Method for manufacturing foaming composite molding, in-mold foaming molding unit, foaming composite molding, and mold for foaming composite molding

Patent metadata

Field	Value
Publication number	US-11077588-B2
Application number	US-201816146280-A
Country	US
Kind code	B2
Filing date	Sep 28, 2018
Priority date	Mar 29, 2016
Publication date	Aug 3, 2021
Grant date	Aug 3, 2021

Abstract

A method of producing a foamed composite molded product includes fixing an exposed part of an insert material on a fixing part provided in a mold, the insert material being inserted in an in-mold foamed molded product made of a thermoplastic resin; introducing a polyurethane liquid into the mold; and producing the foamed composite molded product by foaming the polyurethane liquid in the mold. The foamed composite molded product includes an in-mold foamed molded product unit including the insert material and the in-mold foamed molded product; and a polyurethane foam. At least part of the insert material is exposed to an outside of the in-mold foamed molded product, and the in-mold foamed molded product unit and the polyurethane foam are integrated.

First claim

What is claimed is:

1. A method of producing a foamed composite molded product, the method comprising:
fixing an exposed part of an insert material on a fixing part provided in a mold, wherein the insert material is inserted in an in-mold foamed molded product constituted by thermoplastic resin expanded particles;
introducing a polyurethane liquid into the mold after fixing the exposed part; and
producing the foamed composite molded product by foaming the polyurethane liquid in the mold,
wherein the foamed composite molded product comprises:
an in-mold foamed molded product unit comprising the insert material and the in-mold foamed molded product; and
a polyurethane foam,

wherein at least part of the insert material is exposed to an outside of the in-mold foamed molded product,
wherein the in-mold foamed molded product unit and the polyurethane foam are integrated, and
wherein a plurality of fixing parts are provided in the mold, and the plurality of fixing parts fix respective exposed parts of the insert material.

2. The method according to claim 1 , wherein
the insert material is exposed to the outside of the in-mold foamed molded product through at least one selected from the group consisting of:
a blind hole formed in the in-mold foamed molded product;
a through hole formed in the in-mold foamed molded product;
a gap between two molded body pieces, wherein the in-mold foamed molded product is divided into a plurality of the molded body pieces; and
a perimeter of an outer surface of the in-mold foamed molded product.

3. The method according to claim 1 , wherein the fixing part comprises a magnetic body, and the exposed part of the insert material is fixed by magnetically attaching the exposed part to the magnetic body.

4. The method according to claim 1 , wherein the fixing part comprises an engagement part, and the exposed part of the insert material is fixed by engaging the exposed part with the engagement part of the fixing part.

5. The method according to claim 1 , wherein during the fixing, a surface of the in-mold foamed molded product unit where the exposed part of the insert material is provided at the surface, is in contact with the mold.

6. A method of producing a foamed composite molded product, the method comprising:
fixing an exposed part of an insert material on a fixing part provided in a mold, wherein the insert material is inserted in an in-mold foamed molded product constituted by thermoplastic resin expanded particles, wherein the thermoplastic resin is one or more selected from the group consisting of polyolefin resin, polystyrene resin, styrene-modified polyolefin resin, olefin-modified polystyrene resin, and polyester resin;
introducing a polyurethane liquid into the mold after fixing the exposed part; and
producing the foamed composite molded product by foaming the polyurethane liquid in the mold,
wherein the foamed composite molded product comprises:
an in-mold foamed molded product unit comprising the insert material and the in-mold foamed molded product; and
a polyurethane foam,

wherein at least part of the insert material is exposed to an outside of the in-mold foamed molded product, and
wherein the in-mold foamed molded product unit and the polyurethane foam are integrated.

7. The method according to claim 1 ,
wherein introducing the polyurethane liquid is performed by pouring the polyurethane liquid onto a surface of the in-mold foamed molded product, and
wherein the at least part of the insert material is exposed from an exposed surface of the in-mold foamed molded product that is opposite to the surface where the polyurethane liquid is introduced.

Assignees

• Kaneka Corp

Inventors

• TOBIMATSU Yuki
• Sameshima Masahiko

Classifications

• B29C33/12 Primary

  with incorporated means for positioning inserts, e.g. labels {(positioning reinforcements B29C70/541)} · CPC title

• B29C39/28

  with means to avoid flashes {(B29C39/30 takes precedence)} · CPC title

• B29C33/16

  using magnetic means · CPC title

• B29C44/1285

  the preformed part being foamed · CPC title

• B29K2105/048

  Expandable particles, beads or granules · CPC title