JP3877566B2

JP3877566B2 - Skin integrated foam molded product, method for producing the skin, and method for producing the skin integral foam molded product

Info

Publication number: JP3877566B2
Application number: JP2001312722A
Authority: JP
Inventors: 和人都築
Original assignee: Inoac Corp
Current assignee: Inoac Corp
Priority date: 2001-10-10
Filing date: 2001-10-10
Publication date: 2007-02-07
Anticipated expiration: 2021-10-10
Also published as: JP2003117928A

Description

【０００１】
【発明の属する技術分野】
この発明は、表皮一体発泡成形品、その表皮の製造方法及び表皮一体発泡成形品の製造方法に関する。
【０００２】
【従来の技術】
自動車のインストルメントパネルやその他の自動車内装材等においては、プラスチック製コアとプラスチック製表皮を発泡成形型の型内に配置し、前記コアと表皮間でポリウレタン等の液状発泡原料を発泡させて、コア表面に発泡体と該発泡体を覆う表皮を一体に形成した表皮一体発泡成形品が多用されている。また、前記表皮一体発泡成形品には、図２１及びその断面図である図２２に示すように前記発泡体が表皮で覆われたパット６２をコア６１の表面の一部に有する部分パッドタイプのものが、自動車の種類や内装デザイン等に応じてしばしば用いられている。
【０００３】
前記部分パッドタイプの表皮一体発泡成形品６０はコア６１表面の所要部に凹部６３が形成され、該凹部６３内に発泡体７０の表面が表皮６６で覆われたパッド６２が設けられた構造からなる。前記表皮６６の意匠面６７周縁の少なくとも一部は表皮裏側へ折れ曲がってシール用側面６８とされ、該シール用側面６８の外面が前記コア６１の凹部６３の側壁６４内面６５と当接している。
【０００４】
前記部分パッドタイプの表皮一体発泡成形品の製造は、図２３に示すように、発泡成形型７５の上型７６に前記コア６１を凹部６３内底面が下型７７を向くように配置し、他方、下型７７に前記表皮６６を意匠面６７の裏側６７ａがコア６１の凹部６３内底面６３ａを向くように配置し、前記表皮６６とコア６１との間に液状発泡原料Ｌを注入して前記発泡体７０を発泡成形することによりなされている。その際、前記表皮６６のシール用側面６８は、コア６１の凹部６３の側壁６４内面６５と対向するようにして配置され、前記液状発泡原料Ｌの発泡によって増大する型内圧力、及び型内に充満する液状発泡原料Ｌ（発泡体）により外向きに押圧されて凹部６３の側壁内面６５に圧着し、それによって表皮周縁をシールして液状発泡原料が表皮周縁から意匠面側へバリとなって漏出するのを防止する。なお、図示の符号６１ａは予めコア６１に形成された原料注入孔、７８は原料注入ヘッド、７８ａは原料注入ヘッドの先端、７９は予め上型７６に形成された原料注入ヘッド先端を挿入するための挿入孔を表す。
【０００５】
ところで、前記部分パッドタイプの表皮一体発泡成形品の製造にあっては、液状発泡原料Ｌが前記表皮６６のシール用側面６８とコア６１の凹部６３の側壁内面６５間から漏出して、表皮６６の意匠面６７にバリが付着し易いといった問題がある。
【０００６】
そこで、図２４に示すように、前記シール用側面６８の自由端６９と基部７０Ａとの中間位置に断面コの字形状の凹溝７１を設けた表皮７２を用いることが提案されている。その場合、前記シール用側面６８における凹溝７１両側、すなわち自由端６９側と基部７０Ａ側をコア６１の凹部６３側壁６４内面６５に密着させてシールし、前記表皮７２のシール用側面６８とコアの凹部側壁内面６５間に侵入する発泡原料については表皮の凹溝７１に収容して、それ以上表皮７２の意匠面側へ漏出しないようにされる。
【０００７】
しかし、前記凹溝７１に収容される発泡原料の量が多いと、表皮７２はシール用側面６８の基部７０Ａを支点として、シール用側面６８がコア６１の凹部６３内方へ変形し、それによって生じるシール用側面６８とコアの凹部側壁内６５間の隙間から表皮７２の意匠面に発泡原料が漏出することがある。
【０００８】
さらに、前記シール用側面６８の隙間による漏出量を少しでも減らすためには、コアの凹部６３の側壁内面６５と重なるシール用側面６８の長さｄを長くする必要があり、その結果、発泡成形品の設計に制約を受け、デザイン等の自由度が少なくなる問題が発生する。また、前記シール用側面６８は凹溝７１両側の部分６８ａ，６８ｂが面一に成形されているため、表皮一体発泡成形時に表皮のシール用側面６８とコアの凹部側壁内面６５間に僅かな位置ずれがあっても発泡原料がシール用側面６８とコアの凹部側壁内面６５間から漏出し易くなる。したがって、表皮一体発泡成形時における表皮とコアの位置精度を厳しく行う必要があり、製造作業が面倒になる。しかも、作業にはバラツキが避けられないため、一定して正確な位置精度を得るのは極めて難しかった。
【０００９】
また、近年では、図２５に示すように、前記シール用側面６８に薄肉ヒンジ部６８ｃを一カ所設けて断面略くの字形状にしたもの、さらには薄肉ヒンジ部６８ｃより先端側６８ｄを薄くしたものが提案されている。しかし、このものにあっては、前記薄肉ヒンジ部６８ｃより先端側６８ｄが波打ちやすく、シール側面６８が充分にそのシール効果を発揮できないことがある。さらに、前記薄肉ヒンジ部６８ｃにおいては、前記表皮のシール用側面６８とコアの凹部側壁内面６５間に侵入する発泡原料の量が多い場合、その侵入発泡原料を確実に収容することができず、確実なシール効果が得られないおそれがある。
【００１０】
【発明が解決しようとする課題】
この発明は、前記の点に鑑み提案されたもので、表皮一体発泡成形品の製造に際して表皮のシール用側面とコアの凹部側壁間からの発泡原料の漏出を生じ難くし、しかも、表皮とコアとの位置合わせに厳密な精度が必要なく、さらに表皮一体発泡成形品の設計自由度が高くなる表皮一体発泡成形品、その表皮の簡単な製造方法及び表皮一体発泡品の製造方法を提供しようとするものである。
【００１１】
【課題を解決するための手段】
請求項１の発明は、表面に凹部が形成されたコアと、前記凹部の側壁内面に対するシール用側面が意匠面の周縁に形成されて前記意匠面裏側がコアの凹部内底面と対向するようにして該凹部内に配置されたプラスチック製表皮と、前記コアの凹部と表皮間で発泡成形された発泡体とよりなる表皮一体発泡成形品において、前記表皮のシール用側面には、複数の屈曲頂点を有し該屈曲頂点が薄肉となった拡縮変形可能な複合屈曲部が当該シール用側面裏側へ屈曲形成されていると共に、前記シール用側面の自由端がコアの凹部内面に当接又は近接していることを特徴とする。
【００１２】
また、請求項２の発明は、請求項１において、シール用側面の自由端から該自由端に最も近い屈曲頂点までの間に当該自由端に最も近い屈曲頂点よりも厚みの大なる厚肉部を設けたことを特徴とする。
【００１３】
さらに、請求項３の発明は、加熱したスラッシュ成形型の型面にプラスチックパウダーを付着させ、溶融後冷却して型面形状に賦形されたプラスチック皮膜を脱型して表皮を得るパウダースラッシュ成形法を用い、表皮一体発泡成形時のコアに対するシール用側面が表皮の意匠面周縁の少なくとも一部に形成された表皮一体発泡成形品用表皮を製造するに際し、前記スラッシュ成形型には、表皮のシール用側面を形成する型面に、該成形型内へ突出する三つ以上の頂点を有する突条を形成しておき、前記スラッシュ成形型の型面にプラスチックパウダーを付着させる際、前記突条における三つ以上の内方突出頂点でプラスチックパウダーの付着量を少なくし、前記型面に付着したプラスチックパウダーの溶融冷却後、前記各内方突出頂点で形成された三つ以上の屈曲頂点が他の部分よりも薄肉になった屈曲部分をシール用側面に有するプラスチック被膜を脱型し、その後、前記プラスチック被膜の屈曲部分における三つ以上の屈曲頂点のうち当該被膜の意匠面から最も遠い屈曲頂点で切断することによって、シール用側面裏側へ屈曲し、かつ二つ以上の屈曲頂点を有する複合屈曲部がシール用側面に形成された表皮を得ることを特徴とする表皮一体発泡成形品用表皮の製造方法に係る。
【００１４】
請求項４の発明は、加熱したスラッシュ成形型の型面にプラスチックパウダーを付着させ、溶融後冷却して型面形状に賦形されたプラスチック皮膜を脱型して表皮を得るパウダースラッシュ成形法を用い、表皮一体発泡成形時のコアに対するシール用側面が表皮の意匠面周縁の少なくとも一部に形成された表皮一体発泡成形品用表皮を製造するに際し、前記スラッシュ成形型には、表皮のシール用側面を形成する型面に、該成形型内へ突出する二つの頂点を有する断面略Ｍ字形状の突条を意匠面形成用型面と略平行に形成しておき、前記スラッシュ成形型の型面にプラスチックパウダーを付着させる際、前記突条における二つの内方突出頂点でプラスチックパウダーの付着量を少なくし、前記型面に付着したプラスチックパウダーの溶融冷却後、前記各内方突出頂点で形成された二つの屈曲頂点が他の部分よりも薄肉になった屈曲部分をシール用側面に有するプラスチック被膜を脱型し、その後、前記プラスチック被膜における該被膜の意匠面から遠い屈曲頂点よりも先端側の位置で切断することによって、シール用側面裏側へ屈曲し、かつ二つの屈曲頂点を有する複合屈曲部がシール用側面に形成された表皮を得ることを特徴とする表皮一体発泡成形品用表皮の製造方法に係る。
【００１５】
加えて、請求項５の発明は、請求項３又は４において、スラッシュ成形型の型面の突条において、複数の頂点のうち、少なくとも前記表皮の意匠面を形成する型面から最も遠い頂点が、前記表皮の意匠面を形成する型面から突条までのシール用側面を形成する型面の延長線よりもスラッシュ成形型の外方側に位置していることを特徴とする。
【００１６】
また、請求項６の発明は、コアの表面に形成された凹部と、前記凹部の側壁内面に対するシール用側面が意匠面の周縁に形成されて前記意匠面裏側がコアの凹部内底面と対向するようにして該凹部内に配置されたプラスチック製表皮との間で液状発泡原料を発泡させて、前記コア及び表皮と一体に発泡体を形成する表皮一体発泡成形品の製造方法において、前記表皮のシール用側面には、複数の屈曲頂点を有し該屈曲頂点が薄肉となった拡縮変形可能な複合屈曲部を当該シール用側面裏側へ屈曲形成しておき、前記表皮をコアの凹部に配置して前記発泡原料の発泡を行うことを特徴とする。
