Method for manufacturing molded foam, and molded foam

Patent metadata

Field	Value
Publication number	US-12358191-B2
Application number	US-201917441090-A
Country	US
Kind code	B2
Filing date	Dec 16, 2019
Priority date	Mar 25, 2019
Publication date	Jul 15, 2025
Grant date	Jul 15, 2025

Abstract

Provided are a method for manufacturing a molded foam, and a molded foam. A method for manufacturing a molded foam includes: a molding step of molding the molded foam; and a releasing step of opening a fixed mold and a mobile mold and extruding the molded foam from the fixed mold by an ejector pin. The molded foam has an inclined face that is inclined relative to a direction of opening the mold. The inclined face has a recess for extruding of the molded foam by the ejector pin. The tip surface of the ejector pin has a first extruding surface that is perpendicular to the mold opening direction and forms a bottom face of the recess, and a second extruding surface that is inclined relative to the first extruding surface.

First claim

The invention claimed is:

1. A molded foam comprising:
an inclined face that is configured to be inclined relative to a mold opening direction of a mold;
a first recess on the inclined face, the first recess being configured to let an ejector pin extrude the molded foam;
a pin mark configured to be formed by a tip surface of the ejector pin; and
a second recess that is opposite to the first recess, with a part of the molded foam between the first recess and the second recess,
wherein:
the pin mark has: a first region that is configured to be perpendicular to the mold opening direction and defines a semicircular bottom face of the first recess; a second region that is inclined relative to the first region and defines a part of the inclined face; and a straight line portion that divides the pin mark between the first region and the second region;
the first recess includes: (i) the semicircular bottom face that is flat; and (ii) a side face that is a part of a cylindrical surface and configured to extend in the mold opening direction, and includes a first arc portion that adjoins the semicircular bottom face and connects respective ends of the straight line portion;
the second region includes a semicircular inclined face defined by a second arc portion that adjoins the semicircular inclined face and connects the respective ends of the straight line portion;
in a cross section of the molded foam including the first region and the second region, the first region has a first end on a first side opposite to the second region;
the second region has a second end on a second side opposite to the first region; and
a straight line that passes through the first end and is configured to extend in the mold opening direction and a plane that passes through the second end and is configured to be perpendicular to the mold opening direction intersect in the second recess.

2. The molded foam according to claim 1 , wherein the second region is inclined by 20° or more and 70° or less relative to the first region.

3. The molded foam according to claim 1 , wherein, viewed from the mold opening direction, an area ratio of the first region to the pin mark is 25% or more and 75% or less.

4. The molded foam according to claim 1 , wherein the molded foam has:
an oblong outer shape having, in a plan view, transverse sides and longitudinal sides;
a first part on a first of the transverse sides; and
a second part on a second of the transverse sides,
wherein:
the transverse sides are shorter than the longitudinal sides;
the second part is thinner than the first part; and
the recess and the pin mark are at the second part.

5. The molded foam according to claim 1 , wherein the second recess includes a top face that is configured to be perpendicular to the mold opening direction, and a side face that is configured to extend in the mold opening direction from an end of the top face.

6. The molded foam according to claim 5 , further comprising an upper end face, wherein:
the inclined face extends downward from the upper end face;
a groove is defined in the upper end face; and
the top face of the second recess is configured to be underneath the groove in the mold opening direction.

7. The molded foam according to claim 1 , further comprising an upper end face, wherein:
the inclined face extends downward from the upper end face; and
a groove is defined in the upper end face.

Assignees

• Sekisui Plastics

Inventors

• Otsuki Masaki
• Fukuta Atsushi

Classifications

• B29L2031/30

  Vehicles, e.g. ships or aircraft, or body parts thereof {(vanes or blades B29L2031/08, air bags B29L2022/027)} · CPC title

• B29C44/58

  Moulds · CPC title

• B60N2/90

  Details or parts not otherwise provided for · CPC title

• B29C44/3426

  Heating by introducing steam in the mould · CPC title

• B29L2031/771

  Seats · CPC title