Molded articles and methods for manufacturing molded articles

Abstract

To solve the problem of conventional molded articles in which insufficient strength is considered to be a problem.SOLUTION: There is provided a molded article of a rigid foam of a first resin. In the molded article, a foam with an open cell structure is embedded, and the foam is impregnated with the first resin.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The present disclosure relates to a molded article of resin and a method for manufacturing the same.

Background Art

[0002] As a conventional molded article, a foam-molded one is known (for example, see Patent Document 1).

Prior Art Document

Patent Document

[0003]

Patent Document 1

[0013] , FIG. 2, etc.)

Summary of the Invention

Problems to be Solved by the Invention

[0004] In the above-mentioned molded article, insufficient strength may be a problem.

Means for Solving the Problems

[0005] A first aspect of the invention made to solve the above problems is a molded article of a rigid foam of a first resin, in which a foam having an open cell structure is embedded, and the first resin is impregnated in the foam.

Brief Description of the Drawings

[0006] [Figure 1] A plan sectional view showing the state of attachment of the molded article according to the first embodiment to a vehicle [Figure 2] A perspective view of the molded article [Figure 3] (A) A plan sectional view of the attachment portion of the molded article, (B) A side sectional view of the attachment portion of the molded article [Figure 4] (A) A perspective view of the embedded foam in which a cut is formed, (B) A sectional view of the embedded foam installed in the lower mold [Figure 5]Side cross-sectional view of foamed resin raw material and embedded foam inside a closed mold. [Figure 6] (A) Side cross-sectional view of the foamed resin material that has entered the molded recess while foaming, (B) Plane cross-sectional view of the foamed resin material that has entered the molded recess while foaming [Figure 7] Side cross-sectional view of a molded product formed in a mold. [Modes for carrying out the invention]

[0007] [First Embodiment] The molded product 10 of this embodiment, shown in Figures 1 and 2, is made of foamed resin, specifically a molded product of rigid foam. In this embodiment, the molded product 10 is an EA (Energy Absorption) material mounted on a vehicle, and when the vehicle collides, it receives the load from the occupants and is compressed and broken, thereby mitigating the impact on the occupants. As shown in Figure 1, the molded product 10 as an EA material is attached, for example, to a trim 60 (door trim, etc.).

[0008] In this embodiment, the molded product 10 has a main body portion 11 and a mounting portion 20. The main body portion 11 is the part that receives the load from the occupants during a vehicle collision. As shown in Figures 1 and 2, for example, the main body portion 11 is block-shaped, with its back surface 13 facing the trim 60 and its opposite front surface 12 facing the vehicle body.

[0009] The mounting portion 20 is a part for attaching the molded product 10 to the vehicle. In this embodiment, the mounting portion 20 is a protruding portion of the molded product 10. Specifically, the mounting portion 20 protrudes from the side of the main body 11 that connects the front side 12 and the back side 13. In this embodiment, the mounting portion 20 extends from the end of the side of the main body 11 on the back side 13 side, and a pair of mounting portions are provided on opposite sides of the main body 11.

[0010] A mounting hole 22 is formed through the mounting portion 20. The mounting portion 20 is placed against the trim 60 and fixed to the trim 60 by a fastening member 61 that passes through the mounting hole 22, thereby fixing the molded product 10 to the trim 60. For example, the fastening member 61 may be a screw or a rivet. Alternatively, for example, the fastening member 61 may be a resin projection protruding from the trim 60, which is passed through the mounting hole 22 and then melted at its tip to expand into a flange shape.

[0011] In this embodiment, the mounting portion 20 is a flat, roughly rectangular parallelepiped shape, facing the trim 60 in its thickness direction, with the mounting hole 22 extending in that thickness direction. As shown in Figure 2, an outer edge projection 21 is formed on the front surface of the mounting portion 20 (the surface facing away from the trim 60). The outer edge projection 21 has a rib structure and protrudes from three sides of the outer edge of the front surface of the mounting portion 20, excluding the side that connects to the main body portion 11, forming a roughly U-shape. The rib structure of the outer edge projection 21 makes it possible to increase the rigidity of the mounting portion 20.

