This invention is a mattress core that is manufactured as a single unit. It is made up of individual cones that have different configurations resulting in different densities at different portions of the mattress. There are three main ways to accomplishing this goal: columns of different sizes and shapes, columns with different hole diameters, and columns with different density foam used to create them. A key advantage of this invention is that it is a single mattress made from a single mold and does not require multiple parts to be put together.

Lightweight and strong components may be manufactured using self-skinning foam material compositions by the processes described herein. One or more mandrels may be inserted into a molding tool, and a self-skinning foam material composition may be injected into the molding tool. After closing the molding tool, the self-skinning foam material composition may expand and cure to form a component, and one or more skins may be formed on exterior and/or interior surfaces of the component. For example, an external skin may be formed on an exterior surface of the component in contact with surfaces of the molding tool, and one or more internal skins may be formed on one or more interior surfaces of negative space spars of the component in contact with surfaces of the one or more mandrels.

Lightweight and strong components may be manufactured using foam material compositions and resin coating materials by the processes described herein. One or more mandrels and/or a molding tool may be coated with resin coatings, the one or more mandrels may be inserted into the molding tool, and a foam material composition may be injected into the molding tool. After closing the molding tool, the foam material composition may expand and cure to form a component, and heat may be applied to cure the resin coatings into skins. For example, an external skin may be formed by the resin coatings on an exterior surface of the component in contact with surfaces of the molding tool, and one or more internal skins may be formed by the resin coatings on one or more interior surfaces of negative space spars of the component in contact with surfaces of the one or more mandrels.

A manufacturing method of a seat structure member includes forming a protrusion that protrudes inward on an inside surface of a portion that forms a foaming chamber for a seat pad, on one die and another die that form the foaming chamber. Applying, to a cover, a region that will not be integrated with the seat pad when the seat pad is foam molded, at a location on the cover that corresponds to a location of the protrusion when placing the cover on the inside surface of the foaming chamber. The method further includes arranging the cover following a shape of the protrusion and foam molding the seat pad and forming a space of a recessed portion between the seat pad and the cover, by releasing the one die and the other die after foam molding the seat pad.

Insulating molded part having an upper part and a bottom part. The upper part and bottom part are formed as an integral injection molded or die-cast part. Further, cavities, between the upper part and the bottom part, are arranged as chambers separated from one another in an air-tight manner and the upper part and the bottom part are formed in respective cuboid manners, and the upper part is offset in a diagonal direction in relation to the bottom part.

A seat pad (1) includes a surface portion (1a) configured of a polyurethane foam (11). In the surface portion (1a), wiring grooves (2) for wiring a wire harness (3) are formed. Each wiring groove (2) has a groove width W narrower than the diameter (? 3) of the harness (3), and a groove depth (D) deeper than the diameter ?3 of the harness (3). A seat pad manufacturing method uses, as a molding die, a molding die that has groove-forming protrusions to form the wiring grooves (2) and has holes formed in side surfaces of the groove-forming protrusions. A polyurethane foam material is supplied to an interior of the molding die, and when a molded product is removed from the molding die, molded portions formed in the holes are forcibly pulled out of the holes of the groove-forming protrusions.

The present invention provides a synthetic resin foaming molding die, a manufacturing method of a synthetic resin foaming molded article using the molding die, and a synthetic resin foaming molded article molded by the manufacturing method, which can prevent generation of a large-size void(s). The molding die (10) comprises an upper die (16) and a lower die (12) and having a cavity (29) defined by the upper die and the lower die, and a parting line 22 (communicating portion) communicating the cavity (29) and an ambient air. A rod-like member (24) is provided in fluid passage to allow the synthetic resin foaming material to flow to the parting line (22), in a protruding manner from the cavity surface.

The present invention provides a method for manufacturing a molded foam product which can reduce blisters on the surface and foaming failure in injection molding of a molten resin containing a fluid in a supercritical state even in the case of manufacturing a molded product designed to have a small thickness, thereby giving a molded foam product having excellent heat insulation. The method of the present invention is a method for manufacturing a molded foam product through injection molding of a molten resin containing a fluid in a supercritical state, the method including a step of injecting the molten resin into a cavity formed in a mold and moving a portion of the mold to increase the volume of the cavity before the molten resin injected into the cavity completely solidifies, the cavity being communicated only with a single resin injection port, the mold having a dimple which has a substantially hemispherical shape and is situated to face the resin injection port, the mold having a minimum gap size of 0.2 mm or greater in the cavity during injection of the molten resin.

A method for manufacturing a seat cushion material, the seat cushion material including a front layer part and a back layer part having a back side surface, the method including: preparing for molding the seat cushion by attaching the back layer part to an upper die having an upper cavity surface; molding the seat cushion material by adding foamed resin raw material forming on a lower cavity surface of a lower die and then by closing the upper die to which the back layer part is attached, the lower cavity surface being provided with a plurality of protrusions which is configured to be brought into contact with a seating surface side of the back layer part and press the back layer part against the upper cavity surface when the upper die to which the back layer part is attached is closed; and demolding the molded seat cushion material.

A method for manufacturing a seat cushion material, the seat cushion material including a front layer part and a back layer part, the back layer part having a back side surface, and a concave portion being provided in the back side surface, the method including: preparing for molding the seat cushion material by attaching the back layer part to an upper die which has an upper cavity surface and a convex portion that can be fitted into the concave portion in such a manner that the back side surface is brought into contact with the upper cavity surface; molding the seat cushion material by adding foamed resin raw material forming the front layer part on a lower cavity surface of a lower die and then by closing the upper die to which the back layer part is attached; and demolding the molded seat cushion material.