JP6546122B2 - Method for producing foam molded article - Google Patents

Description

  The present invention relates to a method of manufacturing a foam molded article such as an instrument panel of a vehicle.

  Patent Document 1 discloses a method of manufacturing an instrument panel of a vehicle having a core material having resin rigidity, a foam material laminated on a predetermined covering area of the core material, and a skin to be covered on the foam material. Is disclosed. Briefly described, a core and a skin which are molded in advance are set in a mold. An instrument panel is manufactured by filling the foaming raw material from the gate of the mold through the injection port of the core material, filling the space between the core material and the skin and foaming and solidifying it.

  Although not disclosed in Patent Document 1, an opening for installing a device such as a navigation device is formed in a central portion of a core of an instrument panel, and a wide main covering region above the opening in the core, The foam and skin may be laminated over the narrow secondary coverage area under the opening and the lateral coverage area to the side of the opening. In this case, an instrument panel is manufactured as follows. The core material and the skin are set in the mold, and the main filling space of the core covering area, the side covering area, the subcoating area and the corresponding main area, side area and subarea of the skin, the main filling space, Form side filling space, sub-filling space. In this set state, the foam raw material is injected from the injection portion of the core material, and the foam raw material is filled in the order of the main filling space, the side filling space, and the sub-filling space.

  However, since the foam material is filled into the sub-filling space through the route bypassing the device installation opening as described above (ie, the route passing through the main filling space and the side filling space), There was a risk that filling could not be performed reliably. In order to ensure filling of the secondary filling space, a high injection pressure is required, which leads to an increase in manufacturing cost.

  Patent Document 2 discloses a method of manufacturing an instrument panel similar to Patent Document 1. In this patent document 2, the speaker mounting recess of the core material is covered with a masking plate, the foam material is injected from the injection portion of this masking plate, and filling around the mounting recess from the space between the skin and the masking plate It is filled in a space (a filling space formed by the core material and the skin). According to this method, the foam material can be smoothly filled in the filling space.

JP 2012-228788 A JP, 2013-929, A

  It is also conceivable to foam-mold an instrument panel having an opening for device installation by applying the technology of Patent Document 2. That is, the masking plate is set in the opening for equipment installation, and the foam material is supplied from the injection part of the masking plate to the main filling space and the side filling space as well as the sub-filling space. However, this technique requires an additional masking plate, and after foam molding, it requires removal of the masking plate and removal of the skin and foam covering the entire opening for equipment installation, which increases the manufacturing cost. It is inevitable.

The present invention has been made to solve the above problems, and comprises a core having an opening, a foam to be laminated on a predetermined covered area of the core, and a skin to be laminated to the foam. In a method of manufacturing a foam molded article, wherein a predetermined covering area of the core material includes a main covering area disposed on one side across the opening and a sub covering area disposed on the other side and narrower than the main covering area. ,
The core has an injection part on the one side of the opening and a bridging runner component which extends from the edge of the one side to the edge of the other side of the opening to cross the opening, and the skin is the core And having a cross-linked runner component corresponding to the cross-link runner component of the core material and having the main and sub segments respectively corresponding to the main coating region and the sub-coating region of the material;
The core and the skin are set in a mold, and a main filling area is formed by the main coating area of the core and the main area of the skin, and a sub-coating area of the core and a sub-area of the skin Forming a secondary filling space, and forming a crosslinking runner by the crosslinking runner constituting part of the core material and the crosslinking runner constituting part of the skin,
By injecting the foaming raw material from the injecting portion, the foaming raw material is filled into the main filling space and into the sub-filling space via the crosslinking runner, and the foaming raw material is further foamed and solidified,
The method is characterized in that, after foaming and solidification of the foam material, the cross-linked runner filled with the foam material is removed from the opening.

  According to the above method, the sub-filling space can be reliably filled with the foam material through the crosslinking runner. After foam molding, the crosslinking runners are removed from the openings, so that the original role of the openings is not impaired. Moreover, this post-processing is easy.

