Foam molded product and manufacturing process for it

Abstract

Foam molded product (1), comprising: a foam body (2); a deployment material (12) comprising at least one display unit and one detection unit attached to the foam body (2); a surface material (5) attached to a surface of the foam body (2) to which at least the insert material (12) is attached; and a flexible layer (11) arranged between the insert material (12) and the surface material (5) and on the surface of the foam body (2) to which at least the insert material (12) is attached; wherein the insert material (12) includes a wiring element (4) with a length that projects from a dividing line (PL) of the foam molded product (1), and the foam molded product (1) further comprises a soft sealing material (7) formed around the separation line (PL).

Description

AREA OF TECHNOLOGY

[0001] The present invention relates to a foam molded product and a method for manufacturing it. STATE OF THE ART

[0002] A resin molded product in which a touch sensor is mounted is used in an interior part of a vehicle (for example, a dashboard), a control panel for a household appliance, or the like. For example, such a molded product can be formed by arranging a surface material 101 and a touch sensor 102 in the specified order on a mold surface of one of a pair of molds 103, 103 ( Fig. 32A), Closing the forms ( Fig. 32B) and injecting a molten resin, such as a thermoplastic resin, into a mold cavity for one-piece molding ( Fig. 32C). In other words, the molded product can be produced by so-called insert molds using a touch sensor as the insert material. In such a manufacturing process, a molded product 100, which includes the touch sensor decorated with the surface material 101, can be obtained by injection molding.

[0003] DE 10 2006 008 385 A1 discloses a single- or multi-layered plastic skin as a surface coating of coated objects, wherein areas are arranged in the plastic skin in which the plastic skin has a switching, sensor or signal transmission function.

[0004] DE 103 52 044 A1 discloses an input device for initiating switching operations by a user located inside a motor vehicle. The input device is equipped with a detection device for detecting a switching action and generating a switching signal based thereon, a support device for providing a load-bearing structure to accommodate the detection device, and a padded or foam material section that has an outer surface section accessible to the user and is coupled to the support device.

[0005] JP S56-50 833 A discloses an instrument panel formed from a core plate of metal or hard plastic, which is firmly bonded to a shock-absorbing pad made of foamed polyurethane, and on the surface of the pad is a surface layer. An electronic device is mounted inside the pad, and an electronic circuit for a clock is embedded in the pad on the back of the display.

[0006] EP 1 249 369 A1 discloses an interior trim part of a motor vehicle with at least one electrical component, consisting of a dimensionally stable support part, an outer skin and an intermediate layer.

[0007] WO 2004 / 069 578 A2 discloses an interior component for a vehicle, comprising a carrier body provided with a sensor-functional surface structure and an interior-side cover layer, wherein different output signals can be generated by means of the surface structure depending on the point of application. The cover layer is flexible and completely covers the sensor-functional surface structure.

[0008] EP 1 935 604 A2 discloses a method for producing a plastic skin with embedded films or planar carriers with conductive tracks, electronic circuits or switching elements by rotational sintering, wherein the films or carriers are covered with a polymeric layer which prevents a reaction between the plastic skin and the conductive tracks, and the films or carriers are applied to the molded skin which is not yet fully cured and cooled and are joined to the molded skin by gluing or melting before the back foaming is applied. SUMMARY OF THE INVENTION Technical Problem

[0009] However, the molded product obtained by the known manufacturing process has a resin on the back of the insert material; therefore, if the insert material is touched, the hard structure of the resin molded product can be transferred to a finger in the present mold. Furthermore, the known manufacturing process is injection molding, and excessive stress, which is likely to damage the insert material, can be exerted on it depending on the pressure and temperature of the resin during molding.

[0010] The present invention thus serves to solve the problems described above, and one objective of the present invention is to provide a molded foam product from which the soft structure can be obtained as a whole, including the position of any insert material, and a manufacturing process for producing the molded foam product. A further objective of the present invention is to provide a manufacturing process in which excessive stress is not exerted on the insert material. Solution to the problem

[0011] The present invention is provided in the appended claims 1, 3, and 9. The dependent claims contain advantageous embodiments of the invention. The following description serves to facilitate understanding of the invention. Some aspects are described below as means of solving the problems. These aspects can be combined as needed. A foam molded product according to one aspect of the present invention includes: a foam body; an insert material comprising at least one display unit and a detection unit attached to the foam body; includes, and a surface material attached to a surface to which at least the insert material is attached.

[0012] The foam molded product further includes a flexible layer that is arranged between the insert material and the surface material and on the surface to which at least the insert material is attached.

[0013] The foam molded product may further include a base substrate located on a surface opposite the surface to which the insert material of the foam body is attached.

[0014] The insert material can include a wiring element with a length extending from a parting line of the foam molded product, and the foam molded product can further include a soft sealing material formed around the parting line.

[0015] The insert material may include a wiring element with a length extending to the rear of the foam molded product through a through-hole formed in the foam body and base substrate, and the foam molded product may further include a soft sealing material formed within the through-hole.

[0016] The detection unit enclosed in the operating material can be a touch sensor, and the touch sensor can be mounted in such a way that a detection surface is exposed on the surface of the foam body.

[0017] The surface material may have a translucency and the foam molded product may further include a light source located on a rear surface of the surface material or the touch sensor.

[0018] The detection unit enclosed in the operating material can be a pulse switch, and the pulse switch can be mounted in such a way that a pressure surface is exposed on the surface of the foam body.

[0019] The surface material may be translucent. The display unit embedded in the insert material may be a laminate of a label with a transparent display section and a light source, and the label may be positioned so that it is exposed on the surface of the foam body.

[0020] The surface material may be translucent. The display unit enclosed in the insert material may be a dot matrix display device, and the dot matrix display device may be mounted in such a way that a display surface is exposed on the surface of the foam body.

[0021] A method for producing a foam molded product according to one aspect of the present invention includes: an arrangement step of the attached part for preparing a pair of molds, comprising a first mold and a second mold, and for arranging an attached part in which a insert material, comprising at least one of a display unit and a detection unit, and a surface material are attached to one another such that the surface material is in contact with a mold surface of the first mold; a mold closing step for closing the pair of molds; a molding step for injecting a foam resin into a mold cavity formed by closing the molds and foaming the foam resin to form a foam body; a mold opening step for opening the pair of molds;and a removal step for removing a molded product in which the attached part and the foam body are integrated.;

[0022] In the case of the fixed part, a flexible layer is attached between the insert material and the surface material.

[0023] A method for producing a foam molded product according to one aspect of the present invention includes: a surface material arrangement step for producing a pair of molds, comprising a first mold and a second mold, and for arranging a surface material on a mold surface of the first mold; an insert material arrangement step for arranging an insert material, comprising at least one of a display unit and a detection unit, on one surface of the surface material opposite the other surface of the surface material that is in contact with the mold surface; a mold closing step for closing the pair of molds; a molding step for injecting a foam resin into a mold cavity formed by closing the molds and foaming the foam resin to form a foam body; a mold opening step for opening the pair of molds; and The process includes a removal step for removing a molded product in which the surface material, the insert material, and the foam body are integrated. The method for producing a foam molded product further includes a flexible layer placement step for arranging a flexible layer between the surface material and the insert material.

[0024] The process for producing the foam molded product may further include a base substrate arrangement step for arranging a base substrate on a mold surface of the second mold prior to the mold closing step.

[0025] The insert material includes a wiring element with a length projecting to a parting surface of the first form, and a soft sealing material is formed on at least one of the parting surfaces of the first form and a parting surface of the second form.

[0026] A method for producing a foam molded product according to one aspect of the present invention includes: a material arrangement step for producing a pair of molds, comprising a first mold and a second mold, and for arranging a material comprising at least one of a display unit and a detection unit on a mold surface of the first mold; a mold closing step for closing the pair of molds; a molding step for injecting a foam resin into a mold cavity formed by closing the molds and foaming the foam resin to form a foam body; a mold opening step for opening the pair of molds; and a removal step for removing a molded product in which the material and the foam body are integrated.