【００１７】
請求項７の発明は、請求項６において、シール用側面の自由端を、表皮の意匠面から複合屈曲部基部までの間のシール用側面の延長線よりも表皮外方へ突出した状態で形成しておき、前記表皮をコアの凹部内に配置した際に前記シール用側面の自由端をコアの凹部外方へ付勢した状態で凹部内壁面に圧接させることを特徴とする。
【００１８】
【発明の実施の形態】
以下添付の図面に従ってこの発明を詳細に説明する。
図１はこの発明の一実施例に係る表皮一体発泡成形品の断面図、図２は図１のＡ部分拡大断面図、図３は他の実施例に係る表皮一体発泡成形品の断面図である。図４はこの発明の表皮の製造方法に係る一実施例を示すスラッシュ成形装置の断面図、図５は図４のＢ部分拡大断面図、図６は同実施例におけるプラスチックパウダー付着時を示すスラッシュ成形装置の断面図、図７は図６のＣ部分拡大断面図、図８は同実施例における脱型後のプラスチック被膜の断面図、図９は図８のＤ部分における屈曲頂点での切断時を示す拡大断面図である。また、図１０はこの発明の表皮一体発泡成形品の製造方法に係る一実施例を示す発泡成形型の断面図、図１１は図１０のＥ部分における拡大断面図、図１２は同実施例における発泡時を示す発泡成形型の断面図、図１３は図１２のＦ部分の拡大断面図、図１４はこの発明の他の実施例に係る表皮一体発泡成形品製造時における発泡成形型の部分拡大断面図である。図１５はこの発明のさらに他の実施例の表皮の製造方法に係るスラッシュ成形装置の断面図、図１６は図１５のＧ部分拡大断面図、図１７は同実施例におけるプラスチックパウダー付着時を示すスラッシュ成形装置の断面図、図１８は図１７のＨ部分拡大断面図、図１９は同実施例における脱型後のプラスチック被膜の断面図、図２０は図１９のＩ部分における屈曲頂点より先端側での切断時を示す拡大断面図である。
【００１９】
図１及び図２に示す表皮一体発泡成形品１０は、この発明の一実施例に係るもので、従来技術の項で説明した図２１と同様の自動車のインストルメントパネルに用いられる。この表皮一体発泡成形品１０は、車両前後方向に対応する成形品前後方向の一部に、車幅方向と対応する成形品左右方向両端まで、プラスチック製コア１１の表面１２の一部にパッド２１が形成された、いわゆる部分パッド一体発泡成形品と称されるものである。
【００２０】
前記コア１１は表皮一体発泡成形品１０の本体部となるもので、所望の成形品（この例ではインストルメントパネル）形状に形成されており、表面１２のパッド２１が設けられる部分に、パッド２１の大きさに合致した凹部１３が形成されている。前記凹部１３は、周縁の少なくとも一部に側壁１４が形成され、表皮一体発泡成形品の形状や大きさ等に応じて所望の深さとされている。
【００２１】
パッド２１は、表皮２２によってポリウレタン等の発泡体３０が覆われたものからなり、前記コア１１の凹部１３に配置された表皮２２と該凹部１３の内底面１３ａ間で液状発泡原料から発泡体３０を形成することにより、表皮２２と発泡体３０が一体に形成され、かつその際の発泡体３０の接着性を利用してコア１１の凹部１３及び表皮２２と発泡体３０が接着したものである。
【００２２】
前記表皮２２は、前記コア１１の凹部１３にはまる大きさ及び形状にパウダースラッシュ成形された軟質塩化ビニル樹脂やオレフィン系熱可塑性エラストマー等のプラスチック製からなり、意匠面２３周縁の少なくとも一部には前記凹部１３の側壁１４内面１５に対するシール用側面２４が表皮２２の裏側へ屈曲形成され、表皮２２の意匠面２３裏側がコアの凹部１３内底面１３ａと対向するようにして凹部１３に配置されている。前記シール用側面２４は、パッド２１の発泡体３０を発泡成形する際にコア１１の凹部側壁内面１５と圧着してシールし、液状発泡原料が表皮２２の周縁から漏出するのを防止するものであり、コア１１の凹部側壁内面１５と対向する位置に複合屈曲部２６が形成されている。
【００２３】
前記複合屈曲部２６は、複数（この例では二つ）の屈曲頂点２６ａ，２６ｃがシール用側面裏側２５へ屈曲して該複数の屈曲頂点２６ａ，２６ｃが薄肉になったもので、前記表皮２２の意匠面２３と略平行の突条にシール用側面２４に設けられている。また、この例の複合屈曲部２６は、その自由端（開放端）２６ｂがシール用側面２４の自由端（開放端）２４ｂとなるように形成されると共に、コア１１の凹部１３内面と当接するシール部になっている。
【００２４】
前記表皮２２の複合屈曲部２６にあっては、複合屈曲部の自由端２６ｂとシール用側面の自由端２４ｂが一致しているため、表皮２２の意匠面２３からシール用側面の自由端２４ｂ（複合屈曲部の自由端２６ｂ）までの距離、すなわちシール用側面２４の長さを、従来の部分パッド表皮一体発泡成形品における表皮のシール用側面の長さよりも短くでき、表皮２２、コア１１及び表皮一体発泡成形品１０の設計自由度を高めることができる。
【００２５】
また、前記表皮２２の複合屈曲部２６にあっては、この表皮一体発泡成形品１０の製造時、発泡体３０のための発泡原料が表皮２２とコア１１の凹部１３内面間で充満し、さらに表皮２２の複合屈曲部自由端２６ｂとコアの凹部１３側壁内面１５間を通って表皮２２の意匠面２３側へ漏出しようとする場合、その漏出しようとする発泡原料を複合屈曲部２６内に収容して表皮意匠面２３まで漏出するのを防止することができる。しかも、前記表皮２２のシール用側面２４の自由端２４ｂはコアの凹部１３内面（この例では側壁内面１５）に当接又は近接した状態となり、当該シール用側面２４の自由端２４ｂとコアの凹部１３内面間から発泡原料が侵入し難くなっている。
【００２６】
さらに、前記複合屈曲部２６は、その複数の屈曲頂点２６ａ，２６ｃが薄肉となっているために拡縮変形可能性に優れる。したがって、前記シール用側面２４とコアの凹部１３側壁内面１５間に侵入する発泡原料の多い少ないによって複合屈曲部２６が変形し、前記侵入発泡原料を確実に収容保持できる。それに加えて、前記表皮２２及びコア１１の成形上のバラツキ及び表皮２２をコアの凹部１３に配置する際の位置関係のバラツキ等によって、前記シール用側面２４の自由端２４ｂがコアの凹部１３側壁内面１５と干渉する場合でも、前記複合屈曲部２６が変形してシール用側面の自由端２４ｂをコアの凹部側壁内面１５に圧接し、前記漏出を効率良く防止できる。特に、後に説明する図９に示すように、予め前記表皮２２のシール用側面２４の自由端２４ｂを、表皮２２の複合屈曲部２６と意匠面２３間のシール用側面２４ａの延長線ｍよりも表皮外方側Ｓへ突出した状態で形成しておけば、前記シール用側面２４の自由端２４ｂをコア１１の凹部１３外方へ付勢した状態でコアの凹部１３内面に圧接できるため、前記シール性がより高くなる。
【００２７】
また、前記シール用側面２４は前記複合屈曲部２６の存在によって剛性が高まっているのみならず、さらにこの例では前記シール用側面２４の自由端２４ｂから該自由端２４ｂに最も近い屈曲頂点２６ｃまでの間に、当該自由端２４ｂに最も近い屈曲頂点２６ｃよりも厚みの大なる厚肉部２６Ｇを設けたため、その厚肉部２６Ｇの存在によってシール用側面２４の自由端２４ｂ側でも剛性が高くなっている。その剛性増大により、前記シール用側面２４の波打ちをより効果的に抑えることができ、前記シール用側面２４の自由端２４ｂ側をコアの凹部１３内面に当接あるいは近接し易くなり、確実なシール効果が得られる。
【００２８】
また、図３に示す他の実施例の表皮一体発泡成形品１０Ａのように、前記構成の表皮２２をコア１１の凹部１３に配置して表皮一体発泡成形する際に、前記表皮２２の複合屈曲部２６が開いてその自由端２６ｂ側がコアの凹部１３における側壁１４間で凹部内底面１３ａに圧接した場合でも、前記複合屈曲部２６及びその自由端２６ｂ側による良好なシール性が、図１の実施例の場合と同様に得られる。そのため、表皮一体発泡成形時に表皮２２の配置にバラツキがあっても、製造された表皮一体発泡成形品１０Ａの品質が一定し、美観が良好になる。
【００２９】
前記表皮２２の製造は、公知のパウダースラッシュ成形法を利用して次のようにして行われる。図４は前記表皮の製造に用いられる一実施例のスラッシュ成形装置４０の断面図、図５はそのＢ部分の拡大断面図である。スラッシュ成形装置４０はバケット４１とスラッシュ成形型４５とよりなる。
【００３０】
前記バケット４１は、プラスチックパウダーＰを収容するもので、上方が開口した容器状に形成されている。このバケット４１の開口４２外周には、パウダースラッシュ成形型４５と合着できるように、フランジ部４２ｆが形成されている。前記プラスチックパウダーＰは、軟質塩化ビニル樹脂やオレフィン系熱可塑性エラストマー等、パウダースラッシュ成形に用いられる公知のプラスチックパウダーから適宜選択される。
【００３１】
前記スラッシュ成形型４５は電鋳型からなり、前記表皮形状の型面４６を内側に有する。符号４６ａは前記表皮の意匠面２３を形成する型面（以下意匠面形成用型面）、４６ｂは表皮のシール用側面２４を形成する型面（以下シール用側面形成用型面）である。前記シール用側面形成用型面４６ｂには、該成形型４５内へ突出する三つの頂点４９ａ〜４９ｃを有する突条４９を意匠面形成用型面４６ａから離して、且つ意匠面形成用型面４６ａと略平行方向に形成されている。なお、前記突条４９は、この例のように三つの頂点を有するものに限られず、それ以上の頂点を有するものであってもよい。また、この例では、前記突条４９の三つの頂点４９ａ〜４９ｃのうち、前記意匠面形成用型面４６ａから最も遠い位置の頂点４９ｃが、前記意匠面形成用型面４６ａと突条４９間のシール用側面を形成する型面４６ｃの延長線ｎよりも、スラッシュ成形型の外方側Ｔに位置している。前記突条４９のサイズ等は適宜とされるが、一例として前記三つの頂点４９ａ〜４９ｃにおけるｄ１が２ｍｍ、ｄ２が１．５ｍｍ、ｄ３が３ｍｍ、ｄ４が２ｍｍの場合を挙げる。
【００３２】
また、前記型面４６の外周には前記バケット４１のフランジ部４２ｆに対応するフランジ部４６ｆが設けられ、該フランジ部４６ｆを前記バケット４１のフランジ部４２ｆと合着させることにより、当該スラッシュ成形型４５がバケット４１と組み合わされる。さらに、前記スラッシュ成形型４５の外面には、パウダースラッシュ成形時に前記型面４６を所要温度に加熱するために、加熱オイル等の熱媒を循環させるパイプ等からなる加熱手段４７が適宜数設けられている。
【００３３】
このパウダースラッシュ成形装置４０は、図示しない回転機構により、前記バケット４１とスラッシュ成形型４５とを組み合わせた状態でそれらが交互に倒立するように回転可能に構成されている。
