Molded foam products; manufacturing methods for molded foam products and car seats.

Abstract

This invention addresses the problem of providing a molded foam article having an integrated feeling and minimal warpage. A molded foam article 1 having an outer-shell-structure part 6 and an insert 11, the insert 11 being embedded in the outer-shell-structure part 6. The outer-shell-structure part 6 is separated into divided foam segments 15a, 15b. The divided foam segments 15a, 15b have a missing part 16 in which the foam body is missing. A fitting member 20 is mounted on the missing part 16. The foam molded article 1 is suitable as a rigidity-imparting member for a seat for an automobile.

Description

Foam molded product, method for manufacturing foam molded product, and automobile seat The present invention relates to foam molded products. The foam molded product of the present invention is one in which an insert material such as a metal is embedded in a foam and integrated. The foamed molded product of the present invention has less warpage and less impairs the feel of the molded product (feel when sitting on the foamed molded product) and rigidity. Furthermore, the foamed molded product of the present invention is suitable as a material for imparting rigidity to automobile seats. The present invention also relates to a method for manufacturing a foam molded product. Foam molded products are known in which an insert material made of metal or the like and a foam are integrally molded. This type of foam molded product can be manufactured by a manufacturing method called so-called insert molding. Patent Document 1 discloses a foam molded product in which an annular metal part is integrally molded around the outer periphery of a foam body. Further, Patent Document 1 discloses an invention in which the foamed molded product is employed as a core material (rigidity imparting material) of an automobile seat. By the way, if foamed olefin resin particles with excellent cushioning properties are used as the material for the foam, and the insert material is set in a mold and molded so that the insert material is embedded around the outer periphery of the foam, the insert material and the foamed material will be separated. Warping may occur, which is thought to be caused by the difference in shrinkage rates. Therefore, when a foam molded product having the above-mentioned structure is used as a part that requires precision, such as a part for an automobile seat, it may be difficult to assemble it with other parts. Hereinafter, the reason why a foam molded product warps will be explained. A foam molded product is one in which an insert material is attached to a mold, pre-foamed beads are introduced into a cavity of the mold, and the pre-foamed beads are foamed within the cavity to integrate the insert material and the foam. However, when the insert material is set in the mold as described above and the pre-expanded beads are foamed and molded within the mold, the formed foamed product may warp. The cause of this is presumed to be the difference in shrinkage rate between the insert material and the foam. That is, the pre-expanded beads of olefin resin are heated and expanded in the mold, and the foam surrounds the insert material. The foam of the foam molded product taken out from the mold shrinks as the temperature decreases. On the other hand, the insert material embedded in the foam does not substantially shrink. For example, if the insert material is made of metal and the foam is made of olefin resin, the adhesive force between the insert material and the foam is weak, and the interface thereof moves relative to each other. However, the insert material is annular and has some large volume parts. Therefore, a portion of the insert material becomes physically engaged with the foam within the foam, and the insert material becomes in a state as if compressive force was applied from both ends. As a result, the insert material flexes under stress due to shrinkage of the foam. If the amount of deflection is large, the insert material will be deformed beyond its elastic range and will be plastically deformed. As mentioned above, the foam shrinks immediately after being molded, but returns to its original volume over time. However, the insert material inside is not completely restored and remains bent. As a result, warpage may occur in the foamed molded product. When a foam molded product is used for parts that particularly require precision, such as automobile parts, the warpage that occurs in the foam molded product cannot be ignored in terms of quality. Measures to deal with this problem are disclosed in Patent Documents 2 and 3. The invention disclosed in Patent Document 2 is to mold a foam with a groove in which an insert material is placed, and after molding the foam, insert the insert material into the groove to complete the foam molded product. On the other hand, the invention disclosed in Patent Document 3 is to mold a foam molded product containing an insert material, and form a groove in the foam molded product immediately after molding. More specifically, an insert material is attached to a mold, pre-foamed beads are introduced into a cavity of the mold, and the pre-foamed beads are foamed within the cavity to create a foam molded product in which the insert material and foam are integrated. Shape. Immediately after the foam molded product is removed from the mold, a cutter knife is used to cut into the surface of the foam molded product to form grooves. Patent No. 5344395 Publication JP 2016-22292 Publication JP 2015-174340 Publication According to the inventions disclosed in Patent Documents 2 and 3, the problem of warpage occurring in foam molded products is solved. However, according to the inventions described in Patent Documents 2 and 3, an additional step is required after the foam molding step, and this step requires skill. Moreover, according to the inventions disclosed in Patent Documents 2 and 3, new problems are also a concern. In particular, in the invention disclosed in Patent Document 2, it takes time and effort to incorporate the insert material over substantially the entire outer periphery of the molded body after molding, and the groove is formed narrow enough to hold the insert material. There is a concern that if the precision of the material is poor, it will be difficult to assemble. In particular, in the invention disclosed in Patent Document 3, the foam molded product taken out from the mold is cut with a sharp cutter knife. Therefore, it takes time and effort. Also, since foam molded products are used as car seats, they repeatedly bend when people sit on them. In the invention disclosed in Patent Document 3, since there is a cut in the foam with a cutter knife, stress concentration occurs at the bottom of the cut groove, and the repeated stress caused by a person sitting on the foam causes the foam to There is a possibility of premature breakage. Incidentally, the present applicant has also considered measures to solve the problem of warping in foam molded products, and has previously filed a patent application (Japanese Patent Application No. 2015-064956, unpublished). The invention filed by the present applicant is a foam molded product having a structure in which the foam is divided into a plurality of parts and the insert material and the foam can move relative to each other. According to the foam molded product proposed by the applicant, even if the foam undergoes a volume change after foam molding, the insert material moves relative to the foam, so no compressive force is applied to the insert material, and the insert material Deflection is alleviated. Therefore, the warping of the foam molded product is alleviated. The invention filed by the present applicant can reduce warping of foam molded products. However, with this configuration, gaps are created between the foams, so when a foam molded product is used as a part of a car seat, for example, and is used for ``sitting'' on it, the comfort of sitting may vary depending on the location. could have occurred. When a foam molded product is used as a stiffening member for an automobile seat, a foam layer of urethane or the like may be provided on the surface of the foam molded product. Therefore, the above-mentioned problem of the difference in sitting comfort seems to be alleviated by flowing the urethane raw material into the gap and filling the gap when the urethane resin and the foam molded product are integrated. However, since olefin resins and urethane resins have different material characteristics, the problem of poor sitting comfort may still persist. Furthermore, in the above invention filed by the present applicant, since the foam, which was previously a single piece, is divided into a plurality of segmented foam pieces, especially in the case of large foam molded products, when lifted, the whole may bend, and in some cases There is also a possibility that it may be bent. That is, since the foam molded product is used as a member for imparting rigidity to an automobile seat, it is moved between various devices and molds until it becomes a final product, that is, an automobile seat. At that time, there is a concern that the material may be bent due to its own weight or irreversible deformation may occur. Furthermore, when being carried, it may be elastically deformed by its own weight, making it difficult to maintain a certain shape, and there is also a concern that it may be difficult to carry. In view of the above circumstances, the present invention improves the invention previously proposed by the applicant and provides a measure for improving the difference in sitting comfort felt depending on the part when used as a seat core material etc. With the goal. That is, an object