JP3767982B2 - Foam molded article having opening and method for forming opening - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a foam molded article having an opening and a method for forming the opening.
[0002]
[Prior art]
Some foamed molded products in which a skin is laminated on a base material through a foam have a component mounting opening O as seen in an automotive instrument panel shown in FIG. The opening O is fitted with a register of an air conditioner outlet.
[0003]
Conventionally, there are several methods for forming the opening portion O, but a method of forming the opening portion O in a subsequent step is generally used for a foam molded product formed by a known skin integral foam molding method or the like. That is, as shown in FIG. 7, the periphery of the opening removal scheduled portion 55 of the foam molded product 50 molded by the skin integral foam molding method or the like is cut by a known cutting means such as a water jet, hot press, cold press, etc. A method of forming a desired opening O by cutting from the skin 53 toward the base 51 and removing the opening removal scheduled portion 55 is the mainstream. Reference numeral 52 is a foam.
[0004]
Further, as shown in FIG. 8, the component 60 fitted into the component mounting opening O of the foamed molded product 50 is provided with a required number of locking claws 61 on the side, and the component mounting opening. When the component 60 is fitted into the portion O, the locking claw 61 is locked to the back surface of the opening peripheral edge Oa of the base 51, and the outer peripheral flange 62 formed on the outer end side of the component 60 and the locking claw By clamping the peripheral edge of the component mounting opening O with 61, the component 60 can be fixed and prevented from falling off.
[0005]
However, the formation of the component mounting opening O by the cutting means has a low accuracy and easily causes a dimensional error. For example, in the water jet method, it is inevitable that an error of about 0.5 mm occurs on one side of the cutting line. Also, in a press method such as hot press or cold press, the part to be removed for opening of the foam molded product is pressed and cut with a blade. At that time, the cutting part, that is, the periphery of the opening is pushed in the pressing direction. It was crushed and easily deformed.
[0006]
The dimensional error and low accuracy of the opening caused by such cutting are shown in FIG. 8 when the component 60 is fitted in the component mounting opening O and fixed to fix the component 60 as shown in FIG. However, it is difficult to engage with the peripheral edge Oa of the opening of the base material 51, or the engagement becomes shallow and the component 60 is easily detached from the component mounting opening O.
[0007]
In particular, the opening peripheral edge Oa of the base material 51 is made of a material having higher rigidity than the skin 53, and therefore has a higher rigidity than the opening peripheral edge of the skin 53. This is a part where the positive pawl 61 can be reliably locked and the parts can be fixed. Therefore, the dimensional error or deformation of the opening edge periphery Oa of the base material 51 due to the cutting has a much larger influence on the fixing of the component 60 than the dimensional error or deformation of the opening edge periphery on the skin 53 side.
[0008]
Furthermore, when the hardness is reduced due to deterioration of the foam 52 due to a change with time, heat in the vehicle, or the like, resulting in a decrease in the thickness of the peripheral edge Oa of the opening, the locking claws 61 and the outer peripheral flange 62 of the part are formed. There is also a problem that the clamping force of the opening peripheral edge Oa is reduced, and the component 60 is likely to be detached from the component mounting opening O, and problems such as rattling are likely to occur.
[0009]
[Problems to be solved by the invention]
The present invention has been made in view of the above points, and securely inserts a part into an opening formed by cutting and removing without being affected by low accuracy at the time of cutting, and reliably over a long period of time. It is an object of the present invention to provide a foamed molded product that can lock and fix a component and a method of forming an opening thereof.
[0010]
[Means for Solving the Problems]
That is, the invention of claim 1 has a component mounting opening formed by a cutting means such as a press in a required portion of a foam molded product in which a skin is laminated on a base material via a foam, and the component mounting The locking claw formed on the side of the component fitted into the opening for the component is locked to the back side of the peripheral edge of the opening of the component mounting opening, and the periphery of the component mounting opening is In the foam molded product having a structure sandwiched between the side portions, a bent piece bent toward the skin side at a position corresponding to the locking claw is inclined toward the inner side of the opening portion of the base material at the periphery of the opening portion of the base material. A base portion of the bent piece is formed as a locking portion with a locking claw, and a skin-side end portion of the bent piece is at a cutting line position of the opening of the base material.
