Foamed molding with soft insert component and its molding method
AssigneeCalsonic Kansei Corporation
InventorShigeyuki Katou
Life of this patent
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Abstract
A soft insert component having a rigid body portion in the vicinity of a marginal part of one surface side is insert molded in integration to a foamed molding. The foamed molding with the soft insert component includes a triple layered structure having a skin material, a core material, and a foamed layer. The skin material includes an insert component fixing portion onto which the soft insert component can be fixed. The core material includes a rigid body-supporting portion able to support the rigid body portion while resisting against a compression force applied to the soft insert component during foam molding, and the foamed layer is formed between the core material and a skin layer formed of the skin material and the soft insert component.
Claims6
A foamed molding comprising:
- a foamed molding body portion having a triple-layered structure including a skin material forming a first surface of said foamed molding body portion, a core material forming a second surface of said foamed molding body portion opposite said first surface, and a foamed layer between said skin material and said core material;
- and
- a soft insert component insert-molded integrally with said foamed molding body portion, said soft insert component including a skin material part arranged substantially co-planar with said skin material of said foamed molding body portion, a rigid body portion at a position adjacent to said core material of said foamed molding body portion, and a soft material layer between said rigid body portion and said skin material part, said rigid body portion having a groove formed therein;
- wherein said skin material of said foamed molding body portion has an insert component fixing portion holding said soft insert component, said insert component fixing portion of said skin material having a facing end flange part inserted within said groove of said rigid body portion of said soft insert component so that said insert component fixing portion engages with said rigid body portion;
- wherein said core material of said foamed molding body portion has a rigid body-supporting portion protruding from an inner surface of said core material facing said foamed layer so as to support said engagement of said insert component fixing portion of said skin material and said rigid body portion of said soft insert component against a compression force applied to said soft insert component during foam molding;
- and
- wherein said foamed layer is arranged continuously between said core material of said foamed molding body portion and said skin material of said foamed molding body portion, and said foamed layer is arranged continuously between said core material of said foamed molding body portion and said soft insert component.
Dependencies are inferred from the claim text.