Molding method for manufacturing expansion-molded insert-embedded resin product

Claim 1

A molding method for manufacturing an expansion-molded, insert-embedded foamed resin product comprising: forming a skin in the shape corresponding to that of a desired exterior surface of the expansion-molded, insert-embedded product; forming by foaming a first expansion-molded layer inside of the skin to have a substantially uniform thickness, said first expansion-molded layer being formed over at least that entire interior portion of the skin which forms the configuration of a final product of said expansion-molded insert-embedded product and defining a concave inner space; performing treatments of trimming the edge portions of said first expansion-molded layer having said skin thereon and of providing at a desired location in said first expansion-molded layer having said skin thereon an opening for mounting therein an accessory; and forming by foaming a second expansion-molded layer using a die having a protruded portion which fits into the opening for mounting an accessory and by filling said concave inner space of the first expansion-molded layer and simultaneously embedding an insert member therein while keeping the insert member positioned at a desired location in said concave inner space defined by the first expansion-molded layer, said second expansion-molded layer functioning as a stiffening member for giving rigidity to said expansion-molded, insert-embedded resin product.