JP3135837B2 - Skin-integral foamed resin molded product and method for producing the same - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a molded article of a foamed resin integral with a skin and a method of manufacturing the same, and more particularly to a measure for sealing during molding.

[0002]

2. Description of the Related Art In general, for example, an instrument panel or the like, which is an interior part of an automobile, is formed by integrally molding a foam between a skin and a base material. When such a skin-integrated foamed resin molded article is molded, for example, Japanese Patent Application Laid-Open No. 7-2
As disclosed in Japanese Patent No. 85138, the skin is set on the lower mold of the molding die, and the base material is set on the upper mold of the molding die. The foamed resin raw material is injected between the skin and the base material in this state to foam and harden.

As another manufacturing method, Japanese Patent Laid-Open No. 7-3
As disclosed in Japanese Patent No. 14469, an outer skin having an edge portion curved in a J-shaped cross section is set in a lower mold of a molding die,
In this state, after holding the edge portion of the skin with a holding member so as not to fall down, the molding die is closed, and a foamed resin material is injected between the skin and the base material to foam and harden. There is also a method.

[0004]

However, in the former method, since the edge of the skin is curved inward and merely abuts against the inner surface of the base material, the foam While the foaming pressure acts during molding, the edge of the skin can be brought into pressure contact with the base material, but the foaming pressure also acts on the leading edge of the skin to produce a foamed resin material between the skin and the base material. And the leaked foamed resin raw material adheres to a molded article or a molding die to cause burrs, thereby deteriorating the appearance of the molded article, and increasing the number of deburring steps, thereby reducing workability.

Further, in the latter method, although the edge of the skin is held by the holding member, this only prevents the edge of the skin from falling down. In this case, the foaming pressure acts on the leading edge of the skin and the foamed resin material enters between the skin and the base material to form burrs, as in the above case. In addition to deteriorating the appearance, the number of deburring steps increases and the workability decreases.

The present invention has been made in view of such a point, and an object of the present invention is to prevent a foamed resin material from leaking during molding.

[0007]

In order to achieve the above-mentioned object, the present invention provides a flexible sealing means at an edge of a skin, and the sealing means is connected to the edge of the skin by foaming pressure. It is characterized by being positively pressed against the material.

More specifically, the present invention is directed to a skin-integral foamed resin molded article in which a foam is integrally molded between a skin and a base material, and a method for producing the same. Was.

That is, the first to fifth solutions of the present invention relate to the former skin-integrated foamed resin molded product, and the first solution is a wall close to the outer periphery and orthogonal to the wall close to the outer periphery. A peripheral wall having an L-shaped cross section including the inner peripheral wall portion is formed on the outer periphery of the foam molding region of the base material. On the other hand, a flexible sealing means is provided at the edge of the skin. And
The edge of the skin is brought into contact with the outer wall of the base material such that a small gap is formed between the tip of the edge of the skin and the inner wall of the base material. Further, the sealing means is elastically deformed by a foaming pressure at the time of molding the foam, pressed against the small gap side, and pressed against the inner peripheral wall portion of the base material.

According to a second aspect of the present invention, in the first aspect, the sealing means is formed of a sealing material which is a separate member from the skin, and the sealing material is joined to the back side of the edge of the skin. Features.

According to a third aspect of the present invention, in the second aspect, as the sealing means, a foamed resin material of open cells which allows passage of gas generated at the time of molding the foamed body and prevents passage of the foamed resin material is used. It is characterized by adoption.

According to a fourth aspect of the present invention, in the first aspect, the sealing means is constituted by a front end portion of an edge portion of the skin,
A thin hinge portion is provided at a base end of the seal portion including the distal end portion.

According to a fifth aspect of the present invention, in the first aspect, the sealing means is constituted by a front end portion of the edge portion of the skin,
It is characterized in that the thickness of the seal portion comprising the distal end portion is set to be thinner than that of the proximal end portion of the edge portion.

