Method for producing a foamed resin molding

• US 4,891,081 A
• Filed: 11/28/1986
• Issued: 01/02/1990
• Est. Priority Date: 12/04/1985
• Status: Expired due to Term

• Current Assignee: Tokai Chemical Industries, Ltd.
• Original Assignee: Tokai Chemical Industries, Ltd.
• Inventors: Takahashi, Shuichi, Nishida, Kiyomi
• Primary Examiner(s): Ball, Michael W.
• Assistant Examiner(s): AFTERGUT, JEFFRY H
• Application Number:
  US06/935,856
• Time in Patent Office: 1,131 Days
• Field of Search: 156/78, 264/46.4, 264/46.6, 264/45.2, 264/46.7, 297/DIG. 1, 428/319.3, 428/318.8
• US Class Current: 156/78
• CPC Class Codes: B29C 33/10 with incorporated venting means
• CPC Class Codes: B29C 44/1214 Anchoring by foaming into a preformed part, e.g. by penetrating through holes anchoring by moulding in general B29C37/0078; outsert moulding B29C45/14344, B29C70/74
• CPC Class Codes: B29C 44/16 shaped by the expansion of the material
• CPC Class Codes: B29K 2105/20 Inserts
• CPC Class Codes: B29L 2031/3005 Body finishings
• CPC Class Codes: B60R 19/22 containing mainly cellular material, e.g. solid foam
• CPC Class Codes: B60R 21/04 Padded linings for the vehicle interior ; Energy absorbing structures associated with padded or non-padded linings
• CPC Class Codes: Y10T 428/249989 Integrally formed skin
• CPC Class Codes: Y10T 428/249991 Synthetic resin or natural rubbers

Abstract

A method and a foamed resin molding in which a skin layer is formed by pressing an expansible film against and into conformity with cavity walls of a mold or a bag-like cover member by foaming pressure of a foamable resin and a foamed resin body molded concurrently and integrally under the skin layer, which facilitate the easy parting of the moldings from the mold without parting agent.

Claims

1. A method for producing a foamed resin molding, comprising the steps of:

interposing a bag-shaped expansible film in a cavity of a mold with an opening in alignment with a parting line of said mold;

interposing an insert in said bag-shaped expansible film;

extracting air from said bag shaped film to conform the film to the shape of the insert prior to charging with a foamable resin;

charging a foamable resin into said bag-shaped expansible film from said opening;

molding a foamed resin body by foaming said foamable resin while concurrently shaping said bag-shaped expansible film by expanding same by pressure generated by said foaming against and into conformity with the shape of said mold cavity, thereby connecting said insert integrally with the foamed resin body; and

ejecting said foamed resin body covered with a skin layer of the expanded said bag-shaped expansible film and containing said insert as a core from said mold.

2. The method of claim 1, wherein said foamable resin is charged into said bag-shaped expansible film through an opening thereof after placing said bag-shaped expansible film in said mold cavity with said opening in alignment with a resin charging port of said mold.

3. The method of claim 1, wherein said bag-shaped expansible film is constituted by a pair of expansible films with marginal edge portions thereof fixedly gripped by clamping said mold.

4. The method of claim 1, wherein said foamable resin is foamed after placing in said mold cavity said bag-shaped expansible film charged with said foamable resin.

5. The method of claim 1, further comprising the steps of:

applying adhesive to at least one part of the surface of said skin layer after ejection of said foamed resin body; and

depositing pile fibers on the adhesive-applied surface of said skin layer to form a piled portion thereon.

6. The method of claim 1, further comprising the step of coating with paint at least one part of the surface of said skin layer to form a coating layer thereon after said step of ejecting said foamed resin body.

7. The method of claim 1, further comprising the step of degassing said foamed resin body after said step of foaming said foamable resin.

8. A method for producing a foamed resin molding, comprising the steps of:

placing a bag-shaped expansible film in a bag-shaped cover member, wherein the bag-shaped cover member resists deforming force of foaming pressure sufficiently to resist deformation;

foaming a foamable resin in said bag-shaped expansible film, while concurrently shaping said bag-shaped expansible film by expanding same against and into conformity with the shaped cover member using pressure generated by foaming the resin.

9. The method of claim 8, wherein said bag-shaped cover member is placed in the cavity of a mold and formed into a predetermined shape by being pressed against the cavity walls of said mold by expansion of said bag-shaped expansible film.

10. A method of claim 9, further comprising:

interposing an insert in said bag-shaped expansible film before the foaming step, whereby during the foaming step said insert is integrally connected to the foamed resin body as a core thereof.

11. The method of claim 8, further comprising the step of extracting air from said bag-shaped expansible film before said step of foaming said foamable resin.

12. The method of claim 8, further comprising the step of degassing said foamed resin body after said step of foaming said foamable resin.