of the present invention is to provide a foam molded product with less warpage and a sense of unity, and a method for manufacturing the same. Another object of the present invention is to provide a comfortable automobile seat. As a result of extensive research to solve the above problems, the present inventors have developed a structure in which an insert material is embedded in the foam using olefin resin particles, and is divided into grooves at left and right intervals. It has been found that by installing embedded members made of the same material as the foam in the groove-like spaces of the molded foam, it is possible to improve the rigidity of the entire molded product and the feeling of touch and sitting comfort depending on the location. . The embodiment completed based on the above knowledge is that in a foam molded product that has an outer shell component and an insert material, and in which part or all of the insert material is embedded in the outer shell component, the outer shell component is located on the main body side. This is a foam molded product having a foam, and having a missing part where the foam is missing in the middle part of the main body side foam, and a separate fitting member is attached to the missing part. It is desirable that the missing portion be formed at a position where it is possible to alleviate the stress applied to the insert material when the volume of the outer shell component changes. In each of the above embodiments, the insert material has an engaging part that engages with the foam inside the main body foam, and a connecting part that connects two or more of the engaging parts, and the missing part is the connecting part of the insert material. It is desirable that it be in the part corresponding to the part. In each of the above embodiments, the insert material has an engaging portion that engages with the foam inside the main body side foam, and a connecting portion that connects two or more of the engaging portions, and the missing portion is formed by the engaging portion of the insert material. It is desirable that it be located in the part corresponding to the joint. In each of the above aspects, it is desirable that the missing portion is a portion where the insert material is exposed. In each of the above embodiments, it is desirable that the main body foam is separated into a plurality of divided foam pieces, and the missing portion is between the divided foam pieces. In each of the above embodiments, it is desirable that the main component of the fitting member is the same foam as the foam forming the main body foam. In each of the above embodiments, it is desirable that the surface shape of the fitting member attached to the missing portion smoothly connect with the surface shape of the foam constituting the main body side foam in the vicinity of the missing portion. In each of the above embodiments, it is desirable that the fitting member physically engages with the foam that constitutes the main body foam. In each of the above embodiments, it is desirable that the fitting member physically engages with the insert material. The embodiment of the automobile seat is an automobile seat having the foam molded product of each of the above embodiments, a cushion layer, and a skin layer. As for the production method, a part or all of the insert material is embedded in a foam made of olefin resin, and a main body foam is formed in which a missing part where the foam is missing is formed in the middle part of the foam. A foam molded product comprising a main body molding step, a fitting member forming step of molding a fitting member to be attached to the missing portion, and a step of attaching the fitting member to the missing portion of the main body side foam. This is the manufacturing method. In the above-described aspect, it is desirable that the main body side foam is constituted by a plurality of divided foam pieces, and the gaps are formed between the divided foam pieces. In each of the above embodiments, the volume of the main body foam changes after molding, and after the volume change of the main body foam converges after the main body molding step, the fitting member can be attached to the missing portion. desirable. The foam molded product of the present invention and the foam molded product manufactured by the manufacturing method of the present invention have less warpage and a sense of unity. Moreover, the automobile seat of the present invention is comfortable to sit on. FIG. 1 is a perspective view of a foam molded product according to an embodiment of the present invention. FIG. 2 is a partially cross-sectional perspective view of an automobile seat using the foam molded product of FIG. 1 as a stiffening member. FIG. 2 is an exploded perspective view of the foam molded product of FIG. 1. FIG. FIG. 2 is an AA cross-sectional perspective view of the foam molded product in FIG. 1. FIG. (a) is a perspective view of a rigidity imparting member employed in another embodiment of the present invention, and (b) is a side view thereof, in which the bulging portion is shaded. (a) is a perspective view of a rigidity imparting member employed in yet another embodiment of the present invention, and (b) is a side view thereof, in which the bulging portion is shaded. (a) to (c) are cross-sectional views of the vicinity of the missing part when a fitting member is attached to the missing part of the outer shell component, in the manufacturing process of a foam molded product according to still another embodiment of the present invention. . (a) is a perspective view of a stiffening member employed in a foamed molded product according to still another embodiment of the present invention, and (b) is a view thereof in the direction of arrow A. (a) thru|or (c) are sectional views of the vicinity of a missing part when attaching a fitting member to the missing part of an outer shell structure part, and are the manufacturing process of the foam molded article of FIG. FIG. 7 is an exploded perspective view of a foam molded product according to still another embodiment of the present invention. 11 is a cross-sectional perspective view of the foam molded product of FIG. 10. FIG. FIG. 7 is an exploded perspective view of a foam molded product according to still another embodiment of the present invention. FIG. 7 is an exploded perspective view of a foam molded product according to still another embodiment of the present invention. FIG. 7 is an exploded perspective view of a foam molded product according to still another embodiment of the present invention. FIG. 7 is an exploded perspective view of a foam molded product according to still another embodiment of the present invention. FIG. 7 is an exploded perspective view of a foam molded product according to still another embodiment of the present invention. FIG. 17 is a plan view of the foam molded product shown in FIG. 16. FIG. 7 is an exploded perspective view of a foam molded product according to still another embodiment of the present invention. 19 is a plan view of the foam molded product shown in FIG. 18. FIG. (a) is a perspective view of an insert material employed in the foam molded product of FIG. 1, and (b) to (f) are perspective views of modified examples of the insert material. Embodiments of the present invention will be further described below. FIG. 1 illustrates a foam molded product 1 according to an embodiment of the present invention. As shown in FIG. 2, the foam molded product 1 is used as a rigidity imparting member (core material) for an automobile seat 2. As is well known, the automobile seat 2 is composed of a stiffening member (foamed molded product 1), a cushion layer 3, and a skin layer 5. The automobile seat 2 is manufactured by mounting a skin material (skin layer 5) and a stiffening member (foam molded product 1) on an integral mold (not shown), and forming a gap between the stiffening member (foam molded product 1) and the skin material, for example. A foamed urethane raw material such as polyol and polyisocyanate is injected to integrate a stiffening member (foamed molded product 1), a cushion layer 3, and a skin layer 5. The skin layer 5 may be made of resin, cloth or leather. The method of manufacturing the automobile seat 2 is not limited, and may include placing a separately molded cushion layer 3 on a stiffening member (foamed molded product 1) and wrapping it with cloth or the like (skin layer 5). Good too. The foamed molded product 1, which is a rigidity imparting member, has an insert material 11 embedded in an outer shell component 6 made of foam. The outer structure part 6 of this embodiment is composed of a main body foam 10 and a fitting member 20, as will be described later, and a part of the insert material 11 is embedded in the main body foam 10. Further, a part of the insert material 11 is exposed from the main body side foam 10. The insert material 11 has an annular shape as shown in FIGS. 1, 2, and 20(a), and has a substantially rectangular planar shape. The insert material 11 employed in this embodiment is approximately rectangular as described above, and has two long sides 22a and 22b arranged in parallel as shown in FIGS. 1, 2, and 20(a). It has two short sides 23a and 23b. The insert material 11 of the present invention is insert-molded and built into the outer shell component 6, more precisely, at a position substantially near the outer periphery of the main body foam 10, and is different from the case where the insert material 11 is made of only foamed resin. Made of materials with sufficient strength to increase overall strength. The material of the insert material 11 is preferably a metal material such as iron-based material. Although the manufacturing method and material for the insert material 11 are