The sixth and seventh solutions of the present invention relate to the latter method for producing a skin-integrated foamed resin molded article,
An object of the manufacturing method is a skin-integrated foamed resin molded product according to the first to fifth solutions. Among them, a sixth solution means is to first set a skin molded in a predetermined shape in advance in a lower mold of a molding die in a mold-open state of the molding die, and to set a base material molded in a predetermined shape in advance to the molding die. After setting in the upper mold, the upper mold is closed with respect to the lower mold, and the mold is clamped, and the edge of the skin is narrowed between the tip and the inner peripheral wall of the base material. Is brought into contact with the outer peripheral wall portion of the base material so as to be formed. Next, a foaming resin material is injected from the injection head provided in the upper mold through the injection hole of the base material between the base material and the skin to foam the material, and the sealing means is elasticized by the foaming pressure at the time of forming the foam. Deformed and pressed against the small gap side,
It is characterized in that the base material is pressed against the inner peripheral wall portion. That is, a method of injecting the foamed resin raw material in a mold-clamped state.

[0017] A seventh solution is to first set a skin molded in a predetermined shape in a lower mold of a molding die in a mold-open state of the molding die, and to set a base material molded in a predetermined shape in advance in the molding die. After setting in the upper mold, a foamed resin material is injected from the injection head onto the skin of the lower mold. Next, the upper mold is closed with respect to the lower mold, and the molding mold is clamped, so that a small gap is formed between the tip of the outer skin and the inner peripheral wall of the base material. Then, the base material is brought into contact with the outer peripheral wall portion of the base material. Thereafter, the foamed resin material is foamed, and the sealing means is elastically deformed by the foaming pressure at the time of molding the foam, pressed against the small gap side, and pressed against the inner peripheral wall portion of the base material. That is, it is a method of injecting the foamed resin raw material in the mold opened state.

With the above arrangement, in the first to seventh solving means of the present invention, the edge of the skin abuts against the outer peripheral wall of the substrate in a mold-clamped state, and the tip of the edge of the skin is formed. A small gap is formed between the substrate and the inner peripheral wall portion of the substrate. Then, the sealing means provided at the edge of the outer skin is elastically deformed by the foaming pressure at the time of molding the foam, pressed against the small gap side, and pressed against the inner peripheral wall of the base material.

Therefore, the elastic deformation of the sealing means prevents the foamed resin material from intruding between the edge of the skin and the base material due to the foaming pressure, and prevents the foamed resin material from leaking to the outside. Does not occur. Therefore, the appearance of the molded article is not deteriorated by staining the surface of the molded article. Further, the deburring step is unnecessary, and the workability is improved.

In particular, in the second solution, since the sealing material, which is a separate member from the skin, is bonded to the back surface of the edge of the skin, the foaming pressure is in the direction of pressing against the bonding portion. And the sealing material does not come off.

According to the third solution, only the gas generated at the time of molding is released to the outside of the sealing material, so that no nest due to gas accumulation is generated and the quality of the molded product is improved.

In the fourth and fifth solving means, the seal portion is easily bent by the mold clamping operation, and the defective seal is prevented.

[0021]

Embodiments of the present invention will be described below with reference to the drawings.

(Embodiment 1) FIG. 9 shows an instrument panel 1 which is an interior part of an automobile as a molded article of a skin-integrated foamed resin. The instrument panel 1 as a skin-integrated foamed resin molded product according to Embodiment 1 of the present invention includes:
As shown in FIG. 1, a foam made of a rigid polyurethane foam or the like is provided between a resin skin 3 made of, for example, polyvinyl chloride and a resin base material 5 made of an ABS resin (acrylonitrile / butadiene / styrene resin). Reference numeral 7 denotes a three-layer structure integrally formed.

On the outer periphery of the foam 7 forming area of the base material 5,
A stepped portion which is one step lower than the inside is formed, and the stepped-down portion is a peripheral wall having an L-shaped cross section including an outer peripheral wall 9a and an inner peripheral wall 9b orthogonal to the outer peripheral wall 9a. 9
Is composed.

On the other hand, a sealing material 13 as a flexible sealing means is bonded to the back side of the edge portion 11 of the skin 3 by an adhesive (not shown). This sealing material 1
Reference numeral 3 denotes an open-cell foam resin material made of a flexible polyurethane foam or the like, which is a separate member from the edge portion 11 of the skin 3, and allows the gas generated during molding of the foam 7 to pass therethrough. It blocks the passage of raw materials. Accordingly, it is possible to prevent only the gas from leaking to the outside during molding and to prevent the occurrence of nests due to gas accumulation, and to improve the quality of the instrument panel 1.

The edge 11 of the skin 3 is in contact with the outer peripheral wall 9 a of the base material 5, and the tip of the edge 11 of the skin 3 and the inner peripheral wall 9 of the base 5 are contacted. 9b is formed with a small gap C.

