Patent ID: 6863849

Claim:
A method of molding a composite foam molding element comprising: attaching a top side member to a first die side of a cavity between a pair of dies capable of closing and opening to form a cavity for foam molding and a back side member to a second die side of said cavity; and a charging process comprising: providing a charging space between the top and back side members; supplying raw material beads made of a foam resin to the charging space; discharging air from a plurality of work piece nozzles located at the side of the die wherein the back side member is located; starting air discharging from a work piece nozzle located at a most distant position from a charger for supplying raw material beads when the raw material beads are supplied; charging raw material beads during said starting air discharging and sequentially discharging air from work piece nozzles located successively closer to a work piece nozzle located at the most proximal position from the charger as raw material beads are charged; and heating charged raw material beads to cause foaming and fusion to integrate a top side member and a back side member with each other via a foam member.