【００３４】
上記成形装置４０を用いる表皮の製造においては、公知のパウダースラッシュ成形法に従い、まず、バケット４１とスラッシュ成形型４５をクランプ等により組み合わせ、前記スラッシュ成形型４５の型面４６を加熱手段４７により加熱しながらバケット４１及び成形型４５を所要回数，所要時間回転させることにより、バケット４１内のプラスチックパウダーＰを、加熱された成形型４５の型面４６へ移動及び付着させて、図６及び図７に示すように、所要厚みのプラスチックパウダー付着層２２ａを型面４６に形成する。前記成形装置４０の回転の際、スラッシュ成形型４５が下方位置になったとき、当該成形型の型面４６では、平坦部分及び谷部分でプラスチックパウダーＰが堆積し易いのに対し、突部ではプラスチックパウダーＰが堆積し難いため、前記シール用側面形成用型面４６ｂの突条４９における三つの頂点４９ａ〜４９ｃではプラスチックパウダーＰの付着量が少なくなり、頂点４９ａ，４９ｂ間のＶ溝４９ｄ部分（谷部分）及び頂点４９ｂ，４９ｃ間のＶ溝４９ｅ部分（谷部分）でプラスチックパウダーＰの付着量が多くなる。
【００３５】
前記型面に付着したプラスチックパウダーＰが型面の熱により溶融ゲル化した後、前記加熱を停止して冷却し、前記型面４６にプラスチック被膜２２ｂを形成する。そのプラスチック被膜２２ｂは、前記突条４９における三つの頂点４９ａ〜４９ｃで形成された三つの屈曲頂点２６ａ，２６ｃ，２６ｅ（２６ｅは後の自由端２６ｂと一致）が薄肉、該屈曲頂点２６ａ，２６ｃ間の２６ｄ、屈曲頂点２６ｃ，２６ｅ間の２６ｆが厚肉となって内面が前記三つの頂点４９ａ〜４９ｃを有する突条４９と対応する形状に形成された蛇腹状凹溝２７を、前記シール用側面形成用型面４６ｂで形成されたシール用側面２４に有する。なお、前記成形型４５の型面４６の加熱温度及び回転数（加熱時間）等の成形条件は、プラスチックパウダーＰの溶融温度及び形成する表皮の厚み等を考慮して定められる。
【００３６】
前記プラスチック被膜２２ｂを脱型し、その後、図８及び図９に示すように、プラスチック被膜２２ｂの凹溝２７における三つの屈曲頂点２６ａ，２６ｃ，２６ｅのうち当該被膜２２ｂの意匠面２３から最も遠い位置の屈曲頂点２６ｅで切断して、略Ｍ字形状にシール用側面２４裏側２５へ屈曲して突出した蛇腹状の複合屈曲部２６をシール用側面２４に有する表皮２２を得る。前記屈曲頂点２６ｅの切断部はシール用側面２４の自由端２４ｂとなり、この例では複合屈曲部２６の自由端２６ｂを構成する。また、前記切断時に被膜２２ｂの屈曲頂点２６ｅで切断するため、切断位置を間違えにくく、しかも切断する屈曲頂点２６ｅが前記のように薄肉になっているため、切断し易く、切断作業が容易である。さらに、前記表皮２２はシール用側面２４の自由端２４ｂ（切断位置の屈曲頂点２６ｅ）と屈曲頂点２６ｃ間の部分２６Ｇが前記のように厚肉部となっている。
【００３７】
さらに、前記のように被膜２２ｂの凹溝２７は、屈曲頂点２６ａ，２６ｃ間の２６ｄ及び屈曲頂点２６ｃ，２６ｅ間の２６ｆのそれぞれが、前記型面の突条４９の頂点４９ａ，４９ｂ間のＶ字形状及び前記突条４９の頂点４９ｂ，４９ｃ間のＶ字形のそれぞれを反転させた三角形状に形成され、屈曲頂点２６ａ，２６ｃ間の中央位置２６ｇから屈曲頂点２６ａ，２６ｃ及び屈曲頂点２６ｃ，２６ｅ間の中央位置２６ｈから屈曲頂点２６ｃ，２６ｅに向けてそれぞれ厚みが薄くなっており、前記屈曲頂点２６ｅで切断して形成された自由端２６ｂの厚みが、凹溝２７の他の部分である前記屈曲頂点２６ａ，２６ｃの厚みよりも厚くなっているため、前記自由端２６ｂの剛性が高まる。この自由端２６ｂは前記コアの凹部１３の内面に対するシール部とされる。
【００３８】
さらにまた、前記のように被膜２２ｂの凹溝２７を形成する型面の突条４９は、該突条４９の三つの頂点４９ａ〜４９ｃのうち、前記表皮の意匠面形成用型面４６ａから最も遠い位置の頂点４９ｃが、前記意匠面形成用型面４６ａと突条４９間のシール用側面形成用型面４６ｃ延長線ｎよりも、スラッシュ成形型の外方側Ｔに位置している。そのため、前記最も遠い位置の頂点４９ｃで成形されてその後切断形成されるシール用側面の自由端２４ｂは、図９のように、表皮２２の複合屈曲部２６と意匠面２３間のシール用側面２４ａの延長線ｍよりも表皮外方側Ｓへ突出して位置することになる。
【００３９】
次に、前記表皮２２を用いる表皮一体発泡成形品１０の製造方法について、図１０ないし図１３に基づいて説明する。なお、図示の発泡成形型５０は、従来から表皮一体発泡成形に用いられているものであって、上型５１と下型５５とを備える分割式のものである。
【００４０】
図１０及び図１１に示すように、発泡成形型５０内に前記コア１１と表皮２２を配置する。コア１１は凹部１３内底面１３ａが下型５５を向くように上型５１の型面５２側に配置され、他方、表皮２２は意匠面２３の裏側がコア１１の凹部１３内底面１３ａと対向するように下型５５の型面５６側に配置される。その際、前記表皮２２のシール用側面２４は、コア１１の凹部１３の側壁１４内面１５と対向するようにして配置され、前記シール用側面２４の自由端２４ｂがコアの凹部の側壁内面１５に当接又は近接する。その際、前記シール用側面２２は複合屈曲部２６の存在により剛性が高くなるのみならず、前記厚肉部２６Ｇの存在により自由端２４ｂ側の剛性が高まるので、シール用側面２４の波打ち等の変形を防止して、シール用側面２４の自由端２４ｂを確実に凹部の側壁内面１５に当接あるいは近接させることができる。さらに前記複合屈曲部２６はその屈曲頂点２６ａ，２６ｃが薄肉になっているため、表皮２２とコア１１の製造時及び配置時に複合屈曲部２６とコアの凹部側壁１４間に位置のバラツキがあってシール用側面２４における自由端２４ｂがコアの凹部側壁１４と干渉することがあっても、複合屈曲部２６が有する薄肉の屈曲頂点２６ａ，２６ｃが変形可能性に優れる構造であるため、この構造を有する複合屈曲部２６が変形し、シール用側面２４の自由端２４ｂがコアの凹部側壁内面１５に当接又は近接することができる。
【００４１】
さらに、前記のようにシール用側面２４の自由端２４ｂが、前記複合屈曲部２６と意匠面２３間のシール用側面２４ａの延長線ｍよりも表皮２２外方へ突出して位置するように形成されているため、コア１１と表皮２２の配置時、シール用側面２４の自由端２４ｂがコアの凹部１３の側壁内面１５と干渉して自由端２４ｂ側が側壁内面１５により表皮２２内方へ押し曲げられた状態になる。しかも前記複合屈曲部２６の屈曲頂点２６ａ，２６ｃが薄肉になっているため、該複合屈曲部２６の変形可能性が優れており、前記干渉が強い場合でも複合屈曲部２６の押し曲げ変形が可能になる。そして前記押し曲げに対する反発によって、シール用側面２４の自由端２４ｂは、コアの凹部１３外方へ付勢された状態となり、コアの凹部側壁内面１５に圧着してコアの凹部側壁内面１５と表皮のシール用側面２４間をより確実にシールする。しかも、前記のように表皮２２とコア１１の位置関係にバラツキがあっても、そのバラツキをより確実に吸収できる。なお、前記発泡成形型５０へのコア１１と表皮２２の配置は、下型５５に表皮２２とコア１１を配置して発泡成形型５０を閉じる方法であっても、あるいはその他の方法であってもよく、適宜選択される。
【００４２】
続いて、前記コア１１の凹部１３内底面１３ａと表皮２２との間にポリウレタン等の液状発泡原料Ｌを所定量注入し、図１２のように、コア１１と表皮２２間で発泡体３０を発泡成形し、その際の接着性によってコア１１と表皮２２と発泡体３０が一体となった表皮一体発泡成形品１０を発泡成形型５０内に成形する。図示の符号１６は予めコア１１に形成された原料注入孔、５３は原料注入ヘッド、５３ａは原料注入ヘッド５３の先端、５４は予め上型５１に形成された原料注入ヘッド先端５３ａを挿入するための挿入孔を表す。なお、この実施例では、発泡成形型の型閉め後に液状発泡原料Ｌを原料注入ヘッド５３によって注入するクローズド注入法が採用されているが、発泡成形型の型閉め前に液状発泡原料を注入するオープン注入法を採用してもよい。
【００４３】
前記発泡成形の際、前記表皮２２のシール用側面２４は、自由端２４ｂがコアの凹部側壁内面１５と当接し、さらに該自由端２４ｂが発泡成形時の圧力でもって押圧されて、コア１１の凹部１３の側壁内面１５に圧着し、それによって前記シール用側面２４と前記凹部側壁１４間に液状発泡原料Ｌが侵入するのを阻止する。さらに前記シール用側面２４の自由端２４ｂと凹部側壁内面１５間を強引に通ってシール用側面２４と凹部側壁１４間に液状発泡原料Ｌが侵入する場合には、図１３に示すように、前記複合屈曲部２６内に発泡原料Ｌ（発泡体）を収容し、それ以上表皮２２の意匠面２３側へ漏出するのを防止する。
【００４４】
前記発泡成形後、発泡成形型５０の型開き及び成形品の脱型を行えば、図１に示した部分パッドタイプの表皮一体発泡成形品１０が得られる。
【００４５】
また、図１４のように、前記表皮２２をコア１１の凹部１３に配置する際、表皮２２の複合屈曲部２６がシール用側面２４の自由端２４ｂとコアの凹部内底面１３ａが接触して開いた場合にも、前記と同様に自由端２４ｂによるシール効果及び複合屈曲部２６内への発泡原料収容の両方によって発泡原料の漏出を防止することができる。
【００４６】
さらに、前記パウダースラッシュ成形法を利用した他の実施例に係る表皮２２の製造方法について、図１５ないし図１８を用いて説明する。図１５はこの実施例の表皮の製造に用いられるスラッシュ成形装置４０Ａ断面図、図１６はそのＧ部分の拡大断面図である。このスラッシュ成形装置４０Ａは、前述した実施例と同様のバケット４１とスラッシュ成形型４５Ａとよりなる。
【００４７】
この実施例のスラッシュ成形型４５Ａは、そのシール用側面形成用型面４６ｂに、前記成形型４５Ａ内へ突出する二つの頂点４９ｆ，４９ｇ間がＶ溝４９ｈとなった断面略Ｍ字形状の突条４９Ａを意匠面形成用型面４６ａから離して、且つ該意匠面形成用型面４６ａと略平行方向に形成されている。なお、前記Ｍ字の形は、この例のように二つの頂点４９ｆ，４９ｇが広がるように拡開する等適宜の形状とすればよい。また、この例では、前記突条４９の二つの頂点４９ｆ，４９ｇのうち、前記意匠面形成用型面４６ａから遠い位置の頂点４９ｇが、前記意匠面形成用型面４６ａと突条４９Ａ間のシール用側面を形成する型面４６ｃの延長線ｏよりも、スラッシュ成形型の外方側Ｕに位置している。前記突条４９Ａのサイズ等は適宜とされるが、一例として前記Ｖ溝４９ｈの谷から頂点４９ｆ，４９ｇまでの距離が２ｍｍ、ｄ５の値が２ｍｍ、前記延長線ｏと頂点４９ｇ間の距離ｘが１．５ｍｍの場合を挙げる。
【００４８】