arbitrary, a wire rod with a circular cross-sectional shape that is bent can be preferably used because it is easy to form. The insert material 11 may have ribs, rods, plates, etc. attached thereto for attaching the final product, the automobile seat 2, to other parts. In this embodiment, illustrations of ribs and the like are omitted to simplify the explanation, but the present invention can be applied by partially attaching a plate or the like to the insert material 11 or by attaching a plate or the like to the insert material 11 itself. Does not prevent production. When the insert material 11 is manufactured from a wire rod with a circular cross section (for example, a round bar), the diameter of the wire rod with a circular cross section is determined by the ease of bending, strength retention after processing, weight, which is especially important in automobiles, etc. For reasons such as processing accuracy and resulting cost, a suitable thickness is 1 to 6 mm, preferably 2 to 5 mm. The insert material 11 of the present invention forms a closed structure by bending the wire rod described above so as to substantially follow the outer periphery of the outer shell component 6 and joining the ends. The overall size of the insert material 11, that is, the total length and width, is freely selected in consideration of ease of filling with foamed resin particles, ease of spreading when the foamed resin particles expand, and ease of exerting rigidity. can do. When the total length and total width of the insert material 11 are short, the insert material 11 is deeply buried in the outer shell component 6, and the distance from the end of the outer shell component 6 to the insert material 11 is large, filling with foamed resin particles This makes it easier for the foamed resin particles to spread. For example, if the distance from the outer end of the outer shell component 6 to the insert material 11, that is, the distance between the short sides 26a, 26b of the outer shell of the outer shell component 6 and the short sides 23a, 23b of the insert material 11, is 5 mm or more, foaming is possible. Can be filled with resin particles. From this point of view, it is preferable that the distance from the outer end of the outer shell component 6 to the insert material 11 is 10 mm or more. On the other hand, if the distance from the outer end of the outer shell component 6 to the insert material 11 is excessively long, the stiffening effect of the insert material may not be effectively exhibited. Therefore, the distance from the outer end of the outer shell component 6 to the insert material is preferably within 100 mm, and more preferably within 50 mm. As the joining method when forming the insert material 11 into an annular shape, known methods such as welding, abutment, and caulking with metal fittings can be selected. Next, the outer shell component 6 will be explained. The outer shell structure part 6 of this embodiment is comprised by the main body side foam 10 and the fitting member 20. In the present embodiment, the cross-sectional shape of the outer shell structure part 6 is approximately an "inverted L" shape, and includes a horizontal base part 12 and a support base part 13 that hangs down from one long side of the horizontal base part 12. When the outer shell component 6 is observed as a whole, it has a shape of a rectangular parallelepiped with a large notch 17 formed at one corner. The main body foam 10 of the outer shell component 6 constitutes the main body portion of the foam molded product 1. The main body side foam body 10 of the outer shell structure part 6 constitutes most of the outer shell of the foam molded product 1 and the outer shell structure part 6, but the middle part is missing and there is a groove-shaped gap in the center (the missing part 16 ). The main body foam 10 of this embodiment has an insert material 11 integrally embedded in the foam. In the main body foam 10 of this embodiment, the foam is separated into a plurality of divided foam pieces 15a and 15b, as shown in FIG. The foam constituting the main body foam 10 is divided into two or more parts in the longitudinal direction perpendicular to the opening / closing direction of the mold, and a gap is provided between them. Note that this divided structure can be easily realized by providing the cavity of the mold with a shape that realizes division, such as a partition. Therefore, the main body foam 10 of this embodiment has a missing portion 16 in the middle portion. In this embodiment, the divided foam pieces 15a and 15b have a symmetrical shape and the same size. Therefore, the missing portion 16 is located at the center of the main body foam 10. In the drawings, the width Wa of the missing portion 16 is drawn wider than it actually is in order to facilitate understanding. The width Wa of the missing portion 16 is about 5 mm to 100 mm, more preferably about 10 mm to 80 mm, and still more preferably about 15 mm to 60 mm. In this embodiment, the insert material 11 is buried so that each side 22a, 22b, 23a, 23b is parallel to the outer shell of the outer shell component 6. Therefore, the long sides 22a, 22b of the insert material 11 are arranged parallel or substantially parallel to the long sides 25a, 25b of the outer shell component 6. Further, the short sides 23a and 23b of the insert material 11 are arranged parallel or substantially parallel to the short sides 26a and 26b of the main body side foam 10. On the other hand, in the present embodiment, one of the divided foam pieces 15a, 15b is completely independent from the other divided foam pieces 15a, 15b, and both are closer to the short sides 26a, 26b of the outer shell 6. in position. The entire short sides 23a and 23b of the insert material 11 are embedded in the divided foam pieces 15a and 15b. That is, one short side 23a of the insert material 11 is completely embedded in one of the divided foam pieces 15a. The other short side 23b of the insert material 11 is completely embedded in the other segmented foam piece 15b. Also, a part of the long sides 22a, 22b that are connected to the other short side 23b of the buried insert material 11 are buried in the divided foam pieces 15a, 15b. In the main body foam 10 of this embodiment, there is no foam between the divided foam pieces 15a and 15b (missing portion 16). That is, in the main body side foam 10 of this embodiment, one of the divided foam pieces 15a, 15b is completely independent from the other divided foam pieces 15a, 15b, and there is a gap between the divided foam pieces 15a, 15b ( There is no foam in the missing portion 16). Therefore, in this embodiment, the insert material 11 is exposed in the missing portion 16. More specifically, the middle portion of the two long sides 22a and 22b of the insert material 11 is exposed in the cutout portion 16. In this embodiment, only the two long sides 22a and 22b of the insert material 11 connect the left and right divided foam pieces 15a and 15b, and the two long sides 22a of the insert material 11 corresponding to the missing portion 16 connect the left and right divided foam pieces 15a and 15b. , 22b, the entire circumference in the cross-sectional direction is exposed. In the missing portion 16, it is preferable that the insert material 11 is completely exposed to the outside as in the present embodiment, but within the allowable range of warpage of the foam molded product 1, at least a portion may be made of foam. May be covered. The foamed molded product 1 of the present embodiment is characterized in that a fitting member 20 is fitted into the missing portion 16 described above. The shape of the fitting member 20 is as if the divided foam pieces 15a, 15b were thinly sliced, and the cross-sectional shape (hereinafter referred to as cross-sectional shape) cut parallel to the short sides 26a, 26b of the main body foam 10 is as follows. The cross-sectional shape is similar to that of the divided foam pieces 15a and 15b. That is, the fitting member 20 is a member that fills the gap (missing part 16) in the main body foam 10 and connects the divided foam pieces 15a and 15b, and in this embodiment, the cross-sectional shape is approximately "inverted L". It has a horizontal base part 32 and a support base part 33 that hangs down from one long side of the horizontal base part 32. The difference between the cross-sectional shape of the fitting member 20 and the cross-sectional shapes of the divided foam pieces 15a and 15b is that in the divided foam pieces 15a and 15b, the rod-shaped portion of the insert material 11 is embedded, The fitting member 20 is provided with relief notches 28a and 28b for allowing the rod-shaped portion of the insert material 11 to escape. The width (thickness) Wb of the fitting member 20 is slightly wider than the width Wa of the missing portion 16 described above. In the foam molded product 1 of this embodiment, as shown in FIG. 1, a fitting member 20 is attached to a missing portion 16 formed in the middle portion of the main body foam 10 where the foam is missing. In the foamed molded product 1 with the fitting member 20 attached, divided foam pieces 15a and 15b separated into left and right sides are gently connected by the fitting member 20. Specifically, the horizontal base part 12 of one divided foam piece 15a, the horizontal base part 32 of the fitting member 20, and the horizontal base part 12 of the other divided foam piece 15b are smoothly connected without a large step. , substantially forming one curved surface. However, since the fitting member 20 is provided with relief notches 28a and 28b for allowing the rod-shaped portion of the insert material 11 to escape, this portion is a discontinuous surface as shown in FIG. Further, the intermediate portions of the long sides 22a, 22b of the