Daisen Industry Co., Ltd.

Shigeki Yoshimura

Iwao Nohara

Kiyotaka Ida

Yasutaka Tate

Akimasa Shimazaki

After heating the expandable resin beads to sealing temperature of expandable resin beads in the presence of heated steam, foam cells are sealed and cooled while controlling the foaming amount. The foaming amount is controlled by pressure control on the expandable resin beads in the mold. Mutually adjacent foam cells are softened, fused, and bonded on contact faces, and thereby a foamed molding is manufactured. This foamed molding is characterized by three-dimensional permeable pores of volume porosity of 10 to 40% among foam cells, having bending limit strength of at least 10N. Without using adhesive resin, a foamed molding having enough strength and desired porous structure is obtained.

Foamed molding and its manufacturing method

A method of molding a composite foam molding element comprising attaching a top side member to a first die side of a cavity between a pair of dies and a back side member to a second die side of the cavity; supplying raw material beads made of a foam resin to an intervening charging space; discharging air from a plurality of work piece nozzles located at the side of the die wherein the back side member is located; starting air discharging from a work piece nozzle located at a most distant position from a charger for supplying raw material beads when the raw material beads are supplied; charging raw material beads during the starting air discharging step and sequentially discharging air from work piece nozzles located successively closer to a work piece nozzle located at the most proximal position from the charger as raw material beads are charged; and heating charged raw material beads to cause foaming and fusion to integrate a top side member and a back side member with each other via a foam member.

Apparatus and method of molding composite foam molding element and composite foam molding element obtained by the same

Apparatus for integrally molding articles with a foam member, including a charger for supplying raw material beads made of resin to a die cavity containing articles for integral molding with foam, a plurality of work piece nozzles each having a nozzle opening in fluid communication with the cavity. At least one of the workpiece nozzles is located at a position corresponding to an opening located in an article located in the die. A plurality of exhaust nozzles for exhausting air from the cavity, the exhausting air beginning with a group of exhaust nozzles at locations maximally distant from the raw material charging port, and groups of exhaust nozzles located successively closer to the raw material charging port, each group in turn for sequentially exhausting air from the cavity, while the port is charging the cavity with raw material beads.

Growing community of inventors

Ena-gun, Japan

Shigeki Yoshimura