synthetic materials, and synthetic materials, in particular from plant fibre, natural fibre, and animal fibre, more in particular from felt, cotton, hemp, jute, silk, wool, polyester, polyamide, polyacrylic, elastane, rayon, acetate silk, viscose, polypropylene, and polyacrylate,.

[0038] In an exemplary embodiment of the present method the sheet has a thickness of 0.1-5 mm, in particular 0.2-4 mm, such as 1-2.5 mm. The first and optional second sheets are typically rather thin.

[0039] In an exemplary embodiment of the present method the polymeric foam has a thickness of 3-25 mm, such as 4-16 mm. Especially in view of a piano, the foam need not be too thick, or too thin. Suitable thicknesses are found to be in the above ranges. In an exemplary embodiment of the present method the thickness is selected from constant and variable. In particular when having a piano, a thickness of the polymeric foam may vary, such as to provide suitable folding lines. Fig. 3c shows an example thereof.

[0040] In an exemplary embodiment the present product is a piano, in particular a piano with at least one folding line, more in particular 1-3 folding lines at each side.

[0041] In an exemplary embodiment of the present product the piano, when folded, is configured to have a 1-20% larger surface area at a top section than at a bottom section thereof.

[0042] In an exemplary embodiment of the present product the piano is configured to form a tray when folded, in particular wherein the piano has a central section, at each side of the central section a fold line, and opposing the fold line at each side of the central section a peripheral section, wherein opposing peripheral sections with respect to a respective horizontal or vertical axis of the piano are the same.

[0043] In an exemplary embodiment of the present product the piano, when folded, is configured to have gradually extending side planes with respect to a centre of the piano.

[0044] In an exemplary embodiment of the present product the piano has two perpendicular axes of symmetry, and / or wherein a fold line is provided as an indentation having a downward face at an edge of a centre section of the piano, and a rising face, and / or wherein the piano is provide with a non-woven or woven sheet at a first side thereof, typically the side forming the inner part of the tray when folded, and optional with a non-woven or woven sheet at a second side thereof opposite to the first side, and / or wherein the each side section of the piano increases in width from the fold line to an outer edge thereof, and / or wherein at least one section of the piano has at least one recess, in particular a regular recess, such as a circular recess, more in particular 1-10 recesses per 100 cm2, and / or wherein the recesses are equally distributed over a surface of the piano, and / or wherein a recess has a surface area of 5-100 m2, and / or wherein the piano, when folded, forms a tray with a volume of 1-50 dm3, in particular 5-25 dm3, more in particular 12-20 dm3.

[0045] In an exemplary embodiment the present injection mould apparatus further comprises a gripper for gripping a non-woven or woven sheet, wherein the gripper comprises a set of first moveable pointed rods, and a set of second moveable pointed rods, a first set of points of the pointed rods extending substantially perpendicular from a first gripper surface, and a second set of points of the pointed rods extending under an angle of 30-60 degrees with respect to the first gripper surface, in particular 40-50 degrees, and wherein an opposite end of the pointed rods extends from a second surface of the gripper opposite to the first surface of the gripper.

[0046] The invention is further detailed by the accompanying figures and examples, which are exemplary and explanatory of nature and are not limiting the scope of the invention. To the person skilled in the art it may be clear that many variants, being obvious or not, may be conceivable falling within the scope of protection, defined by the present claims.

[0047] SUMMARY OF THE FIGURES

[0048] Figure 1a-x, 2a-q and 3a-c show exemplary embodiments of the present invention.

[0049] DETAILED DESCRIPTION OF THE FIGURES

[0050] In the figures:

