Foamed molded product, method for manufacturing the same, and mold

Abstract

To provide a foam molding product that can suppress tearing around through holes on a side face, a manufacturing method for the foam molding product, and a molding form that can be used optimally in the manufacturing method for the foam molding product.SOLUTION: A foam molding product 1 has a pad material 10 and a first member 11. A side face of the pad material 10 has such a shape that a front surface side of the foam molding product 1 protrudes outward more than a back surface side of the foam molding product 1, and has an unfinished through hole 104 having a chipped portion 104a formed such that at least a part of a peripheral wall of the through hole 12 on the front surface side of the foam molding product 1 is chipped. The foam molding product 1 has a through hole 12 formed on a side face by attaching the first member 11 to the chipped portion 104a of the pad material 10. A molding form 2 for molding the pad material 10 having the above shape does not make a portion of a lower mold 21 side of an unfinished through hole molding section 233 into an undercut shape.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The present invention relates to a foamed molded product, a method for manufacturing the same, and a mold, and more particularly, to a foamed molded product suitable for use in a backrest portion or a seat portion of a vehicle seat, a method for manufacturing the same, and a mold suitable for use in the manufacture of a foamed molded product.

Background Art

[0002] In a backrest portion or a seat portion of a vehicle seat, a cover (skin) is placed on a foamed molded product made of a foamed resin material. The foamed molded product is generally formed by filling a foaming raw material into a mold and foaming it. Such a foamed molded product may have through-holes formed on its side surface for mounting accessories such as a switch device or an armrest.

[0003] For example, Patent Document 1 discloses a foamed molded product in which one or more through-holes penetrating in the thickness direction of a wall portion serving as a side surface of the foamed molded product are formed. In this Patent Document 1, the through-holes on the side surface of the foamed molded product are formed by protruding a through-hole forming portion for forming a through-hole from a part of the molding surface of a core mold provided on the upper mold into a cavity formed when the upper mold and the lower mold are closed, and flowing and filling a foaming raw material around this through-hole forming portion.

Prior Art Documents

Patent Documents

[0004]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0005] According to the technique of Patent Document 1, it is possible to obtain a foamed molded product in which the wall portion (side surface) has a shape substantially perpendicular to the front surface side or the back surface side of the foamed molded product and the wall portion (side surface) has through-holes.

[0006] However, in recent years, the sides of foamed molded products are sometimes designed so that the front side protrudes outward more than the back side.

[0007] When attempting to form a through-hole on the side of a foamed molded product with this shape, conventional molds result in an undercut shape in the lower part of the through-hole molding area, that is, the part that forms the surface of the foamed molded product. This can cause the area around the through-hole to tear when the upper mold is opened relative to the lower mold.

[0008] This invention has been made in view of the above problems, and aims to provide a foamed molded product that can suppress tearing around through holes on the sides, a method for manufacturing the foamed molded product, and a mold that can be suitably used in the method for manufacturing the foamed molded product. [Means for solving the problem]

[0009] The first invention is, A foamed molded product having at least one through hole on its side, The pad material that constitutes the surface, back surface, and part of the side of the foamed molded product, It comprises a first member, which is a separate component from the pad material and constitutes a part of the side surface of the foamed molded product, The side surface of the pad material has a shape in which the front surface of the foamed molded product protrudes outward more than the back surface of the foamed molded product. The side surface of the pad material has an incomplete through-hole with a missing portion formed such that at least a part of the peripheral wall of the through-hole on the surface side of the foamed molded product is missing. The first member is attached to the missing portion of the incomplete through-hole on the side surface of the pad material, thereby forming the through-hole on the side surface of the foamed molded product. It is a foamed molded product.

[0010] The second invention is, in the first invention, The hardness of the first component described above is greater than or equal to the hardness of the pad material described above. It is a foamed molded product.

[0011] The third invention is, in the first or second invention, The first member described above constitutes a part of the side surface of the foamed molded product and a part of the surface of the foamed molded product. It is a foamed molded product.

