In-mold foamed molding unit and method for producing in-mold foamed molding unit

An in-mold foamed molded product unit, comprising:

• an in-mold foamed molded product made of a thermoplastic resin;
• and
• an insert material,
• wherein:
• at least a portion of the insert material is embedded in the in-mold foamed molded product,
• the insert material has a frame shape which is substantially rectangular and comprises comprising a first set of opposite sides and a second set of opposite sides,
• a portion of the insert material that corresponds to the first set of opposite sides is a first extending portion, and a portion of the insert material that corresponds to the second set of opposite sides is a second extending portion,
• each of the first extended portion and each of the second extended portion are straight or contain bent and/or curved portions,
• the insert material includes four corners at ends of the first extending portion and ends of the second extending portion, the four corners represent four corners of an imaginary quadrangle,
• the first extending portion and the second extending portion overlap with four sides of the imaginary quadrangle except for the bent and/or curved portions of the first extending portion and the second extending portion,
• the bent and/or curved portions of the first extending portion and the second extending portion are drawn apart from the four sides of the imaginary quadrangle,
• the first extending portion is entirely embedded in the in-mold foamed molded product except for a portion of the first extending portion,
• the second extending portion includes an exposed portion that is exposed to the outside of the in-mold foamed molded product,
• the exposed portion follows a shrinkage and expansion of the in-mold foamed molded product, and
• at least a portion of the exposed portion has a thickness that is thinner than a thickness of the first extending portion of the insert material.

A method for producing an in-mold foamed molded product unit, the method comprising:

• molding an in-mold foamed molded product such that at least a portion of an insert material is embedded in the in-mold foamed molded product,
• wherein:
• the in-mold foamed molded product unit comprises:
• an in-mold foamed molded product made of a thermoplastic resin;
• and
• an insert material
• the insert material has a frame shape comprising a first set of opposite sides and a second set of opposite sides,
• a portion of the insert material that corresponds to the first set of opposite sides is a first extending portion, and a portion of the insert material that corresponds to the second set of opposite sides is a second extending portion,
• each of the first extended portion and each of the second extended portion are straight or contain bent and/or curved portions,
• the insert material includes four corners at ends of the first extending portion and ends of the second extending portion, the four corners represent four corners of an imaginary quadrangle,
• the first extending portion and the second extending portion overlap with four sides of the imaginary quadrangle except for the bent and/or curved portions of the first extending portion and the second extending portion,
• the bent and/or curved portions of the first extending portion and the second extending portion are drawn apart from the four sides of the imaginary quadrangle,
• the molding of the in-mold foamed molded product provides the first extending portion being entirely embedded in the in-mold foamed molded product except for a portion of the first extending portion,
• the molding of the in-mold foamed molded product provides the second extending portion with an exposed portion that is exposed to the outside of the in-mold foamed molded product,
• the exposed portion follows a shrinkage and expansion of the in-mold foamed molded product, and
• at least a portion of the exposed portion has a thickness that is thinner than a thickness of the first extending portion of the insert material.