[0012] In this embodiment, the rigid foam 19 is rigid polyurethane foam, but is not limited to this, and may be rigid polyethylene foam, rigid polypropylene foam, or rigid phenolic foam, for example.

[0013] As shown in Figure 1, a foam 30 is embedded in the molded product 10. In this embodiment, the foam 30 (hereinafter referred to as "embedded foam 30" as appropriate) has an open-cell structure, that is, the foam cells are in communication with each other and the foam cells are open on the outer surface of the embedded foam 30. Furthermore, the embedded foam 30 is a defilmed foam in which the cell membranes (so-called mirrors) between the foam cells have been removed. In defilmed foam, only the three-dimensional network structure of the resin remains after the cell membranes have been removed. For example, the cell membranes may be removed by blowing them off with a blast of combustion gas, or by hydrolysis with alkali.

[0014] In this embodiment, as shown in Figures 1 and 3, the embedded form 30 is positioned to fit within the mounting portion 20. The aforementioned mounting hole 22 penetrates the mounting portion 20 and the embedded form 30 (see Figure 3(A)). In this embodiment, although the embedded form 30 is smaller in size than the mounting portion 20, the outer edge of the embedded form 30 is sized to overlap with three sides of the outer edge projection 21 in the thickness direction of the mounting portion 20. In this embodiment, the embedded form 30 is also roughly rectangular in shape, corresponding to the roughly rectangular shape of the mounting portion 20. In this embodiment, the embedded form 30 is not embedded in the main body portion 11 or the outer edge projection 21.

[0015] The embedded foam 30 and the resin (first resin) of the rigid foam 19 are color-coded for identifiable purposes. This allows the presence or absence of the embedded foam 30 inside the molded product 10 to be visually confirmed from the outside of the molded product 10. In the molded product 10 of this embodiment, for example, the skeletal structure of the resin on the surface of the embedded foam 30 is visible from the outside of the molded product 10. Alternatively, the embedded foam 30 and the first resin of the rigid foam 19 can be made the same color, making them indistinguishable from the outside of the molded product 10, thus making it impossible to visually confirm the presence or absence of the embedded foam 30 from the outside of the molded product 10.

[0016] In the molded product 10 of this embodiment, the embedded foam 30 is impregnated with the first resin of the rigid foam 19. For example, the first resin impregnated into the embedded foam 30 may be foamed, and in this case, its foaming ratio may be lower than that of the first resin outside the embedded foam 30. The first resin of the rigid foam 19 may be impregnated only on the surface of the embedded foam 30, or it may be impregnated into the interior of the embedded foam 30 (for example, the entire embedded foam 30).

[0017] In the example of this embodiment, the embedded form 30 is a polyurethane foam, and for example, it may be a polyester-based urethane foam or a polyether-based urethane foam. Note that the embedded form 30 is not limited thereto, and for example, it may be a polyethylene foam, a polypropylene foam, a phenol foam, or the like.

[0018] The molded product 10 of this embodiment is manufactured, for example, as follows. First, as shown in FIG. 4(A), the embedded form 30 is prepared. A cut 31 is formed in the embedded form 30. For example, in the example shown in FIG. 4(A), the cut 31 has a configuration in which slits penetrating the embedded form 30 cross each other in a cross shape. As will be described later, the embedded form 30 is installed in the mold 50 shown in FIG. 5 before foam molding. Note that the cut 31 may be, for example, a single slit or may have a configuration in which three or more slits intersect at one location.

