Molded foam and mold

• US 7,947,356 B2
• Filed: 02/27/2007
• Issued: 05/24/2011
• Est. Priority Date: 03/22/2006
• Status: Active Grant

• Current Assignee: Archem, Inc.
• Original Assignee: Bridgestone Corporation
• Inventors: Hirata, Yutaka, Niitu, Masahito
• Primary Examiner(s): LONEY, DONALD J
• Application Number:
  US11/711,054
• Publication Number:
  US 20070281132A1
• Time in Patent Office: 1,547 Days
• Field of Search: 428/167, 428/192, 428/158, 297/215.16, 297/228.12, 297/452.15, 297/452.26, 297/452.48, 297/452.6
• US Class Current: 428/167
• CPC Class Codes: B29C 44/38 into a closed space, i.e. to make articles of definite length B29C44/365 and B29C44/367 take precedence
• CPC Class Codes: B29C 44/588 with means for venting, e.g. releasing foaming gas
• CPC Class Codes: B60N 2/7017 characterised by the manufacturing process; manufacturing upholstery or upholstery springs not otherwise provided for
• CPC Class Codes: Y10T 428/24496 Foamed or cellular component
• CPC Class Codes: Y10T 428/2457 Parallel ribs and/or grooves
• CPC Class Codes: Y10T 428/24777 Edge feature

Abstract

A molded foam containing no voids and a mold for forming such a molded foam are provided. A molded foam 5 has an external corner 5a where a small rib 10 is formed and a recessed step 7 where thin plate-like ribs 11 are formed. The rib 10 has a triangular cross-sectional shape in a direction perpendicular to the longitudinal direction of the recessed step 7. The rib 10 is tapered from the base to an end thereof in a direction in which the rib 10 protrudes. The ribs 11 are arranged at intervals in the longitudinal direction of the recessed step 7.

Claims

1. A molded foam comprising a recessed, step-shaped groove in an outer surface thereof, the molded foam comprising one or more thin plate-like ribs connected to first and second surfaces of the groove which define the deepest portion thereof and wherein the molded foam is a car seat pad.

2. The molded foam according to claim 1, wherein the groove is a step for engagement with a backboard.

3. The molded foam according to claim 1, wherein the groove extends along an overhang.

4. The molded foam according to claim 1, wherein the ribs are arranged at intervals in the longitudinal direction of the groove.

5. A mold for forming the molded foam according to claim 1, the mold having a ridge for forming the groove and one or more recesses disposed in the ridge for forming the ribs.

6. The molded foam according to claim 1, wherein part of the rib is adjacent to a parting line.

7. The molded foam according to claim 1, wherein the rib is a triangular plate.

8. The molded foam according to claim 1, wherein the first surface and the second surface meet at a recessed corner, the corner forming the deepest part of the groove, and

wherein the groove is open substantially opposite to the each of the first surface and the second surface.

9. The molded foam according to claim 1, wherein the groove is formed at an external corner of the foam, the first surface being substantially parallel to a front surface of the external corner, and the second surface being substantially parallel to a top surface of the external corner.