[0011]
According to the invention of claim 2, there is provided a part mounting opening used for fitting a part by removing a part to be removed for opening of a foam molded product in which a skin is laminated on a base material through a foam by cutting around the periphery. In the forming method, the base member is previously projected on the cut line of the base portion for opening removal of the base member, corresponding to the position of the locking claw formed on the side portion of the component, and projecting toward the skin side. The portion is formed in a hollow shape that opens on the back side of the base material, and is cut so as to divide the convex portion of the base material at the time of cutting and removing the portion to be removed for opening of the foamed molded product. The bent piece constituted by the wall portion is left on the periphery of the opening of the base material, and the base portion of the bent piece is used as a locking portion with the locking claw.
[0012]
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, the present invention will be described in detail with reference to the accompanying drawings.
FIG. 1 is a cross-sectional view of a foamed molded product according to one embodiment of the present invention after the parts are mounted on the opening, FIG. 2 is a plan view of the back of the opening of the embodiment shown in FIG. FIG. 4 is a perspective view showing the vicinity of the opening of the substrate by removing the foam and the skin in the embodiment shown in FIG. 1, and FIG. 4 is the removal for opening of the foam molded product in one embodiment of the opening forming method of the present invention. FIG. 5 is a partially cutaway perspective view showing the planned opening removal portion of the base material used in the foamed molded product.
[0013]
First, an embodiment of the foam molded article of the invention of claim 1 will be described with reference to FIGS. The illustrated foam molded article 10 is obtained by laminating a skin 31 on a base material 11 with a foam 21 interposed therebetween, and is integrated by a skin integral foam molding method or the like. This foam molded product has a component mounting opening O formed by cutting and removing the opening removal planned portion 35 (shown in FIG. 4) by a known cutting means such as a water jet or a press after the integration. The desired part 41 is fitted into the opening O at a required position. The opening O has a shape substantially equal to the outer peripheral shape of the component 41. Further, in this example, the periphery of the opening O has a stepped shape that is recessed toward the back side of the foam molded product 10 so that the outer surface of the component 41 and the surface 33 of the foam molded product 10 are flush with each other.
[0014]
The component 41 is formed according to the use of a foam molded product such as a register of an automobile air conditioner, and an outer peripheral flange portion 43 is formed on the outer end side of the case 42. Locking claws 44 project from the outer peripheral flange portion 43 at a predetermined interval at a position separated by a distance corresponding to the peripheral thickness of the component mounting opening O of the foam molded product. The case 42 in this example has a rectangular shape when viewed from the front, and a total of four locking claws 44 project outwardly on a pair of opposing side surfaces.
[0015]
The base material 11 is for maintaining the shape of the foamed molded product 10 and imparting rigidity. In this example, the base material 11 is formed into a molded product shape by injection molding, and after being integrated with the foam 21 and the skin 31. The base material opening 12 formed by cutting and removing the base material opening planned removal portion 12A (shown in FIG. 5) described later, and the bent piece formed on the periphery of the base material opening 12 by the cutting and removing 13. FIG. 3 shows the opening 12 of the base material 11 without the foam 21 and the skin 31.
[0016]
The bent piece 13 is formed to bend toward the skin 31 at a position corresponding to the locking claw 44 of the component 41 at the periphery of the opening 12 of the base material, and the skin side end 13 a is the base 12 opening 12. This is the cutting line position. The bent piece 13 is inclined to the inside of the opening 12 of the base material, the base portion 13b of the bent piece 13 is positioned outward from the position of the cutting line 16 of the opening portion 12 of the base material, and the base portion 13b is locked. It is the latching | locking part 14 which the nail | claw 44 latches. Therefore, the locking portion 14 is not cut by the cutting means when cutting the foam molded article 10 when the opening O is formed, and the original locking effect can be maintained without changing the size or shape. .
[0017]
The foam 21 is for imparting buffering properties to the foam molded article 10 and is made of polyurethane foam or the like. An opening 22 is formed in the foam 21. The opening 22 of the foam is formed together with the opening 12 of the base material 11 and the opening 32 of the skin 31 described later by cutting and removing after the integration.
[0018]
The skin 31 is made of an appropriate material such as a thermoplastic resin such as vinyl chloride resin or a fabric, and is formed into a molded product shape by injection molding, powder slush molding, sewing, or the like. This skin 31 has an opening 32 formed by cutting and removing after the integration, and the skin opening 32, the opening 12 of the substrate 11, and the opening 22 of the foam 21 are components. A mounting opening O is formed.