この成形装置４０Ａを用いる表皮の製造においては、前述した実施例と同様に、公知のパウダースラッシュ成形法によって、図１７及び図１８に示すように、所要厚みのプラスチックパウダー付着層２２ａが型面４６に形成される。この実施例においても、スラッシュ成形型４５Ａの型面４６におけるシール用側面形成用型面４６ｂの突条４９Ａでの二つの頂点４９ｆ，４９ｇではプラスチックパウダーＰの付着量が少なく、頂点４９ｆ，４９ｇ間のＶ溝４９ｈ部分（谷部分）及び突条４９Ａの意匠面形成用型面４６ａから遠い側の基部でプラスチックパウダーＰの付着量が多くなる。
【００４９】
その後、前記型面４６に形成されたプラスチックパウダー付着層２２ａが所定の成形条件によって溶融後に冷却固化されたプラスチック被膜２２ｂは、前記突条４９Ａにおける二つの頂点４９ｆ，４９ｇで形成された二つの屈曲頂点２６Ｃ，２６Ｄが薄肉、該屈曲頂点２６Ｃ，２６Ｄ間の２６Ｅ及び前記突条４９Ａの意匠面形成用型面４６ａから遠い側の基部で形成された部分２６Ｆが厚肉となって内面が前記突条４９ＡのＭ字と対応する断面略Ｗ字形状に形成された凹溝２７を、前記シール用側面形成用型面４６ｂで形成されたシール用側面２４に有する。
【００５０】
そして、前記プラスチック被膜２２ｂを脱型後、図１９及び図２０に示すように、プラスチック被膜２２ｂの凹溝２７における二つの屈曲頂点２６Ｃ，２６Ｄのうち、当該被膜２２ｂの意匠面２３から遠い位置の屈曲頂点２６Ｄよりも表皮外方側であるＹの値が３〜４ｍｍの位置で切断し、略Ｍ字形状にシール用側面２４裏側２５へ屈曲した複合屈曲部２６をシール用側面２４に有する表皮２２を得る。前記切断部は、シール用側面２４の自由端２４ｂとなる。これにより、前記表皮２２のシール用側面２４は自由端２４ｂ側に前記厚肉部２６Ｇが存在して自由端側の剛性が高められるため、この表皮２２を用いた表示一体発泡成形品の製造においては、前記表皮２２の複合屈曲部２６によるシール用側面２４の剛性増大と、前記厚肉部２６Ｇによるシール用側面２４の自由端２４ｂ側の剛性増大により、シール用側面２４の波打ちを確実に防止でき、前記シール用側面２４がコアの凹部１３内面に発泡圧で密着し、高いシール性を発揮することができる。また、前記シール用側面２４とコアの凹部１３側壁１４間に発泡原料が侵入することがあってもその侵入した発泡原料を複合屈曲部２６に収容保持できるため、発泡原料の漏出を防止することができる。
【００５１】
【発明の効果】
以上図示し説明したように、請求項１に係る表皮一体発泡成形品の発明によれば、表皮のシール用側面が有する複合屈曲部により、表皮のシール用側面とコアの凹部側壁間を通って表皮の意匠面側へ漏出しようとする発泡原料を前記複合屈曲部に収容することができるため、表皮のシール用側面とコアの凹部側壁間からの発泡原料の漏出に起因する意匠面のバリを生じ難くでき、しかも、この表皮一体発泡成形品にあっては、表皮とコアとの位置合わせに厳密な精度が必要なくなり、さらに表皮一体発泡成形品の設計自由度が高くなるという効果が得られる。加えて、表皮のシール用側面は、前記複合屈曲部の存在によりその剛性を高めることができるため、表皮のシール用側面とコアの凹部側壁間からの発泡原料の漏出に起因する意匠面のバリを生じ難くすることができる。
【００５２】
また、請求項２に係る表皮一体発泡成形品の発明によれば、シール用側面の自由端から該自由端に最も近い屈曲頂点までの間に当該自由端に最も近い屈曲頂点よりも厚みの大なる厚肉部が設けられており、その厚肉部によりシール用側面の自由端の剛性が高められるため、前記シール用側面が有する複合屈曲部と合わせた剛性の増大により、シール用側面の波打ちを確実に防止することができ、前記シール用側面のコアの凹部側壁に対するシール性を高め、表皮のシール用側面とコアの凹部側壁間からの発泡原料の漏出に起因する意匠面のバリを生じ難くすることができる。
【００５３】
さらに、請求項３ないし５に係る表皮一体発泡成形品用表皮の製造方法の発明によれば、表皮一体発泡成形品の製造時に表皮のシール用側面とコアの凹部側壁間からの発泡原料の漏出に起因する意匠面のバリを生じ難くでき、しかも、表皮とコアとの位置合わせに厳密な精度が必要なくなり、さらに表皮一体発泡成形品の設計自由度が高くなる利点を有する表皮を容易に、かつ精度良く得ることができる。
【００５４】
加えて、請求項６及び７に係る表皮一体発泡成形品の製造方法の発明によれば、表皮のシール用側面とコアの凹部側壁間からの発泡原料の漏出に起因する意匠面のバリを生じ難くでき、しかも、表皮とコアとの位置合わせに厳密な精度が必要なくなり、さらに表皮一体発泡成形品の設計自由度が高くなるという効果が得られる。
【図面の簡単な説明】
【図１】この発明の一実施例に係る表皮一体発泡成形品の断面図である。
【図２】図１のＡ部分拡大断面図である。
【図３】他の実施例に係る表皮一体発泡成形品の断面図である。
【図４】この発明の表皮の製造方法に係る一実施例を示すスラッシュ成形装置の断面図である。
【図５】図４のＢ部分拡大断面図である。
【図６】同実施例におけるプラスチックパウダー付着時を示すスラッシュ成形装置の断面図である。
【図７】図６のＣ部分拡大断面図である。
【図８】同実施例における脱型後のプラスチック被膜の断面図である。
【図９】図８のＤ部分における屈曲頂点での切断時を示す拡大断面図である。
【図１０】この発明の表皮一体発泡成形品の製造方法に係る一実施例を示す発泡成形型の断面図である。
【図１１】図１０のＥ部分における拡大断面図である。
【図１２】同実施例における発泡時を示す発泡成形型の断面図である。
【図１３】図１２のＦ部分の拡大断面図である。
【図１４】この発明の他の実施例に係る表皮一体発泡成形品製造時における発泡成形型の部分拡大断面図である。
【図１５】この発明のさらに他の実施例の表皮の製造方法に係るスラッシュ成形装置の断面図である。
【図１６】図１５のＧ部分拡大断面図である。
【図１７】同実施例におけるプラスチックパウダー付着時を示すスラッシュ成形装置の断面図である。
【図１８】図１７のＨ部分拡大断面図である。
【図１９】同実施例における脱型後のプラスチック被膜の断面図である。
【図２０】図１９のＩ部分における屈曲頂点より先端側での切断時を示す拡大断面図である。
【図２１】従来における表皮一体発泡成形品を示す斜視図である。
【図２２】図２１の断面図である。
【図２３】従来の表皮一体発泡成形品の製造時を示す発泡成形型の断面図である。
【図２４】従来の他の例における発泡成形型の要部を示す部分断面図である。
【図２５】従来のさらに他の例における発泡成形型の要部を示す部分断面図である。
【符号の説明】
１０表皮一体発泡成形品
１１コア
１３コアの凹部
１４コアの凹部側壁
１５コアの凹部側壁内面
２１パッド
２２表皮
２３表皮の意匠面
２４表皮のシール用側面
２４ｂシール用側面の自由端
２５シール用側面裏側
２６複合屈曲部
２６Ｇ厚肉部
２６ａ，２６ｃ，２６Ｃ，２６Ｄ屈曲頂点
２６ｅ，２６Ｄ意匠面から遠い位置の屈曲頂点
３０発泡体
４０，４０Ａスラッシュ成形型
４６型面
４９突条
４９ａ，４９ｂ，４９ｃ，４９ｆ，４９ｇ内方突出頂点
４９ｃ，４９ｇ意匠面形成用型面から遠い位置の内方突出頂点
５０発泡成形型
ｎ，ｏスラッシュ成形型のシール用側面形成用型面延長線
Ｌ液状発泡原料
Ｐプラスチックパウダー[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a skin-integrated foam-molded product, a method for manufacturing the skin, and a method for manufacturing a skin-integrated foam-molded product.
[0002]
[Prior art]
In automotive instrument panels and other automotive interior materials, a plastic core and a plastic skin are placed in a foam molding mold, and a liquid foaming material such as polyurethane is foamed between the core and the skin, Skin-integrated foam-molded products in which a foam and a skin covering the foam are integrally formed on the core surface are frequently used. Further, the skin-integrated foam-molded product is of a partial pad type having a pad 62 covered with the skin as a part of the surface of the core 61 as shown in FIG. 21 and FIG. Things are often used depending on the type of car and the interior design.
[0003]
The partial pad type skin-integrated foam molded product 60 has a structure in which a concave portion 63 is formed in a required portion of the surface of the core 61 and a pad 62 in which the surface of the foam 70 is covered with a skin 66 is provided in the concave portion 63. Become. At least a part of the peripheral edge of the design surface 67 of the skin 66 is bent to the skin back side to be a sealing side surface 68, and the outer surface of the sealing side surface 68 is in contact with the inner surface 65 of the side wall 64 of the recess 63 of the core 61.