[0012] The fourth invention is, A method for manufacturing a foamed molded product having at least one through hole on its side, A step of preparing a pad material which constitutes the surface, back surface, and part of the side surface of the foamed molded product by molding with a mold, and a first member which constitutes part of the side surface of the foamed molded product separately from the pad material, The process includes the step of attaching the first member to the side surface of the pad material, The side surface of the pad material has a shape in which the front surface of the foamed molded product protrudes outward more than the back surface of the foamed molded product. The side surface of the pad material has an incomplete through-hole with a missing portion formed such that at least a part of the peripheral wall of the through-hole on the surface side of the foamed molded product is missing. By attaching the first member to the missing portion of the incomplete through hole on the side surface of the pad material, the through hole on the side surface of the foamed molded product is formed. This describes a method for manufacturing foamed molded products.

[0013] The fifth invention is, in the fourth invention, Around the missing portion of the incomplete through hole in the pad material, and on at least one of the first members, A marking portion is formed on the side surface of the pad material, which serves as a guide when attaching the first member. This describes a method for manufacturing foamed molded products.

[0014] The sixth invention is, A mold for molding a pad material used in the production of a foam molded product having a lower mold, an upper mold, and a core mold provided in the upper mold, and having at least one through hole on a side surface. The pad material constitutes a surface, a back surface, and a part of a side surface of the foam molded product. The side surface of the pad material has a shape that protrudes outward more on the surface side of the foam molded product than on the back surface side of the foam molded product. The side surface of the pad material has an incomplete through hole having a missing part formed so that at least a part of the surface side of the foam molded product of the peripheral wall of the through hole is missing. The core mold has an incomplete through hole forming part for forming the incomplete through hole protruding from a part of the molding surface of the core mold into a cavity formed when the upper mold and the lower mold are closed. The tip surface of the incomplete through hole forming part faces the molding side surface of the lower mold in a state where the upper mold and the lower mold are closed. It is a mold.

[0015] A seventh invention is the invention according to the sixth invention. The lower mold has a concave part or a convex part for forming a mark part around the missing part of the incomplete through hole in the pad material. It is a mold.

Effect of the Invention

[0016] According to the foamed molded article of the first invention, even if the side surface of the pad material projects outward on the surface side of the foamed molded article rather than on the back side of the foamed molded article, the side surface of the pad material has a missing portion formed so as to have a shape in which at least a part of the surface side of the foamed molded article of the peripheral wall of the through-hole to be formed is missing. Therefore, according to the foamed molded article of the first invention, at the time of its manufacture, the lower die side portion of the through-hole forming portion for forming the pad material (the portion for forming the surface side of the foamed molded article of the peripheral wall of the through-hole to be formed) does not have an undercut shape. Therefore, according to the foamed molded article of the first invention, at the time of its manufacture, when the upper die is opened with respect to the lower die and the pad material is taken out from the mold, it is possible to suppress the occurrence of breakage around the incomplete through-hole. After the pad material is molded, by attaching the first member to the missing portion of the incomplete through-hole that exhibits an incomplete shape in that there is a missing portion with respect to the peripheral wall of the through-hole to be formed, a foamed molded article with a complete through-hole formed on the side surface can be obtained. Therefore, according to the foamed molded article of the first invention, the effect of obtaining a foamed molded article capable of suppressing breakage around the through-hole on the side surface can be obtained.

[0017] According to the foamed molded article of the second invention, in addition to the effect of the first invention, since the hardness of the first member is equal to or greater than the hardness of the pad material, when the foamed molded article is covered with a cover, the effect of preventing the appearance from deteriorating without the cover developing wrinkles can be obtained.

[0018] According to the foamed molded article of the third invention, in addition to the effect of the first invention or the second invention, the effect of being able to stably obtain a foamed molded article having a surface even around the formed through-hole can be obtained.

[0019] According to the manufacturing method of the foamed molded product of the fourth invention, even if the side surface of the pad material protrudes further outward than the back surface of the foamed molded product, the side surface of the pad material has an incomplete through-hole with a missing portion formed such that at least a part of the peripheral wall of the through-hole to be formed on the surface side of the foamed molded product is missing. Therefore, according to the manufacturing method of the foamed molded product of the fourth invention, the mold for forming the pad material does not have an undercut shape in the lower mold side portion of the incomplete through-hole forming section (the portion that forms the surface side of the peripheral wall of the through-hole to be formed on the foamed molded product). Therefore, according to the manufacturing method of the foamed molded product of the fourth invention, when the upper mold is opened relative to the lower mold to remove the pad material from the mold, it is possible to suppress the occurrence of tearing around the incomplete through-hole, and after forming the pad material, by attaching the first member to the missing portion of the incomplete through-hole which exhibits an incomplete shape in that there is a missing portion relative to the peripheral wall of the through-hole to be formed, a foamed molded product with a complete through-hole formed on the side surface of the foamed molded product can be obtained. Therefore, according to the method for manufacturing foamed molded articles of the fourth invention, it is possible to obtain foamed molded articles that can suppress tearing around through holes on the sides.