[0019] As shown in FIG. 5, the mold 50 is provided with an upper mold 51 and a lower mold 52. The back surface 13 of the molded product 10 is molded by the upper mold 51, and the front surface 12 of the molded product 10 is molded by the lower mold 52. The lower mold 52 is provided with a main recess 52U for molding the main body portion 11 of the molded product 10. As shown in FIG. 4(B), a molding recess 70 for molding the attachment portion 20 is provided at the opening edge of the main recess 52U in the lower mold 52. A molding protrusion 71 for molding the attachment hole 22 protrudes from the bottom surface of the molding recess 70.

[0020] The embedded form 30 is installed in the molding recess 70 of the lower mold 52. At this time, the molding protrusion 71 is inserted into the notch 31 of the embedded form 30, and the molding protrusion 71 penetrates the embedded form 30. In the example of this embodiment, when the embedded form 30 is arranged in the molding recess 70 in this way, it is supported by the molding protrusion 71 and floats from the bottom surface of the molding recess 70, and is arranged below the opening edge of the molding recess 70 (that is, a gap is formed between the embedded form 30 and the upper mold 51 when the mold is closed). Further, the embedded form 30 is arranged so as to overlap the outer edge recess 72 provided on the bottom surface of the molding recess 70 from above in order to mold the outer edge protrusion 21 of the molded product 10.

[0021] As shown in FIGS. 4 and 5, the foaming resin raw material G, which is the raw material of the rigid form 19, is injected into the lower mold 52. Then, the foaming resin raw material G accumulates at the bottom of the main recess 52U. The injection of the foaming resin raw material G may be performed before or after the installation of the embedded form 30 in the lower mold 52. In the latter case, the injection of the foaming resin raw material G may be performed after the mold 50 is closed.

[0022] Then, in the closed mold 50, the foaming resin raw material G is foamed. Then, the foaming resin raw material G gradually increases in bulk in the cavity of the mold 50 while foaming. Then, as shown in FIGS. 6(A) and 6(B), the foaming resin raw material G enters the molding recess 70 while foaming. Here, it is difficult for the foaming resin raw material G to reach the end portion away from the foaming start position of the foaming resin raw material G such as in the molding recess 70. Therefore, there may arise a problem that it is difficult to fill the molding recess 70 with the foaming resin raw material G in which the foaming and curing (resinification) has advanced. And it is conceivable that the strength of the mounting portion 20 becomes insufficient due to the decrease in this filling property. For this reason, for example, air is exhausted to the outside from the joint of the upper mold 51 and the lower mold 52 around the molding recess 70 to improve the filling property into the molding recess 70, but further improvement in the filling property is desired.

[0023] In contrast, in this embodiment, by installing the embedded foam 30 in the molding recess 70, it is possible to improve the resin filling efficiency into the molding recess 70. Also, since the molding protrusion 71 is provided in the molding recess 70, it is thought that the foamed resin raw material G may not easily flow around. However, by installing the embedded foam 30 in the molding recess 70, it is possible to impregnate the embedded foam 30 with the foamed resin raw material G, thereby improving the resin filling efficiency into the molding recess 70. In this way, by installing the embedded foam 30 in the molding recess 70, the foamed resin raw material G is impregnated into the embedded foam 30, and it is possible to improve the overall resin filling efficiency in the molding recess 70 compared to the case where the embedded foam 30 is not present. In this way, it is possible to fill the cavity of the mold 50 with foamed resin raw material G even in the fine details at the ends (i.e., the upper part) that are far from the foamed resin raw material G coming up from below (for example, the molding recess 70 and the outer edge recess 72 shown in Figure 6(A)).

[0024] In this embodiment, since the embedded foam 30 has an open-cell structure, the foaming resin raw material G is impregnated into the embedded foam 30. In the example shown in Figures 6(A) and 6(B), a gap is formed between the embedded foam 30 and the inner surface of the molded recess 70. However, since the foaming resin raw material G is impregnated into the embedded foam 30, the rigid foam 19 can be filled into the molded recess 70 and the outer edge recess 72 even if such a gap is not formed.