insert material 11 exposed within the missing portion 16 are accommodated in escape notches 28a, 28b of the fitting member 20, as shown in FIG. The direction in which the fitting member 20 is fitted into the main body foam 10 is not limited, but it is perpendicular to the plane equivalent portion of the main body foam 10 that is exposed when the mold is opened when molding the main body foam 10. It is easy and suitable to insert from this direction. When applied to this embodiment, it is desirable to insert the fitting member 20 from the surface side of the horizontal base portion 12 of the main body foam 10, as shown in FIG. The fitting member 20 is preferably fitted to such an extent that the surface of the horizontal base portion 32 thereof is at the same height as the horizontal base portion 12 of the divided foam pieces 15a, 15b, and no difference in level occurs. This is preferable because it reduces not only the difference in strength but also the discomfort caused by the difference in level. Particularly for areas that form a design or function surface, it is best to fit them to the extent that no difference in level occurs. Note that if a hole is provided for design or functionality, it is obvious that no fitting should be done in that part. The above-mentioned fitting member 20 may be molded separately, or if there is room in the size of the mold for molding the main body side foam 10, the fitting member 20 may be molded at the same time when molding the main body side foam 10. You may do so. Alternatively, the fitting member 20 may be obtained by cutting a foamed material formed into a plate shape or a block shape into a predetermined shape by cutting or the like. The material of the fitting member 20 preferably has the same compressive strength as the divided foam pieces 15a and 15b of the main body side foam 10, which is the main body part, and is a foam made of substantially the same material and density. It is even more preferable. As a result, for example, when the foam molded product 1 is used as a core material (rigidity imparting member) of an automobile seat, it is possible to reduce the difference in sitting comfort caused by the difference in strength, that is, the sense of discomfort. Of course, it is also possible to use the fitting member 20 with a different compressive strength or density than that of the segmented foam pieces 15a and 15b, but in this case, the sense of decrease in rigidity compared to when the fitting member 20 is not fitted cannot be improved. However, there is a possibility that you may still feel uncomfortable about the feeling of sitting. It is desirable that the shape of the fitting member 20 is such that the projected shape of its end faces 27a, 27b is the same as or similar to the projected shape of the end faces 36a, 36b of the divided foam pieces 15a, 15b. Further, in order to reduce the difference in sitting comfort, it is preferable that the lengths La and Lb of the upper surface portions of both the horizontal platform parts 12 and 32 are approximately the same length. If the length Lb of the horizontal base portion 32 of the fitting member 20 is less than the length La of the divided foam pieces 15a, 15b, this may be due to the absence of the fitting member 20 in the local part or end where the fitting member 20 is not installed. A sense of discomfort may occur. If the foam molded product 1 is used in a product where the parts without the fitting member 20 have virtually no effect on the overall rigidity, the length Lb of the fitting member 20 and the divided foam pieces 15a, 15b The lengths La may be different. In addition, even when the foam molded product 1 is used in an automobile seat, there is a low possibility that a feeling of discomfort will occur due to the absence of the fitting member 20 in local areas or edges where the fitting member 20 is not installed, or In the case where the discomfort is not a problem because no passenger is seated in that part, the length Lb of the fitting member 20 and the length La of the divided foam pieces 15a and 15b may be different. An example of the width Wb of the fitting member 20 is to make it slightly wider than the width Wa of the cutout portion 16, which is the groove-like interval, as described above. According to this configuration, the fitting member 20 is installed so as to push open the divided molded body (split foam pieces 15a, 15b), and the fitting member 20 is securely fixed to the main body side foam body 10. According to this configuration, the end surface 27 of the fitting member 20 and the end surfaces 36 of the divided foam pieces 15a, 15b are strongly pressed together, and the fitting member 20 physically engages with the foam forming the main body side foam 10. The preferable difference between the width Wb of the fitting member 20 and the width Wa of the cutout 16 is determined by the width Wa of the cutout 16, which is the distance between the end faces 36a, 36b of the split foam pieces 15a, 15b, and the width of the split foam pieces 15a, 15b. Although it is not possible to make a general statement because it depends on the material, the width Wb of the fitting member 20 may be made larger than the width Wa of the cutout portion 16 to such an extent that it can be locked by friction or lateral pressure caused by being spread and fixed. For example, if the width Wa of the cutout portion 16, which is a groove-like interval, is about 30 mm, the fitting member 20 can be sufficiently locked by increasing the width Wb of the fitting member 20 by approximately the same amount to about 0.5 mm. If the width Wb of the fitting member 20 is too large, fitting installation becomes difficult. Furthermore, even if the split foam pieces 15a and 15b have approximately the same thickness, the end faces 36a and 36b of the split foam pieces 15a and 15b have slight irregularities and fluff when cut, so the fitting member 20 can be locked by friction with them. It is. Further, instead of making the fitting member 20 wider as a whole, only a part thereof may be made wider (thicker), and the other parts may be made thinner or the same as the width Wa of the missing portion 16. If the entire part is made thicker (wider), the fitting member 20 may be difficult to install due to the large resistance when it is installed in the missing part 16, but this point can be improved by making only one part wider (thicker). In the fitting member 35 shown in FIG. 5, only the upper side 29 of the horizontal base portion 32 (the shaded portion in FIG. 5b) is formed to be wide. In other words, a protrusion is provided on the end surface 27 of the fitting member 35 and on the side surface of the horizontal base portion 32. The fitting member 37 shown in FIG. 6 widens only the long side ends 38 and 40 on the upper side of the horizontal table part 32 and a part 43 of the support table part 33 (the shaded part in FIG. 6b). It is molded. That is, in the fitting member 37 shown in FIG. 6, there are protrusions at both long side ends 38 and 40 on the upper side of the horizontal base part 32, and at a part 43 of the support base part 33 (the shaded part in FIG. 6b). There is a department. Furthermore, like the fitting member 42 shown in FIG. 7, the convex portions 41 may be provided in a scattered manner. If a partially wide portion is provided or a convex portion 41 is provided, a gap as shown in FIG. A gap 45 is created. On the other hand, since the convex portion 41 and the like strongly press the end surfaces 36a, 36b of the divided foam pieces 15a, 15b and deform the end surfaces 36a, 36b of the divided foam pieces 15a, 15b, the member 42 is firmly fitted into the missing portion 16. It can be installed in FIG. 7 shows how the fitting member 42 is inserted into the missing portion 16 and installed. At the initial stage of insertion, only the convex portion 41a on the lower side is covered with the split foam, as shown in FIG. 7(b). It comes into close contact with the end surfaces 36a, 36b of the pieces 15a, 15b. At the initial stage of insertion, only the convex portion 41a on the lower side is in close contact with the end surfaces 36a, 36b of the divided foam pieces 15a, 15b, so that the subsequent pushing force is small. Finally, as shown in FIG. 7(c), the upper convex portion 41b also comes into close contact with the end surfaces 36a, 36b of the divided foam pieces 15a, 15b. However, in the area where the convex portion 41 does not exist, a gap 45 is formed as shown in FIG. 7(c). The ratio of the total area of ​​the protruding portions such as the convex portion 41 to the area of ​​the end surfaces 27a, 27b of the fitting members 35, 37, 42 is determined by the shape of the end surfaces 36a, 36b of the divided foam pieces 15a, 15b, and therefore cannot be generalized. Although it cannot be determined, it is possible to install and lock the foam without falling off if the surface is in contact with the foam, for example, 10 to 60%, preferably 20 to 40%. Further, a partially widened portion can be easily realized by forming or cutting the surface in advance so as to create unevenness. In this embodiment, the protrusions 41 and the like are provided on the end surfaces 27a and 27b of the fitting members 35, 37, and 42, but protrusions and the like may be provided on the main body foam 10 side. Further, it is also possible to propose a method of making the entire fitting member 76 tapered along the fitting direction as a method of making the installation easier. In this embodiment, as shown in FIGS. 8 and 9, the cross-sectional shape (hereinafter referred to as the front shape) of the fitting member 76 cut parallel to the long sides 25a and 25b of the main body side foam 10 is trapezoidal, and the fitting member 76 The end surfaces 27a and 27b are generally tapered inclined