[0004]
As shown in FIG. 23, the partial pad type skin-integrated foam-molded product is manufactured by arranging the core 61 on the upper mold 76 of the foam mold 75 so that the bottom surface of the recess 63 faces the lower mold 77, The skin 66 is arranged on the lower mold 77 so that the back side 67a of the design surface 67 faces the inner bottom surface 63a of the recess 63 of the core 61, and the liquid foaming raw material L is injected between the skin 66 and the core 61. The foam 70 is formed by foam molding. At that time, the sealing side surface 68 of the skin 66 is disposed so as to face the inner surface 65 of the side wall 64 of the recess 63 of the core 61, and the pressure inside the mold increases due to the foaming of the liquid foam raw material L, and the inside of the mold. Pressed outward by the filled liquid foam raw material L (foam) and pressed against the side wall inner surface 65 of the recess 63, thereby sealing the outer periphery of the skin, and the liquid foam raw material becomes a burr from the outer periphery of the skin to the design surface side. Prevent leakage. The reference numeral 61a shown in the figure is a raw material injection hole formed in the core 61 in advance, 78 is a raw material injection head, 78a is a front end of the raw material injection head, and 79 is a tip for inserting a front end of the raw material injection head formed in the upper die 76 in advance. Represents the insertion hole.
[0005]
By the way, in the manufacture of the partial pad type skin integral foam molded product, the liquid foam raw material L leaks from between the sealing side surface 68 of the skin 66 and the side wall inner surface 65 of the recess 63 of the core 61, There is a problem that burrs are likely to adhere to the design surface 67.
[0006]
Therefore, as shown in FIG. 24, it has been proposed to use a skin 72 provided with a groove 71 having a U-shaped cross section at an intermediate position between the free end 69 of the sealing side surface 68 and the base portion 70A. In that case, both sides of the concave groove 71 in the side surface for sealing 68, that is, the free end 69 side and the base portion 70 </ b> A side are sealed to the inner surface 65 of the concave portion 63 side wall 64 of the core 61 and sealed. The foaming raw material that enters between the inner surfaces 65 of the concave side walls is accommodated in the concave grooves 71 of the outer skin, and is prevented from leaking further to the design surface side of the outer skin 72.
[0007]
However, when the amount of the foaming raw material accommodated in the concave groove 71 is large, the outer skin 72 is deformed inwardly into the concave portion 63 of the core 61 by using the base portion 70A of the sealing side surface 68 as a fulcrum, thereby Foaming raw material may leak to the design surface of the skin 72 from the gap between the sealing side surface 68 and the concave side wall 65 of the core.
[0008]
Further, in order to reduce the amount of leakage due to the gap between the sealing side surfaces 68 as much as possible, it is necessary to increase the length d of the sealing side surface 68 that overlaps the side wall inner surface 65 of the core recess 63. As a result, foam molding is performed. There is a problem that the degree of freedom of design is reduced due to restrictions on product design. Further, since the sealing side surface 68 is formed so that the portions 68a and 68b on both sides of the concave groove 71 are flush with each other, a slight position is provided between the sealing side surface 68 of the skin and the inner surface 65 of the concave side wall of the core during integral foam molding. Even if there is a deviation, the foaming material is likely to leak from between the sealing side surface 68 and the inner surface 65 of the concave side wall of the core. Therefore, it is necessary to strictly perform the positional accuracy of the skin and the core at the time of skin integral foam molding, and the manufacturing work becomes troublesome. In addition, since variations in work are inevitable, it has been extremely difficult to obtain a constant and accurate position accuracy.
[0009]
In recent years, as shown in FIG. 25, a thin hinge portion 68c is provided on the sealing side surface 68 so as to have a substantially U-shaped cross section, and the tip side 68d is made thinner than the thin hinge portion 68c. Things have been proposed. However, in this case, the tip side 68d is more likely to corrugate than the thin hinge portion 68c, and the seal side surface 68 may not sufficiently exhibit its sealing effect. Furthermore, in the thin-walled hinge portion 68c, when there is a large amount of foaming raw material that enters between the sealing side surface 68 of the skin and the inner surface 65 of the concave side wall of the core, the intruding foaming raw material cannot be reliably contained, There is a possibility that a reliable sealing effect cannot be obtained.
[0010]
[Problems to be solved by the invention]
The present invention has been proposed in view of the above points, and makes it difficult for leakage of the foaming raw material from between the sealing side surface of the skin and the concave side wall of the core during the production of the skin-integrated foam-molded product. To provide a skin-integrated foam-molded product that does not require strict accuracy in positioning, and has a high degree of freedom in designing a skin-integrated foam-molded product, a simple manufacturing method of the skin, and a method of manufacturing a skin-integrated foam product To do.
[0011]
[Means for Solving the Problems]
According to the first aspect of the present invention, a core having a recess formed on the surface, and a sealing side surface with respect to the inner surface of the side wall of the recess are formed on the periphery of the design surface so that the back side of the design surface faces the inner bottom surface of the recess of the core. A plurality of bent vertices on the side surface for sealing of the skin, wherein the plastic skin disposed in the recess and a foam formed by foaming between the core recess and the skin The bending apex became thin Scaleable / deformable The composite bent portion is bent to the back side of the sealing side surface, and the free end of the sealing side surface is in contact with or close to the inner surface of the concave portion of the core.
[0012]
Further, the invention of claim 2 is the thick portion according to claim 1, wherein the thickness is larger than the bending vertex closest to the free end between the free end of the sealing side surface and the bending vertex closest to the free end. Is provided.
[0013]
Further, the invention of claim 3 is a powder slush molding in which a plastic powder is attached to the mold surface of a heated slush molding mold, and after cooling, the plastic film formed into the mold surface shape is removed by molding to obtain a skin. When manufacturing a skin for a skin-integrated foam molded product in which the side surface for sealing with respect to the core at the time of skin-integrated foam molding is formed on at least a part of the peripheral edge of the design surface of the skin, When forming a ridge having three or more vertices protruding into the mold on the mold surface forming the sealing side surface, when the plastic powder is attached to the mold surface of the slash mold, the ridge Reduce the amount of plastic powder adhering at three or more inwardly projecting vertices in the mold, and melt and cool the plastic powder adhering to the mold surface. The plastic film having the bent portion on the side surface for sealing having a bent portion where the three or more bent vertices are thinner than the other portions is demolded, and then, among the three or more bent vertices in the bent portion of the plastic coating By cutting at the bending vertex furthest from the design surface of the coating, it is possible to obtain a skin that is bent to the back side of the sealing side surface and has a composite bending portion having two or more bending vertices formed on the sealing side surface. It relates to the manufacturing method of the skin for skin integral foam-molded articles.
[0014]
The invention of claim 4 is a powder slush molding method in which a plastic powder is attached to the mold surface of a heated slush mold, cooled and then cooled to remove the plastic film formed into the mold surface shape to obtain a skin. When manufacturing the skin for the skin-integrated foamed molded article, the side surface for sealing with respect to the core at the time of the skin-integrated foam molding is formed on at least a part of the peripheral edge of the design surface of the skin, the slush mold is used for sealing the skin The mold surface forming the side surface has two vertices protruding into the mold. The cross section is approximately M-shaped Ridge Almost parallel to the mold surface for design surface formation When the plastic powder is adhered to the mold surface of the slush mold, the amount of the plastic powder adhered is reduced at the two inwardly projecting vertices of the ridge, and the plastic powder adhered to the mold surface is melted. After cooling, the plastic film having the bent portion formed on each of the inward protruding vertices and having a bent portion on the side surface for sealing that is thinner than the other portion is demolded, and then the coating in the plastic film is removed. By cutting at a position on the tip side from the bending vertex far from the design surface of the surface, the skin is bent to the back side of the sealing side surface, and a composite bending part having two bending vertices is obtained on the sealing side surface. The present invention relates to a method for producing a skin for an integral foamed molded article.
[0015]
In addition, the invention of claim 5 is the invention according to claim 3 or 4, wherein, in the ridge of the mold surface of the slash mold, the vertex farthest from the mold surface forming at least the design surface of the skin is among the plurality of vertices. The slush mold is located on the outer side of the extension line of the mold surface forming the side surface for sealing from the mold surface forming the design surface of the skin to the ridge.
[0016]
In the invention of claim 6, a recess formed on the surface of the core and a side surface for sealing with respect to the inner surface of the side wall of the recess are formed on the periphery of the design surface, and the back side of the design surface faces the bottom surface in the recess of the core. In the manufacturing method of the skin-integrated foam-molded product, the liquid foam raw material is foamed between the plastic skin disposed in the recess and the foam is integrally formed with the core and the skin. The side surface for sealing has a plurality of bending vertices, and the bending vertices are thin. Scaleable / deformable A composite bent portion is bent to the back side of the sealing side surface, and the skin is disposed in a concave portion of the core to foam the foaming raw material.
[0017]
The invention of claim 7 is the invention according to claim 6, wherein the free end of the side surface for sealing is formed in a state of protruding outward from the extended line of the side surface for sealing between the design surface of the skin and the base of the composite bent portion. In addition, when the skin is disposed in the recess of the core, the free end of the side surface for sealing is pressed against the inner wall surface of the recess in a state in which the free end is biased to the outside of the recess of the core.
[0018]
DETAILED DESCRIPTION OF THE INVENTION
The present invention will be described in detail with reference to the accompanying drawings.
1 is a cross-sectional view of a skin-integrated foam-molded product according to an embodiment of the present invention, FIG. 2 is a partial enlarged cross-sectional view of FIG. 1 and FIG. 3 is a cross-sectional view of a skin-integrated foam-molded product according to another embodiment. is there. 4 is a cross-sectional view of a slush molding apparatus showing an embodiment of the method of manufacturing the skin according to the present invention, FIG. 5 is an enlarged cross-sectional view of part B of FIG. 4, and FIG. 6 is a slash showing plastic powder adhering in the embodiment. FIG. 7 is an enlarged sectional view of a portion C in FIG. 6, FIG. 8 is a sectional view of the plastic film after demolding in the same embodiment, and FIG. 9 is a cut at a bending vertex in a portion D of FIG. FIG. FIG. 10 is a cross-sectional view of a foam molding die showing an embodiment of the method for manufacturing a skin-integrated foam-molded article of the present invention, FIG. 11 is an enlarged cross-sectional view of portion E in FIG. 10, and FIG. FIG. 13 is an enlarged cross-sectional view of a portion F in FIG. 12, and FIG. 14 is a partial enlarged view of the foam-molding die when manufacturing a skin-integrated foam-molded product according to another embodiment of the present invention. It is sectional drawing. 15 is a cross-sectional view of a slush molding apparatus according to a method of manufacturing a skin according to still another embodiment of the present invention, FIG. 16 is an enlarged cross-sectional view of a portion G of FIG. 15, and FIG. FIG. 18 is an enlarged sectional view of a portion H in FIG. 17, FIG. 19 is a sectional view of the plastic film after demolding in the same embodiment, and FIG. It is an expanded sectional view which shows the time of cutting | disconnection by.