[0027] A method for producing a foam molded product according to one aspect of the present invention includes: a material arrangement step for producing a pair of molds, comprising a first mold and a second mold, and for arranging a material comprising at least one of a display unit and a detection unit on a mold surface of the first mold; a base substrate arrangement step for arranging a base substrate on a mold surface of the second mold; a mold closing step for closing the pair of molds; a molding step for injecting a foam resin into a mold cavity formed by closing the molds and foaming the foam resin to form a foam body; a mold opening step for opening the pair of molds; and a removal step for removing a molded product in which the material, the base substrate, and the foam body are integrated.

[0028] A method for producing a foam molded product according to one aspect of the present invention includes: a material placement step for producing a pair of molds, comprising a first mold and a second mold, and for placing a material comprising at least one of a display unit and a detection unit on a mold surface of the first mold; a base substrate placement step for placing a base substrate on a mold surface of the second mold; a mold closing step for closing the pair of molds; a molding step for injecting a foam resin into a mold cavity formed by closing the molds and foaming the foam resin to form a foam body; a mold opening step for opening the pair of molds; and a removal step for removing a molded product in which the material, the base substrate, and the foam body are integrated.and a fastening step for attaching a surface material to the molded product so that the surface material covers the insert material.

[0029] A method for producing a foam molded product according to one aspect of the present invention includes: a base substrate arrangement step for preparing a pair of molds, comprising a first mold having a molding surface with a projecting section having the same size in a top view as a insert material, including at least one of a display unit and a detection unit, and a second mold, and for arranging a base substrate on a molding surface of the second mold; a mold closing step for closing the pair of molds; a molding step for injecting a foam resin into a mold cavity formed by closing the molds and foaming the foam resin to form a foam body including a recessed section formed by the projecting section of the first mold; and a mold opening step for opening the pair of molds.a removal step for removing a molded product in which the base substrate and the foam body are integrated; and a fixing step for attaching a surface material which is attached to the molded product with the insert material in such a way that the insert material is fitted into the recessed section.

[0030] A method for producing a foam molded product according to one aspect of the present invention includes: a base substrate arrangement step for preparing a pair of molds, comprising a first mold having a molding surface with a projecting section having the same size in a top view as a insert material, including at least one of a display unit and a detection unit, and a second mold, and for arranging a base substrate on a molding surface of the second mold; a mold closing step for closing the pair of molds; a molding step for injecting a foam resin into a mold cavity formed by closing the molds and foaming the foam resin to form a foam body including a recessed section formed by the projecting section of the first mold; and a mold opening step for opening the pair of molds.a removal step for removing a molded product in which the base substrate and the foam body are integrated; an insert material application step for applying an insert material to the recessed section so that at least one of a display surface of the display unit and a detection surface of the detection unit is exposed; and a fastening step for fastening a surface material to the molded product so that the surface material covers the insert material.

[0031] In the previously mentioned method for manufacturing the foam molded product according to one of the aspects, the detection unit enclosed in the input material can be a touch sensor or a pulse switch.

[0032] Furthermore, in the aforementioned method for manufacturing the foam molded product, the surface material can have a light transmittance according to one of the aspects, and the display unit enclosed in the insert material can be a laminate of a label having a transparent display section and a light source, or a dot matrix display device. Advantageous effects of the invention

[0033] The foam molding product according to one aspect of the present invention is configured to include: a foam body; an insert material enclosing at least one display unit and one sensing unit attached to the foam body; and a surface material attached to a surface to which at least the insert material is attached. Accordingly, the foam molding product according to one aspect of the present invention is configured such that the foam body is formed on the back side of the insert material. Therefore, the soft structure can be obtained as a whole, including a position of the insert material.

[0034] A method for producing a foam molded product according to one aspect of the present invention is configured to include: an arranging step of the attached part for preparing a pair of molds, comprising a first mold and a second mold, and for arranging an attached part in which a insert material, comprising at least one of a display unit and a detection unit, and a surface material are attached to one another such that the surface material is in contact with a mold surface of the first mold; a mold closing step for closing the pair of molds; a molding step for injecting a foam resin into a mold cavity formed by closing the molds and foaming the foam resin to form a foam body; a mold opening step for opening the pair of molds;and a removal step for removing a molded product in which the attached part and the foam body are integrated.;

[0035] A method for producing a foam molded product according to one aspect of the present invention is further configured to include: a surface material arrangement step for producing a pair of molds comprising a first mold and a second mold, and for arranging a surface material on a mold surface of the first mold; an insert material arrangement step for arranging an insert material comprising at least one of a display unit and a detection unit on one surface of the surface material opposite the other surface of the surface material in contact with the mold surface; a mold closing step for closing the pair of molds; a molding step for injecting a foam resin into a mold cavity formed by closing the molds and foaming the foam resin to form a foam body; a mold opening step for opening the pair of molds;and a removal step for removing a molded product in which the surface material, the insert material and the foam body are integrated.

[0036] A method for producing a foam molded product according to one aspect of the present invention is further configured to include: a material placement step for producing a pair of molds comprising a first mold and a second mold, and for placing a material, including at least one indicator unit and one sensing unit, on a mold surface of the first mold; a mold closing step for closing the pair of molds; a molding step for injecting a foam resin into a mold cavity formed by closing the molds and foaming the foam resin to form a foam body; a mold opening step for opening the pair of molds; and a removal step for removing a molded product in which the material and the foam body are integrated.

[0037] A method for producing a foam molded product according to one aspect of the present invention is further configured to include: a material placement step for producing a pair of molds comprising a first mold and a second mold, and for placing a material, including at least one indicator unit and one sensing unit, on a mold surface of the first mold; a base substrate placement step for placing a base substrate on a mold surface of the second mold; a mold closing step for closing the pair of molds; a molding step for injecting a foam resin into a mold cavity formed by closing the molds and foaming the foam resin to form a foam body; and a mold opening step for opening the pair of molds.and a removal step for removing a molded product in which the insert material, the base substrate and the foam body are integrated.;

[0038] A method for producing a foam molded product according to one aspect of the present invention is further configured to include: a material placement step for producing a pair of molds comprising a first mold and a second mold, and for placing a material, including at least one indicator unit and one sensing unit, on a mold surface of the first mold; a base substrate placement step for placing a base substrate on a mold surface of the second mold; a mold closing step for closing the pair of molds; a molding step for injecting a foam resin into a mold cavity formed by closing the molds and foaming the foam resin to form a foam body; and a mold opening step for opening the pair of molds.a removal step for removing a molded product in which the insert material, the base substrate and the foam body are integrated; and a fixation step for attaching a surface material to the molded product so that the surface material covers the insert material.

[0039] According to the two previously mentioned methods for manufacturing the foam molded product, the foam body is formed on the back of the insert material. Therefore, the soft structure can be obtained as a single unit, including the insert material. Furthermore, since the foam resin is injected and foamed, excessive stress is not exerted on the insert material.

[0040] Furthermore, a method for producing a foam molded product according to one aspect of the present invention is configured to include: a base substrate arrangement step for preparing a pair of molds, comprising a first mold having a molding surface with a projecting section having the same size in a top view as a insert material, including at least one of a display unit and a detection unit, and a second mold, and for arranging a base substrate on a molding surface of the second mold; a mold closing step for closing the pair of molds; a molding step for injecting a foam resin into a mold cavity formed by closing the molds, and foaming the foam resin to form a foam body that includes a recessed section formed by the projecting section of the first mold;a mold opening step for opening the pair of molds; a removal step for removing a molded product in which the base substrate and the foam body are integrated; and a fixing step for attaching a surface material that is fixed to the molded product with the insert material in such a way that the insert material is fitted into the recessed section.

[0041] Furthermore, a method for producing a foam molded product according to one aspect of the present invention is configured to include: a base substrate arrangement step for preparing a pair of molds, comprising a first mold having a molding surface with a projecting section having the same size in a top view as a insert material, including at least one of a display unit and a detection unit, and a second mold, and for arranging a base substrate on a molding surface of the second mold; a mold closing step for closing the pair of molds; a molding step for injecting a foam resin into a mold cavity formed by closing the molds, and foaming the foam resin to form a foam body that includes a recessed section formed by the projecting section of the first mold;a mold opening step for opening the pair of molds; a removal step for removing a molded product in which the base substrate and the foam body are integrated; an insert material application step for applying an insert material to the recessed section so that at least one of a display surface of the display unit and a sensing surface of the sensing unit is exposed; and a fastening step for fastening a surface material to the molded product so that the surface material covers the insert material.