The sealing material 13 is elastically deformed by the foaming pressure at the time of molding the foam 7, pressed against the small gap C side, and pressed against the inner peripheral wall 9 b of the base material 5.

The above sealing means is shown in FIG.
It may be configured as shown in FIG. The sealing means shown in FIG. 4 (a) is constituted by the front end portion of the edge portion 11 of the skin 3, and the sealing portion 11a comprising the front end portion is provided.
Is provided with a thin hinge portion 11b. Accordingly, the seal portion 11a can be easily bent with the thin hinge portion 11b as a fulcrum, as shown by the imaginary line in FIG. Due to the ease with which the seal portion 11a bends, poor sealing can be prevented.

The sealing means shown in FIG. 4 (b) is constituted by the front end portion of the edge 11 of the skin 3, and the thickness of the seal portion 11a formed by the front end portion is as follows.
It is set to be thinner than that of the base end portion of the edge portion 11. Thus, the seal portion 11a can be easily bent with the base end as a fulcrum, as shown by a virtual line in FIG. 4B. Due to the ease with which the seal portion 11a bends, poor sealing can be prevented.

The skin 3 in which the seal portions 11a are integrated can be easily formed by a slash molding method.

Next, a method of manufacturing the instrument panel 1 configured as described above will be described.

First, as shown in FIG. 2, a molding die 25 including an upper die 21 and a lower die 23 is prepared. Then, the upper mold 21 is pivoted upward with the hinge 27 as a fulcrum to open the mold 25, and in the state where the mold 25 is opened, the skin 3 previously formed into a predetermined shape by a slash molding method or the like. The mold 25 is set on the lower mold 23. A sealing material 13 is joined to the back side of the edge 11 of the skin 3. On the other hand, the base material 5 previously formed into a predetermined shape by an injection molding method or the like is set in the upper mold 21 of the molding die 25.

Next, an injection head 29 is arranged above the lower die 23, and the injection head 29 is used to place the skin 3 of the lower die 23 on the lower die 23.
The foamed resin material R is poured on the top.

Thereafter, as shown in FIG.
Is closed with respect to the lower mold 23, and the molding die 25 is clamped. A small gap C is formed between the tip of the edge portion 11 of the skin 3 and the inner peripheral wall 9b of the base material 5. So as to contact the outer peripheral wall 9a of the base material 5 as described above.

Thereafter, the foamed resin material R is foamed to form a foam 7. At this time, the sealing material 13
Is elastically deformed by the foaming pressure at the time of molding the foam 7, pressed against the small gap C side, and pressed against the inner peripheral wall portion 9 b of the base material 5.

This prevents the foaming resin material R from intruding between the edge 11 of the skin 3 and the base material 5 due to the foaming pressure due to the elastic deformation of the sealing material 13. It is possible to prevent the raw material R from leaking to the outside and eliminate the generation of burrs. Therefore, the appearance of the surface of the formed instrument panel 1 can be prevented from being contaminated by burrs. Further, the need for a deburring step is eliminated, and workability can be improved.

Further, the sealing material 13 is connected to the edge 11 of the skin 3.
Since the foaming pressure acts in the direction of strengthening the joining, the sealing material 13
Can be prevented from peeling off.

After the foaming resin material R has been cured, the upper mold 21 is rotated upward about the hinge 27 to open the mold, and the molded instrument panel 1 is removed.

(Embodiment 2) FIG. 5 shows an instrument panel 1 as an epidermis-integrated foamed resin molded product according to Embodiment 2 of the present invention. The fifth embodiment has the same configuration as that of the first embodiment except that the shape of the fifth embodiment is slightly different from that of the first embodiment. In other words, on the outer periphery of the foam 7 forming region of the base material 5 of the present example, a rising portion which rises upward from the inside thereof is formed, contrary to the first embodiment, and the rising portion is the outer peripheral wall portion 9a. And an inner peripheral wall 9b orthogonal to the outer peripheral wall 9a and an inner peripheral wall 9b.
Therefore, in this example, the same components as those in the first embodiment are denoted by the same reference numerals, and detailed description thereof will be omitted. However, since the manufacturing method is different from that of the first embodiment, the manufacturing method of this example will be described below.