[0019]
A skin-integrated foam-molded article 10 shown in FIGS. 1 and 2 relates to an embodiment of the present invention, and is used for an automobile instrument panel similar to FIG. 21 described in the section of the prior art. This skin-integrated foam molded product 10 has a pad 21 on a part of the surface 12 of the plastic core 11 in a part of the molded product front-rear direction corresponding to the vehicle longitudinal direction and to both ends of the molded product corresponding to the vehicle width direction. The so-called partial pad-integrated foamed molded product is formed.
[0020]
The core 11 is a main body part of the skin-integrated foam molded product 10 and is formed in a desired molded product (instrument panel in this example), and the pad 21 on the surface 12 where the pad 21 is provided. A recess 13 that matches the size of is formed. The concave portion 13 has a side wall 14 formed on at least a part of the periphery, and has a desired depth according to the shape and size of the skin-integrated foam-molded product.
[0021]
The pad 21 is formed by covering a foam 30 such as polyurethane with a skin 22, and the foam 30 is formed from a liquid foam raw material between the skin 22 disposed in the recess 13 of the core 11 and the inner bottom surface 13 a of the recess 13. In this case, the skin 22 and the foam 30 are integrally formed, and the recess 13 of the core 11 and the skin 22 and the foam 30 are bonded using the adhesiveness of the foam 30 at that time. .
[0022]
The skin 22 is made of a plastic such as a soft vinyl chloride resin or an olefin-based thermoplastic elastomer that is powder slush molded to a size and shape that fits into the recess 13 of the core 11, and at least part of the periphery of the design surface 23. A side surface for sealing 24 with respect to the inner surface 15 of the side wall 14 of the recess 13 is bent to the back side of the skin 22, and the design surface 23 of the skin 22 is arranged in the recess 13 so that the back side faces the inner bottom surface 13 a of the recess 13 of the core. Yes. The sealing side surface 24 is used to prevent the liquid foam material from leaking out from the peripheral edge of the skin 22 by pressure-bonding and sealing the inner surface 15 of the concave side wall of the core 11 when foaming the foam 30 of the pad 21. In addition, a composite bent portion 26 is formed at a position facing the inner surface 15 of the recess side wall of the core 11.
[0023]
The composite bent portion 26 has a plurality (two in this example) of bent vertices 26a and 26c bent toward the back side 25 for sealing, and the plurality of bent vertices 26a and 26c are thinned. Are provided on the side surface 24 for sealing on a protrusion substantially parallel to the design surface 23. In addition, the composite bent portion 26 of this example is formed so that its free end (open end) 26 b becomes the free end (open end) 24 b of the sealing side surface 24, and abuts against the inner surface of the recess 13 of the core 11. It is a seal part.
[0024]
In the composite bent portion 26 of the skin 22, the free end 26 b of the composite bent portion and the free end 24 b of the side surface for sealing coincide with each other, so that the free end 24 b ( The distance to the free end 26b) of the composite bent portion, that is, the length of the sealing side surface 24 can be made shorter than the length of the sealing side surface of the skin in the conventional partial pad skin integrated foam molded product. The degree of freedom in designing the skin-integrated foamed molded product 10 can be increased.
[0025]
Further, in the composite bent portion 26 of the skin 22, the foam raw material for the foam 30 is filled between the skin 22 and the inner surface of the concave portion 13 of the core 11 during the production of the skin integrated foam molded product 10. When leaking to the design surface 23 side of the skin 22 through the composite bent portion free end 26b of the skin 22 and the inner surface 15 of the side wall 13 of the core, the foaming material to be leaked is accommodated in the composite bent portion 26. Thus, leakage to the skin design surface 23 can be prevented. Moreover, the free end 24b of the sealing side surface 24 of the skin 22 is in contact with or close to the inner surface of the concave portion 13 (in this example, the side wall inner surface 15), and the free end 24b of the sealing side surface 24 and the concave portion of the core It is difficult for the foaming raw material to enter from between the 13 inner surfaces.
[0026]
Further, the composite bent portion 26 has excellent possibility of expansion / contraction deformation because the plurality of bent vertices 26a and 26c are thin. Accordingly, the composite bent portion 26 is deformed by the small amount of foaming material entering between the sealing side surface 24 and the inner surface 15 of the side wall 15 of the recess 13 of the core, so that the intruding foaming material can be reliably accommodated and held. In addition, the free end 24b of the sealing side surface 24 becomes the side wall of the recess 13 of the core due to variations in molding of the skin 22 and the core 11 and variations in positional relationship when the skin 22 is disposed in the recess 13 of the core. Even when interfering with the inner surface 15, the composite bent portion 26 is deformed and the free end 24b of the side surface for sealing is pressed against the inner surface 15 of the recess side wall of the core, so that the leakage can be prevented efficiently. In particular, as shown in FIG. 9, which will be described later, the free end 24b of the sealing side surface 24 of the skin 22 is preliminarily placed above the extension line m of the sealing side surface 24a between the composite bent portion 26 of the skin 22 and the design surface 23. If formed in a state protruding to the outer skin outer side S, the free end 24b of the sealing side surface 24 can be pressed against the inner surface of the recess 13 of the core while being urged outward of the recess 13 of the core 11. The sealing performance becomes higher.
[0027]
Further, not only the rigidity of the sealing side surface 24 is increased by the presence of the composite bent portion 26, but also in this example, from the free end 24b of the sealing side surface 24 to the bent vertex 26c closest to the free end 24b. Since the thick portion 26G having a thickness larger than the bending vertex 26c closest to the free end 24b is provided between the two, the rigidity on the free end 24b side of the sealing side surface 24 is increased due to the presence of the thick portion 26G. ing. Due to the increased rigidity, the undulation of the sealing side surface 24 can be more effectively suppressed, and the free end 24b side of the sealing side surface 24 can be easily brought into contact with or close to the inner surface of the concave portion 13 of the core. An effect is obtained.
[0028]
Further, like the skin integrated foam molded product 10A of another embodiment shown in FIG. 3, when the skin 22 having the above-described structure is disposed in the recess 13 of the core 11 and the foam integrated foam molding is performed, the composite bending of the skin 22 is performed. Even when the portion 26 is opened and the free end 26b side is pressed against the inner bottom surface 13a of the recess between the side walls 14 of the recess 13 of the core, the good sealing performance by the composite bent portion 26 and the free end 26b side is shown in FIG. It is obtained in the same manner as in the example. Therefore, even if there is variation in the arrangement of the skin 22 at the time of skin integral foam molding, the quality of the manufactured skin integral foam molded product 10A is constant, and the aesthetic appearance is improved.
[0029]
The skin 22 is manufactured using a known powder slush molding method as follows. FIG. 4 is a cross-sectional view of a slush molding apparatus 40 of one embodiment used for manufacturing the skin, and FIG. 5 is an enlarged cross-sectional view of a portion B thereof. The slush molding device 40 includes a bucket 41 and a slush molding die 45.
[0030]
The bucket 41 accommodates the plastic powder P and is formed in a container shape having an open top. A flange portion 42 f is formed on the outer periphery of the opening 42 of the bucket 41 so that it can be attached to the powder slush mold 45. The plastic powder P is appropriately selected from known plastic powders used for powder slush molding, such as soft vinyl chloride resin and olefin thermoplastic elastomer.
[0031]
The slush mold 45 is made of an electric mold and has the skin-shaped mold surface 46 on the inner side. Reference numeral 46a denotes a mold surface (hereinafter referred to as a design surface forming mold surface) that forms the design surface 23 of the skin, and 46b denotes a mold surface (hereinafter referred to as a seal side surface forming mold surface) that forms the side surface 24 for sealing the skin. On the sealing side surface forming mold surface 46b, a protrusion 49 having three apexes 49a to 49c protruding into the forming mold 45 is separated from the design surface forming mold surface 46a, and the design surface forming mold surface is provided. It is formed in a direction substantially parallel to 46a. In addition, the said protrusion 49 is not restricted to what has three vertices like this example, You may have more vertices. In this example, among the three vertices 49 a to 49 c of the protrusion 49, the vertex 49 c farthest from the design surface forming mold surface 46 a is between the design surface forming mold surface 46 a and the protrusion 49. It is located on the outer side T of the slush mold from the extension line n of the mold surface 46c that forms the side surface for sealing. The size and the like of the protrusion 49 are set as appropriate. As an example, the case where d1 at the three apexes 49a to 49c is 2 mm, d2 is 1.5 mm, d3 is 3 mm, and d4 is 2 mm is given.
[0032]
Further, a flange portion 46f corresponding to the flange portion 42f of the bucket 41 is provided on the outer periphery of the mold surface 46, and the flange portion 46f is joined to the flange portion 42f of the bucket 41, whereby the slash mold 45 is combined with the bucket 41. Further, the outer surface of the slush mold 45 is provided with an appropriate number of heating means 47 including pipes for circulating a heat medium such as heating oil in order to heat the mold surface 46 to a required temperature during powder slush molding. ing.
[0033]
The powder slush molding device 40 is configured to be rotatable by a rotating mechanism (not shown) so that the bucket 41 and the slush molding die 45 are alternately inverted in a combined state.
[0034]
In manufacturing the skin using the molding apparatus 40, according to a known powder slush molding method, first, the bucket 41 and the slash molding die 45 are combined by a clamp or the like, and the mold surface 46 of the slush molding die 45 is heated by the heating means 47. While rotating the bucket 41 and the mold 45 for the required number of times and for the required time, the plastic powder P in the bucket 41 is moved and adhered to the mold surface 46 of the heated mold 45, as shown in FIGS. As shown in FIG. 3, a plastic powder adhesion layer 22a having a required thickness is formed on the mold surface 46. When the slash mold 45 is in the lower position during the rotation of the molding apparatus 40, the plastic powder P tends to be deposited on the flat surface and the valley on the mold surface 46 of the mold. Since plastic powder P is difficult to deposit, the amount of plastic powder P adhering is reduced at the three apexes 49a to 49c of the protrusion 49 of the sealing side surface forming mold surface 46b, and the V groove 49d portion between the apexes 49a and 49b. The adhesion amount of the plastic powder P increases in the (valley part) and the V groove 49e part (valley part) between the apexes 49b and 49c.
[0035]
After the plastic powder P adhering to the mold surface is melted and gelled by the heat of the mold surface, the heating is stopped and cooled to form the plastic film 22b on the mold surface 46. The plastic coating 22b has three bent vertices 26a, 26c and 26e (26e coincides with the free end 26b later) formed by the three apexes 49a to 49c of the protrusion 49, and the bent vertices 26a and 26c. The bellows-shaped concave groove 27 formed in a shape corresponding to the protrusion 49 having the three vertices 49a to 49c with the inner wall 26d and the bent vertices 26c and 26e between 26f thick and the inner surface having the three vertices 49a to 49c. The sealing side surface 24 is formed by the side surface forming mold surface 46b. The molding conditions such as the heating temperature and the rotation speed (heating time) of the mold surface 46 of the mold 45 are determined in consideration of the melting temperature of the plastic powder P, the thickness of the skin to be formed, and the like.