[0020] According to the manufacturing method of the foamed molded product of the fifth invention, in addition to the effects of the fourth invention, the further effect of being able to easily attach the first member to the side surface of the pad material is obtained.

[0021] According to the molding die of the sixth invention, the lower mold side portion of the unfinished through-hole molding section (the portion of the peripheral wall of the through-hole to be formed that forms the surface side of the foamed molded product) does not become undercut. Therefore, according to the molding die of the sixth invention, when the upper mold is opened relative to the lower mold and the pad material is removed from the molding die, it is possible to suppress the occurrence of tearing around the unfinished through-hole, thus providing the advantage of being suitably used in the above-mentioned method for manufacturing foamed molded products.

[0022] According to the molding die of the seventh invention, in addition to the effects of the sixth invention, a marking portion can be easily formed around the missing portion of the incomplete through-hole in the molded pad material using a recess or a protrusion, thereby providing the effect of facilitating the attachment work when attaching the first member to the side surface of the pad material in the above-described method for manufacturing foamed molded products. [Brief explanation of the drawing]

[0023] [Figure 1] Figure 1 is a perspective view of a foamed molded product according to one embodiment. [Figure 2] Figure 2 is an exploded perspective view of a foamed molded product showing the pad material and first component that constitute the foamed molded product according to one embodiment, and is also a perspective view showing the pad material and first component prepared by the manufacturing method of the foamed molded product according to one embodiment. [Figure 3] Figure 3 is a cross-sectional view taken along the line III-III of a foamed molded product according to one embodiment shown in Figure 1. [Figure 4] (a) is a magnified view of a portion of the cross-section of the foamed molded product shown in Figure 3, and (b) is a diagram showing a modified example of the foamed molded product shown in (a). [Figure 5] Figure 5 is a perspective view of a molding die according to one embodiment (with the upper mold open relative to the lower mold). [Figure 6] Figure 6 is a perspective view of a molding die according to one embodiment (with the core mold open relative to the upper mold). [Figure 7] Figure 7 is a cross-sectional view taken along the line VII-VII of the mold shown in Figure 5, when it is in a closed state. [Figure 8] Figure 8 is a cross-sectional view of a comparative mold according to one embodiment, drawn in correspondence with the mold in the closed state shown in Figure 7. [Modes for carrying out the invention]

[0024] A foamed molded product according to one embodiment, its manufacturing method, and the mold will be described with reference to Figures 1 to 8.

[0025] (Foam molded product) The structure of the foamed molded product 1 of this embodiment will be explained with reference to Figures 1 to 4. As illustrated in Figures 1 to 4, the foamed molded product 1 of this embodiment is used for the backrest portion of a vehicle seat. The foamed molded product 1 is not limited to this and may be used for the seat portion of a vehicle seat, etc. In this embodiment, the foamed molded product 1 is assembled to a backrest frame (not shown) that forms the skeleton of the backrest portion of the vehicle seat. The foamed molded product 1 can be made of, for example, a soft urethane material such as urethane foam.

[0026] The foamed molded product 1 has at least one through-hole 12 on its side. In this embodiment, the through-hole 12 is used as a hole for arranging a switch device for a vehicle seat. The through-hole 12 may also be a hole for attaching an armrest for a vehicle seat, or the like.

[0027] The foamed molded product 1 comprises a pad material 10 and a first member 11. The foamed molded product 1 may also have a backing material (not shown) on the back surface of the pad material 10. The backing material reinforces the pad material 10 and prevents the generation of abnormal noise by preventing the pad material 10 from directly contacting the backrest frame. The backing material can be made of, for example, nonwoven fabric. The backrest (seat) of a vehicle seat is usually covered with a cover (surface) made of cloth, resin, leather, etc., but the cover is not shown in Figures 1 to 4.