[0025] When the foamed resin raw material G foams and hardens, and the cavity of the mold 50 is filled with rigid foam 19, a molded product 10 is obtained (see Figure 7).

[0026] Furthermore, a detection device (for example, a device equipped with a camera, etc.) may be used to detect whether or not the embedded foam 30 is installed in the molding recess 70 of the mold 50. In this case, if it is detected that the embedded foam 30 is in the molding recess 70, an injection device (for example, a robot) may be used that injects the foam resin raw material G into the mold 50, while not injecting the foam resin raw material G if it is not detected. In this way, it is possible to prevent the foam resin raw material G from being injected into the mold 50 when the embedded foam 30 is not placed in the molding recess 70.

[0027] Furthermore, an output device may be provided to notify the system by display or sound if the embedded foam 30 is not detected by the detection device. Alternatively, a transport device (for example, a device that transports the mold 50 to each manufacturing process (the embedded foam 30 installation process, the foam resin raw material G injection process, the foam molding process, etc.)) may be used to transport the mold 50 to each manufacturing process. Then, based on the detection result of the detection device (the presence or absence of the embedded foam 30), the system may decide whether or not to inject the foam resin raw material G using the injection device. If the embedded foam 30 is not installed and the injection is not performed, the control device may be used to return the mold 50 to the embedded foam 30 installation process. The above is a description of the manufacturing method for the molded product 10.

[0028] As described above, the molded product 10 of this embodiment has an embedded foam 30, and the embedded foam 30 is impregnated with the first resin of the rigid foam 19. By impregnating the embedded foam 30 with the first resin of the rigid foam 19 in this way, it is possible to increase the strength compared to a molded product made only of rigid foam 19, and to suppress insufficient strength of the molded product. For example, in the molded product 10 of this embodiment, the first resin of the foamed resin raw material G is filled between the resin skeleton of the embedded foam 30, and it is possible to suppress insufficient strength of the mounting part 20 compared to a molded product in which the entire mounting part 20 is made of rigid foam 19. In addition, since the first resin inside the embedded foam 30 is foamed, and its foaming ratio is lower than that of the first resin outside the embedded foam 30, it is possible to increase the strength of the part of the molded product 10 in which the embedded foam 30 is embedded.

[0029] The number of foam cells in the embedded foam 30 is preferably 6 to 24 cells / 25 mm. By setting the number of foam cells in the embedded foam 30 to 24 cells / 25 mm or less, the foam cells of the embedded foam 30 become larger, making it easier to impregnate the first resin of the rigid foam 19 into the embedded foam 30. This makes it possible to increase the density of the part of the molded product 10 in which the embedded foam 30 is embedded, thereby increasing the strength of that part. Furthermore, if the number of foam cells in the embedded foam 30 is 6 cells / 25 mm or more, the skeletal structure of the foam resin becomes denser, making it possible to make the strength of the part in which the foam is embedded more uniform.

[0030] As described above, the molded product 10 may be applied to EA material mounted on a vehicle, in which case the portion where the embedded foam 30 is embedded may be used as a mounting portion for attaching the molded product 10 to the vehicle. In this way, it is possible to stabilize the mounting state of the molded product 10.

[0031] In this case, if the molded product has a protruding mounting portion 20, and the resin filling capacity of the molding recess 70 in the mold 50 for molding the mounting portion 20 is low, the hardness of the mounting portion 20 will decrease. As a result, the fastening of the molded product 10 to the vehicle by the fastening member 61 may loosen easily, making it difficult to securely fix the molded product 10. Furthermore, this loosening of the fastening may result in the generation of abnormal noises.

[0032] In contrast, with conventional molded products made entirely of rigid foam 19, if the hardness of the rigid foam 19 is increased in an attempt to increase the hardness of the mounting portion 20, the hardness of the main body portion 11 also increases. This can lead to another problem: it becomes difficult to compressively break the main body portion 11 and effectively absorb impact energy.