[0036]
The plastic film 22b is removed from the mold, and then, as shown in FIGS. 8 and 9, the three bent vertices 26a, 26c, and 26e in the concave groove 27 of the plastic film 22b are farthest from the design surface 23 of the film 22b. By cutting at the bending vertex 26e at the position, a skin 22 having a bellows-like compound bent portion 26 on the sealing side surface 24 that is bent and protruded into the back side 25 of the sealing side surface 24 in a substantially M shape is obtained. The cut portion of the bent apex 26e becomes the free end 24b of the sealing side surface 24, and in this example, constitutes the free end 26b of the composite bent portion 26. Further, since the cutting is performed at the bending vertex 26e of the coating 22b at the time of cutting, the cutting position is not easily mistaken, and the bending vertex 26e to be cut is thin as described above, so that it is easy to cut and the cutting work is easy. . Further, in the skin 22, the portion 26G between the free end 24b (bending vertex 26e at the cutting position) and the bending vertex 26c of the sealing side surface 24 is a thick portion as described above.
[0037]
Further, as described above, the concave groove 27 of the coating 22b is such that 26d between the bent vertices 26a and 26c and 26f between the bent vertices 26c and 26e are respectively V V between the apexes 49a and 49b of the protrusion 49 on the mold surface. It is formed in a triangular shape by reversing each of the letter shape and the V shape between the vertices 49b and 49c of the protrusion 49, and the bent vertices 26a and 26c and the bent vertices 26c and 26e from the central position 26g between the bent vertices 26a and 26c. The thickness of the free end 26b formed by cutting at the bending vertex 26e is the other part of the concave groove 27. The thickness is reduced from the central position 26h to the bending vertex 26c, 26e. Since it is thicker than the bending vertices 26a and 26c, the rigidity of the free end 26b is increased. The free end 26b serves as a seal portion for the inner surface of the recess 13 of the core.
[0038]
Furthermore, the protrusion 49 of the mold surface that forms the concave groove 27 of the coating 22b as described above is the most from the apex 49a to 49c of the protrusion 49 from the design surface forming mold surface 46a of the skin. A distant apex 49c is located on the outer side T of the slush mold with respect to the extension surface n for sealing side surface forming mold surface 46c between the design surface forming mold surface 46a and the protrusion 49. Therefore, the free end 24b of the sealing side surface formed by the vertex 49c at the farthest position and then cut and formed is the sealing side surface 24a between the composite bent portion 26 of the skin 22 and the design surface 23 as shown in FIG. Thus, it is positioned so as to protrude to the outer skin side S from the extension line m.
[0039]
Next, the manufacturing method of the skin integral foam-molded article 10 using the skin 22 will be described with reference to FIGS. The illustrated foaming mold 50 is conventionally used for integral foam molding of the skin, and is a split type including an upper mold 51 and a lower mold 55.
[0040]
As shown in FIGS. 10 and 11, the core 11 and the skin 22 are arranged in the foaming mold 50. The core 11 is disposed on the mold surface 52 side of the upper mold 51 so that the inner bottom surface 13a of the recess 13 faces the lower mold 55, and the back surface of the design surface 23 of the outer skin 22 faces the inner bottom surface 13a of the recess 13 of the core 11. In this way, the lower mold 55 is disposed on the mold surface 56 side. At that time, the sealing side surface 24 of the skin 22 is disposed so as to face the inner surface 15 of the side wall 14 of the recess 13 of the core 11, and the free end 24 b of the sealing side surface 24 is arranged on the side wall inner surface 15 of the core recess. Abut or close. At that time, the rigidity of the sealing side surface 22 is increased not only by the presence of the composite bent portion 26 but also by the presence of the thick portion 26G, the rigidity of the free end 24b side is increased. Deformation can be prevented, and the free end 24b of the sealing side surface 24 can be reliably brought into contact with or close to the side wall inner surface 15 of the recess. Further, since the bent vertices 26a and 26c of the composite bent portion 26 are thin, there is a variation in position between the composite bent portion 26 and the concave side wall 14 of the core when the skin 22 and the core 11 are manufactured and arranged. Even if the free end 24b of the side surface 24 for sealing may interfere with the concave side wall 14 of the core, the thin bent vertices 26a and 26c of the composite bent portion 26 are excellently deformable. The composite bent portion 26 having the deformation can be deformed, and the free end 24b of the sealing side surface 24 can be brought into contact with or close to the inner surface 15 of the concave side wall of the core.
[0041]
Further, as described above, the free end 24b of the sealing side surface 24 is formed so as to protrude outward from the extension line m of the sealing side surface 24a between the composite bent portion 26 and the design surface 23. Therefore, when the core 11 and the skin 22 are arranged, the free end 24b of the sealing side surface 24 interferes with the side wall inner surface 15 of the recess 13 of the core, and the free end 24b side is pushed and bent by the side wall inner surface 15 into the inner skin 22. It becomes a state. Moreover, since the bending vertices 26a and 26c of the composite bent portion 26 are thin, the deformability of the composite bent portion 26 is excellent, and even when the interference is strong, the composite bent portion 26 can be pushed and deformed. become. The free end 24b of the sealing side surface 24 is urged to the outside of the concave portion 13 of the core due to the repulsion against the pushing and bending, and is crimped to the inner surface 15 of the concave portion side wall of the core and the inner surface 15 of the concave portion side wall of the core. Between the sealing side surfaces 24 is more reliably sealed. In addition, even if the positional relationship between the skin 22 and the core 11 varies as described above, the variation can be more reliably absorbed. The core 11 and the skin 22 may be disposed on the foam mold 50 either by placing the skin 22 and the core 11 on the lower mold 55 and closing the foam mold 50 or by other methods. It is often selected as appropriate.
[0042]
Subsequently, a predetermined amount of a liquid foaming material L such as polyurethane is injected between the inner bottom surface 13a of the recess 13 of the core 11 and the skin 22, and the foam 30 is foamed between the core 11 and the skin 22 as shown in FIG. The skin-integrated foam-molded product 10 in which the core 11, the skin 22, and the foam 30 are integrated is molded into the foam-molding mold 50 by the molding. The reference numeral 16 shown in the drawing is a raw material injection hole formed in the core 11 in advance, 53 is a raw material injection head, 53a is the tip of the raw material injection head 53, and 54 is for inserting a raw material injection head tip 53a formed in the upper mold 51 in advance. Represents the insertion hole. In this embodiment, a closed injection method in which the liquid foam raw material L is injected by the raw material injection head 53 after the foam molding die is closed is employed, but the liquid foam raw material is injected before the foam molding die is closed. An open injection method may be adopted.
[0043]
At the time of foam molding, the sealing side surface 24 of the skin 22 has a free end 24b abutting against the inner surface 15 of the concave side wall of the core, and the free end 24b is pressed with pressure during foam molding. A pressure is applied to the side wall inner surface 15 of the recess 13, thereby preventing the liquid foam raw material L from entering between the sealing side surface 24 and the recess side wall 14. Further, when the liquid foam raw material L penetrates between the free side 24b of the sealing side surface 24 and the recess side wall inner surface 15 and penetrates between the sealing side surface 24 and the recess side wall 14, as shown in FIG. The foamed raw material L (foam) is accommodated in the composite bent portion 26 and is prevented from leaking further to the design surface 23 side of the skin 22.
[0044]
After the foam molding, if the foam mold 50 is opened and the molded product is removed, the partial pad type skin-integrated foam molded product 10 shown in FIG. 1 is obtained.
[0045]
Further, as shown in FIG. 14, when the skin 22 is disposed in the recess 13 of the core 11, the compound bent portion 26 of the skin 22 opens when the free end 24b of the sealing side surface 24 and the inner bottom surface 13a of the core contact with each other. In this case, the leakage of the foamed raw material can be prevented by both the sealing effect by the free end 24b and the foamed raw material accommodation in the composite bent portion 26 as described above.
[0046]
Furthermore, the manufacturing method of the skin 22 which concerns on the other Example using the said powder slush molding method is demonstrated using FIG. 15 thru | or FIG. FIG. 15 is a cross-sectional view of a slush molding apparatus 40A used for manufacturing the skin of this embodiment, and FIG. 16 is an enlarged cross-sectional view of the G portion. The slush molding device 40A includes a bucket 41 and a slash molding die 45A similar to those in the above-described embodiment.
[0047]
The slash mold 45A of this embodiment has a substantially M-shaped cross section in which a seal groove side surface forming mold surface 46b has a V groove 49h between two apexes 49f and 49g protruding into the mold 45A. The strip 49A is formed away from the design surface forming mold surface 46a and in a direction substantially parallel to the design surface forming mold surface 46a. In addition, what is necessary is just to make the shape of the said M-shape into appropriate shapes, such as expanding so that two vertexes 49f and 49g may spread like this example. In this example, of the two apexes 49f and 49g of the protrusion 49, the apex 49g far from the design surface forming mold surface 46a is between the design surface forming mold surface 46a and the protrusion 49A. It is located on the outer side U of the slush mold from the extension line o of the mold surface 46c that forms the side surface for sealing. The size and the like of the protrusion 49A is appropriate, but as an example, the distance from the valley of the V groove 49h to the apex 49f, 49g is 2 mm, the value of d5 is 2 mm, and the distance x between the extension line o and the apex 49g Is 1.5 mm.
[0048]
In the production of the skin using the molding apparatus 40A, as in the above-described embodiment, the plastic powder adhesion layer 22a having a required thickness is formed on the mold surface 46 by a known powder slush molding method as shown in FIGS. Formed. Also in this embodiment, the amount of adhesion of the plastic powder P is small at the two apexes 49f and 49g of the ridge 49A of the sealing side surface forming mold surface 46b in the mold surface 46 of the slash mold 45A, and the distance between the apexes 49f and 49g is small. The adhesion amount of the plastic powder P increases at the V groove 49h portion (valley portion) and the base portion far from the design surface forming mold surface 46a of the protrusion 49A.
[0049]
Thereafter, the plastic film 22b formed by melting the plastic powder adhesion layer 22a formed on the mold surface 46 under a predetermined molding condition and then cooling and solidifying the plastic film 22b is formed by two bent portions 49f and 49g formed on the protrusion 49A. The vertices 26C and 26D are thin, and the portion 26F formed by the base 2626 between the bent vertices 26C and 26D and the base portion 46a far from the design surface forming mold surface 46a of the protrusion 49A is thick and the inner surface is the protrusion. A concave groove 27 having a substantially W-shaped cross section corresponding to the M-shape of the strip 49A is provided on the sealing side surface 24 formed by the sealing side surface forming mold surface 46b.
