Process for producing polyurethane-foam product molded integrally with insert and expansion-molding mold for the same

A process for producing a polyurethane-foam product molded integrally with an insert, wherein a molded body, including a substrate and a polyurethane-foam molded body being molded integrally with the substrate, is produced, the substrate being disposed in an expansion-molding mold as the insert, the process comprising the steps of:

• forming a fine groove-shaped polyurethane-foam relief groove and a polyurethane-foam adjuster in at least one of an end of the substrate and a mold surface of the expansion-molding mold which contacts with the substrate, the polyurethane-foam relief groove communicating with a cavity of the expansion-molding mold, the polyurethane-foam adjuster being in communication with the polyurethane-foam relief groove and having a volume larger than that of the polyurethane-foam relief groove;
• and
• adjusting the leakage of polyurethane foam, which is foamed in the cavity, with the polyurethane-foam adjuster, and removing polyurethane foam, which is formed by the polyurethane-foam relief groove and the polyurethane-foam adjuster, from the expansion-molding mold in such a state that it is bonded integrally with said molded product;
• wherein at least one of said end of the substrate and said mold surface of the expansion-molding mold is provided with a second polyurethane-foam relief groove which communicates said polyurethane-foam adjuster with the outside of said expansion-molding mold;
• and
• wherein said leakage of the polyurethane foam flows through said second polyurethane-foam relief groove after providing a time lag following the flowing of the polyurethane foam through said polyurethane-foam relief groove.

A process for producing a polyurethane-foam product molded integrally with an insert, wherein a molded body, including a substrate and a polyurethane-foam molded body being molded integrally with the substrate, is produced, the substrate being disposed in an expansion-molding mold as the insert, the process comprising the steps of:

• forming a fine groove-shaped polyurethane-foam relief groove and a polyurethane-foam adjuster in at least one of an end of the substrate and a mold surface of the expansion-molding mold which contacts with the substrate, the polyurethane-foam relief groove communicating with a cavity of the expansion-molding mold, the polyurethane-foam adjuster being in communication with the polyurethane-foam relief groove and having a volume larger than that of the polyurethane-foam relief groove;
• and
• adjusting the leakage of polyurethane foam, which is foamed in the cavity, with the polyurethane-foam adjuster, and removing polyurethane foam, which is formed by the polyurethane-foam relief groove and the polyurethane-foam adjuster, from the expansion-molding mold in such a state that it is bonded integrally with said molded product;
• wherein at least one of said end of the substrate and said mold surface of the expansion-molding mold is provided with a second polyurethane-foam relief groove which communicates said polyurethane-foam adjuster with the outside of said expansion-molding mold;
• and
• wherein said second polyurethane-foam relief groove has a smaller cross sectional area than that of said polyurethane-foam relief groove.