[0051] 10 first support, e.g. table

[0052] 11 second support, e.g. table

[0053] 20 sheet, e.g. felt

[0054] 30 injection moulded object

[0055] 31 melted polymer

[0056] 51 mould; A-side

[0057] 52 mould; B-side

[0058] 53 ejector pin

[0059] 61 needle of first set

[0060] 62 needle of second set

[0061] 63 needle of third set

[0062] 70 gripper, such as robot gripper

[0063] 71 plunger

[0064] 72 (pneumatic) cylinder

[0065] 73 push back rod

[0066] 80 heat source, such as IR-heat source

[0067] 90 press

[0068] Fig. 1a-aa shows an exemplary method. In fig. 1a a felt is provided on a table. The gripper approaches the table. The gripper has a set of first needles and a set of second needles, which may be moved relative to the gripper. In fig. 1b the gripper approaches the felt, presses against the felt (fig. 1c) and then a first or second set of needles, typically the second set first, is extended through the gripper and through the felt (figs. 1d-f). Therewith the felt is firmly attached to the gripper. The gripper then moves away from the table (fig. 1g) and is positioned such that it can approach the first mould, e.g. by rotation of the gripper (fig. 1g). Then the gripper including the felt approaches the mould (fig. 1h). The gripper may be a robotic gripper, or operated in an automated fashion, or operated in an auto mechanical manner, or combinations thereof. In other words, the present process may be fully automated, or partly automated. The gripper then is typically provided with a plunger system, comprising at least one piston, and maybe further provided with push back rods for easy release (fig. 1i). The gripper is the moved to the first mould such that the felt comes into close contact with the first mould (figs, lj-1l). the push back rods also protect the needles and the mould from being damaged. The first and second sets of needles are then retracted from the felt, into the gripper, while the push back rods keep the felt in position and away from the first mould (figs. 1m-1p). In the mean time the cylinder and pneumatic rods can be released from the gripper (figs. 1n-1o). The felt is present against the first mould by the push back rods (fig. 1q). Then a third set of needles is provided through the first mould, extending through the felt (figs. 1r-1t). The felt is now firmly attached and in close contact with the surface of the first mould. The gripper is then released from the first mould (fig. 1u). Now the second mould is provided, optionally with ejector pins, and positioned against the first mould to form a combined mould with an enclosed space (figs. 1v-lw). Polymeric foam is provided through injection openings (fig. 1x), the third set of needles is retracted (fig. 1y) the second and first mould are separated from one and another (fig. 1z) and the obtained mould product is released form the (first) mould (fig. 1aa).

[0069] Figs. 2a-q show a further exemplary method. A moulded product, with or without first sheet, is provided and moved with a robotic gripper to a table (figs. 2a-b). The gripper is removed (fig. 2c). Then a heat source, such as an IR-lamp, is provided (fig.2d), brought into proximity of the moulded product (fig. 2e) where it starts to melt a top surface or surface layer of the moulded product (figs. 2f-2g). The heat source is moved away (fig. 2g), the partly melted moulded product is taken by a gripper and is rotated (fig.2h-2i) to be in orientation for adhering of the second sheet. It is then brought into contact with the second sheet (fig. 2j), a press is provided (fig. 2k) to provide pressure to the combined mould / second sheet (fig. 21) during a sufficient time (fig. 2m) to adhere the mould and the sheet together. The press is removed (fig. 2n, the combined mould / felt is left to rest (fig. 2o), the ripper is moved away from the product (fig. 2p) and the product is obtained (fig. 2q).

[0070] Fig. 3a shows a piano obtained by the present method, having two axes of symmetry, three weld lines per side section, and recesses in the central section. This piano can be folded into the tray of fig. 3b. Fig. 3c shows an example of fold line, wherein a central section is at a left side, quickly decreasing in thickness there where the fold line is provided, whereas a side section shown gradually increases in thickness to the right thereof, therewith providing a good fit of the side sections with the central section when folded.

Claims

AMENDED CLAIMS received by the International Bureau on 10 December 2025 (10.12.2025)

1. A method of providing a moulded polymeric foam with a first woven or non-woven sheet, comprising(i) providing the first sheet,(ii) moving the first sheet with a gripper to an injection mould apparatus, wherein the gripper comprises at least two sets of moveable pointed rods,(iii) positioning the first sheet with the gripper in the mould apparatus in a first mould, the sheet facing the first mould,(iv) controlling a constant distance between the first sheet and first mould,(v) releasing the gripper and removing the gripper from the mould apparatus,(vi) providing a second mould complementary to the first mould on the first mould forming an enclosed mould, and(vii) providing a polymeric foam on the first sheet.

2. The method according to claim 1, further comprising before (vii) providing the polymeric foam, providing a second sheet in a second mould, and / or releasing the second mould and removing the polymeric foam- sheet from the mould apparatus.

3. The method according to any of claims 1-2, wherein the sheet is provided on a flat surface, such as a table, wherein the gripper comprises needles, a first set of points of the pointed rods extending substantially perpendicular from a first gripper surface, and a second set of points of the pointed rods extending under an angle of 30-60 degrees with respect to the first gripper surface, in particular 40-50 degrees, and wherein an opposite end of the pointed rods extends from a second surface of the gripper opposite to the first surface of the gripper, and wherein the points of the pointed rods are provided through the sheet.

4. The method according to claim 3, wherein first the points of the second set of pointed rods are provided through the sheet, and then the points of the first set of pointed rods.

5. The method according to any of claims 1-4, wherein the gripper is provided with at least one moveable plunger, wherein movement of the at least one plunger is perpendicular to a / the first surface of the gripper, and wherein the at least one plunger provides (iv) controlling of the constant distance.

6. The method according to claim 5, wherein the movement of the at least plunger is controlled by at least one piston, in particular at least one releasable piston.

7. The method according to any of claims 1-6, wherein before (vii) providing the polymeric foam the / a second set of pointed rods is retracted from the sheet.

8. The method according to any of claims 1-7, wherein the first mould is provided with mould release rods, in particular pointed mould release rods, such as needles, wherein the mould release rods are configured to extend through the first mould, and are configured to release the gripper from the formed polymeric foam / sheet from the first mould.

9. The method according to claim 8, wherein the mould release rods are retracted after providing the polymeric foam.

10. The method according to any of claims 1-9, comprising Providing the injection moulded product with or without the sheet,Moving the moulded product with a second gripper, such as s robot gripper, to a flat surface, such as a second table, Melting a top surface of the moulded product, such as with an infrared source,Moving the moulded product with the melted top surface to a first table, the first table comprising a second sheet of woven or non- woven material, andAdhering the top surface to the sheet.