[0033] In contrast, in the molded product 10 of this embodiment, by embedding the embedded foam 30 within the mounting portion 20 and impregnating the embedded foam 30 with the first resin of the rigid foam 19, it is possible to harden the mounting portion 20 (i.e., partially the molded product 10), thereby suppressing insufficient strength of the mounting portion 20. This ensures stable attachment of the molded product 10 to the mounting target, such as a vehicle, and suppresses the problem of abnormal noise. Furthermore, by configuring the molded product 10 so that the embedded foam 30 is provided in the mounting portion 20 but not in the main body portion 11, it is possible to increase the strength of the mounting portion 20 while ensuring the absorption of impact energy.

[0034] In the molded product 10 of this embodiment, a mounting hole 22 is formed in the mounting portion 20, and the mounting hole 22 penetrates the mounting portion 20 along with the embedded foam 30 inside it. By providing the embedded foam 30 impregnated with the first resin around the mounting hole 22 in this way, it is possible to suppress insufficient strength around the mounting hole 22. This makes it possible to further stabilize the mounting state of the molded product 10.

[0035] In the manufacturing method of the molded product 10 of this embodiment, when the embedded form 30 is placed in the molding recess 70 of the mold 50, the molding projection 71 is inserted into the notch 31 formed in the embedded form 30 and penetrates the embedded form 30. In this way, the embedded form 30 can be easily penetrated by the molding projection 71, and the formation of the mounting hole 22 that penetrates the embedded form 30 becomes easier. [Examples]

[0036] The embodiments described above will be further explained below with reference to examples and comparative examples, but the molded articles of this disclosure are not limited to the following examples.

[0037] 1. Composition of molded articles of the examples and comparative examples In Examples 1 to 5 and Comparative Example 1, molded articles (EA material) were obtained in the same manner as in the first embodiment described above. In each molded article, the resin (first resin) of the rigid foam 19 was the same, and the rigid foam 19 was rigid polyurethane foam. In Examples 1 to 5, only the configuration of the embedded foam 30 differed. In Examples 1 to 4, the thickness of the embedded foam 30 was 10 mm, and in Example 5, the thickness of the embedded foam 30 was 5 mm. In Examples 1 to 5, the size of the embedded foam 30 as viewed from the thickness direction was approximately the same. In Examples 1 to 5 and Comparative Example 1, the thickness around the mounting hole 22 of the mounting part 20 was 12 mm.

[0038] <Example 1> For the buried foam 30, we used "Malt Filter MF-8" (8±2 cells / 25mm) manufactured by Inoac Corporation.

[0039] <Example 2> For the buried foam 30, we used "Malt Filter MF-13" manufactured by Inoac Corporation (cell count: 13+3,-2 / 25mm).

[0040] <Example 3> For the buried foam 30, we used "Malt Filter CFH-13" (13±3 cells / 25mm) manufactured by Inoac Corporation.

[0041] <Example 4> For the buried foam 30, we used "Malt Filter CFH-20" (20±4 cells / 25mm) manufactured by Inoac Corporation.

[0042] <Example 5> For the buried foam 30, we used "Malt Filter CFH-30" (30±4 cells / 25mm) manufactured by Inoac Corporation.

[0043] <Comparative Example 1> In the molded product of Comparative Example 1, the embedded foam 30 is not embedded. The molded product of Comparative Example 1 differs from the molded products of Examples 1 to 5 only in that the embedded foam 30 is not provided.

[0044] 2. Evaluation Method For each example and comparative example, the outer shape of the mounting portion 20 was observed, and the Asker C hardness (according to JIS K7312) was measured and compared. As shown in Figures 2 and 3(A), the measurement position for the Asker C hardness was a position on the protruding tip side of the mounting portion 20, closer to the mounting hole 22, and was at position A, which is midway between the mounting hole 22 and the outer edge protrusion 21 in the protruding direction of the mounting portion 20.

