Provided is a method of producing a foamed article molded integrally with a surface cover in which a plurality of stock solutions of a foam resin are injected into a bag-shaped surface cover (11), and a core body (12) made of a foam resin is molded integrally with the surface cover (11). A discharge port of a nozzle (20) through which the plurality of stock solutions are injected into the surface cover (11) is covered with a mesh body (14), and the plurality of stock solutions are injected into the surface cover (11) through the mesh body (14).

An injection molding system and method are disclosed. The injection molding system includes a molding device and injector. The molding device defines a mold cavity and includes an inlet portion in communication with the mold cavity. The injector includes a discharging channel. An end portion of the inlet portion and an end portion of the discharging channel have non-planar end surfaces respectively, which are engageable with each other.

In a skin integral molded article which is formed by filling the inside of a skin which is formed into a bag shape with a foamed body and molding the foamed body integrally with the skin, an opening through which a foaming raw material is supplied into the skin is formed in the skin, in one side skin and other side skin which are formed with the opening being interposed, the one-side skin is bent into inside the opening, the other-side skin is provided with a part disposed ahead of a part which is bent into inside the opening and is formed to be pliable, and the part which is disposed ahead of the other-side skin part and is formed to be pliable is formed in contact with a leading end part of the one-side skin part which is bent into the opening.

A molded foam manufacturing apparatus 1 includes a cylinder 2 in which a plasticization zone 21 where a thermoplastic resin is plasticized and melted, a starvation zone 22 where the molten resin is put into a starvation state and an injected physical foaming agent is dissolved in the molten resin, and a feeding zone 23 where the molten resin in which the physical foaming agent is dissolved is compressed and metered are provided in this order from an upstream side, and a screw 3 that is installed inside the cylinder 2 so as to be freely rotatable around an axis of the cylinder and has flights formed in a spiral shape on an outer circumference of a shaft 31, wherein a lead angle R of the flights of the screw 3 corresponding to the feeding zone 23 is set smaller than a lead angle of the flight corresponding to the starvation zone 22, and the number of pieces of the flight of the screw 3 corresponding to the feeding zone 23 is set smaller than the number of pieces of the flight corresponding to the starvation zone 22. In this way, it is possible to prevent a decrease in the flow rate of the molten resin transported in the starvation zone and the feeding sone and manufacture high-quality molded foams with high production efficiency.

In a method for producing a polymer composite board from plastic waste, in which the plastic waste is processed in an extruder in a melt-kneading step to form a melt, the melt is introduced into an injector and injected under pressure into a cavity of a closed mold by the injector, in order to form a board. The melt is formed from a free-flowing agglomerate and a blowing agent. The free-flowing agglomerate is produced from unsorted, mixed plastic waste, and the melt is introduced into the closed mold via an injection nozzle along an end side of the cavity, in which mold the melt is foamed and cooled to form a foamed core layer of the polymer composite board.

An injection-molding system includes an extruding system configured to produce a mixture; a discharging channel communicable with the extruding system and including an outlet configured to discharge the mixture; and molding devices configured to receive the mixture. Each of the molding devices includes a hollow space, and a feeding port communicable with the hollow space and engageable with the outlet. An injection-molding method includes providing an extruding system configured to produce a mixture, a discharging channel including an outlet, and first and second molding devices; engaging the outlet with the first molding device; injecting the mixture into the first molding device; disengaging the outlet from the first molding device; moving the discharging channel away from the first molding device and toward the second molding device; engaging the outlet with the second molding device; injecting the mixture into the second molding device; and disengaging the outlet from the second molding device.

The invention is a process for making molded polymer foams, especially laminated panels that include a central foam layer and a facing layer on one or both sides. A flexible film dispenser (10) is folded or rolled and introduced into a mold cavity (7) through an opening (6) in the mold. The dispenser is unfolded or unrolled inside the film cavity and a foam precursor is pumped through the dispenser and into the mold cavity. The dispenser has multiple outlets (16) through which the foam precursor enters the mold cavity. This permits a more uniform distribution of the foam precursor throughout the mold cavity and reduces defects while improving product quality.

A foam molding method includes: moving a screw backward to take air into a heating barrel through a nozzle part in a state in which a shut-off nozzle is opened, the shut-off nozzle that opens or closes the nozzle part for injecting the molten resin and is disposed on a heating barrel; closing the shut-off nozzle and moving the screw forward, to diffuse the air taken into the heating barrel, in the molten resin in the heating barrel; feeding the molten resin forward while dispersing the air as the air bubbles in the molten resin by moving the screw backward while rotating it in a state in which the shut-off nozzle is closed; and opening the shut-off nozzle, to inject the molten resin containing the dispersed air bubbles into the cavity.

A molded foam manufacturing apparatus 1 includes a cylinder 2 in which a plasticization zone 21 where a thermoplastic resin is plasticized and melted, a starvation zone 22 where the molten resin is put into a starvation state and an injected physical foaming agent is dissolved in the molten resin, and a feeding zone 23 where the molten resin in which the physical foaming agent is dissolved is compressed and metered are provided in this order from an upstream side, and a screw 3 that is installed inside the cylinder 2 so as to be freely rotatable around an axis of the cylinder and has flights formed in a spiral shape on an outer circumference of a shaft 31, wherein a lead angle R of the flights of the screw 3 corresponding to the feeding zone 23 is set smaller than a lead angle of the flight corresponding to the starvation zone 22, and the number of pieces of the flight of the screw 3 corresponding to the feeding zone 23 is set smaller than the number of pieces of the flight corresponding to the starvation zone 22. In this way, it is possible to prevent a decrease in the flow rate of the molten resin transported in the starvation zone and the feeding sone and manufacture high-quality molded foams with high production efficiency.