[0028] In this embodiment, direction A1 (forward direction of the vehicle) shown in Figure 3 is the surface side of the foamed molded product 1 and pad material 10, and direction A2 (rear direction of the vehicle) is the back side of the foamed molded product 1 and pad material 10. Also, in the width direction W of the foamed molded product 1 and pad material 10 shown in Figures 1 and 3, the right direction R is the right side of the foamed molded product 1 and pad material 10, and the left direction L is the left side of the foamed molded product 1 and pad material 10. Since the foamed molded product 1 in this embodiment is used in a vehicle seat, which is a part of an automobile, the above left and right directions are expressed as viewed from the perspective of an occupant facing forward. Also, in the vertical direction H of the foamed molded product 1 and pad material 10 shown in Figure 1, the upward direction H1 is the upper side of the foamed molded product 1 and pad material 10, and the downward direction H2 is the lower side of the foamed molded product 1 and pad material 10. Furthermore, the outside of the foamed molded product 1 and pad material 10 refers to the direction perpendicular to the A1 and B1 directions and facing outward. Therefore, the direction B1 along the width direction W of the foam molded product 1 and pad material 10 shown in Figures 1 and 3, which is opposite to the direction facing the center of the width direction W of the foam molded product 1 and pad material 10, is on the outside of the foam molded product 1 and pad material 10, and the direction B2 facing the center of the width direction W of the foam molded product 1 and pad material 10 is on the inside of the foam molded product 1 and pad material 10. Similarly, the direction along the vertical direction H of the foam molded product 1 and pad material 10 shown in Figure 1, which is opposite to the direction facing the center of the vertical direction H of the foam molded product 1 and pad material 10 (not shown), is on the outside of the foam molded product 1 and pad material 10, and the direction facing the center of the vertical direction H of the foam molded product 1 and pad material 10 (not shown) is on the inside of the foam molded product 1 and pad material 10.

[0029] Specifically, the pad material 10 includes a main body portion 101, an upper portion (not shown) provided above the main body portion 101, a lower portion 102 provided below the main body portion 101, and side portions 103 provided on the left and right sides of the main body portion 101.

[0030] The upper part has a wall portion (not shown) extending from the upper end of the main body portion 101 toward the back side of the pad material 10, and a protruding portion (not shown) extending from the tip of this wall portion toward the bottom side of the pad material 10. The lower part 102 has a wall portion 102a extending from the lower end of the main body portion 101 so as to be inclined toward the back side of the pad material 10 and toward the outward side.

[0031] Each side portion 103 has a wall portion 103a extending from the left and right ends of the main body portion 101 toward the back side of the pad material 10, and a protruding portion 103c extending inward in the width direction W of the pad material 10 from the tip portion 103b of the wall portion 103a. As shown in the enlarged view in Figure 4(a), the tip portion 103b of the wall portion 103a is positioned inward in the width direction W of the pad material 10 by a distance δ from the outermost protruding surface portion of the wall portion 103a.

[0032] The pad material 10 constitutes the surface, back surface, and a portion of the side surface of the foamed molded product 1. Here, the statement that the pad material 10 constitutes a portion of the side surface of the foamed molded product 1 means that, before the first member 11, which is a separate component from the pad material 10, is attached to the side surface of the pad material 10, the side surface of the pad material 10 does not completely constitute the entire side surface of the foamed molded product 1. In the state where the first member 11 is attached to the side surface of the pad material 10, as described later, the side surface of the pad material 10 and the first member 11 constitute the entire side surface of the foamed molded product 1.

[0033] Specifically, the side surface of the pad material 10 is composed of a wall portion (not shown) that constitutes the upper part (not shown) of the pad material 10, a wall portion 102a that constitutes the lower part 102 of the pad material 10, and each wall portion 103a that constitutes each side portion 103 of the pad material 10. In this embodiment, as illustrated in Figure 4(a), the side surface of the pad material 10 composed of each wall portion 103a has a shape in which the front surface of the foamed molded product 1 protrudes outward in the width direction W more than the back surface of the foamed molded product 1.

[0034] The side surface of the pad material 10 has an incomplete through-hole 104. In this embodiment, the incomplete through-hole 104 is more specifically formed in the wall portion 103a that constitutes one (left) side portion 103 of the pad material 10. Although not shown in the figures, the incomplete through-hole 104 may also be formed in the wall portion 103a that constitutes the other (right) side portion 103 of the pad material 10, or in the wall portion (not shown) that constitutes the upper part of the pad material 10.