[0050]
Then, after removing the plastic coating 22b, as shown in FIGS. 19 and 20, the two bent vertices 26C and 26D in the concave groove 27 of the plastic coating 22b are located far from the design surface 23 of the coating 22b. The skin having a composite bent portion 26 on the side surface 24 for sealing, which is cut at a position where the Y value on the outer side of the bending vertex 26D is 3 to 4 mm and bent to the back side 25 of the sealing side surface 24 in a substantially M shape. Get 22. The cutting portion becomes the free end 24 b of the sealing side surface 24. As a result, the sealing side surface 24 of the skin 22 has the thick portion 26G on the free end 24b side and the rigidity on the free end side is enhanced. Therefore, in the manufacture of the display-integrated foam molded product using the skin 22 The side wall 24 for sealing is reliably prevented from undulating by increasing the rigidity of the side surface 24 for sealing by the composite bent portion 26 of the skin 22 and increasing the rigidity of the free side 24b of the side surface 24 for sealing by the thick portion 26G. Further, the sealing side surface 24 can be brought into close contact with the inner surface of the concave portion 13 of the core by foaming pressure, and high sealing performance can be exhibited. Further, even if the foaming raw material enters between the sealing side surface 24 and the core recess 13 side wall 14, the foaming raw material that has entered can be accommodated and held in the composite bent portion 26, so that leakage of the foaming raw material is prevented. Can do.
[0051]
【The invention's effect】
As shown and described above, according to the invention of the skin-integrated foam-molded article according to claim 1, the composite bent portion of the skin sealing side surface passes between the skin sealing side surface and the core recess side wall. Since the foaming raw material that is about to leak to the design surface side of the skin can be accommodated in the composite bent portion, the burr on the design surface caused by the leakage of the foaming raw material from between the side surface for sealing the skin and the side wall of the concave portion of the core In addition, in this skin-integrated foam-molded product, there is no need for strict accuracy in aligning the skin and the core, and the design flexibility of the skin-integrated foam-molded product is increased. . In addition, since the rigidity of the sealing side surface of the skin can be increased due to the presence of the composite bent portion, the burrs on the design surface caused by leakage of the foaming raw material from between the sealing side surface of the skin and the recess side wall of the core can be improved. Can be made difficult to occur.
[0052]
According to the invention of the skin-integrated foam-molded article according to claim 2, the thickness between the free end of the sealing side surface and the bent vertex closest to the free end is larger than the bent vertex closest to the free end. The thick wall portion is provided and the rigidity of the free end of the sealing side surface is increased by the thick wall portion. Can be reliably prevented, the sealing performance of the sealing side surface against the side wall of the concave portion of the core is enhanced, and the burr on the design surface due to leakage of the foaming raw material from between the sealing side surface of the skin and the side wall of the concave portion of the core is generated. Can be difficult.
[0053]
Furthermore, according to the invention of the method for manufacturing a skin for a skin-integrated foam-molded product according to claims 3 to 5, leakage of foaming raw material from between the sealing side surface of the skin and the recess side wall of the core during the manufacture of the skin-integrated foam-molded product It is difficult to produce burrs on the design surface due to the above, and it is not necessary to strictly align the position of the skin and the core. In addition, it can be obtained with high accuracy.
[0054]
In addition, according to the invention of the manufacturing method of the skin-integrated foam-molded article according to claims 6 and 7, the design surface burr is caused by leakage of the foaming raw material from between the sealing side surface of the skin and the recess side wall of the core. In addition, there is no need for strict accuracy for alignment between the skin and the core, and the design freedom of the skin-integrated foam-molded product is increased.
[Brief description of the drawings]
FIG. 1 is a cross-sectional view of a skin-integrated foam-molded product according to an embodiment of the present invention.
FIG. 2 is an enlarged cross-sectional view of a portion A in FIG.
FIG. 3 is a cross-sectional view of a skin integrated foam-molded product according to another embodiment.
FIG. 4 is a cross-sectional view of a slush molding device showing one embodiment according to the method of manufacturing the skin of the present invention.
FIG. 5 is an enlarged cross-sectional view of a portion B in FIG.
FIG. 6 is a cross-sectional view of the slush molding device showing when the plastic powder is adhered in the same embodiment.
7 is an enlarged cross-sectional view of a portion C in FIG.
FIG. 8 is a cross-sectional view of the plastic film after demolding in the same example.
FIG. 9 is an enlarged cross-sectional view showing a state of cutting at a bending vertex in a portion D of FIG. 8;
FIG. 10 is a cross-sectional view of a foam molding die showing one embodiment according to the method for producing a skin-integrated foam molded product of the present invention.
11 is an enlarged cross-sectional view of a portion E in FIG.
FIG. 12 is a cross-sectional view of a foaming mold showing foaming in the same example.
13 is an enlarged cross-sectional view of a portion F in FIG.
FIG. 14 is a partially enlarged cross-sectional view of a foam molding die when manufacturing a skin-integrated foam molded product according to another embodiment of the present invention.
FIG. 15 is a cross-sectional view of a slush molding device according to a method of manufacturing a skin according to still another embodiment of the present invention.
16 is an enlarged sectional view of part G in FIG. 15;
FIG. 17 is a cross-sectional view of the slush molding device showing when the plastic powder is adhered in the same embodiment.
18 is an enlarged cross-sectional view of a portion H in FIG.
FIG. 19 is a cross-sectional view of the plastic film after demolding in the same example.
20 is an enlarged cross-sectional view showing a state of cutting at the tip side from the bending vertex in the I portion of FIG.
FIG. 21 is a perspective view showing a conventional skin-integrated foam-molded product.
22 is a cross-sectional view of FIG. 21. FIG.
FIG. 23 is a cross-sectional view of a foam molding die showing the production of a conventional skin-integrated foam molded product.
FIG. 24 is a partial cross-sectional view showing a main part of a foam molding die in another conventional example.
FIG. 25 is a partial cross-sectional view showing a main part of a foam molding die in still another conventional example.
[Explanation of symbols]
10 Skin integrated foam molding
11 core
13 Core recess
14 Recess side wall of core
15 Recess side wall inner surface of core
21 Pad
22 epidermis
23 Design surface of the epidermis
24 Skin sealing side
24b Side free end for sealing
25 Back side for sealing
26 Compound bend
26G thick part
26a, 26c, 26C, 26D Bending vertex
26e, 26D Bending vertex far from the design surface
30 Foam
40,40A slush mold
46 mold surface
49 ridges
49a, 49b, 49c, 49f, 49g Inward protruding vertices
49c, 49g Inward protruding vertex far from the design surface forming mold surface
50 Foam mold
n, o Surface extension line for forming side faces for sealing slush molds
L Liquid foaming raw material
P Plastic powder

Claims

A core having a recess formed on the surface and a sealing side surface with respect to the inner surface of the side wall of the recess are formed on the periphery of the design surface, and the design surface back side is disposed in the recess so as to face the bottom surface of the core in the recess. In a skin-integrated foam-molded product comprising a plastic skin and a foam molded between the core recess and the skin,
A composite bent portion having a plurality of bent vertices and having a thin bent bend is bent on the side surface for sealing of the skin so as to be able to expand and contract to the back side of the side surface of the seal. A skin-integrated foam-molded article characterized in that a free end is in contact with or close to an inner surface of a concave portion of a core.

2. The thick portion having a larger thickness than the bending vertex closest to the free end is provided between the free end of the side surface for sealing and the bending vertex closest to the free end. Skin integrated foam molding.

At the time of integral foam molding using the powder slush molding method in which plastic powder is attached to the mold surface of a heated slush mold, and then melted and cooled to remove the plastic film shaped into the mold surface shape to obtain the skin When manufacturing the skin for the integral foam molded article of the skin in which the side surface for sealing with respect to the core is formed on at least a part of the peripheral edge of the design surface of the skin,
In the slush mold, a ridge having three or more vertices protruding into the mold is formed on the mold surface forming the sealing side surface of the skin,
When attaching plastic powder to the mold surface of the slash mold, reduce the amount of plastic powder attached at three or more inwardly projecting vertices on the ridge,
After melting and cooling the plastic powder adhering to the mold surface, a plastic coating having a bent portion on the side surface for sealing, wherein three or more bent vertices formed at the inwardly protruding vertices are thinner than the other portions. Demold,
Then, by bending at the bending vertex furthest from the design surface of the coating film among the three or more bending vertices in the bent portion of the plastic coating, it bends to the back side of the sealing side surface and has two or more bending vertices. A method for producing a skin for a skin-integrated foam-molded article, wherein a skin having a composite bent portion formed on a side surface for sealing is obtained.

At the time of integral foam molding using the powder slush molding method in which plastic powder is attached to the mold surface of a heated slush mold, and then melted and cooled to remove the plastic film shaped into the mold surface shape to obtain the skin When manufacturing the skin for the integral foam molded article of the skin in which the side surface for sealing with respect to the core is formed on at least a part of the peripheral edge of the design surface of the skin,
The slush mold has a substantially M-shaped protrusion having two vertices projecting into the mold on the mold surface forming the sealing side surface of the skin, in a direction substantially parallel to the design surface forming mold surface. To form,
When attaching plastic powder to the mold surface of the slush mold, the amount of plastic powder attached is reduced at the two inward protruding vertices of the ridge,
After melting and cooling the plastic powder adhering to the mold surface, the plastic film having two bent vertices formed at the inwardly protruding vertices are thinner than the other portions on the sealing side is removed. And
After that, by cutting at a position closer to the tip side than the bending vertex far from the design surface of the coating film in the plastic coating, the composite bending portion having two bending vertices is bent to the back side of the sealing side surface. A method for producing a skin for a skin-integrated foam-molded article, wherein the skin is formed.

In the ridge of the mold surface of the slush mold, at least the vertex that is farthest from the mold surface that forms the design surface of the skin is a seal from the mold surface that forms the design surface of the skin to the ridge. 5. The method for producing a skin for a skin-integrated foam-molded product according to claim 3, wherein the skin is located on the outer side of the slush molding die with respect to the extension line of the mold surface forming the side surface.

A concave portion formed on the surface of the core and a side surface for sealing with respect to the inner surface of the side wall of the concave portion are formed on the periphery of the design surface, and the back side of the design surface is disposed in the concave portion so as to face the bottom surface in the concave portion of the core. In the method for producing a skin-integrated foam-molded product, foaming a liquid foaming raw material between the plastic skin and forming a foam integrally with the core and the skin,
The side surface for sealing the skin has a plurality of bending vertices and the bending vertices are thinned, and a bending portion that can be expanded and contracted is bent and formed on the back side of the sealing surface,
A method for producing a skin-integrated foam-molded article, wherein the foam is formed by disposing the skin in a recess of a core.

The free end of the side surface for sealing is formed in a state of projecting outward from the extension of the side surface for sealing between the design surface of the skin and the base of the composite bend, and the skin is formed in the recess of the core. The method for producing a skin-integrated foam-molded product according to claim 6, wherein when disposed, the free end of the side surface for sealing is pressed against the inner wall surface of the recess while being urged outward of the core recess.