First, as shown in FIG. 6, a molding die 25 including an upper die 21 and a lower die 23 is prepared. Then, the upper mold 21 is pivoted upward with the hinge 27 as a fulcrum to open the mold 25, and in the state where the mold 25 is opened, the skin 3 previously formed into a predetermined shape by a slash molding method or the like. The mold 25 is set on the lower mold 23. At this time, considering the shape of the instrument panel 1 to be molded, the lower mold 2
As in the first embodiment, there is no side wall for supporting the edge 11 of the skin 3 on the outer periphery of the forming surface of the lower surface 3, and therefore, the supporting plate 31 is moved back and forth with respect to the forming surface of the lower die 23 by the expansion and contraction operation of the cylinder 33. The supporting plate 31 is protruded by the extension operation of the cylinder 33 so that the edge 11 of the skin 3
From outside so that it does not fall over. It is to be noted that the sealing material 13 is joined to the edge 11 of the skin 3 as in the first embodiment. On the other hand, the base material 5 previously formed into a predetermined shape by an injection molding method or the like is placed in the molding die 25.
Is set on the upper mold 21.

Next, the upper mold 21 is rotated downward with the hinge 27 as a fulcrum, and closed with respect to the lower mold 23 to form the mold 2.
5 is clamped, and the edge 11 of the skin 3 is fixed to the outer peripheral wall of the base material 5 so that a small gap C is formed between the tip and the inner peripheral wall 9b of the base material 5. It is brought into contact with the portion 9a.

Thereafter, as shown in FIG. 7, a foamed resin raw material R was injected between the base material 5 and the skin 3 through the injection hole 5a of the base material 5 from an injection head 29 provided in the upper die 21. Then, as shown in FIG. 8, the support plate 31 is retracted by the contraction operation of the cylinder 33, the foamed resin material R is foamed in the retracted state, and the sealing material 13 is foamed by the foaming pressure at the time of molding the foam 7. The base material 5 is elastically deformed and pressed against the small gap C to be pressed against the inner peripheral wall 9 b of the base material 5.

Thereafter, after the foaming resin material R is cured, the upper mold 21 is rotated upward with the hinge 27 as a fulcrum to open the mold, and the molded instrument panel 1 is removed.

Therefore, in this example, the same operation and effect as those of the first embodiment can be obtained.

Also in this embodiment, the sealing means is replaced by a seal member 13 which is a member separate from the edge 11 of the skin 3.
As shown in FIG. 4 (a), it is constituted by the distal end portion of the edge 11 of the skin 3, and a thin hinge portion 11b is provided at the base end of the seal portion 11a, or as shown in FIG. 4 (b). As described above, the outer skin 3 may be constituted by the thin seal portion 11a formed by the front end portion of the edge portion 11.

[0045]

As described above, according to the present invention,
The sealing means provided at the edge of the skin is elastically deformed by the foaming pressure at the time of molding the foam, and the sealing means is provided on the side of the small gap formed between the edge of the skin and the outer peripheral wall of the base material. Since it is pressed against and pressed against the inner peripheral wall of the base material, it is possible to prevent leakage of the foamed resin raw material to the outside of the mold so that burrs do not occur, and it is possible to make a molded article with good appearance without contamination. In addition, the workability can be improved by the absence of the deburring step.

[Brief description of the drawings]

FIG. 1 is a cross-sectional view of an instrument panel as a skin-integrated foamed resin molded product according to Embodiment 1 of the present invention, corresponding to a cross-sectional view taken along line AA of FIG.

FIG. 2 is a cross-sectional view showing a step of injecting a foamed resin material into a mold in an open state in a method of manufacturing an instrument panel as a skin-integrated foamed resin molded product according to Embodiment 1 of the present invention.

FIG. 3 is a cross-sectional view showing a step of foaming and curing a foamed resin material in a mold in a mold-clamped state in a method of manufacturing an instrument panel as a skin-integrated foamed resin molded article according to Embodiment 1 of the present invention. is there.

FIG. 4A is an enlarged view showing a modified example of a skin edge portion;
(B) is an enlarged view which shows another modification of a skin edge part.

FIG. 5 is a cross-sectional view of an instrument panel as a skin-integrated foamed resin molded product according to Embodiment 2 of the present invention, corresponding to a cross-sectional view taken along line BB of FIG.

FIG. 6 is a cross-sectional view showing a step of setting a skin and a base material in a mold in an open state in a method of manufacturing an instrument panel as a skin-integrated foamed resin molded product according to Embodiment 2 of the present invention. .