Preferably, the cross-linked runner component of the core has an extension extending to the injection part, and the cross-link runner component of the skin also has an extension corresponding to the extension of the cross-linked runner component of the core And feed the foamed material injected from the injection section directly to the crosslinking runner.
According to this, it is possible to more reliably fill the sub-filling space with the foam material.

  In one aspect of the present invention, the foam-molded article is an instrument panel, and the core has an opening for installing the device as the opening at the center in the left-right direction, and the core is for installing the device The main covering area and the injection part are provided on the upper side of the opening, and the sub covering area is on the lower side.

Preferably, the core material has first and second coating regions divided into right and left as the main coating region, and is located to the side of the device installation opening, and the second coating region and the sub-coating region And the skin has first and second regions corresponding to the first and second coating regions of the core material as the main region , and the side surfaces of the core material has a side region corresponding to the covered region, the set state to the mold, the first of said core member, the first second covered area and the skin, in the second region, the Side filling that forms first and second filling spaces as a main filling space and connects the second filling space and the sub-filling space between the side covering area of the core and the side area of the skin Form a space.

Preferably, the core has first and second runner components extending from the injection portion to the first and second covering regions, and the skin has a first and second runner configuration of the core. And a first runner constituting part of the core material and a first runner constituting part of the skin in the set state to the mold. The second runner component of the core material and the second runner component of the skin form a second runner, and the foam raw material from the injection unit is divided into the first and second runners and the crosslinking. The flow is divided into runners, sent to the first and second filling spaces via the first and second runners, and sent to the sub-filling space via the crosslinking runners.

  ADVANTAGE OF THE INVENTION According to this invention, the foam-molded article which has an opening can be manufactured, suppressing the raise of manufacturing cost.

It is a perspective view of a pre-shaped core material used by the instrument panel manufacturing method of one embodiment of the present invention. It is a perspective view of the preformed outer skin used by the same embodiment. It is a perspective view which abbreviate | omits a metal mold and shows the state which set the said core material and outer_skin | epidermis in the metal mold | die reversely up and down. It is a perspective view which shows the instrument panel which the post-process after foam molding completed. It is a schematic sectional drawing which shows the core material and skin which were set in the metal mold | die, and the foam material shape | molded between these.

  Hereinafter, an embodiment of the present invention will be described with reference to the drawings. The schematic configuration of an instrument panel as a product will be described first with reference to FIG. The instrument panel includes a core 10 extending in the left-right direction, a foam 20 covering a predetermined covered area of the core 10, and a skin 30 covering the foam. An opening 11 for installing a device such as a navigation device is formed at the central portion in the left-right direction of the core member 10.

Hereinafter, the manufacturing method of an instrument panel is demonstrated to process order.
Molding of Core Material 10 The core material 10 shown in FIG. 1 is molded by injection molding. In the core material 10, the predetermined covering area covered by the foam material 20 and the skin 30 is a main covering area 12 located on the upper side of the opening 11 and occupying a wide area, and a side covering located on the right side of the opening 11 It has a region 13 and a narrow sub-covering region 14 located below the opening 11. The main covering area 12 includes a first covering area 12a and a second covering area 12b which are divided into right and left.
The second covering area 12 b is continuous with the side covering area 13, and the side covering area 13 is continuous with the sub-covering area 14.

  In the core member 10, the injection portion 15 is formed in the vicinity of the center of the upper edge of the opening 11, and the first runner configuration portion 16 extends from the injection portion 15 to the first covering region 12a. A second runner component 17 extends from the injection part 15 to the second covering area 12.

  Furthermore, the core material 10 has a bridged runner component 18 that crosses the opening 11 and spans the upper edge and the lower edge thereof. The cross-link runner component 18 has an extension 18 a extending to the injection portion 15 and connects the injection portion 15 and the sub-covering region 14.

