Process for producing foam moldings with an insert
First Claim
1. A process for producing a foam molding including an insert of predetermined shape wherein the insert is set in a mold consisting essentially of a core block and a cavity block for foaming a foamable material in a cavity defined in said mold so as to form a foamed body on one side of said insert, said process comprising the steps of:
- preparing an insert assembly consisting of said insert and a film having portions adhering to a surface of said insert on said one side thereof, said film extending so as to match a partial profile of said foamed body and covering a surface of said core and cavity blocks, said film further having skirt portions adapted to extend between respective joining portion of said core and cavity blocks;
setting said insert assembly on said one of the core and cavity blocks such that said skirt portions extend over the surface of said joining portion of the one block;
enclosing said cavity by joining said core and cavity blocks such that said skirt portions are pinched by said joining portions; and
pouring said foamable material into a space formed between said film and a surface of the other blocks to define said cavity.
1 Assignment
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Accused Products
Abstract
Process for producing foam moldings with an insert executed in a mold for foam molding consisting of a core block and a cavity block. The process comprises steps of: (a) having a film adhering to and covering the insert on one side thereof where a foam layer is formed; (b) letting the skirt portion of the film to be pinched or sandwiched by the uniting portion of the two blocks while the foaming process is executed on a foamable material; and (c) forming integrally the foam layer on that side of the insert, with the film being retained between the insert and the foam layer to be obtained.
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Citations
10 Claims
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1. A process for producing a foam molding including an insert of predetermined shape wherein the insert is set in a mold consisting essentially of a core block and a cavity block for foaming a foamable material in a cavity defined in said mold so as to form a foamed body on one side of said insert, said process comprising the steps of:
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preparing an insert assembly consisting of said insert and a film having portions adhering to a surface of said insert on said one side thereof, said film extending so as to match a partial profile of said foamed body and covering a surface of said core and cavity blocks, said film further having skirt portions adapted to extend between respective joining portion of said core and cavity blocks; setting said insert assembly on said one of the core and cavity blocks such that said skirt portions extend over the surface of said joining portion of the one block; enclosing said cavity by joining said core and cavity blocks such that said skirt portions are pinched by said joining portions; and pouring said foamable material into a space formed between said film and a surface of the other blocks to define said cavity. - View Dependent Claims (3, 4, 5, 6, 7, 8, 9, 10)
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2. A process for producing a foam molding including at least one insert of predetermined shape wherein the insert is set in a mold consisting of a core block and a cavity block for foaming a foamable material in a cavity defined in said mold so as to form a foamed body on one side of said insert, said process comprising the steps of:
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setting said insert on one of said core and cavity blocks; covering a surface of said one of the core and cavity blocks with a film having portions adhering to a surface of said insert on said one side thereof, said film extending so as to match a partial profile of said foamed body and further having skirt portions adapted to extend between respective joining portions of said core and cavity blocks, said insert and said film constituting an insert assembly; enclosing said cavity by joining said core and cavity blocks such that said skirt portions are pinched by said joining portions; and
pouring said foamable material into a space formed between said film and a surface of the other block to define said cavity.
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Specification