11. The method according to claim 10, wherein adhering is performed under pressure, such as a pressure of 50-500 kPa.

12. The method according to any of claims 3-11, wherein the pointed rods have a diameter of 1-10 mm, in particular wherein the first set pointed rods have a diameter of 7-9 mm, and wherein the second set pointed rods have a diameter of 1-4 mm, and / or wherein the form of the points of the pointed rods is selected from symmetrical with respect to a longitudinal axis of the rod, and onesided acute angle, such as 50-80 degrees at a longest side of the rod with respect to a longitudinal axis of the rod, and / or wherein the rod is selected from hollow, and solid, and / or wherein the rod is made from a material selected from a metal, and an alloy.

13. The method according to any of claims 10-12, wherein the polymer of the foam and of the melted top surface each individually are selected from thermoplastic polymers, more in particular from poly acrylates, poly alkadienes, poly amides, poly carboxylic acids, poly ethers, poly esters, poly imidazoles, poly sulfones, poly oxyalkylenes, poly ketones, poly imides, poly alkylenes, poly chlorides, poly phenylene oxides and sulphides, poly vinylidene fluoride, poly tetra fluoro ethylene, poly urethanes, and copolymers thereof, and combinations thereof, in particular from Low Density Poly-Ethylene, High Density Poly- Ethylene, Poly-Propylene, Poly-Styrene, Acrylonitrile Butadiene Styrene, Poly-Amide, Poly-Carbonate, Acrylonitrile Styrene Acrylate, and optionally comprising 1-20 wt.% filler, such as Talcum, Glass fibre, and Glass beads, 0.1-5 wt.% Flame retardant, 0.01-5 wt.% UV-Stabilizer, 0.1-5 wt.% Color Masterbatch, 0.1-5 wt.% Physical Blowing Agent, and 0.1-5 wt.% Chemical Blowing Agent, and / or wherein the foam has a specific density of 0.8-2 kg / dm3, in particular 0.9-1.5 kg / dm3.

14. The method according to any of claims 2-13, wherein the material of the first and second sheet each independently is selected from natural materials, semi-synthetic materials, and synthetic materials, in particular from plant fibre, natural fibre, and animal fibre, more in particular from felt, cotton, hemp, jute, silk, wool, polyester, polyamide, polyacrylic, elastane, rayon, acetate silk, viscose, polypropylene, and polyacrylate, and / or wherein the sheet has a thickness of 0.1-5 mm, in particular 0.2-4 mm, such as 1-2.5 mm, and / or wherein the polymeric foam has a thickness of 3-25 mm, such as 4-16 mm, and / or wherein the thickness is selected from constant and variable.

15. Product obtained by a method according to any of claims 1-14, wherein the product is a piano with at least one folding line, for use as a support, more in particular a damping support.

16. Product according to claim 15, wherein the product is a piano, with 1-3 folding lines at each side.

17. Product according to claim 16, wherein the piano, when folded, is configured to have a 1-20% larger surface area at a top section than at a bottom section thereof, and / or wherein the piano is configured to form a tray when folded, in particular wherein the piano has a central section, at each side of the central section a fold line, and opposing the fold line at each side of the central section a peripheral section, wherein opposing peripheral sections with respect to a respective horizontal or vertical axis of the piano are the same, and / or wherein the piano, when folded, is configured to have gradually extending side planes with respect to a centre of the piano, and / or wherein the piano has two perpendicular axes of symmetry, and / or wherein a fold line is provided as an indentation having a downward face at an edge of a centre section of the piano, and a rising face, and / or wherein the piano is provide with a non-woven or woven sheet at a first side thereof, typically the side forming the inner part of the tray when folded, and optional with a non-woven or woven sheet at a second side thereof opposite to the first side, and / or wherein the side section of the piano increases in width from the fold line to an outer edge thereof, and / or wherein at least one section of the piano has at least one recess, in particular a regular recess, such as a circular recess, more in particular 1-10 recesses per 100 cm2, and / or wherein the recesses are equally distributed over a surface of the piano, and / or wherein a recess has a surface area of 5-100 m2, and / or wherein the piano, when folded, forms a tray with a volume of 1-50 dm3, in particular 5-25 dm3, more in particular 12-20 dm3.

18. An injection mould apparatus, comprising a first mould,a second mould complementary to the first mould, characterized in that the first mould comprises at least one transit opening, wherein the at least one transit opening is configured for transition of a set of third moveable pointed rods, wherein the second mould optionally comprises a set of ejector pins, and further comprising a gripper for gripping a non-woven or woven sheet, wherein the gripper comprises a set of first moveable pointed rods, and a set of second moveable pointed rods, a first set of points of the pointed rods extending substantially perpendicular from a first gripper surface, and a second set of points of the pointed rods extending under an angle of 30-60 degrees with respect to the first gripper surface, in particular 40-50 degrees.

19. The injection mould apparatus according to claim 18, wherein wherein an opposite end of the pointed rods extends from a second surface of the gripper opposite to the first surface of the gripper.

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