The outer skin 30 shown in FIG. 2 of the outer skin 30 is molded by powder slush molding, heat press molding, vacuum molding or the like. The skin 30 is made of PVC or the like, and has a shape corresponding to the covered area of the core 10 and the runner component. Specifically, the skin 30 has a first area 32 a corresponding to the first covered area 12 a of the core 10, a second area 32 b corresponding to the second covered area 12 b, and a side corresponding to the side covered area 13. A partial region 33, a secondary region 34 corresponding to the secondary covering region 14, a cover portion 35 corresponding to the injection portion 15, a first runner configuration portion 36 corresponding to the first runner configuration portion 16 of the core member 10, and a core A second runner constituting portion 37 corresponding to the second runner constituting portion 17 of the material 10 and a crosslinked runner constituting portion 38 corresponding to the crosslinked runner constituting portion 18 of the core material 10 are provided. A main area 32 is constituted by the first area 32a and the second area 32b which are divided into the left and right of the epidermis 30. The cross-link runner component 38 has an extension 38 a corresponding to the extension of the cross-link runner component 18 of the core 10, and the extension 38 a is connected to the cover 15.

As shown in FIGS. 3 and 5 of the core material 10 and the skin 30, the core material 10 and the skin 30 of the above configuration are set in a mold 50. For example, the skin 30 is set in the lower mold 52 and fixed by vacuum suction from suction holes provided in the lower mold. Then, the core material 10 is set from above. The coated regions 12 a, 12 b, 13, 14 of the core material 10, the injection portion 15, and the runner components 16 to 18 are disposed in the cavity between the lower die 52 and the upper die 51 together with the skin 30. The injection portion 15 of the core material 10 is connected to the gate of the upper mold 51.

  The core 10 and the skin 30 are disposed opposite to each other in the cavity of the mold 50, and a filling space and a runner are formed therebetween. Specifically, the first and second covering regions 12a and 12b, the side covering regions 13, the sub covering regions 14 of the core material 10, the first and second regions 32a and 32b of the skin 30, and the side regions 13; In the subregion 14, first and second filling spaces 42a and 42b, a side filling space 43, and a subfilling space 44 are respectively formed. The first and second filling spaces 42 a and 42 b constitute a main filling space 42.

  Furthermore, the first runner component 16, the second runner component 17, the cross-linked runner component 18 of the core material 10, the first runner component 36, the second runner component 37 and the cross-link runner component 38 of the skin 30. Thus, the first runner 46, the second runner 47, and the bridge runner 48 are formed.

Foam molded foam raw material, for example, a two-liquid mixed type foamed urethane raw material is injected from the gate of the mold 50 into the injection portion 15 of the core material 10. The foam material from the inlet 15 is supplied directly to the first runner 46, the second runner 47, and the crosslinking runner 48 in a branched manner. The foam material supplied to the first runner 46 is filled in the first filling space 42 a, and the foam material supplied to the second runner 47 is filled in the second filling space 42 b and the side from the second filling space 42 The filling space 43 is filled.

The foam material supplied to the crosslinking runner 48 is filled into the sub-filling space 44. Without the cross-link runner 48, the foam material to the secondary filling space 44 is forced to pass through the opening 11 bypass route, ie, through the second runner 47, the second filling space 42b, and the side filling space 43, In the present embodiment, the sub-filling space 44 can be filled with the foam material directly from the crosslinking runner 48. Therefore, the sub-filling space 44 can be reliably filled with the foam material without increasing the injection pressure.
The foam material is foamed and solidified in the filling spaces 42a, 42b, 43, 44 and the runners 46, 47, 48 to form the foam material 20. When the foam molding is completed, the molded article is removed from the mold.

Excision of Cross-Linking Runner 48 The cross-linking runner 48 traverses the instrument installation opening 11. After foam molding, as shown in FIG. 4, the cross-link runner 48 which is an obstacle during installation of the device is cut out from the opening 11, whereby the instrument panel 10 is completed. At this time, the injection portion 15 of the core material 10, the cover portion 35 of the skin 30, and the foam material 20 between them are also cut off.