[0045] 3. Evaluation Results In Examples 1-4, the shape of the molded product 10 was good, and the shape of the mounting portion 20 was also good. In the molded product of Comparative Example 1, there were instances of material loss such as dents in the part of the mounting portion 20 that was on the protruding tip side (especially the part that was further forward than the mounting hole 22). In the molded product of Example 5, there were instances of dents in one side of the outer edge protrusion 21 of the mounting portion 20 that was further forward than the mounting hole 22. Although the shape was not as good as that of the molded products in Examples 1-4, the dents were smaller and the shape was better than that of the molded product in Comparative Example 1. Furthermore, the Asker C hardness of the molded products 10 in Examples 1-5 was 80, 81, 85, 90, and 93, respectively, while it was 72 in Comparative Example 1. When the cross-section of the mounting portion 20 was observed, it was found that in Example 5, the first resin was less likely to impregnate the embedded foam 30 compared to Examples 1-4. Based on the above, it was confirmed that in Examples 1 to 5, the moldability was better than in Comparative Example 1, and the mounting portion 20 became harder, thus improving its strength.

[0046] [Other embodiments] (1) The molded product 10 is not limited to EA material attached to the door trim, but may also be, for example, EA material that absorbs impact energy by receiving load from the knees or soles of the feet of vehicle occupants (so-called knee bolsters or tibia pads). Furthermore, the molded product 10 may be EA material provided on other vehicles, not just vehicles, or may be used for purposes other than EA material. Also, the shape of the molded product 10 is not limited to the shape of the above embodiment. For example, the molded product 10 may have a configuration in which the mounting portion 20 with the mounting hole 22 is formed does not protrude, or may have a configuration in which the mounting portion 20 is not provided. In these cases as well, it is sufficient that the embedded foam 30 impregnated with the first resin is embedded in the molded product 10.

[0047] (2) In the above embodiment, the embedded form 30 was housed within the mounting portion 20, but it may extend into the main body portion 11. Also, in the above embodiment, the embedded form 30 is not embedded within the outer edge projection portion 21, but the embedded form 30 may be positioned within the outer edge projection portion 21. In this case, for example, the embedded form 30 may be provided with a projection that extends into the outer edge projection portion 21. Also, the embedded form 30 may be embedded only within the main body portion 11. Furthermore, in the above embodiment, at least one part of the embedded form 30 overlapped with the outer edge projection portion 21 in the thickness direction of the mounting portion 20, but it is not necessary for them to overlap.

[0048] (3) The foaming ratio of the first resin impregnated and foamed within the embedded foam 30 may be the same as or higher than the foaming ratio of the first resin outside the embedded foam 30. Also, the first resin impregnated within the embedded foam 30 may not foam at all.

[0049] (4) In the above embodiment, the outer edge projection 21 was roughly U-shaped, but it may be formed only on one side of the outer edge of the front surface of the mounting portion 20 on the side of the projection tip of the mounting portion 20, or it may be formed only on both sides of the first projection, or the portion formed on the one side and the portions formed on both sides may be separate. Also, the outer edge projection 21 may not be provided at all.

[0050] (5) Instead of forming a notch 31 in the embedded foam 30, a through hole may be formed. This through hole only needs to be large enough for the molding projection 71 of the mold 50 to be inserted. If the through hole is made narrower than the molding projection 71, when the molding projection 71 is inserted into the through hole, the embedded foam 30 can be lifted above the bottom surface of the molding recess 70, making it easier for the foam resin raw material G to enter between the bottom surface of the molding recess 70 and the embedded foam 30.

[0051] (6) In the above embodiment, the mounting hole 22 penetrated the mounting portion 20 along with the embedded form 30, but the mounting hole 22 may be configured not to penetrate the embedded form 30. For example, the mounting hole 22 may be located away from the embedded form 30, or the mounting hole 22 and the embedded form 30 may be located adjacent to each other such that the embedded form 30 is exposed on the inner circumferential surface of the mounting hole 22.