[0042] According to the two previously mentioned methods for manufacturing the foam molded product, the foam body is formed on the back of the insert material. Therefore, the soft structure, including the insert material, can be obtained as a single unit. Furthermore, the foam body is molded, and then the insert material is attached to it. Therefore, excessive stress is not exerted on the insert material. BRIEF DESCRIPTION OF THE DRAWINGS

[0043] None of the accompanying figures fully illustrate the features of the present invention. Instead, the figures depict partial aspects of the invention, serving to explain it. Fig. 1A to Fig. Figure 1C are schematic cross-sectional views illustrating a foam molded product according to an embodiment of the present invention. Fig. 2A to Fig. Figures 3C are schematic cross-sectional views illustrating a foam molded product according to another embodiment of the present invention. Fig. 3A to Fig. Figures 3C are schematic cross-sectional views illustrating a foam molded product according to a further embodiment of the present invention. Fig. Figure 4A is a schematic perspective view illustrating a foam molded product according to another embodiment of the present invention. Fig. 4B is an AA cross-sectional view of Fig. 4A. Fig. Figure 4C is a schematic cross-sectional view illustrating a foam molded product according to a further embodiment of the present invention. Fig. Figure 5A is a schematic perspective view illustrating a foam molded product according to another embodiment of the present invention. Fig. 5B is an AA cross-sectional view of Fig. 5A. Fig. Figure 5C is a schematic cross-sectional view illustrating a foam molded article according to a further embodiment of the present invention. Fig. 6A and Fig. Figure 6B are schematic cross-sectional views illustrating a foam molded product according to another embodiment of the present invention. Fig. 7A and Fig. Figure 7B are schematic cross-sectional views illustrating a foam molded product according to another embodiment of the present invention. Fig. 8A to Fig. Figure 8C are schematic cross-sectional views illustrating a foam molded product with a touch sensor according to an embodiment of the present invention. Fig. Figures 9A to 9C are schematic cross-sectional views illustrating a foam molded product with a touch sensor according to another embodiment of the present invention. Fig. Figures 10A to 10F are schematic cross-sectional views illustrating an example of a foam molded product with a touch sensor and a light source according to an embodiment of the present invention. Fig. 11A and Fig. Figure 11B are schematic cross-sectional views illustrating an example of a foam molded product with a timing switch according to an embodiment of the present invention. Fig. Figure 12 is a schematic cross-sectional view illustrating a foam molded product with a laminate of a label and a light source according to an embodiment of the present invention. Fig. 13A and Fig. Figure 13B are schematic cross-sectional views illustrating a foam molded product with a laminate of a label and a light source according to another embodiment of the present invention. Fig. Figure 14A is a schematic cross-sectional view illustrating a foam molded product with a dot matrix display device according to an embodiment of the present invention. Fig. Figure 14B is a schematic top view of the dot matrix display device. Fig. 15A and Fig. Figure 15B are schematic cross-sectional views illustrating a foam molded product with a dot matrix display device according to another embodiment of the present invention. Fig. Figures 16A to 16E are schematic cross-sectional views illustrating a method for producing a foam molded product according to an embodiment of the present invention. Fig. Figure 17 is a schematic cross-sectional view illustrating a method for producing a foam molded product according to another embodiment of the present invention. Fig. 18A and Fig. Figure 18B are schematic cross-sectional views illustrating a method for producing a foam molded product according to another embodiment of the present invention. Fig. Figures 19A to 19C are schematic cross-sectional views illustrating a method for producing a foam molded product according to a further embodiment of the present invention. Fig. Figures 20A to 20D are schematic cross-sectional views illustrating a method for producing a foam molded product according to another embodiment of the present invention. Fig. Figures 21A to 21F are schematic cross-sectional views illustrating a method for producing a foam molded product according to another embodiment of the present invention. Fig. Figures 22A to 22E are schematic cross-sectional views illustrating a method for producing a foam molded product according to a further embodiment of the present invention. Fig. Figures 23A to 23F are schematic cross-sectional views illustrating a method for producing a foam molded product according to another embodiment of the present invention. Fig. Figures 24A to 24F are schematic cross-sectional views illustrating a method for producing a foam molded product according to another embodiment of the present invention. Fig. 25A and Fig. Figure 25B are schematic cross-sectional views illustrating a method for producing a foam molded product according to a further embodiment of the present invention. Fig. Figures 26A to 26E are schematic cross-sectional views illustrating an example of a mold used in a method for producing a foam molded product according to an embodiment of the present invention. Fig. Figure 27 is a schematic cross-sectional view illustrating an example of a method for producing a foam molded product with a timing switch according to an embodiment of the present invention. Fig. Figure 28 is a schematic cross-sectional view illustrating a method for producing a foam molded product with a timing switch according to another embodiment of the present invention. Fig. 29A and Fig. Figure 29B are schematic cross-sectional views illustrating an example of a method for producing a foam molded product with a laminate of a label and a light source according to an embodiment of the present invention. Fig. 30A and Fig. Figure 30B are schematic cross-sectional views illustrating an example of a method for producing a foam molded product with a dot matrix display device according to an embodiment of the present invention. Fig. 31A and Fig. Figure 31B are schematic cross-sectional views illustrating an example of a method for producing a foam molded product with a dot matrix display device according to an embodiment of the present invention. Fig. 32A to 32C and Fig. Figure 32E are schematic cross-sectional views illustrating an example of a known method for manufacturing a foam molded product. DESCRIPTION OF EXECUTION FORMS

[0044] An example of a foam molded product and a manufacturing process for it according to an embodiment of the present invention are described with reference to the drawings.

[0045] A foam molded product 1 according to an embodiment of the present invention includes a foam body 2, an insert material 12 which includes at least one of a display unit and a detection unit attached to the foam body 2, and a surface material 5 which is attached to a surface to which at least the insert material 12 is attached (see Fig. 1A to 1C).

[0046] The foam body 2 is a molded body made from a resin and a foaming agent. The resin is not particularly restricted, and a thermoplastic resin, a thermosetting resin, or the like can be applied. For example, a urethane resin, a vinyl chloride resin, an olefin resin, a styrene-based resin, a silicon-based resin, or the like can be applied. Of the resins, a soft resin such as urethane resin is preferably applied because it provides greater flexibility to the foam body 2. Air bubbles contained in the foam body 2 can be interconnected cells or closed cells. The foam body 2, formed from the resin as described above, is also formed on the back side of the insert material 12.Thus, when the insert material 12 is touched by a user, the user can feel the soft structure as a whole, including the insert material 12, with one finger. (Emergency equipment)

[0047] The deployment material 12 can include either a display unit or a detection unit, or it can include either one. The display unit includes a display surface 121, and the detection unit includes a detection surface 123. For example, icons such as graphics, numbers, symbols, or the like, static images, and videos are displayed on the display surface 121. The detection unit detects, for example, force, distance, heat, light, sound, smell, or the like via the detection surface 123.

[0048] The insert material 12 is mounted such that at least one of the display surface 121 and the detection surface 123 is exposed on the surface of the foam body 2. The configuration in which a step between the surface of the foam body 2 and the detection surface 123 is essentially missing (see Fig. 1A), the configuration in which the insert material 12 is applied to the surface of the foam body 2 (see Fig. 1B) is layered, or the configuration in which the insert material 12 protrudes slightly from the surface of the foam body 2 (see Fig. 1C), for example, can be provided. The insert material 12 can be attached, for example, by attaching the insert material to the surface of the foam body 2, placing the insert material on the surface of the foam body 2, or fitting the insert material into the foam body 2.

[0049] The surface material 5 is attached to the surface to which at least the insert material 12 is attached. Therefore, the surface material can only be attached to the surface to which the insert material 12 is attached, as shown in Fig. 1A, or can be attached to the surface where the insert material 12 is attached and to the side surfaces of the foam body 2, as shown in Fig. 1B and Fig. Figure 1C illustrates this. For example, a vinyl chloride resin, an elastomeric resin, a polyurethane resin, an olefin-based resin, a polyester resin, a silicon-based resin, natural leather, synthetic leather, artificial leather, a nonwoven fabric, various woven fabrics, or the like can be applied as a surface material 5. A surface material formed by a known process, such as slurry molding or vacuum forming, is applied as the surface material 5. The surface material 5 is then attached, for example, by means of an adhesive, a tape, or the like.