surfaces. Here, the fitting member 76 employed in this embodiment has a trapezoidal front shape, and the end surfaces 27a and 27b of the fitting member 76 are tapered inclined surfaces as a whole, so that the fitting member 76 is similar to that shown in FIG. 9(a). It is easy to insert the fitting member 76 from the surface side of the horizontal base portion 12 of the main body side foam body 10. Further, the end surfaces 27a, 27b of the fitting member 76 are in close contact with the end surfaces 36a, 36b of the divided foam pieces 15a, 15b due to the wedge effect, and are physically engaged with the foam forming the main body foam 10. Therefore, the fitting member 76 does not easily separate from the missing portion 16. In the present embodiment, the fitting member 76 is processed into a tapered shape, but a tapered shape may be formed on the side of the missing portion 16, or a tapered shape may be formed on both the fitting member 76 and the missing portion 16. As another example, it is also preferable to physically engage and fix a part of the fitting member to the exposed insert material 11 as shown in FIG. When adopting this configuration, the width Wb of the fitting member 48 may be made slightly thinner than the width Wa of the missing portion 16. Of course, the fitting member 48 may be physically engaged with both the main body foam 10 and the insert material 11 in combination with the above-described configuration. In the foamed molded product 47 shown in FIG. 10, engaging portions 46a and 46b are provided on the lower surface of the horizontal base portion 32 of the fitting member 48. The engaging portions 46a, 46b extend in the direction along the long sides 22a, 22b of the insert material 11. In this embodiment, when the fitting member 48 is inserted into the missing portion 16, the long sides 22a, 22b of the insert material 11 engage with the engaging portions 46a, 46b as shown in FIG. 11, thereby preventing the fitting member 48 from falling off. prevent. In this case, the fitting member 48 remains in the main body foam 10 by being locked to the exposed insert material 11. For this purpose, a locking shape may be formed in advance on the relevant portion of the fitting member 48 so as to match the insert material 11. The shape of the engaging portions 46a, 46b is preferably slightly smaller than the width (diameter in the case of a round cross section) of the insert material 11 in order to ensure that the insert material 11 is locked or does not fall off. Further, although the engaging portions 46a and 46b illustrated in FIG. 10 are groove-shaped, the groove-shaped opening may be narrowed to make the inside wider than the opening. 12 to 15 show modifications of the fitting member. The fitting member 50 shown in FIG. 12 has only a portion corresponding to the horizontal base portion 32 and does not have a portion corresponding to the support base portion 33. The fitting member 51 shown in FIG. 13 is an example in which engaging parts 46a and 46b are provided on the lower surface of the horizontal base part 32, and there is no support base part. The foamed molded product 52 shown in FIG. 14 has an opening in the center when completed. The divided foam pieces 15a and 15b constituting the main body side foam 10 of the foam molded product 52 have cutout portions 31 on their end faces. The fitting member is divided into two parts, and has a rear fitting member 53 attached to one long side 25a of the main body foam 10 and a front fitting member 55 attached to the other long side 25b. There is. The foamed molded product 78 shown in FIG. 15 exemplifies a case where the fitting member has a three-part structure. In the foamed molded product 78, the fitting members include a front fitting member 56, a central fitting member 57, and a rear fitting member 58. The fitting member has engaging portions 60a, 60b, and has a structure that engages the engaging portions 60a, 60b with the long sides 22a, 22b of the insert material 11 to prevent the fitting members 56, 57, 58 from falling off. . Here, in this embodiment, the front fitting member 56 is provided with an engaging portion 60b, and the rear fitting member 58 is provided with an engaging portion 60a. In this embodiment, the engaging portions 60a and 60b are grooves extending parallel to the horizontal platform portion 32. In this embodiment, the front fitting member 56 and the rear fitting member 58 are moved in a direction parallel to the horizontal base portion 32 and attached to the missing portion 16, as shown by the arrows in FIG. In the embodiment described above, the main body foam 10 is separated into two divided foam pieces 15a and 15b, but it may be separated into a larger number of pieces. Further, the two divided foam pieces 15a, 15b have the same size, and the missing portion 16 is provided at the center of the main body side foam 10 in the width direction, but the size of the divided foam pieces 15a, 15b is They may be different. In this case, the missing portion 16 is provided at a position away from the center. In the embodiment described above, the main body foam 10 is divided into divided foam pieces 15a and 15b along straight lines parallel to the short sides 23a and 23b of the insert material 11, but it is divided along diagonal lines and curved lines. may have been done. Further, the insert material 11 may be divided in a direction parallel to the long sides 22a, 22b, or may be divided in a cross shape. In the embodiment described above, the missing portion 16 is located at a position corresponding to the long sides 22a, 22b of the insert material 11, and has a size that straddles the two long sides 22a, 22b. , 22b or the position and size corresponding only to the short sides 23a, 23b. In the embodiment described above, the insert material 11 is made of an iron-based rod-shaped member. The segmented foam pieces 15a and 15b are made of pre-expanded beads of olefin resin that are heated in a mold to expand and wrap around the insert material 11. However, the adhesive force between the iron-based insert material 11 and the olefin-based foam is weak, and the interface thereof moves relative to each other. However, the insert material 11 has a rectangular annular shape and has two long sides 22a, 22b and two short sides 23a, 23b, and the short sides 23a, 23b are entirely covered with the divided foam pieces 15a, It is buried in 15b. Here, the short sides 23a, 23b of the insert material 11 are located at the ends of the long sides 22a, 22b, and are bent with respect to the long sides 22a, 22b. Therefore, when the long sides 22a and 22b of the insert material 11 are pushed or pulled in the axial direction as shown by the arrow X in FIG. It physically engages with the body and prevents relative movement of the long sides 22a, 22b. In this way, the insert material 11 employed in this embodiment has engaging portions (short sides 23a, 23b) that engage with the foam inside the divided foam pieces 15a, 15b. Moreover, the long sides 22a and 22b of the insert material 11 function as a connecting part that connects the engaging parts (short sides 23a and 23b). Looking at it from a different perspective, the long sides 22a and 22b of the insert material 11 are the engaging parts, and the short sides 23a and 23b function as connecting parts that connect the engaging parts. As explained in the background technology section, the main body foam 10 employed in this embodiment is also produced by attaching the insert material 11 to a mold, introducing pre-foamed beads into the cavity of the mold, and inserting the pre-foamed beads into the cavity. It is made by foaming and integrating the insert material 11 and the foam. However, the main body foam 10 employed in this embodiment is separated into a plurality of divided foam pieces 15a and 15b as shown in FIG. 3, and the adhesive force between the insert material 11 and the foam is weak. The interface moves relative to each other. Therefore, no stress is applied to the insert material 11 even if the divided foam pieces 15a, 15b change in volume in the direction along the long sides 25a, 25b. In other words, the missing portion 16 is formed at a position where it is possible to alleviate the stress applied to the insert material 11 when the volume of the outer shell component 6 changes. Therefore, the foamed molded products 1 of the embodiments described above are less likely to warp. In addition, in the foam molded product of the embodiment described above, since the fitting member 20 is attached to the missing portion 16, even though the main body side foam 10 is separated into the divided foam pieces 15a and 15b, a certain amount of There is a sense of unity. Therefore, it does not wobble when you carry it around. Furthermore, since there are few defects on the surface of the main body foam 10, even when used as a rigidity imparting member for an automobile seat, it is unlikely to cause a feeling of discomfort to a person sitting on it. In the embodiment described above, the insert material 11 has short sides 23a and 23b that serve as engaging portions that engage with the foam inside the foam. There are long sides 22a and 22b as connecting parts that connect two or more engaging parts (short sides 23a and 23b). In the embodiment described above, the missing portion 16 is located at a portion corresponding to the long sides 22a, 22b of the insert material 11, which are the connecting portions. The position of the missing portion 16 is not limited to the long sides 22a, 22b of the insert material 11, which are the connecting portions, but may be provided at the portions corresponding to the short sides 23a, 23b, which are the engaging portions. The foam molded product 62 shown in FIGS. 16 and 17 has a slit wider than the diameter of the short sides 