A mold, a molding machine, and a foamed molded body manufacturing method are provided that are capable of more reliably preventing ingress of foamed resin into a gas discharge hole using a gas-impermeable member and capable of adequately discharging gas inside the cavity to the cavity outside through the gas discharge hole during foam molding, and that are also capable of achieving good design characteristics in a foamed molded body. A gas discharge hole 5 is provided at a cavity 4 inner face of a mold 1 and discharges gas inside the cavity 4 to outside the cavity 4. A gas-permeable member 6 is disposed inside the cavity 4 of the mold 1 so as to cover the gas discharge hole 5, and a gas-impermeable member 8 is disposed on the gas discharge hole 5 side of the gas-permeable member 6 so as to face the gas discharge hole 5. A portion of the gas discharge hole 5, spanning at least from axial direction intermediate portion of the gas discharge hole 5 to the cavity 4 side of the gas discharge hole 5, is configured with a tapered profile portion 5a that increases in diameter on progression toward the cavity 4 side.

Proposed is an apparatus and method for manufacturing automotive interior materials. The apparatus includes a first mold unit with a first molding surface and a gate disposed on the first molding surface, and a second mold unit provided with a second molding surface facing the first molding surface, wherein a skin is set on the first molding surface; and the first mold unit and the second mold unit are configured, when combined, to provide a volume-variable injection space between the set skin and the first molding surface, wherein the volume-variable injection space is in a first volume state while molten resin is injected through the gate, and after completing the injection of the molten resin, the volume-variable injection space changes to a second volume state that a volume of the injection space is reduced compared to the first volume state to compress the molten resin.

A structural component for a vehicle includes a component including an interior surface defining a first hollow passage and a structural reinforcement contacting the interior surface of the component. The structural reinforcement and component define a cross-section and the structural reinforcement partially fills the cross-section. A process for forming the structural component including inserting a bladder into the first hollow passage defined by the interior surface of the component and inflating the bladder in the first hollow passage, forming a cavity between the bladder and the interior surface, filling the cavity with a polymer resin, and foaming the polymer resin. A system for forming a structural component for a vehicle includes a component including a first hollow passage defined by an interior surface of the component, a bladder insertable into the first hollow passage of the component, and a supply line connected to an interior of the bladder.

A tool for the manufacture of foam parts includes walls enclosing a cavity corresponding to the shape of the foam parts to be manufactured, each wall having an inner surface adjacent to the cavity. At least one of the walls has at least one filamentary wall portion which includes at least one part of the inner surface of the respective wall, and which has layers of filamentary filaments running parallel to one another.

A method for infusing gas into a thermoplastic material includes positioning a sheet of a thermoplastic material into a vertical or substantially vertical position; positioning a sheet of a gas-permeable material into a vertical or substantially vertical position; and winding together the positioned sheet of thermoplastic material sheet and the positioned sheet of gas-permeable material to form a roll of the thermoplastic material interleaved with the gas-permeable material, the interleaved roll having a longitudinal axis oriented in a vertical or substantially vertical position. The method also includes exposing the interleaved roll to an atmosphere of a gas pressurized to infuse the thermoplastic material with the gas, while the longitudinal axis of the interleaved roll is oriented in a vertical or substantially vertical position; and then unwinding the gas-infused interleaved roll, while the longitudinal axis of the interleaved roll remains in a vertical or substantially vertical position.

A structural component for a vehicle includes a component including an interior surface defining a first hollow passage and a structural reinforcement contacting the interior surface of the component. The structural reinforcement and component define a cross-section and the structural reinforcement partially fills the cross-section. A process for forming the structural component including inserting a bladder into the first hollow passage defined by the interior surface of the component and inflating the bladder in the first hollow passage, forming a cavity between the bladder and the interior surface, filling the cavity with a polymer resin, and foaming the polymer resin. A system for forming a structural component for a vehicle includes a component including a first hollow passage defined by an interior surface of the component, a bladder insertable into the first hollow passage of the component, and a supply line connected to an interior of the bladder.

A tool for the manufacture of foam parts includes walls enclosing a cavity corresponding to the shape of the foam parts to be manufactured, each wall having an inner surface adjacent to the cavity. At least one of the walls has at least one filamentary wall portion which includes at least one part of the inner surface of the respective wall, and which has layers of filamentary filaments running parallel to one another.

Proposed is an apparatus and method for manufacturing automotive interior materials. The apparatus includes a first mold unit with a first molding surface and a gate disposed on the first molding surface, and a second mold unit provided with a second molding surface facing the first molding surface, wherein a skin is set on the first molding surface; and the first mold unit and the second mold unit are configured, when combined, to provide a volume-variable injection space between the set skin and the first molding surface, wherein the volume-variable injection space is in a first volume state while molten resin is injected through the gate, and after completing the injection of the molten resin, the volume-variable injection space changes to a second volume state that a volume of the injection space is reduced compared to the first volume state to compress the molten resin.