[0050] The foam molded product 1 can further comprise a flexible layer 11 which is arranged between the core material 12 and the surface material 5 and on the surface to which at least the core material 12 is attached (see Fig. 2A to 2C). For example, a flexible resin, such as an elastomeric resin, a gel, a foam resin obtained by foaming the same resin as the foam body 2, or the like, can be applied as the flexible layer 11. As with the surface material 5, the flexible layer 11 is formed only on the surface to which the insert material 12 is attached (see Fig. 2A and Fig. 2B) or can be formed on the surface to which the insert material 12 is attached and on the side surfaces of the foam body 2 (see Fig. 2C). Since the flexible layer 11 is formed on the display surface 121 of the insert material 12 or the sensing surface 123 of the insert material 12, the insert material 12 is surrounded by a soft material such as the foam body 2 and the flexible layer 11. Therefore, when the insert material 12 is touched by a user, the user can feel the softer structure as a whole, including the insert material 12, with a finger.

[0051] The foam molded product 1 can further enclose a base substrate 6 on a surface opposite the surface of the foam body 2 to which the insert material 12 is attached (see Fig. 3A to 3C). The foam molding product encloses the base substrate 6, thus improving the stiffness, strength, and applicability of the foam molding product. For example, a polypropylene resin, an ABS resin, a polycarbonate resin, a nylon resin, a silicone resin, a polybutylene terephthalate resin, a fiber-reinforced resin, a metal (aluminum, steel, or the like), natural wood, or the like can be applied as the base substrate 6. The surface to which the insert material 12 is attached is the surface of the foam body 2; therefore, the base substrate 6 is formed on the back side of the foam body 2. The base substrate 6 can be applied to a section of the back side of the foam body 2 (see Fig. 3A and Fig. 3B) be formed or can be formed in such a way that it covers the back of the foam body 2 (see Fig. 3C). Note that, as in Fig. Figure 3C illustrates that the surface material 5 can be attached extending over an area of ​​the foam body 2 to the base substrate 6.

[0052] The insert material 12 can further include a wiring element 4 with a length projecting from a separation line PL of the foam molded product 1, and the foam molded product 1 can further include a soft sealing material 7 formed around the separation line PL (see Fig. 4B and Fig. 4C and Fig. 5B and Fig. 5C).

[0053] The insert material 12 includes the wiring element 4, which is electrically connected to an electrode enclosed in at least one of the display unit and the sensing unit. For example, a printed circuit board (FPC) is used as the wiring element. Since the wiring element 4 has a length extending beyond the parting line PL of the foam molded product 1, an external electronic device can be connected to the projecting section of the wiring. The foam molded product 1 includes the soft sealing material 7 formed around the parting line PL.Note that the area around the separation line PL has a structure in which the soft sealing material 7 is in contact with the separation line PL when viewed in cross-section, and a structure in which the soft sealing material 7 is formed near the separation line PL (a structure in which the soft sealing material 7 is also on the wiring element 4, as in . Fig. 4B and Fig. 4C is illustrated, is formed). For example, a urethane resin, an elastomeric resin, a vinyl chloride resin, an olefin-based resin, a styrene-based resin, a silicon-based resin or the like can be applied as the soft sealing material 7.

[0054] Note that the wiring element 4 may protrude from the dividing line PL through the interior of the foam body 2 (see Fig. 6A and Fig. 6B).

[0055] In such a foam molded product 1, the soft sealing material 7 is formed in contact with the wiring element 4, which protrudes from the separation line PL. At the time of assembly of the foam molded product 1, the soft sealing material 7 therefore serves as a cushion and can thus prevent the wire from breaking.

[0056] The insert material 12 can also include the wiring element 4 with a length that projects from the rear of the foam molded product 1 through a through-hole formed in the foam body 2 and in the base substrate 6, and the foam molded product 1 can further include the soft sealing material 7 formed within the through-hole (see Fig. 7A and Fig. 7B).

[0057] The through-hole is formed in the foam body 2 and in the base substrate 6; however, the soft sealing material 7 can only be used within the through-hole of the base substrate 6 (see Fig. 7A) may be formed or may be formed within the through-hole of both the foam body 2 and the base substrate 6 (see Fig. 7B) be formed.

[0058] The foam molded product 1 can be obtained, for example, by integrating the foam body 2 and the base substrate 6 into the through-hole, with the wiring element 4 of the insert material 12 being guided through the through-hole, with the soft sealing material 7 being formed inside the through-hole, and the surface material 5 being attached.

[0059] In the foam molded product 1, configured as just described, the wiring element 4 is concealed beneath the back of the foam molded product 1; therefore, the appearance of the foam molded product 1 can be improved. Furthermore, the soft sealing material 7 is formed in contact with the wiring element 4. Accordingly, the soft sealing material 7 acts as a cushion during the assembly of the foam molded product 1 and can thus prevent the wire from breaking. (Touch sensor)

[0060] The detection unit of the foam molded product 1 enclosed in the insert material 12 is a touch sensor 3 and the touch sensor 3 can be mounted such that a detection surface 3a is exposed on the surface of the foam body 2 (see Fig. 8A to 8C).

[0061] A touch sensor operating in a known sensing method, such as a capacitive sensing method, a pressure-sensitive method, or a resistive layer method, can be used as the touch sensor 3. A touch sensor including a film, glass, or the like as a base substrate can be used as the touch sensor 3; however, with the touch sensor 3 formed from a film base substrate and having a small thickness, a foam molded product with a softer structure can be obtained. The touch sensor 3 is mounted such that the sensing surface 3a is exposed on the surface of the foam body 2. As long as the sensing surface 3a can be exposed on the surface of the foam body 2, for example, the configuration in which a step is substantially present between the surface of the foam body 2 and the sensing surface 3a can be used (see Fig. 8A), the configuration in which the touch sensor 3 is on the surface of the foam body 2 (see Fig. 8B) is layered, or the configuration in which the touch sensor 3 protrudes slightly from the surface of the foam body 2 (see Fig. 8C). The touch sensor 3 can be attached, for example, by attaching the touch sensor to the surface of the foam body 2, by placing the touch sensor on the surface of the foam body 2, or by fitting the touch sensor into the foam body 2. The surface material 5 is preferably attached using, for example, an optical adhesive tape (transparent optical tape) so that the optical properties of the touch sensor 3 are not impaired.

[0062] Between the touch sensor 3 and the surface material 5 (see Fig. 9A to 9C) the flexible layer 11 can be provided.

[0063] The surface material 5 can be translucent and the foam molded product can further include a light source 8 on the back of the surface material 5 or the touch sensor 3 (see Fig. 10A to 10F). An example of the configuration of the surface material 5, which exhibits translucency, includes a configuration in which the surface material 5 is translucent or transparent (may be colored), a configuration in which an opening is provided in the surface material 5, and a configuration in which a section of the surface material 5 has a low thickness. In a case where the foam molded product 1 is used, for example, as a control panel (interior part) of a motor vehicle, at least one of the aforementioned translucent or transparent section, an opening, and a low-density section are formed in the surface material, and thus any pattern (for example, a control symbol) can be formed. The light source 8 is switched on and can thus illuminate any pattern.

[0064] For example, LEDs, inorganic EL, organic EL, or the like can be used as the light source 8. The leaf-shaped light source 8 can be attached to or mounted on the rear surface of the surface material 5 or the touch sensor 3. In the case of mounting the light source 8, any pattern (such as letters, graphics, symbols, etc.) can be formed by the light sources 8 (see Fig. 10B). Such light sources are switched on, and thus any desired pattern can be displayed. As in Fig. As illustrated in Figure 10E, the light source 8 can furthermore be located on the rear surface of the touch sensor 3 and be separate from the touch sensor 3. As shown in Fig. As illustrated in Figure 10F, the light source 8 can also be placed on the rear surface of the touch sensor 3 and on the back of the foam molded product 1. In this case, the foam body 2 is also configured to be translucent, and it is preferable to reduce the thickness of a section of the foam body 2 between the touch sensor 3 and the light source 8.