[0035] Furthermore, although this embodiment shows an example in which the side surface of the pad material 10 has one incomplete through-hole 104, the side surface of the pad material 10 may have multiple incomplete through-holes 104. As will be described later, these incomplete through-holes 104 constitute the completed through-hole 12 when combined with the first member 11. The foamed molded product 1 may have one or more through-holes 12, but it is sufficient that at least one of the through-holes 12 is made using an incomplete through-hole 104.

[0036] The incomplete through-hole 104 has a missing portion 104a formed such that at least a part of the peripheral wall of the through-hole 12 on the surface side of the foamed molded product 1 is missing. In this embodiment, the missing portion 104a is formed on the surface side of the peripheral wall of the square-shaped through-hole 12.

[0037] The first member 11 constitutes a part of the side surface of the foamed molded product 1. The first member 11, when combined with the incomplete through-hole 104, constitutes the completed through-hole 12. Specifically, the first member 11 is formed in a shape corresponding to the missing portion 104a of the incomplete through-hole 104. In this embodiment, the hardness of the first member 11 is set to be greater than or equal to the hardness of the pad material 10 so that the seater does not feel any foreign body sensation and wrinkles do not occur in the cover when the cover is placed over the foamed molded product 1. In addition, the hardness of the first member 11 may be less than the hardness of the pad material 10, as long as it has the hardness necessary for a foamed molded product 1 to be applied to a vehicle seat. The hardness of the first member 11 and the pad material 10 can be measured using a push-pull gauge.

[0038] In this embodiment, as shown in Figure 4(a), the first member 11 constitutes not only a part of the side surface of the foamed molded product 1, but also a part of the surface of the foamed molded product 1. In other words, before the first member 11, which is a separate member from the pad material 10, is attached to the side surface of the pad material 10, the surface of the pad material 10 does not completely constitute the entire surface of the foamed molded product 1, as will be described later. When the first member 11 is attached to the side surface of the pad material 10, the entire surface of the foamed molded product 1 is constituted by the surface of the pad material 10 and the first member 11. The first member 11 is not limited to the shape shown in Figure 4(a). For example, as shown in Figure 4(b), the end on the surface side of the foamed molded product 1 may be formed at an angle, so that it does not constitute a part of the surface of the foamed molded product 1, but only a part of the side surface of the foamed molded product 1.

[0039] In the foamed molded product 1, a through hole 12 is formed on the side surface of the foamed molded product 1 by attaching the first member 11 to the missing portion 104a of the unfinished through hole 104 on the side surface of the pad material 10. The first member 11 can be attached to the missing portion 104a with an adhesive or the like. Alternatively, for example, the first member 11 may be fitted into and held in place by the missing portion 104a without the use of an adhesive.

[0040] In this embodiment, a marker portion 105 is formed around the missing portion 104a of the incomplete through-hole 104 in the pad material 10, serving as a guide when attaching the first member 11 to the side surface of the pad material 10. Specifically, the marker portion 105 is composed of a groove and is formed around the missing portion 104a of the incomplete through-hole 104 on the surface side of the foamed molded product 1. Note that one or more marker portions 105 may be formed. Furthermore, the marker portion 105 may be composed of a projection or the like.

[0041] If a marking portion 105 is formed on the pad material 10, the first member 11 may have a first member-side marking portion 110 that serves as a marker for aligning with the marking portion 105 of the pad material 10 when attaching the first member 11 to the side surface of the pad material 10. The first member-side marking portion 110 can be made up of, for example, grooves or protrusions, similar to the marking portion 105 of the pad material 10, and may be formed as one or more portions.

[0042] Furthermore, the foamed molded product 1 may have a pre-formed through-hole in the upper wall portion (not shown) for attaching a headrest, for example.

[0043] (molding mold) The configuration of the mold 2 in this embodiment will be explained using Figures 5 to 7. As illustrated in Figures 5 to 7, the mold 2 has a lower mold 21, an upper mold 22, and a core mold 23 provided in the upper mold 22. The mold 2 is for molding a pad material 10 used in the manufacture of a foamed molded product 1 having at least one through hole 12 on its side surface. In other words, the mold 2 is for molding a pad material 10 having the aforementioned incomplete through hole 104, and the part corresponding to the first member 11 cannot be molded. In this embodiment, the mold 2 for molding a pad material 10 having the shape shown in Figure 2 will be used as an example for explanation. Also, the C1 direction in Figure 5 is the upper side of the mold 2, and the C2 direction is the lower side of the mold 2.