23a, 23b of the insert material 11 in a region including all of the short sides 23a, 23b, which are the engaging portions of the insert material 11. A missing portion 63 is provided. Within the missing portion 63, the short sides 23a and 23b of the insert material 11 are exposed. Since the missing portion 63 adopted in this embodiment has a width wider than the diameter of the short sides 23a, 23b of the insert material 11, the short sides 23a, 23b move in the direction of the long sides 22a, 22b of the insert material 11. It is possible. Therefore, even if the main body foam 61 undergoes a volume change in the direction along the long sides 25a, 25b, no stress is applied to the insert material 11. Also in this embodiment, the missing portion 63 is formed at a position where it is possible to alleviate the stress applied to the insert material 11 when the main body foam 61 changes in volume. In the foamed molded product 62 shown in FIG. 16 as well, a fitting member 65 is attached to the missing portion 63. In the foamed molded product 80 shown in FIGS. 18 and 19, cutout portions 66a and 66b are formed at portions corresponding to one long side 22a of the insert material 11, which is the connection portion. Furthermore, missing portions 66c and 66d are also formed in portions corresponding to the other long side 22b. In the missing portion 66, the long sides 22a and 22b of the insert material 11 are exposed. This embodiment is recommended when the insert material 11 is provided with a fitting 81 for connecting the foam molded product 80 to another member as shown in FIG. 20(f). An example of the attachment 81 is a skin layer attachment. The cutouts 66a and 66b provided in the foam molded product 80 are substantially through holes, and it is desirable that the fitting 81 be exposed within the through holes. The attachment 81 essentially functions as an engagement portion that engages the foam. The position of the missing portion 16 corresponds to the fitting 81 which is the engaging portion of the insert material 11. In this embodiment, each missing portion 66a, 66b, 66c, and 66d is independent and does not communicate with each other. Therefore, when the main body foam 67 changes in volume in the direction along the long sides 25a and 25b, stress is applied to the insert material 11. However, since the main body foam 67 has a portion in the middle where the foam is missing, the elastic modulus of the main body foam 67 itself is small, and the stress applied to the insert material 11 is small. Also in the foam molded product 80 of this embodiment, fitting members 68 are attached to each of the missing portions 66a, 66b, 66c, and 66d. In the embodiments described above, the insert material 11 has a rectangular annular shape, but the present invention is not limited to this configuration, and the shape of the insert material may be circular or oval. good. In addition, the insert material 11 is not limited to an annular shape, and as shown in FIG. 20(b), there are horizontal bar portions 70a and 70b at both ends that serve as engaging portions, and the insert material 11 is used as a connecting portion that connects the horizontal bar portions 70a and 70b. The vertical bar portion 71 may be provided between the centers of the horizontal bar portions 70a and 70b. As shown in FIG. 20(c), the vertical bar portion 71 may connect the ends of the horizontal bar portions 70a and 70b to form a “U” shape. As shown in FIG. 20(d), there may be lump portions 72a and 72b that serve as engaging portions at both ends, and a vertical bar portion 75 may be provided as a connecting portion that connects the lump portions 72a and 72b. It may be in a lattice shape as shown in FIG. 20(e). Further, as shown in FIG. 20(f), a fitting 81 for connecting the foam molded product 1 to other members may be provided. The material of the insert material 11 is not limited to iron-based materials (including stainless steel), and may be other metals such as aluminum or its alloy, titanium, copper, etc. Moreover, the material of the insert material 11 may be resin. In the embodiment described above, the fitting member 20 is basically made in a fitting member molding process separate from that of the main body foam 10. In many cases, it is molded and produced in a separate location and with separate molding equipment. On the other hand, the main body foam 10 is molded by a main body molding process. In the main body forming process, part or all of the insert material is buried in the main body foam 10 which is made of olefin resin and is in the form of a block, and a missing part 16 where the foam is missing is formed in the middle part of the main body foam 10. This is a step of molding the formed main body foam 10. Specifically, the insert material 11 is attached to a foam mold (not shown) having a convex mold and a concave mold. Between the convex mold and the concave mold, there is a molding cavity forming one segmented foam piece 15a and a molding cavity forming the other segmented foam piece 15b. The two mold cavities are then filled with pre-foamed beads, and then the convex and concave molds are completely closed. Then, with the convex mold and the concave mold completely closed, water vapor of about 0.10 to 0.40 MPa (G) is supplied to the molding cavity through a concave chamber (not shown) to heat and foam the pre-foamed beads. , to form two independent divided foam pieces 15a and 15b by fusion. After heating, foaming and fusing the pre-foamed beads, cooling water is sprayed onto the concave and convex molds from the back side to cool the divided foam pieces 15a and 15b, and then the concave and convex molds are opened. , part or all of the insert material 11 is buried in the main body foam 10, and a missing portion 16 in which the foam is missing is obtained in the middle part of the main body foam 10. Note that after being released from the mold, the divided foam pieces 15a and 15b once shrink and then return to their original shapes. Then, the fitting member 20 is attached to the missing portion 16 of the main body side foam 10, and the foam molded product 1 is completed. Here, it is preferable that the fitting member 20 be fitted after the main body side foam 10 has dried. That is, as described above, the divided foam pieces 15a, 15b are cooled and once contracted, and then their volume is restored. It is likely that it will be easier to fit in while the foam is slightly contracted immediately after molding, but if it is fitted before drying, the fitting member will come into contact with a part of the foam due to the dimensional recovery behavior that accompanies drying. The recovery behavior may be regulated and the warp may not recover sufficiently. In this way, since the volume of the main body foam 10 changes after molding, the fitting member 20 is attached to the missing portion 16 after the volume change of the main body foam 10 has converged after the main body molding process. It is desirable to do so. By fitting the fitting member of the present invention, the overall rigidity is ensured even in the case of a divided molded body, and even when used as a core material for a car seat, there are differences in seating comfort depending on the location. can be made less likely to occur. In this embodiment, the segmented foam pieces 15a and 15b are molded from polyolefin resin. The polyolefin resin constituting the segmented foam pieces 15a, 15b is a polymer containing 75% by weight or more of an olefin monomer. Specific examples of olefinic monomers include ethylene, propylene, butene-1, isobutene, pentene-1, 3-methyl-butene-1, hexene-1, 4-methyl-pentene-1, 3,4 Examples include α-olefins having 2 to 12 carbon atoms such as -dimethyl-butene-1, heptene-1, 3-methyl-hexene-1, octene-1, and decene-1. These may be used alone or in combination of two or more. Further, as specific examples of other monomers having copolymerizability with the olefinic monomer, for example, cyclopentene, norbornene, 1,4,5,8-dimethanol-1,2,3,4,4a , 8,8a,6-octahydronaphthalene, 5-methylene-2-norbornene, 5-ethylidene-2-norbornene, 1,4-hexadiene, methyl-1,4-hexadiene, 7-methyl-1 , 6-octadiene and other dienes. These may be used alone or in combination of two or more. Specific examples of polyolefin resins include polyethylene resins whose main component is ethylene, such as high density polyethylene, medium density polyethylene, low density polyethylene, and linear low density polyethylene, and polypropylene resins whose main component is propylene. can be mentioned. These polyolefin resins may be used alone or in combination of two or more. The polypropylene resin is not particularly limited as long as it contains propylene as the main monomer component, and examples thereof include propylene homopolymer, olefin-propylene random copolymer, olefin-propylene block copolymer, etc. . These may be used alone or in combination of two or more. The polyethylene resin used in this embodiment includes ethylene homopolymer, ethylene-α-olefin random copolymer, ethylene-α-olefin block copolymer, low density polyethylene, high density polyethylene, and linear low density polyethylene. Examples include. The α-olefin mentioned here includes α-olefins having 3 to 15 carbon atoms, and these may be used alone or in combination of two or more. Among these polyethylene resins, ethylene-α-olefin block copolymers containing 1 to 10% by weight of comonomers other than ethylene, or linear low-density polyethylene exhibit good foaming properties. It can be suitably used for in-mold foam molding. The polyolefin resin used in the present invention may further contain cell nucleating agents such as talc, antioxidants, metal deactivators, phosphorus processing stabilizers, ultraviolet absorbers, ultraviolet stabilizers, fluorescent Whitening