[0019]
The component 41 is inserted and fitted into the opening O of the foam molded article 10 having the above-described configuration. At that time, the locking claw 44 of the component 41 is locked to the locking portion 14 of the bent piece 13 at the periphery of the opening of the base material 11, while the outer peripheral flange portion 43 of the component 41 is the opening of the skin 31. Abutting on the front side of the periphery of the portion 33, the periphery of the opening O of the foam molded product is sandwiched between the locking claw 44 and the outer peripheral flange portion 43. As described above, the locking portion 14 of the bent piece 13 of the base material is not cut by the cutting means when the opening O is formed, and thus has the original size and shape, and reliably locks the locking claw 44. The component 41 is firmly fixed. Further, even when the hardness decreases due to deterioration of the foam 21 and the thickness may decrease at the periphery of the opening O of the foam molded article 10, the skin-side end portion 13 a of the bent piece 13 is open to the opening 32 of the skin 31. Since the thickness of the periphery of the opening O is prevented from decreasing by contacting the back side of the periphery, it is possible to maintain strong clamping and fixing of the periphery of the opening O by the locking claw 44 and the outer peripheral flange 43 of the component 41, and the component 41 can be detached or rattled. Can be prevented. In particular, in order to enhance this effect, it is preferable that the skin side end portion 13 a of the bent piece 13 is positioned near the skin 31.
[0020]
Next, an embodiment of a method for forming the component mounting opening O of the foam molded product 10 will be described with reference to FIGS. In addition, about the member of the same name as what was demonstrated in the Example of the foaming molded article 10 which has the said opening part, although it shows using the same code | symbol, in order to distinguish before and after formation of an opening part, the member before opening part formation Is shown with the letter A.
[0021]
The opening O is formed by cutting the opening removal planned portion 35 from the foam molded product 10A in which the base material 11A, the foam 21A and the skin 31A are integrated by a known skin integral foam molding method or the like. Is the method.
[0022]
The base material 11A before the opening O is formed is an injection-molded product in this example, and is made to correspond to the position of the locking claw 44 of the component 44 on the cutting line 16 of the base material opening removal planned portion 12A. Thus, the convex portion 15 protruding to the skin 31A side is formed in a hollow shape that opens on the back surface side of the base material 11A (the back surface side of the foam molded product). The convex portion 15 has a trapezoidal cross-sectional shape in which the wall portions 15a and 15b facing each other across the cutting line 16 of the opening removal planned portion 12A are inclined to the inside of the opening removal planned portion 12A. The base portion of the wall portion 15a that is outside the opening removal planned portion 12A serves as a locking portion 14 for the locking claw 44 of the component 41. The foam 21A and the skin 11A before the opening is formed are made of the materials described in the embodiment of the foam molded article 10 having the opening O. Reference numeral 22A denotes a foam opening removal scheduled portion, and 32A denotes a skin opening removal planned portion.
[0023]
The component mounting opening O is formed on the foamed molded article 10A having the convex portion 15 formed on the base material 11A by a cutting means such as a water jet method or a press method as in the prior art. The part to be cut off is the opening removal planned portion 35 of the foam molded article 10A shown in FIG. 4, and a cutting line 36 (passing through the substrate cutting line 16) around the opening removal planned portion 35 is cut. And an opening O is formed.
[0024]
At that time, the convex portion 15 existing on the cutting line 16 of the opening removal planned portion 12A of the substrate 11A is divided, and the wall portion 15a outside the planned opening removal portion 12A of the convex portion 15 is shown in FIG. As shown, it remains on the periphery of the opening 12 of the substrate as a bent piece 13 bent toward the skin 31 side. Further, at the time of cutting, the locking portion 14 of the base portion of the wall portion 15a (bending piece 13) of the convex portion 15 is in a position that is recessed to the outside of the opening removal planned portion 12A from the cutting line 16 of the base material 10A. Therefore, it can cut | disconnect so that a press blade etc. may not contact the latching | locking part 14, and the high precision before a cutting | disconnection can be maintained.