[0044] The lower mold 21 has a molding surface 211 for molding the surface of the pad material 10 and a molding side surface 212 for molding a part of the side surface of the pad material 10. During the manufacturing of the pad material 10, as shown in Figure 5, for example, foaming raw material is injected into the area G indicated by the circle on the molding surface 211. The upper mold 22 is configured to be able to open and close relative to the lower mold 21 via a hinge portion 24. The upper mold 22 has a molding surface 221 for molding the back surface of the protruding portion of the upper part of the pad material 10.

[0045] As shown in Figure 6, the core mold 23 is configured to open and close relative to the upper mold 22 by the movement of a rod 231 operated by a cylinder (not shown), and has a molding surface 232 for molding a portion of the back surface of the pad material 10. The core mold 23 has an incomplete through-hole molding section 233 that protrudes from a portion of the molding surface 232 of the core mold 23 into the cavity 20 formed when the upper mold 22 and the lower mold 21 are closed, for forming an incomplete through-hole 104.

[0046] In this embodiment, only one incomplete through-hole forming section 233 is provided on the core mold 23 for manufacturing the pad material 10 shown in Figure 2. However, it is not limited to this, and can be provided according to the number of incomplete through-holes 104 to be formed in the pad material 10. The core mold 23 may also have a through-hole forming section 234 for forming through-holes with a completed shape in the pad material 10. The through-hole forming section 234 shown in Figure 5 is for forming through-holes (not shown) for a headrest (not shown) on the upper part (not shown) of the pad material 10.

[0047] Furthermore, in Figure 7, the part labeled P indicates the parting line between the upper mold 22 and the core mold 23. In other words, when the mold 2 is closed, the parting line P between the upper mold 22 and the core mold 23 is located on the upper mold 22 side of the unfinished through-hole molding section 233. In addition, the mold 2 is configured such that the upper mold 22 and the core mold 23 separate when the core mold 23 is opened relative to the upper mold 22, making it easier to clean the area between them (see Figure 6).

[0048] The tip surface 233a of the unfinished through-hole forming section 233 faces the forming side surface 212 of the lower mold 21 when the upper mold 22 and the lower mold 21 are closed together. When the upper mold 22 and the lower mold 21 are closed together, the tip surface 233a of the unfinished through-hole forming section 233a may be in contact with the forming side surface 212 of the lower mold 21, as illustrated in Figure 6, or there may be a small gap between it and the forming side surface 212 of the lower mold 21, although this is not shown.

[0049] In this embodiment, the lower mold 21 has a recess (not shown) or a protrusion (not shown) around the missing portion 104a of the incomplete through hole 104 in the pad material 10 for forming the mark portion 105 described above. If the lower mold 21 has a protrusion, the mark portion 105 consisting of the groove described above can be formed. On the other hand, if the lower mold 21 has a recess, the mark portion 105 consisting of the projection described above can be formed.

[0050] (Method for manufacturing foamed molded products) The steps for manufacturing the foamed molded product 1 of this embodiment will be explained with reference to Figures 1 to 7. The manufacturing method for the foamed molded product 1 of this embodiment is a method for manufacturing a foamed molded product 1 having at least one through hole 12 on its side surface. In this embodiment, the method for manufacturing a foamed molded product 1 having the shape shown in Figure 1 will be used as an example for explanation.

[0051] The manufacturing method for the foamed molded product 1 of this embodiment includes the steps of preparing a pad material 10 that constitutes the surface, back surface, and a part of the side surface of the foamed molded product 1, and a first member 11 that constitutes a part of the side surface of the foamed molded product 1, separate from the pad material 10, and attaching the first member 11 to the side surface of the pad material 10.

[0052] The pad material 10 and the first member 11 are separate components for forming the foamed molded product 1 and are prepared separately. In this embodiment, the pad material 10 can be prepared by mold molding using the mold 2 shown in Figures 5 to 7.