[0065] In such a foam molded product 1, the touch sensor 3 and its surroundings are illuminated by the light source 8; specifically, where touching is easily understood by a user. Additionally, the foam molded product is configured such that the operating symbol is generally less visible when the light source is off, and that the operating symbol is only illuminated when the touch sensor 3 is touched. This creates the visual effect of the operating symbol standing out from the control panel.

[0066] Alternatively, the foam molded product 1 can be provided with the light source 8 and the surface material 5 without including the touch sensor 3. (Clock switch)

[0067] The detection unit of the foam molded product 1 enclosed in the insert material 12 is a pulse switch 13 and the pulse switch 13 can be mounted such that a detection surface 13a is exposed on the surface of the foam body 2 (see Fig. 11A). The pressure surface 13a is an example of the detection surface 123 that detects force.

[0068] The tact switch 13 is a component typically mounted on an electrical circuit (for example, a printed circuit board) and configured to convert the force applied to the pressure surface 13a into an electrical signal and input the signal into the circuit. In other words, a person presses the tact switch 13 to enable the electrical circuit to be switched on or off. A known tact switch can be used as the tact switch 13.

[0069] The tactile switch 13 contains a reversing spring 130. Accordingly, when the switch is pressed, a click is felt. When pressing the switch, a user can actually feel that the switch has been actuated.

[0070] Between the timing switch 13 and the surface material 5 (see Fig. 11B) The flexible layer 11 can be provided. The flexible layer 11 can be provided on a section of the surface where the clock switch 13 is located, as in Fig. 11B illustrates, is attached, or can be provided on the entire surface to which the clock switch 13 is attached. In a case where the flexible layer is applied to a section of the surface to which the clock switch is attached, as in Fig. As illustrated in Figure 11B, a step is formed between a position where the clock switch 13 is located and a position other than the one that includes the clock switch 13. Therefore, a user can locate the position that includes the clock switch 13 by simply touching the foam molded product 1. In a case where the flexible layer 11 is provided over the entire surface where the clock switch is attached, a user can obtain a softer texture by touching any section of the foam molded product 1.

[0071] Furthermore, the foam molded product, including the flexible layer 11, can be configured such that the pressure is 0.5 to 5 mm. The load applied by a finger in the direction perpendicular to the molded product is preferably 1 to 10 N per 1 mm of pressure. With such a configuration, a good pressure feel can be achieved. The surface material 5 is also preferably configured such that the load at the 10% modulus is 20 N or less, and the load at the 30% modulus is 60 N or less. The JIS K7311 tensile test method is used as the method for measuring the load at the 10% modulus and the load at the 30% modulus. Specifically, the load at a 10% elongation of a test specimen is measured as a defined 10% mode value, and the load at a 30% rotation of a test specimen is measured as a defined 30% mode value.In a case where the surface material with such properties is applied, the surface material 5 simply follows when the tactile switch 13 is pressed; therefore, a better user experience can be obtained. (Laminate)

[0072] The surface material 5 of the foam molded product 1 is translucent, and the display unit, which is enclosed in the insert material 12, is a laminate 14 of the label 140, which has a translucent display section 14a and the light source 8. The label 140 can be attached so that it is exposed on the surface of the foam body 2 (see Fig. 12).

[0073] An example of a configuration in which the surface material 5 has translucency includes a configuration in which the surface material 5 is translucent or transparent (may be colored), a configuration in which an opening is provided in the surface material 5, and a configuration in which a section of the surface material 5 has a small thickness. Label 140 has the translucent display section 14a. The translucent display section 14a has any pattern formed by a translucent section 14b and an opaque section 14c (for example, an operating symbol obtained by combining graphics, symbols, letters, numbers, and the like). The translucent display section 14a illuminates the pattern with the light source 8 and can thus display the pattern.For example, LEDs, inorganic EL, organic EL, or the like can be used as the light source 8. The leaf-shaped light source 8 can be attached to or mounted on the label 140. A laminate 14 is positioned such that the label 140 is exposed on the surface of the foam body 2. In other words, the label 140 is located on the back surface of the material 5, and the light source 8 is located on the back surface of the label 140.

[0074] Between surface material 5 and label 140 (see Fig. 13A) the flexible layer 11 can be provided or it can be provided between the label 140 and the light source 8 (see Fig. 13B). In any case, the flexible layer 11 is applied with light transmission.

[0075] Additionally, the surface material 5, the label 140, the light source 8, and the flexible layer 11 can be bonded together, for example, using an optical adhesive film (OCA). All four layers can be bonded together, or some of the four layers can be bonded together. Embossing or grooving is preferably performed on the adhesive surface so that air is easily released when the layers are bonded. (Dot matrix display device)

[0076] The surface material 5 is translucent, and the display unit enclosed in the insert material 12 is a dot matrix display device 15. The dot matrix display device 15 can be mounted such that the display surface 121 is exposed on the surface of the foam body 2 ( Fig. 14A). Additionally, Fig. Figure 14B shows a top view of the dot matrix display device 15 and LEDs, which are not illustrated for the sake of simplicity.

[0077] An example of a configuration in which the surface material 5 has light transmittance includes a configuration in which the surface material 5 is translucent or transparent (may be colored), a configuration in which an opening is provided in the surface material 5, and a configuration in which a section of the surface material 5 has a small thickness.

[0078] The dot matrix display device 15 includes at least one printed circuit board 150, opaque walls 151 formed on the printed circuit board to define the board in a matrix, and LEDs 152 mounted in respective areas 15a defined by the opaque walls. The dot matrix display device 15 selectively illuminates the LEDs 152 and can therefore display a desired pattern (graphics, symbols, letters, numbers, and the like).

[0079] The material of the opaque wall 151 is not particularly restricted; however, if the opaque walls 151 are formed from a soft material, a user may obtain a softer texture when touching the position of the dot matrix display device. For example, rubber, resin exhibiting flexibility, or the like may be used as the soft material. For example, a urethane resin, a vinyl chloride resin, an olefin-based resin, a styrene-based resin, a silicon-based resin, or the like may be used as the resin exhibiting flexibility. Although the entire opaque effect is not achieved, partially black-dyed nonwovens, double raschel fabrics, or foamed resin sheets, or entirely black-dyed nonwovens, double raschel fabrics, or foamed resin sheets with holes formed in them, may also be used.Furthermore, the flexible layer 11 can be provided between the surface material 5 and the dot matrix display device 15 (see . Fig. 15A and Fig. 15B). In such a configuration, the opaque walls 151 and the flexible layer 11 exhibit a softness; therefore, a user can obtain a softer texture when touching the position of the dot-matrix display device. The flexible layer 11, which exhibits light transmission, is applied. As in Fig. 15A and Fig. As illustrated in Figure 15B, the flexible layer 11 can be provided on a section of the surface to which the dot matrix display device 15 is attached, or it can be provided on the entire surface to which the dot matrix display device 15 is attached. Additionally, the flexible layer 11 can be positioned such that the surface of the foam molded product 1 has a protruding section, as shown in Figure 15B. Fig. 15A is illustrated, or may be located such that the surface of the foam molded product 1 is flat, as shown in Fig. 15B illustrates this.

[0080] An example of a method for producing a foam molded product according to an embodiment of the present invention is described below.

[0081] A method for producing a foam molded product of the present invention includes: an arrangement step of the attached part for preparing a pair of molds 9, comprising a first mold 91 and a second mold 92, and for arranging an attached part 10 in which a insert material 12, comprising at least one of the display unit and the detection unit, and the surface material 5 are attached to one another such that the surface material 5 is in contact with a mold surface of the first mold 91; a mold closing step for closing the pair of molds 9; a molding step for injecting a foam resin into a mold cavity formed by closing the molds and foaming the foam resin to form the foam body 2; a mold opening step for opening the pair of molds 9;and a removal step for removing a molded product in which the attached part 10 and the foam body 2 are integrated (see ; Fig. 16A to 16E).

