Process for producing a skin material-laminated foamed thermoplastic resin molding

Claim 1

A process for producing a foamed thermoplastic resin molding comprising a skin material and a thermoplastic resin foam integrally laminated with the skin material, wherein the process uses a mold comprising a male and female mold members which are mutually slidable and whose cavity clearance (t) is adjustable, the process comprising the following steps (1)-(5): (1) skin material supply step for supplying a skin material between the female and male mold members while said members are open with respect to each other; (2) resin injection step including bringing the male mold member and the female mold member close together to make the t to be a resin injection clearance less than (C+5) mm, wherein C is the thickness of the skin material before molding, and injecting a foaming agent-containing molten polyolefin-based resin through a resin supply opening provided in one of the male and female mold members to between the skin material and the mold member, wherein the injection step is commenced at a resin injection clearance of less than (C+5); (3) compression step for shaping the injected polyolefin-based resin by filing it up to an end of a mold cavity by making the t smaller than the resin injection clearance by compression, and simultaneously laminating the skin material integrally with the polyolefin-based resin; (4) foaming step for forming a foamed thermoplastic resin molding by forming a foamed layer through foaming the polyolefin-based resin injected in its molten state through elongating the t after the completion of the shaping of the polyolefin-based resin; and (5) cooling and releasing step including cooling the foamed thermoplastic resin molding in the mold, then opening the mold and taking out the foamed thermoplastic resin.