[0053] Specifically, the upper mold 22 is opened relative to the lower mold 21, and the core mold 23 is opened relative to the upper mold 22. At this time, if a backing material is provided for the pad material 10, the backing material is set in the core mold 23. Then, the core mold 23 is closed relative to the upper mold 22, and a foaming raw material, such as urethane foam, is injected onto the molding surface 211 of the lower mold 21 in the molding die 2. Next, the upper mold 22 and core mold 23 are closed relative to the lower mold 21 to foam the foaming raw material, filling the cavity 20 with the foaming raw material and forming the pad material 10. If a backing material is set, the pad material 10 and the backing material are integrated. Next, the upper mold 22 and core mold 23 are opened relative to the lower mold 21, and the core mold 23 is opened relative to the upper mold 22. Next, the molded pad material 10 is removed from the core mold 23. In addition to the backing material, other components such as wires and chip molded products can also be set in the mold 2 and integrated with the pad material 10.

[0054] As described above, the formed pad material 10 has a shape in which the side surface of the pad material 10 protrudes outward more on the front surface side of the foamed molded product 1 than on the back surface side of the foamed molded product 1. Furthermore, the side surface of the pad material 10 has an incomplete through-hole 104 with a missing portion 104a formed such that at least a part of the peripheral wall of the through-hole 12 on the front surface side of the foamed molded product 1 is missing. In this embodiment, a groove-like marking portion 105 is formed around the missing portion of the incomplete through-hole 104 by a protrusion (not shown) provided on the lower mold 21 of the molding die 2.

[0055] On the other hand, the first member 11 can be prepared, for example, by using a foaming raw material for urethane foam and molding it in a different mold than the one used for the pad material 10. The first member 11 may also be formed by, for example, press molding chip urethane material. In this embodiment, a first member side marking portion 110, which consists of a groove corresponding to the marking portion 105 of the pad material 10, is formed on the surface of the first member 11.

[0056] After preparing the pad material 10 and the first member 11 separately as described above, the first member 11 is attached to the missing portion 104a of the incomplete through hole 104 on the side surface of the pad material 10 to form the through hole 12 on the side surface of the foamed molded product 1. In this embodiment, the attachment of the first member 11 to the missing portion 104a is performed by attaching the first member 11 to the pad material 10 with adhesive so that the position of the mark portion 105 on the pad material 10 and the mark portion 110 on the first member side of the first member 11 are aligned. By going through the above steps, the foamed molded product 1 can be manufactured.

[0057] Next, the foamed molded product of this embodiment, its manufacturing method, and the effects of the mold will be explained in detail.

[0058] Figure 8 shows a cross-sectional view of the mold 2C of the comparative form, drawn in correspondence with the mold 2 of this embodiment shown in the closed state in Figure 7. The mold 2C of the comparative form shown in Figure 2 is for molding a comparative foam molded product (not shown) with a through hole of the finished shape directly formed on the side surface, rather than attaching the first member 11 later. The side surface of the comparative foam molded product has a design in which the front surface protrudes outward more than the back surface, similar to the foam molded product 1 of this embodiment. Therefore, in the mold 2C of the comparative form that molds the comparative foam molded product, the lower part of the through hole forming section 233C provided in the core mold 23C, that is, the part that forms the surface side of the comparative foam molded product, has an undercut shape U. Consequently, in the mold 2C of the comparative form and the manufacturing method of the comparative foam molded product using it, when opening the upper mold 22C relative to the lower mold 21C, tearing is likely to occur around the through hole.

[0059] In contrast, according to the molding die 2 and the manufacturing method of the foamed molded product 1 of this embodiment, even if the side surface of the pad material 10 to be prepared protrudes outward more than the back surface of the foamed molded product 1, the side surface of the pad material 10 has an incomplete through-hole 104 with a missing portion 104a formed such that at least a part of the peripheral wall of the through-hole 12 to be formed on the surface side of the foamed molded product 1 is missing. Therefore, according to the molding die 2 and the manufacturing method of the foamed molded product 1 of this embodiment, the molding die 2 for molding the pad material 10 does not have an undercut shape U in the portion of the incomplete through-hole molding section 233 on the lower mold 21 side (the portion of the peripheral wall of the through-hole 12 to be formed that forms the surface side of the foamed molded product 1). Therefore, according to the molding die 2 and the manufacturing method of the foamed molded product 1 of this embodiment, when the upper mold 22 is opened relative to the lower mold 21 and the pad material 10 is removed from the molding die 2, it is possible to suppress the occurrence of tearing around the incomplete through hole 104. After molding the pad material 10, by attaching the first member 11 to the missing portion 104a of the incomplete through hole 104, which exhibits an incomplete shape in that there is a missing portion 104a relative to the peripheral wall of the through hole 12 to be formed, a foamed molded product 1 with a complete through hole 12 formed on the side can be obtained. Thus, according to the molding die 2 and the manufacturing method of the foamed molded product of this embodiment, the effect is obtained in which a foamed molded product 1 of this embodiment can be obtained that can suppress tearing around the through hole 12 on the side. This effect is obtained because the foamed molded product 1 of this embodiment is composed of the pad material 10 and the first member 11 separately, and the whole is formed by combining the two.