[0082] First, the attached part 10 is positioned on the mold surface of the first mold 91 (see Fig. 16A). The attached part 10 is a part obtained by joining at least one of the display surface 121 of the insert material 12 and the detection surface 123 of the insert material 12 and the surface material 5. For example, a surface material formed by a known method, such as slurry molding or vacuum forming, is applied as the surface material 5. The insert material 12 is attached to the formed surface material 5, for example, with an optical adhesive tape (OCA). The attached part 10 formed as just described is arranged such that the surface material 5 is in contact with the forming surface of the first mold 91.Furthermore, at the time of positioning the attached part 10 on the mold surface, air can be drawn between the attached part 10 and the mold surface through a suction opening (not illustrated) of the first mold, and the attached part 10 can be attached to the mold surface.

[0083] Furthermore, the attached part 10 can be a part obtained by attaching the flexible layer 11 between the insert material 12 and the surface material 5 (see Fig. 17) The insert material 12 and the surface material 5 can each be attached to opposite surfaces of the flexible layer 11, for example with an OCA. In a case where the flexible layer 11 is a material that exhibits adhesive properties or adhesion, the flexible layer 11 can be attached by utilizing its properties.

[0084] Then the pair of forms 9 is closed (see Fig. 16B). In the drawings, the first form 91 is a movable form and the second form 92 is a fixed form; conversely, however, the first form 91 can be a fixed form and the second form 92 can be a movable form. The forms are closed, and thus a form space is created between the first form 91 and the second form 92.

[0085] The foam resin is then injected into the mold cavity and foamed to form the foam body 2 (see Fig. 16C). The foam resin comprises a resin and a foaming agent. The resin is not particularly restricted, and a thermoplastic resin, a thermosetting resin, or the like may be used. For example, a urethane resin, a vinyl chloride resin, an olefin resin, a styrene-based resin, a silicon-based resin, or the like may be used. Of the resins, a soft resin such as urethane resin is preferred, as it can impart more flexibility to the foam body 2. Air bubbles contained in the foam body 2 may be interconnected cells or closed cells. A known method is used as the foaming process. For example, there is a method for injecting a foam resin into a mold cavity, foaming the foam resin, heating or cooling the resin to solidify it, and shaping the foam body.Furthermore, a process (core back process) can be used in which, after the foam resin is injected into the mold cavity, the first mold 91 or the second mold 92 is moved slightly to enlarge the mold cavity, and the foam resin is foamed. The pressure of the foam resin in the molding step is, for example, 0.1 MPa or more and less than 1 MPa in the case of a urethane resin, and the temperature is, for example, 40 °C or higher and 100 °C or lower.

[0086] Thus, the method for producing the foam molded product of one embodiment of the present invention can reduce the pressure and temperature compared to injection molding. Therefore, no excessive load is applied that could damage the input material. Due to the low-temperature and low-pressure molding, the structure of the surface material (reinforcements, fluffy texture, or the like) can also be preserved.

[0087] Then the pair of forms 9 is opened (see Fig. 16D) and the foam molding product 1 removed (see Fig. 16E).

[0088] As described above, the molded foam product can be manufactured according to one embodiment of the present invention.

[0089] In the description above, the attachment step for arranging the attached part 10, in which the surface material 5 and the insert material 12 are attached to each other, is provided on the mold surface of the first mold 91. Alternatively, the following configuration can be used. In other words, the method can include: a surface material arranging step for arranging the surface material 5 on the mold surface of the first mold 91 (see Fig. 18A); a material arrangement step for arranging the material 12, which includes at least one of the display unit and the detection unit, on one surface of the surface material 5 opposite the other surface of the surface material 5 that is in contact with the mold surface (see Fig. 18B); a mold-closing step to close the pair of molds 9 (see Fig. 16B); a molding step for injecting a foam resin into a mold cavity formed by closing the molds, and foaming the foam resin to form the foam body 2 (see Fig. 16C); a mold opening step to open the pair of molds 9 (see Fig. 16D); and a removal step for removing a molded product in which the surface material 5, the insert material 12 and the foam body 2 are integrated (see Fig. 16E). For example, an optical adhesive tape (OCA) is pre-attached to the surface material 5 or the insert material 12, and thus the insert material 12 can be fixed to the surface material 5 in the insert material arrangement step.

[0090] Furthermore, the manufacturing process can also include a flexible layer arrangement step for arranging the flexible layer 11 between the surface material 5 and the insert material 12. In other words, the foam molded product 1 can be obtained by the following steps: a surface material arrangement step for arranging the surface material 5 on the mold surface of the first mold 91 (see Fig. 19A), an arrangement step of the flexible layer for arranging the flexible layer 11 on one surface of the surface material 5 opposite the other surface of the surface material 5 that is in contact with the mold surface (see Fig. 19B), a material arrangement step for arranging the material 12 on one surface of the flexible layer 11 opposite the other surface of the flexible layer 11 that is in contact with the surface material 5 (see Fig. 19C), the mold closing step (see Fig. 16B), the form step (see Fig. 16C), the mold opening step (see Fig. 16D) and the distance step (see Fig. 16E).

[0091] The process for producing the foam molded product may further include a base substrate arrangement step for arranging the base substrate 6 on a mold surface of the second mold 92 prior to the mold closing step (see Fig. 20A to 20D). As long as the base substrate 6 is positioned before the mold closing step, the time for this is not particularly limited. The shape of the base substrate 6 can, for example, be a shape that extends along the mold surface of the second mold 92 (see Fig. 20A and Fig. 20B), a shape that overlaps a parting surface of the second shape 92 (see Fig. 20C) or the like. In the latter case, excess sections of the base substrate 6 are cut off, and thus the foam molded product 1 can be obtained (see Fig. 20D).

[0092] Furthermore, the insert material 12 can have the wiring element 4 with a length that projects towards a separating surface 91a of the first form, and the soft sealing material 7 can be formed on at least one of the separating surfaces 91a of the first form 91 and a separating surface 92a of the second form 92 (see Fig. 21A to 21F).

[0093] The soft sealing material 7 is formed on the parting surface 91a of the first form 91 or on the parting surface 92a of the second form 92, or on both parting surfaces 91a and 92a. The soft sealing material 7 can be formed to cover the parting surfaces 91a and 92a (see Fig. 21A, Fig. 21B and Fig. 21E) or may be formed on part of the separation surfaces 91a, 92a (see Fig. 21C and Fig. 21D). Furthermore, if the separation surface 92a of the second form is covered by the base substrate 6, the soft sealing material 7 can be formed on the base substrate 6 (see Fig. 21F) or may be formed on the separating surface 91a of the first form 91.

[0094] The soft sealing material 7 is formed, and consequently, the formation of burrs caused by foam resin escaping from the mold cavity is prevented during the molding step. Additionally, the soft sealing material 7 is in contact with the wiring element 4, thus reducing the mold closing force acting on the wiring element 4 during the mold closing step. Therefore, damage to the wiring element 4 is prevented.

[0095] A method for producing a foam molded product according to another embodiment of the present invention includes the following: a material arrangement step for preparing a pair of molds 9, comprising the first mold 91 and the second mold 92, and for arranging the material 12, comprising at least one of the display unit and the detection unit, on the mold surface of the first mold 91 (see Fig. 22A), a form-closing step of the pair of forms 9 (see Fig. 22B); a molding step for injecting a foam resin into a mold cavity formed by closing the molds, and for foaming the foam resin to form the foam body 2 (see Fig. 22C); a mold opening step to open the pair of molds 9 (see Fig. 22D); and a removal step for removing a molded product in which the insert material 12 and the foam body 2 are integrated (see Fig. 22E).

[0096] Furthermore, a method for producing a foam molded product according to another embodiment of the present invention includes: a material arrangement step for preparing a pair of molds 9, comprising the first mold 91 and the second mold 92, and for arranging the material 12, comprising at least one of the display unit and the detection unit, on the mold surface of the first mold 91; a base substrate arrangement step for arranging the base substrate 6 on the mold surface of the second mold 92; a mold closing step for closing the pair of molds 9; a molding step for injecting a foam resin into a mold cavity formed by closing the molds and foaming the foam resin to form a foam body 2; a mold opening step for opening the pair of molds 9;and a removal step for removing a molded product in which the insert material 12, the base substrate 6 and the foam body 2 are integrated (see ; Fig. 23A to 23F). Furthermore, the feed material and the base substrate can be arranged simultaneously as illustrated. Alternatively, after the feed material and base substrate have been arranged, the other feed material and base substrate can be arranged.