[0052] (7) In the above embodiment, when the molded product 10 is attached to an object such as a trim 60, the mounting portion 20 does not have to have a mounting hole 22 as long as it functions as a mounting portion for the molded product 10 to the object. For example, the mounting portion 20 may have a mounting recess for attaching the molded product to the object, in which case the mounting recess may penetrate the embedded form 30, or it may form a recess in the embedded form 30 without penetrating the embedded form 30.

[0053] (8) In the above embodiment, when the embedded form 30 was installed in the molding recess 70 of the lower mold 52, the embedded form 30 was floating above the bottom surface of the molding recess 70, but the embedded form 30 may be in contact with the bottom surface of the molding recess 70. Also, when the embedded form 30 is installed in the molding die 50, it may be in contact with the upper mold 51. Also, when the embedded form 30 is installed in the molding recess 70, it may be in contact with the side surface of the inner surface of the molding recess 70, or it may be positioned so as not to overlap the outer edge recess 72 from above.

[0054] (9) For example, the molded product 10 can also be made as a molded product of soft foam, with the embedded foam 30 embedded inside the soft foam. In this case, by installing the embedded foam 30 in the molding recess 70 of the mold 50, it is possible to improve the fillability of the resin into the molding recess 70 of the mold 50, and thus it is possible to suppress insufficient strength of the molded product 10 (especially insufficient strength of the mounting portion 20).

[0055] <Note> The following describes the features extracted from the above embodiments and examples, showing their effects as needed. For ease of understanding, corresponding configurations in the above embodiments will be indicated in parentheses as appropriate, but these features are not limited to the specific configurations indicated in parentheses.

[0056] For example, the following set of features, relating to "resin molded articles and methods for manufacturing the same," can be considered to have been conceived with the background technology that "conventional molded articles are known to be foam-molded (for example, Japanese Patent Publication No. 2008-69825 (paragraph

[0013] , Figure 2, etc.))" and the problem that "the above-mentioned molded articles may suffer from insufficient strength."

[0057] [Feature 1] A molded product of a rigid foam made of a first resin, An open-cell structure foam (buried foam 30) is buried, A molded product in which the foam is impregnated with the first resin.

[0058] This feature makes it possible to suppress insufficient strength in molded products. With this feature, by impregnating the embedded foam with the first resin of rigid foam, it is possible to increase the strength compared to molded products made of rigid foam alone, thereby suppressing insufficient strength in molded products.

[0059] [Feature 2] The molded product according to feature 1, wherein the number of cells in the aforementioned form is 6 to 24 cells / 25 mm.

[0060] By limiting the number of cells in the embedded foam to 24 cells / 25 mm or less, the foam cells become larger, making it easier to impregnate the first resin of the rigid foam into the foam. This increases the density of the foam-embedded portion of the molded product, thereby improving its strength. Furthermore, by limiting the number of cells in the embedded foam to 6 cells / 25 mm or more, the skeletal structure of the foam resin becomes denser, making it possible to achieve more uniform strength in the foam-embedded portion.

[0061] [Feature 3] The molded article according to feature 1 or 2, wherein the first resin in the foam is foamed, and its foaming ratio is lower than that of the first resin outside the foam.

[0062] According to Feature 3, it becomes possible to increase the strength of the part of the molded product in which the foam is embedded.

[0063] [Feature 4] A molded article according to any one of features 1 to 3, wherein the foam and the first resin are color-coded for identifiable purposes.

[0064] According to Feature 4, the presence or absence of foam inside the molded product can be confirmed from the outside of the molded product.

[0065] [Feature 5] The molded product according to any one of features 1 to 4, wherein the molded product is an EA material to be mounted on a vehicle, and the portion in which the foam is embedded is a mounting portion for attaching the molded product to the vehicle.

