Foam molded article, method for manufacturing molded foam article, and seat for automobile

Patent metadata

Field	Value
Publication number	US-11155192-B2
Application number	US-201816210355-A
Country	US
Kind code	B2
Filing date	Dec 5, 2018
Priority date	Jun 14, 2016
Publication date	Oct 26, 2021
Grant date	Oct 26, 2021

Abstract

A foam molding article includes an outer-shell-configuring part, an insert that is at least partially embedded in the outer-shell-configuring part, and a fitting member. The outer-shell-configuring part includes a body side foam member. The body side foam member includes a foam and a missing part where a part of the foam is missing. The missing part is located in an intermediate part of the body side foam member, and the fitting member is mounted in the missing part.

First claim

What is claimed is:

1. A foam molding article comprising:
an outer-shell-configuring part;
an insert; and
a fitting member,
wherein the outer-shell-configuring part comprises a body side foam member,
wherein the insert is at least partially embedded in the body side foam member only,
wherein the body side foam member comprises a foam and a missing part where a part of the foam is missing,
wherein the foam is made of an olefin-based resin,
wherein the missing part is located in an intermediate part of the body side foam member, and
wherein the fitting member is mounted in the missing part.

2. The article according to claim 1 , wherein the missing part alleviates stress applied to the insert by a volume change of the outer-shell-configuring part.

3. The article according to claim 1 , wherein the insert comprises:
two or more engagement parts that are engaged with the foam in the body side foam member; and
a connecting part that connects the two or more engagement parts, and
wherein the connecting part is partially located in the missing part.

4. The article according to claim 1 , wherein the insert comprises:
two or more engagement parts that are engaged with the foam in the body side foam member; and
a connecting part that connects the two or more engagement parts, and
wherein at least one of the engagement parts is partially located in the missing part.

5. The article according to claim 1 , wherein the missing part is a portion where the insert is exposed.

6. The article according to claim 1 ,
wherein the body side foam member is separated into a plurality of divided foam pieces, and
wherein the divided foam pieces are separated by the missing part.

7. The article according to claim 1 , wherein the fitting member is a foam comprising the same ingredient of the foam constituting the body side foam member.

8. The article according to claim 1 , wherein a surface shape of the fitting member is smoothly connected with a surface shape of the foam constituting the body side foam member.

9. The article according to claim 1 , wherein the fitting member is physically engaged with the foam constituting the body side foam member.

10. The article according to claim 1 , wherein the fitting member is physically engaged with the insert.

11. A seat for an automobile comprising:
the foam molding article according to claim 1 ;
a cushion layer; and
a skin layer.

Assignees

• Kaneka Corp

Inventors

• Fujiwara Hiroshi

Classifications

• B60N2/7017 Primary

  characterised by the manufacturing process; manufacturing upholstery or upholstery springs not otherwise provided for · CPC title

• B29C44/00

  Shaping by internal pressure generated in the material, e.g. swelling or foaming {; Producing porous or cellular expanded plastics articles} · CPC title

• B29C44/12

  Incorporating or moulding on preformed parts, e.g. inserts or reinforcements · CPC title

• A47C27/14

  with foamed material inlays · CPC title

• B29K2715/003

  Cellular or porous · CPC title