[0025]
Although it is conceivable that the opening 12 and the bent piece 13 of the base material 11 are formed in advance by injection molding at the time of molding the base material 11, some disadvantages are caused by this method. First, forming such a large opening 12 at the time of molding the base material 11 increases errors caused by various conditions at the time of injection molding, and it is not easy to manage the molding conditions to obtain the required opening dimensions. Moreover, since the locking portion 14 at the base of the bent piece 13 at the periphery of the opening 12 where the component 41 is locked is required to have accuracy, a dimensional error is a big problem. Further, when trying to perform integral foam molding using the base material 11 having such a large opening 12, it is difficult to completely seal the large opening 12. Not only is the waste of the raw material P increased, but an extra work of removing burrs formed by leakage is required. On the other hand, according to the method of the present invention, such a problem does not occur.
[0026]
【The invention's effect】
As illustrated and described above, according to the foamed molded product having an opening of the present invention and the method of forming the opening, the locking portion for the locking claw of the component is formed by a press or the like with low dimensional accuracy. Since the position is recessed outward from the cutting line of the opening of the base material to be cut, the locking portion is not cut by a press blade or the like when the opening is cut, and the dimensional accuracy of the locking portion may be reduced. Absent. Furthermore, since the bending thickness provided at the periphery of the opening of the base material can prevent a decrease in the thickness of the periphery of the opening due to a decrease in hardness due to deterioration or the like of the foam molded product, The fitting and locking of the component to the part can be performed accurately and reliably over a long period of time, and rattling of the component can be prevented.
[Brief description of the drawings]
FIG. 1 is a cross-sectional view of a foamed molded product according to an embodiment of the present invention after a component is mounted on an opening.
FIG. 2 is a plan view showing the back surface of the opening before mounting the component in the embodiment shown in FIG.
FIG. 3 is a perspective view showing the vicinity of the opening of the base material, excluding the foam and the skin, for the embodiment shown in FIG. 1;
FIG. 4 is a cross-sectional view showing an opening removal scheduled portion of a foam molded article in one embodiment of the opening forming method of the present invention.
FIG. 5 is a partially cutaway perspective view showing the surface of an opening removal scheduled portion of a base material used in the foam molded article.
FIG. 6 is a perspective view of an instrument panel having an opening.
FIG. 7 is a cross-sectional view of a part to be removed for opening of a conventional foam molded article.
FIG. 8 is a cross-sectional view showing a state in which a part is fitted into the opening.
[Explanation of symbols]
DESCRIPTION OF SYMBOLS 10 Foam molded article 11 Base material 12 Base material opening part 12A Base material opening scheduled removal part 13 Bending piece 14 Locking part 15 Convex part 16 Base material cutting line 21 Foam 22A Foam opening removal target part 31 Epidermis 32A Opening scheduled portion for opening of skin 35 Opening scheduled removal portion for foam molded product 41 Parts 44 Locking claw O Opening

Claims (2)

The side of a component that has a component mounting opening formed by a cutting means such as a press in a required portion of a foam molded product in which a skin is laminated on a base material via a foam, and is fitted into the component mounting opening Foam molding with a structure in which the latching claw formed in the part is latched to the back side of the peripheral part of the opening part of the base of the part mounting opening, and the peripheral part of the part mounting opening is sandwiched by the side part of the part Product
On the periphery of the opening of the base material, a bent piece bent toward the skin side at a position corresponding to the locking claw is inclined toward the inside of the opening of the base material, and the base of the bent piece is engaged with the locking claw. A foam-molded article having an opening, which is formed as a stop, and an end portion on the skin side of the bent piece is located at a cutting line position of the opening of the base material. In the method of forming the component mounting opening used for fitting the component by removing the opening planned removal portion of the foam molded product in which the skin is laminated via the foam on the base material by cutting around the periphery,
A convex portion that protrudes toward the skin side in advance in correspondence with the position of the locking claw formed on the side portion of the component on the cutting line of the opening scheduled removal portion of the base material on the base material in advance. It is formed in a hollow shape that opens on the side, and is cut and divided so as to divide the convex portion of the base material at the time of cutting and removing the opening removal planned portion of the foam molded product, and is configured by the wall portion of the convex portion A method for forming an opening of a foam molded article, wherein the bent piece is left on the periphery of the opening of the base material, and the base of the bent piece is used as a locking portion with the locking claw.

Images