[0066] According to Feature 5, it becomes possible to stabilize the mounting state of the molded product.

[0067] [Feature 6] The molded product according to feature 5, having a mounting hole that penetrates the mounting portion, including the foam inside it.

[0068] Feature 6 makes it possible to suppress insufficient strength around the mounting holes. This makes it possible to further stabilize the mounting state of the molded product.

[0069] [Feature 7] A molded article according to any one of features 1 to 6, having a first protruding portion (mounting portion 20) in which the aforementioned form is embedded.

[0070] According to Feature 7, it becomes possible to suppress insufficient strength of the first protrusion.

[0071] [Feature 8] The molded article according to feature 7, having a second protrusion (outer edge protrusion 21) that protrudes from the first protrusion and in which the foam is not embedded.

[0072] [Feature 9] The molded article according to feature 8, wherein the second protrusion has a rib structure.

[0073] According to Feature 9, it becomes possible to increase the rigidity of the first protrusion.

[0074] [Feature 10] A method for manufacturing a molded article according to any one of claims 1 to 9, wherein the foam is placed in a mold for molding the molded article, and the foamed resin raw material of the rigid foam is foamed in the mold to produce the molded article.

[0075] This feature makes it possible to suppress insufficient strength in molded products.

[0076] [Feature 11] The mold is provided with a molding projection for forming the mounting hole. A method for manufacturing a molded article according to feature 10, which is dependent on feature 6, wherein a notch is formed in the form and the molded projection is inserted into the notch and penetrates the form.

[0077] According to Feature 11, the foam can be easily passed through the molded protrusion, and the formation of mounting holes that pass through the foam can be easily facilitated.

[0078] [Feature 12] A method for manufacturing a molded product according to feature 10 or 11, comprising using a detection device to detect whether or not the foam is installed in a recess of the mold for forming a first protrusion provided on the molded product, and if the presence of the foam in the recess is detected, the foamed resin raw material is injected into the mold, while if it is not detected, the injection device is not used.

[0079] According to Feature 12, it is possible to prevent the injection of foam resin material into the mold when the foam is not placed in the recess.

[0080] While this specification and drawings disclose specific examples of the technology included in the claims, the technology described in the claims is not limited to these specific examples, but also includes various modifications and changes to these examples, as well as parts of the examples taken individually. [Explanation of Symbols]

[0081] 10 Molded products 19. Rigid foam 20 Mounting part 21 Outer edge projection 22 mounting holes 30 Buried foam 31 cuts 50 mold 70 Molding recess 71 Molded protrusion G Foamed resin raw materials

Claims

1. A molded product of a rigid foam made of a first resin, Open-cell structure foam is embedded, The foam is impregnated with the first resin. The first protruding portion in which the aforementioned form is embedded, A molded product having a second protrusion that protrudes from the first protrusion and in which the foam is not embedded.

2. A molded article of a rigid foam made of a first resin, Open-cell structure foam is embedded, The foam is impregnated with the first resin. A molded article in which the foam and the first resin are color-coded for identifiable purposes.

3. A molded article of a rigid foam of a first resin, Open-cell structure foam is embedded, The foam is impregnated with the first resin. The molded product is an EA material to be mounted on a vehicle, and the portion in which the foam is embedded is a mounting portion for attaching the molded product to the vehicle.

4. A method for manufacturing a molded article of a rigid foam of a first resin having through holes and in which an open-cell structure foam is embedded, In a manufacturing method for producing a molded product, the foam is placed in a mold for molding the molded product, the foamed resin raw material of the rigid foam is foamed within the mold, the foam is impregnated with the first resin, and the molded product is produced, The molding projection for forming the through hole is made to protrude from the inner surface of the molding die, and a notch is formed in the form. A method for manufacturing a molded product, wherein the molded projection is passed through the notch and the foam is supported by the molded projection, thereby forming the molded product.

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