agents, stabilizers such as metal soaps, crosslinking agents, chain transfer agents, lubricants, plasticizers, fillers, reinforcing agents, inorganic pigments, organic pigments, conductivity improvers, flame retardant improvers, interfaces It can be used as a polyolefin resin composition to which additives such as activator-type or polymer-type antistatic agents are added. The polyolefin resin composition used in this embodiment is usually prepared using an extruder, a kneader, a Banbury mixer, a roll, etc. in advance to make it easier to use for pre-foaming. The mixture is melt-mixed and molded into polyolefin resin particles having a desired particle shape such as a cylinder, an ellipse, a sphere, a cube, a rectangular parallelepiped, or the like. The method for producing the pre-foamed polyolefin resin beads used in this embodiment is not particularly limited, but includes dispersing polyolefin resin particles in a dispersion medium together with a dispersant and the like in the presence of a blowing agent in a closed container. A method of heating the resin particles under pressure to a predetermined foaming temperature and impregnating the resin particles with a foaming agent, and then releasing the dispersion inside the closed container into a low pressure area and foaming it while keeping the temperature and pressure inside the container constant. , so-called depressurized foaming is preferred. The heating temperature in the airtight container is preferably from -25°C to the melting point of the polyolefin resin particles and below the melting point of the polyolefin resin particles +25°C, more preferably from -15°C to the melting point of the polyolefin resin particles +15°C. The temperature ranges below ℃. After heating to the temperature and applying pressure to impregnate the polyolefin resin particles with a blowing agent, one end of the sealed container is opened to release the polyolefin resin particles into an atmosphere at a lower pressure than the inside of the sealed container. Polyolefin resin pre-expanded beads can be produced by this method. In producing polyolefin resin pre-foamed beads, there are no particular restrictions on the blowing agent; examples include aliphatic hydrocarbons such as propane, isobutane, normal butane, isopentane, and normal pentane; inorganic gases such as air, nitrogen, and carbon dioxide; Water etc. and mixtures thereof can be used. Hereinafter, embodiments of the present invention will be described in more detail, but the present invention is not limited to the following. The olefin-based foamed resin particles, equipment, and method for evaluating the effects of the present invention used in Examples and Comparative Examples will be described below. (olefin foam resin particles) In the Examples and Comparative Examples, propylene foam resin particles Eperan LBS30C manufactured by Kaneka Corporation were used as the olefin foam resin particles. During molding, the olefin foam resin particles were kept under pressure with compressed air in a pressurized tank for 24 hours, and the internal pressure of the bubbles was increased to the pressure recommended by Kaneka Corporation (approximately 0.2 MPaG) before molding. . (molding equipment) In the Examples and Comparative Examples, an in-mold molding machine for olefin foam resin P300 manufactured by Toyo Kikai Kinzoku was used. (molded body mold) In the example, the approximate dimensions are long side (width direction) 800 mm x short side (vertical direction) 450 mm, the cross section parallel to the short side is approximately L-shaped (similar to Figure 1), and one end of the thinner side is 30 mm. , a single-cavity mold was used in which one end of the other thick side was 55 mm. In addition, the insert material 11, which is made by bending piano wire with a diameter of 3 mm and welding the joint part, is held by a magnet protruding from the mold so that the mold is 10 mm inside from the outer periphery and 15 mm inside from the top surface in the thickness direction. The structure is such that Further, the mold is divided into left and right sides with a groove having a width of 40 mm parallel to the short side at the center of the long side. The insert material 11 is exposed in this groove portion. In Comparative Example 1, a mold without the grooves was used compared to the mold used in the example. (fitting part) After obtaining a plate-shaped molded body using a single-cavity plate-shaped molded body with a long side of 600 mm, a short side of 70 mm, and a thickness of 70 mm, it is cut into a shape that fits into the groove with a cutter knife, A fitting member was obtained. (dry) After the molded product was removed from the mold, it was left at room temperature for 1 hour, and then placed in a drying room at an indoor temperature of 80°C for 24 hours to dry. (Evaluation method) Evaluation point 1 Warpage change Place the molded product on a horizontal surface with the top facing down, and measure the height difference from the center to both ends of the long side (center of the short side). The total value of the measurement results at the two points is defined as the amount of warpage. A ruler with a minimum scale of 0.5 mm was used for measurement. Evaluation point 2 Seating comfort evaluation The feel of the molded product placed on a horizontal surface was evaluated by sitting at three locations: near both ends of the long side and in the center. The feel was evaluated based on the difference in feel between the three locations. large (the feel is very different) and small (there is almost no difference in the feel). Example 1 Using the molded body mold provided with the groove, the insert material is installed in the mold in advance, and olefin resin foam particles are filled, and steam with a main piping steam pressure of 0.6 MPa is guided into the mold, After preheating for 3 seconds, heating on one side for 5 seconds, heating on the other side for 2.5 seconds, and heating on both sides for 11 seconds, water at a pressure of 0.4 MPa adjusted to 40 ° C (Celsius) was sprayed from the back of the mold. A water cooling process of spraying and cooling the mold and the molded body was carried out for 105 seconds, followed by an air cooling process of 50 seconds in which the molded body was left alone, and then the molded body was taken out. The molded product taken out was immediately placed in a drying room, dried under the above conditions, and then left at room temperature (25° C.) for 8 hours. Separately, a plate material for a fitting member was molded using the fitting member mold, and then dried in the same manner as above to obtain a plate material.The fitting member was then cut out using a cutter knife in a shape that matched the groove shape. The thickness at that time was +0.2 mm thicker than the groove width of the dried molded body. The fitting member was fitted into the groove of the molded body and evaluated. the result, Evaluation point 1: Total warpage was 2 mm. Evaluation point 2: No particular discomfort was felt at both ends or in the center. Example 2 Evaluation was performed in the same manner as in Example 1, except that the thickness of the fitting member was made 4 mm thinner than the groove width of the molded body, and a notch groove with a width of 2.8 mm was provided at both ends to engage with the insert material. the result, Evaluation point 1: The total warpage was 3 mm, which was slightly larger than in Example 1. Evaluation point 2: No major discomfort was felt at both ends or the center, but the remaining groove in the center was felt on the buttocks. Example 3 Except for the places where the thickness of the fitted member is increased by +0.2 mm from the groove width of the molded body, it is limited to 50 mm from both ends and 50 mm in the center (the total width is 150 mm, which is set as a total of 30% of the total length of 450 mm). Evaluation was performed in the same manner as in Example 1. the result, Evaluation point 1: The total warpage was 2 mm as in Example 1. Evaluation point 2: No particular discomfort was felt at both ends or in the center. Comparative example 1 A molded product was obtained by molding and drying in the same manner as in Example 1, except that a mold without grooves was used. Since there is no groove, no fitting member was inserted. As a result of the evaluation, Evaluation point 1: The total warpage was 54 mm. Evaluation score 2: There was an uncomfortable feeling of warping in the center. Comparative example 2 A molded body was obtained in the same manner as in Example 1 except that the fitting member was not fitted. As a result of the evaluation, Evaluation point 1: The total amount of warpage was 1 mm or less. Evaluation point 2: There was no support from the grooves in the center compared to both ends, which gave a strange feeling. Furthermore, after the evaluation of score 2, when moving the molded article by holding the end, an unstable behavior was observed in which the insert material bent in the groove part as it was moved and returned to its original shape after the movement was completed. Although the embodiments of the present invention have been described above, the present invention is not limited to the above-described embodiments, and it goes without saying that the configuration can be changed without departing from the gist of the present invention. 1,47, 52,62,78,80 Foam molded product 2 Automobile seats 3 Cushion layer 5 Epidermal layer 6 Outer shell component 10, 61, 67 Main body side foam 15a, 15b split foam pieces 16, 63, 66, missing part 20, 35, 37, 42, 48, 50, 51, 65, 68, 76 Fitting member 46a, 46b engaging part 53 Rear fitting member 55 Front fitting member 56 Front fitting member 57 Central fitting member 58 Rear fitting member 60a, 60b engaging part