FIG. 7 is a cross-sectional view showing a step of injecting a foamed resin material into a molding die in a closed state in a method of manufacturing an instrument panel as a skin-integrated foamed resin molded product according to Embodiment 2 of the present invention.

FIG. 8 is a cross-sectional view showing a step of retracting a support plate after injecting a foamed resin material in a method of manufacturing an instrument panel as a skin-integrated foamed resin molded product according to Embodiment 2 of the present invention.

FIG. 9 is a perspective view of an instrument panel.

[Explanation of symbols]

Reference Signs List 1 instrument panel (skin-integrated foam resin molded product) 3 skin 5 base material 5a injection hole 7 foam 9 peripheral wall 9a outer peripheral wall 9b inner peripheral wall 11 edge 11a sealing part (sealing means) 11b thin hinge Part 13 Sealing material (seal means) 21 Upper die 23 Lower die 25 Mold 29 Injection head C Small gap R Foam resin material

Continuation of front page (58) Field surveyed (Int. Cl. ⁷ , DB name) B29C 39/00-39/44 B29C 33/00-33/76

Claims (7)

(57) [Claims] 1. A skin-integrated foamed resin molded article in which a foam is integrally molded between a skin and a base material, wherein an outer peripheral wall portion and the outer periphery are provided on the outer periphery of the foam molding region of the base material. Section L composed of the leaning wall and the inner circumferential leaning wall orthogonal to the leaning wall
A meandering peripheral wall is formed. On the other hand, a flexible sealing means is provided at an edge portion of the skin, and the edge portion of the skin has a tip and an inner peripheral wall portion of the base material. The sealing means is elastically deformed by the foaming pressure during foam molding and pressed against the small gap side so that a small gap is formed therebetween. A skin-integrated foamed resin molded product which is pressed against an inner peripheral wall portion of a base material. 2. The sealing device according to claim 1, wherein the sealing means is formed of a sealing material that is a separate member from the skin, and the sealing material is joined to a back surface of an edge portion of the skin. Skin-integrated foam resin molded product. 3. The skin according to claim 2, wherein the sealing means is made of a foamed resin material having open cells that allows passage of gas generated during molding of the foam, while preventing passage of the foamed resin raw material. One-piece foam resin molded product. 4. The sealing means comprises a distal end portion of an edge portion of the skin, and a thin hinge portion is provided at a base end of the seal portion including the distal end portion. Item 2. A foam-integrated resin molded article of the skin according to Item 1. 5. The sealing means comprises a distal end portion of an edge portion of the skin, and a thickness of a seal portion formed by the distal portion is set to be thinner than that of a proximal end portion of the edge portion. The molded article of foam integrated with skin according to claim 1, characterized in that: 6. A method for producing a skin-integrated foamed resin molded product according to any one of claims 1 to 5, wherein a skin previously molded into a predetermined shape in a mold opening state of the molding die is formed. After setting the base material previously molded into a predetermined shape in the upper mold, the upper mold is closed with respect to the lower mold, the mold is clamped, and the edge of the skin is set. The base portion is brought into contact with the outer peripheral wall portion of the base material such that a small gap is formed between the tip and the inner peripheral wall portion of the base material, and then the injection head provided on the upper mold The foamed resin raw material is injected between the base material and the skin through the injection hole of the base material and foamed, and the sealing means is elastically deformed by the foaming pressure at the time of foam molding and pressed against the small gap side. A method for producing a molded article of skin-integrated foamed resin, which is brought into pressure contact with the inner peripheral wall of a substrate. . 7. A method for producing a skin-integrated foamed resin molded product according to any one of claims 1 to 5, wherein the skin molded in a predetermined shape in advance with the mold open is provided. While setting in the lower mold, after setting the base material previously molded into a predetermined shape in the upper mold, the foamed resin material is injected from the injection head onto the skin of the lower mold, and then the upper mold is removed. Close the lower mold and close the mold, and close the edge of the skin to the inside of the base so that a small gap is formed between the tip and the inner peripheral wall of the base. Then, the foamed resin material is foamed, and the sealing means is elastically deformed by the foaming pressure at the time of molding the foam, pressed against the small gap side, and pressed against the outer peripheral wall of the base material. A method for producing a skin-integrated foamed resin molded product, comprising: pressing the molded product.