[0097] Furthermore, the method for producing the foam molded product according to another embodiment of the present invention further includes the following: a fastening step for attaching the surface material 5 to the aforementioned molded product, in which the insert material 12, the base substrate 6 and the foam body 2 are integrated, such that the surface material 5 covers the insert material 12 (see Fig. 23F). The surface material 5 is attached later; therefore, there are a number of variations of the surface material 5 that can be used. For example, the surface material 5 can be made of three-dimensionally stitched leather, the surface material 5 with a surface on which a pattern is formed by embossing or surface texturing, or the like. In the manufacturing process of the embodiment, the three-dimensional shape is not crushed; therefore, the decorative properties of the foam molded product can be improved.

[0098] Furthermore, a method for producing a foam molded product according to another embodiment of the present invention includes: a base substrate arrangement step for preparing a pair of molds 9, comprising the first mold 91, which has the mold surface with a projecting section 91b having the same size in a top view as the insert material 12, which includes at least one of the display unit and the detection unit, and the second mold 92, and for arranging the base substrate 6 on the mold surface of the second mold 92; a mold closing step for closing the pair of molds 9; a molding step for injecting a foam resin into a mold cavity formed by closing the molds, and foaming the foam resin to form the foam body 2, which includes a recessed section 2a formed by the projecting section 91b of the first mold 91;a mold opening step for opening the pair of molds 9; and a removal step for removing a molded product in which the base substrate 6 and the foam body 2 are integrated; and a fastening step for fastening the surface material 5, which is attached to the molded product with the insert material 12 in such a way that the insert material 12 is fitted into the recessed section 2a (see ; Fig. 24A to 24F).

[0099] The first mold 91 encloses the aforementioned section 91b on the mold surface. In plan view, the aforementioned section 91b has the same dimensions as the insert material 12, which includes at least one of the display unit and the detection unit. The base substrate 6 is arranged on the mold surface of the second mold 92 (see Fig. 24A). Next, the pair of shapes is closed (see Fig. 24B) and then the foam resin is injected into the mold cavity and foamed to form the foam body 2 (see Fig. 24C). At this point, the recessed section 2a, with the size corresponding to the preceding section 91b, is formed in the foam body 2 by the preceding section 91b of the first mold 91. Next, the pair of molds is opened (see Fig. 24D) and then the foam mold product is removed (see Fig. 24E). The surface material 5, which is attached to the insert material 12, is then attached to the molded product in such a way that the insert material 12 is fitted into the recessed section 2a (see Fig. 24F). At least one of the display surface 121 of the insert material 12 and the detection surface 123 of the insert material 12 is attached to the surface material.

[0100] In Fig. 24F can also attach a fixed part in which the flexible layer 11 is fixed between the surface material 5 and the insert material 12 to the molded product.

[0101] Furthermore, a method for producing a foam molded product according to another embodiment of the present invention includes: a base substrate arrangement step for preparing a pair of molds 9, comprising the first mold 91, which has the mold surface with the aforementioned section 91b having the same size in a top view as the insert material 12, which includes at least one of the display unit and the detection unit, and the second mold 92, and for arranging the base substrate 6 on the mold surface of the second mold 92; a mold closing step for closing the pair of molds 9; a molding step for injecting a foam resin into a mold cavity formed by closing the molds, and foaming the foam resin to form the foam body 2, which includes the recessed section 2a formed by the aforementioned section 91b of the first mold 91;a mold opening step for opening the pair of molds 9; and a removal step for removing a molded product in which the base substrate 6 and the foam body 2 are integrated; an insert material application step for applying the insert material 12 to the recessed section 2a, such that at least one of the display surface 121 of the display unit and the sensing surface 123 of the sensing unit is exposed (see ; Fig. 25A); and a fastening step to attach the surface material 5 to the molded product so that the surface material covers the insert material 12 ( Fig. 25B).

[0102] The steps until the molded product is removed correspond to: Fig. 24A to 24E and are therefore not described. After the removal step, the insert material 12 is attached to the recessed section 2a of the foam body 2 (see Fig. 25A). When the insert material is attached to the recessed section, at least one of the display surface 121 of the display unit and the detection surface 123 of the detection unit are exposed. For the attachment method, the insert material 12 can simply be placed in the recessed section 2a or can be attached to the recessed section 2a with an adhesive or bonding agent.

[0103] After the insertion material 12 has been applied, the flexible layer 11 can also be attached to the surface to which at least the insertion material is attached, and the surface material can also be attached over the surface to which the insertion material and the flexible layer are attached.

[0104] Furthermore, for example, in the Fig. 16A to 16E or Fig. 24A to 24F the first form 91 include the preceding section 91b or a recessed section 91c having a curved surface on the mold face (see Fig. 26A and Fig. 26D). The foreground section 91b or the recessed section 91c, which has the curved surface, is the same size as the insert material in a top view. In this case, a flexible material that can conform to the curved surface is used as the insert material.

[0105] Alternatively, the first form 91 can include the recessed section 91c on the mold surface, which has the same size as the insert material in a top view (see Fig. 26B). When using the first form with the recessed section in the manufacturing process, as described in Fig. In FIGS. 16A to 16E, the insert material can, for example, be positioned in alignment with the recessed section 91c, thus simplifying the positioning of the insert material. When using the first mold with the recessed section in the manufacturing process as shown in FIGS. 24A to 24F, the molded product closes a projecting section 2b, as shown in FIGS. 24A to 24F. Fig. Figure 26C illustrates this. The preceding section 2b has the same size as the insert material 12 in a top view; therefore, positioning when attaching the insert material to the molded product can be easily accomplished.

[0106] As in Fig. As illustrated in Figure 26E, the first mold 91 can also include an uneven section 91d on the mold surface. The insert material is positioned in alignment with the position where the uneven section is formed, and a foam molded product is obtained. In this case, the uneven section allows the user to perceive the position of the insert material within the molded product. Furthermore, the user can feel the softness of the insert material when pressing on it. In other words, the user can work within such a foam molded product without being able to perceive the position of the insert material (blind-touch operation).

[0107] In a case where the insert material includes a wiring element, as in Fig. As illustrated in Figures 24A to 24F, 25A and 25B, only the foam body 2 is processed, or the foam body 2 and the base substrate 6 are processed, and therefore the wiring element may protrude to the back of the foam molded product 1. (Touch sensor)

[0108] The detection unit enclosed in the insert material 12 can be the touch sensor 3. When using the touch sensor 3, in any of the previously mentioned manufacturing processes (see Fig. 16A to 26E) a manufacturing process is applied in which the input material 12 is replaced by the touch sensor 3 and the sensing surface 123 is replaced by the sensing surface 3a of the touch sensor.

[0109] Furthermore, a biosensor can be used instead of the touch sensor 3. The biosensor is, for example, a sensor that can detect biological information from a user, such as temperature, pulse, blood pressure, posture, and the like. Alternatively, both the touch sensor and the biosensor can be used. In this case, the touch sensor and the biosensor can be arranged overlapping or side by side.

[0110] Additionally, a wireless battery charger can be used instead of the touch sensor 3. Furthermore, both the touch sensor 3 and the wireless battery charger can be used. In this case, for example, both the touch sensor and the wireless battery charger are arranged side by side in the foam molded product 1, thus obtaining a foam molded product 1 that is operated via touch and can be charged wirelessly.

[0111] Additionally, the foam molded product 1 can use a biosensor or a wireless battery charger instead of the touch sensor 3 and can furthermore include the light source 8. In this case, the foam molded product 1 can be obtained by omitting the touch sensor 3, which is located in Fig. 10A to 10F is illustrated, which is replaced by the biosensor or the wireless battery charger. In such a foam molded product 1, the light source is advantageously illuminated, for example, during a biological measurement or charging, and the light source is switched off when a biological measurement or charging is complete. (Clock switch)

[0112] The detection unit enclosed in the insert material 12 can be the clock switch 13. When using the clock switch 13, in any of the previously mentioned manufacturing processes (see Fig. 16A to 26E) a manufacturing process is applied in which the input material 12 is replaced by the clock switch 13 and the detection surface 123 is replaced by the pressure surface 13a of the clock switch 13.