Claims

Page 1 of 2 pages of Claims:

1. A molded foam product with an outer frame structure and an insert material in which part or the entire insert material is embedded in the outer frame structure, specifically where the outer frame structure has a missing section in the center of the main foam and a separate insert is installed in that missing section.

2. A molded foam product as described in Claims 1, specifically where the missing section is made at a location capable of relieving the stresses acting on the insert material while the outer frame structure changes volume.

3. A molded foam product as described in Claims 1 or 2, specifically where the insert material has an attachment point that connects to the foam inside the main foam and two or more connecting points that connect such attachment points, and the missing section is supported by the insert material connection. 4.

1. Any of the molded foam products specified in claims 1-3 are characterized by an insert material having interlocking parts that are attached to the inner foam of the main foam and two or more connecting parts that are attached to these interlocking parts. The missing part is supported by the insert material's interlocking parts.

5. Any of the molded foam products specified in claims 1-4 are characterized by a missing part where the insert material is exposed.

6. Any of the molded foam products specified in claims 1-5 are characterized by the main foam being divided into multiple divided foam pieces and between the divided foam pieces there is a missing part.

7. Any of the molded foam products specified in claims 1-6 are characterized by the insert material's primary component being the same foam as the main foam. 8.

9. Any of the molded foam products specified in claims 1-7 are characterized by the shape of the surface of the inserted part, which is fitted in the missing space, being seamlessly continuous with the shape of the surface of the adjacent area of ​​the missing foam in the main foam body.

10. Any of the molded foam products specified in claims 1-8 are characterized by the insert being physically attached to the main foam body.

11. Any of the molded foam products specified in claims 1-9 are characterized by the insert being physically attached to the insert material on page 2 of 2 pages.

12. An automobile seat is characterized by the presence of any of the molded foam products specified in claims 1-10, and by the seat cushion and leather covering.The manufacturing method of the molded foam product specified in claim 12 is characterized by a molding process of the main body of the foam, in which a missing section of foam is created, with some or all of the insert material embedded in the olefin resin foam, and a molding process of the insert part, in which the insert is installed in the missing section of the main body of the foam, and a process of installing the insert part into the missing section of the main body of the foam.

13. The manufacturing method of the molded foam product specified in claim 12 is characterized by the main body of the foam consisting of multiple divided foam pieces, and between these divided foam pieces is the missing section.

14. The manufacturing method of the molded foam product specified in claim 12 or 13 is characterized by the main body of the foam having a volume change after the molding process of the main body, and the installation of the insert part into the missing section after the volume change of the main body of the foam has reached a stabilized state.