  The present invention is not limited to the above embodiment, and various aspects are possible. The present invention is applicable not only to the instrument panel but also to the production of a foam molded article having an opening.

  The present invention is applicable to the manufacture of foam molded articles such as instrument panels.

10 Core material 11 Opening for equipment installation (opening)
12 Main Covering Area 12a First Covering Area 12b Second Covering Area 13 Side Covering Area 14 Secondary Covering Area 15 Injection Section 16 First Runner Construction Section 17 Second Runner Construction Section 18 Crossing Runner Construction Section 18a Extension Section 20 Foam 30 Outer skin 32 main region 32a first region 32b second region 33 side region 34 subregion 36 first runner component 37 second runner component 38 bridge runner component 38a extension 42 main loading space 42a first loading space 42b 2 Filling space 43 Side filling space 44 Secondary filling space 46 First runner 47 Second runner 48 Cross-linking runner 50 Mold

Claims (5)

A core material having an opening, a foam material laminated on a predetermined covering area of the core material, and a skin layer laminated on the foam material, the predetermined covering area of the core material sandwiching the opening In a method of producing a foam molded article comprising a primary covering area disposed on one side and a secondary covering area disposed on the other side and narrower than the primary covering area,
The core has an injection part on the one side of the opening and a bridging runner component which extends from the edge of the one side to the edge of the other side of the opening to cross the opening, and the skin is the core And having a cross-linked runner component corresponding to the cross-link runner component of the core material and having the main and sub segments respectively corresponding to the main coating region and the sub-coating region of the material;
The core and the skin are set in a mold, and a main filling area is formed by the main coating area of the core and the main area of the skin, and a sub-coating area of the core and a sub-area of the skin Forming a secondary filling space, and forming a crosslinking runner by the crosslinking runner constituting part of the core material and the crosslinking runner constituting part of the skin,
By injecting the foaming raw material from the injecting portion, the foaming raw material is filled into the main filling space and into the sub-filling space via the crosslinking runner, and the foaming raw material is further foamed and solidified,
A method for producing a foam-molded article, comprising removing the cross-linked runner filled with the foam material from the opening after foaming and solidification of the foam material. The cross-linked runner component of the core has an extension extending to the injection part, and the cross-link runner component of the skin also has an extension corresponding to the extension of the cross-linked runner component of the core,
The method for producing a foam-molded article according to claim 1, wherein the foam material injected from the injection portion is sent directly to the crosslinking runner.   The foam molded article is an instrument panel, and the core has a device installation opening as the opening at the center in the left-right direction, and the core covers the main coating on the upper side of the device installation opening. The method for producing a foam-molded article according to claim 2, comprising a region and the injection portion, and having the sub-coating region on the lower side. The core material has first and second covering areas divided into right and left as the main covering area, and is located on the side of the device installation opening and connects the second covering area and the sub-covering area. Have a partial coverage area,
The skin has first and second regions corresponding to the first and second covering regions of the core material as the main region, and has side regions corresponding to the side covering regions of the core material. Yes,
In the set state to the mold, the first of said core member, the first second covered area and the skin, in the second region, the first as the main filling space, a second filling space respectively The side filling area which connects and forms the said 2nd filling space and the said sub-filling space is formed, and it forms, and the side covering area | region of the said core material and the side area of the said outer_skin | epidermis are characterized by the above-mentioned. Of the foam molded article of The core has first and second runner components extending from the injection portion to the first and second covering regions, and the skin corresponds to the first and second runner components of the core. First and second runner components,
In the set state to the mold, a first runner is formed by the first runner component of the core and the first runner component of the skin, and a second runner component of the core and the first skin of the skin are formed. Form a second runner with the two runners,
The foamed raw material from the injection part is divided into the first and second runners and the cross-link runner, and sent to the first and second filling spaces through the first and second runners, and also through the cross-link runner. The method for producing a foam-molded article according to claim 4, wherein the method is sent to the sub-filling space.

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