[0060] The present invention is not limited to the embodiments described above, and various modifications are possible without departing from its spirit. Furthermore, each configuration shown in the embodiments can be combined in any way. Also, each claim described in the initial claims of the application can be combined in any way. [Explanation of Symbols]

[0061] 1. Foamed molded product 10 pad material 104 Unfinished through-hole 104a Missing part 11. First Member 12 through holes 2 Molding mold 21 Lower mold 22 Upper mold 23 Core mold 233 Unfinished through-hole molding section 233a Tip surface

Claims

1. A foamed molded product having at least one through hole on its side, The pad material that constitutes the surface, back surface, and part of the side of the foamed molded product, It comprises a first member, which is a separate component from the pad material and constitutes a part of the side surface of the foamed molded product, The side surface of the pad material has a shape in which the front surface of the foamed molded product protrudes outward more than the back surface of the foamed molded product. The side surface of the pad material has an incomplete through-hole with a missing portion formed such that at least a part of the peripheral wall of the through-hole on the surface side of the foamed molded product is missing. The first member is attached to the missing portion of the incomplete through-hole on the side surface of the pad material, thereby forming the through-hole on the side surface of the foamed molded product. Foamed molded product.

2. The hardness of the first component described above is greater than or equal to the hardness of the pad material described above. The foamed molded article according to claim 1.

3. The first member described above constitutes a part of the side surface of the foamed molded product and a part of the surface of the foamed molded product. A foamed molded article according to claim 1 or claim 2.

4. A method for manufacturing a foamed molded product having at least one through hole on its side, A step of preparing a pad material which constitutes the surface, back surface, and a part of the side surface of the foamed molded product by molding with a mold, and a first member which constitutes a part of the side surface of the foamed molded product separately from the pad material, The process includes the step of attaching the first member to the side surface of the pad material, The side surface of the pad material has a shape in which the front surface of the foamed molded product protrudes outward more than the back surface of the foamed molded product. The side surface of the pad material has an incomplete through-hole with a missing portion formed such that at least a part of the peripheral wall of the through-hole on the surface side of the foamed molded product is missing. By attaching the first member to the missing portion of the incomplete through hole on the side surface of the pad material, the through hole on the side surface of the foamed molded product is formed. A method for manufacturing foamed molded products.

5. Around the missing portion of the incomplete through hole in the pad material, and on at least one of the first members, A marking portion is formed on the side surface of the pad material, which serves as a guide when attaching the first member. A method for manufacturing a foamed molded article according to claim 4.

6. A mold for molding a pad material used in the manufacture of a foamed molded product, comprising a lower mold, an upper mold, and a core mold provided in the upper mold, and having at least one through hole on its side, The above-mentioned pad material constitutes the surface, back surface, and part of the side surface of the above-mentioned foamed molded product. The side surface of the pad material has a shape in which the front surface of the foamed molded product protrudes outward more than the back surface of the foamed molded product. The side surface of the pad material has an incomplete through-hole with a missing portion formed such that at least a part of the peripheral wall of the through-hole on the surface side of the foamed molded product is missing. The core mold described above has an incomplete through-hole forming portion that protrudes from a part of the molding surface of the core mold to form the incomplete through-hole in the cavity formed when the upper mold and the lower mold are closed together. The tip surface of the incomplete through-hole forming section, when the upper and lower molds are closed together, faces the forming side surface of the lower mold. Molding mold.

7. The lower mold described above has recesses or protrusions for forming a marking area around the missing portion of the incomplete through-hole in the pad material. The molding die according to claim 6.

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