[0113] A sealing material 16 can also be arranged on the outer circumference of the timing switch 13 (see Fig. 27). With such a configuration, the ingress of foam resin into a moving part of the tactile switch 13 can be prevented, and the tactile feel of the switch can be maintained. Additionally, the sealing material 16 can be soft.

[0114] Furthermore, in a case where the flexible layer 11 is arranged between the surface material 5 and the clock switch 13, the clock switch 13 is preferably arranged such that the outer wall of the clock switch 13 is embedded in the flexible layer 11 (see Fig. 28). With such a configuration, the ingress of foam resin into a moving part of the tactile switch 13 can be prevented and an operating feel of the switch can be maintained. (Laminate)

[0115] The surface material 5 is translucent, and the display unit enclosed in the insert material 12 can be a laminate 14 of the label 140, which has a translucent display section 14a and the light source 8. When using the laminate 14 in any of the previously mentioned manufacturing processes (see Fig. 16A to 26E) a manufacturing process is applied in which the input material 12 is replaced by the laminate 14 of the label 140, which has the transparent display section 14a and the light source 8.

[0116] In a case where the laminate 14 is arranged on the surface material 5, the display surface 121 of the laminate 14 is further arranged in contact with the surface material 5 (see Fig. 29A). In the case of arranging the flexible layer 11, the flexible layer 11 with light transmission is also used and the flexible layer 11 can be arranged between the label 140 and the light source 8 (see Fig. 29B).

[0117] The laminate 14 is attached to the surface material 5, which is inserted into the mold, and is thus fixed in place. Therefore, even if a foam resin is injected into the mold and foamed, it is unlikely that the permeable display section 14a will shift. (Dot matrix display device)

[0118] The surface material 5 is translucent, and the display unit enclosed in the insert material 12 can be the dot matrix display device 15. When using the dot matrix display device 15, in any of the previously mentioned manufacturing processes (see Fig. 16A to 26E) a manufacturing process is applied in which the input material 12 is replaced by the dot matrix display device 15.

[0119] In a case where the dot matrix display device 15 is arranged on the surface material 5, the display surface 121 of the dot matrix display device 15 is further arranged in contact with the surface material 5 (see Fig. 30A). In the case of arranging the flexible layer 11, the flexible layer 11 with light transmission is furthermore used and the flexible layer 11 can be arranged between the display surface 121 of the dot matrix display device 15 and the surface material 5 (see Fig. 30B).

[0120] Additionally, the outermost opaque wall 151 of the dot matrix display device 15 can have a thickness greater than that of the opaque wall 151 located inside the outermost opaque wall 151 (see Fig. 31A). Such a configuration prevents the outermost opaque wall 151 from being deformed inwards by pressure from the foam resin. Furthermore, the same effect can also be achieved by providing a flange 153 on the outermost opaque wall (see Fig. 31B).

[0121] Furthermore, for example, a display using an inorganic or organic electroluminescent material (EL) can be used as the display unit. Alternatively, a display with a fiber optic panel can also be used as the display unit. Furthermore, for example, an infrared sensor, a sound sensor, an odor sensor, a gas sensor, a temperature sensor, an ultrasonic sensor, or the like can be used as the detection unit. Additionally, a heating device or the like can be used in combination with the display unit or the detection unit. List of reference symbols 1 Foam molded product 2 foam bodies 2a In-depth section 2b Foreground section 3 touch sensors 3a Data capture surface 4 Wiring element 5 Surface material 6 Base substrate 7 Soft sealing material 8 Light source 9 Form 91 First Form 91a Separation surface of first form 91b Foreground section 91c In-depth section 91d Uneven Section 92 Second Form 92a Separation surface of second form PL dividing line 10 Attached part 11 Flexible Layer 12 deployment materials 121 Display surface 123 Capture surface 13 tactile switches 13a Printing area 130 Reversing spring 14 Laminat 14a Permeable display section 14b Translucent section 14c Opaque section 140 labels 15-dot matrix display device 15a area 150 circuit boards 151 Opaque wall 152 LED 153 Flange 16 Sealing material 100 molded product 101 Surface material 102 Touch sensor 103 Form

Claims

[1] Foam molded product (1), comprising: a foam body (2); a deployment material (12) comprising at least one display unit and one detection unit attached to the foam body (2); a surface material (5) attached to a surface of the foam body (2) to which at least the insert material (12) is attached; and a flexible layer (11) arranged between the insert material (12) and the surface material (5) and on the surface of the foam body (2) to which at least the insert material (12) is attached; wherein the insert material (12) includes a wiring element (4) with a length that projects from a dividing line (PL) of the foam molded product (1), and the foam molded product (1) further comprises a soft sealing material (7) formed around the separation line (PL). [2] Foam molded product (1) according to claim 1, further comprising a base substrate (6) arranged on a surface opposite the foam body (2) to the surface to which the insert material (12) is attached. [3] Foam molded product (1), comprising: a foam body; an insert material that includes at least one display unit and one detection unit attached to the foam body; a surface material that is attached to a surface to which at least the insert material is attached; a flexible layer (11) arranged between the insert material (12) and the surface material (5) and on the surface of the foam body (2) to which at least the insert material (12) is attached; and a base substrate (6) arranged on a surface of the foam body (2) opposite the surface to which the insert material (12) is attached; wherein the insert material (12) includes a wiring element (4) with a length that projects to the rear of the foam molded product (1) through a through hole formed in the foam body (2) and in the base substrate (6), and the foam molded product (1) further comprises a soft sealing material (7) formed within the through-hole. [4] Foam molded product (1) according to any one of claims 1 to 3, wherein the detection unit enclosed in the insert material (12) is a touch sensor (3) and the touch sensor (3) is mounted such that a detection surface (3a) is exposed on the surface of the foam body (2). [5] Foam molded product (1) according to claim 4, wherein the surface material (5) has a light transmittance, and the foam molded product (1) further comprises a light source (8) arranged on a rear surface of the surface material (5) or of the touch sensor (3). [6] Foam molded product (1) according to any one of claims 1 to 3, wherein the detection unit enclosed in the insert material (12) is a timing switch (13) and the timing switch (13) is mounted such that a pressure surface (13a) is exposed on the surface of the foam body (2). [7] Foam molded product (1) according to any one of claims 1 to 3, wherein the surface material (5) has a light transmittance, the display unit enclosed in the insert material (12) is a laminate (14) of a label (140) having a transparent display section (14a) and a light source (8), and the label (140) is attached in such a way that it is exposed on the surface of the foam body (2). [8] Foam molded product (1) according to any one of claims 1 to 3, wherein the surface material (5) has a light transmittance, the display unit which is enclosed in the insert material (12) has a dot matrix display device (15) is, and the dot matrix display device (15) is mounted such that a display surface (121) is exposed on the surface of the foam body (2). [9] Method for producing a foam molded product (1) comprising the following: an arrangement step of an attached part (10) for preparing a pair of forms comprising a first form (91) and a second form (92), and for arranging the attached part (10) in which an insert material (12) comprising at least one of a display unit and a detection unit, and a surface material (5) are attached to one another such that the surface material (5) is in contact with a form surface of the first form (91); a mold closing step to close the pair of molds; a molding step for injecting a foam resin into a molding space formed by closing the molds, and foaming the foam resin to form a foam body (2); a mold opening step to open the pair of molds; and a removal step for removing a molded product (100) in which the attached part (10) and the foam body (2) are integrated; wherein a flexible layer (11) is attached in the attached part (10) between the insert material (12) and the surface material (5); wherein the insert material (12) has a wiring element (4) with a length that projects towards a separating surface of the first shape (91), and a soft sealing material (7) is formed on at least one of the parting surfaces of the first shape (91) and a parting surface of the second shape (92). [10] Method for producing a foam molded product (1) according to claim 9, wherein the method further comprises: a base substrate arrangement step for arranging a base substrate (6) on a mold surface of the second mold (92). [11] Method for producing a foam molded product (1) according to one of claims 9 to 10, wherein the detection unit enclosed in the input material is a touch sensor or a timing switch.

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