JP2000210968A - Skinned in-mold foamed molded object and production thereof - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a skinned in-mold foamed molded object capable of being reduced in cost by reducing the number of processes and having sufficient rigidity and a method for producing the same. SOLUTION: A skin material 3 is arranged in one mold 6 among two molds 6, 7 constituting a mold 5 and, after the molds 6, 7 are closed, foamable beads are charged in the mold cavity of the mold 5 and heated by steam to be foamed to be welded mutually and these foamed beads are integrally welded to the skin material 3. A heatable pressing portion 10 freely slidable inwardly and outwardly is provided to the surface of the mold 7 and, simultaneously with or after the mutual fusion of the foamed beads and the integral fusion of the foamed beads and the skin material 3, the pressing portion/0 brought to a heated state is slid inwardly to melt and press a formed in-mold foamed molded object 2. By this producing method, a reinforcing layer 4 is formed to at least a part of the exposed surface 2a of the in-mold foamed molded object 2.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an in-mold foam molded article with a skin used for, for example, interior materials for automobiles and a method for producing the same. More specifically, the present invention relates to an in-mold foam molded article covered with a skin material. TECHNICAL FIELD The present invention relates to an in-mold foamed molded product having a skin provided with a reinforcing layer on an unexposed surface and a method for producing the same.

[0002]

2. Description of the Related Art Conventionally, a reinforcing material used to reinforce an in-mold foam molded article is separately made of, for example, a material compatible with the in-mold foam molded article. It is known that insert molding is performed at the same time, or after in-mold foam molding, an adhesive is applied to the in-mold foam molded article with an adhesive.

Further, as disclosed in, for example, Japanese Patent Application Laid-Open No. 58-171924, a foamed resin molded product (foamed in-mold molding) obtained by heating and foaming foamable resin beads (foamed beads) filled in a mold. Body), melting the resin
There is also known a foamed resin molded article having a hardened layer (reinforcing layer) formed on cooling provided on the surface thereof.

[0004]

However, in the above-described simultaneous insert molding and bonding of the reinforcing material, it is necessary to prepare the reinforcing material in advance. For example, when the reinforcing material is formed by injection molding, However, there is a problem that a mold, a molding machine, and the like are required for that purpose, and furthermore, labor and man-hours are required. In addition, when the in-mold foam molded article is large, a large reinforcing material is required, and is disposed in a mold during insert molding, and disposed in a bonding mold or the like during bonding processing. However, there is a problem that it is difficult to reduce the cost because the number of man-hours is increased.

[0005] In the above-mentioned foamed resin molded article, the cured layer is formed only by melting the foamable resin beads. If the melting is insufficient, the foamed resin is added to the cured layer. The foamed structure of the resin beads may remain.
Therefore, in such a case, there is a problem that rigidity is reduced.

SUMMARY OF THE INVENTION The present invention has been made in view of the above-mentioned problems, and it is possible to reduce the number of man-hours so as to reduce the cost and to provide a foamed molded article with a skin having sufficient rigidity and its production. The aim is to provide a method.

[0007]

Means for Solving the Problems In order to achieve the above-mentioned object, the means of claim 1 in the in-mold foam molded article with a skin is that the in-mold foam molded article and the in-mold foam molded article are fused. A skin-in-mold foam molded article having a skin material integrally attached thereto, wherein at least a part of an exposed surface of the in-mold foam molded article, the in-mold foam molded article or foam beads constituting the same is melted. That is, a reinforcing layer formed by pressing is provided.

[0008] In the method for producing a foamed molded article with a skin in the mold, the skin material is arranged on one of the two molds constituting the molding die. After tightening, the foamed beads are filled in the mold, and the foamed beads are foamed by steam heating to be fused to each other, and the foamed beads and the skin material are fused and integrated to produce a foamed molded article with a skin. In the method, a pressing portion which is slidable inward and outward and which can be heated is provided on the surface of the other mold, and the fusion of the foam beads and the fusion of the foam beads and the skin material are integrated. At the same time or after,
By sliding the pressed portion in the heated state inward, melting and pressing the formed in-mold foam, a reinforcing layer is formed on at least a part of the exposed surface of the in-mold foam. It is in.

According to a third aspect of the present invention, a skin material is placed on one of two molds constituting a molding die, the mold is clamped, and then the foamed beads are filled in the mold, and steam is charged. In the method for producing an in-mold foam molded article with a skin in which these foam beads are foamed by heating and fused with each other, and the foam beads and the skin material are fused and integrated, in the surface of the other mold, And a pressing portion that is slidable and heatable outward is provided, and before the fusion of the foam beads to each other and the fusion of the foam beads and the skin material, the pressing portion in a heated state is provided inside. In this case, the reinforcing layer is formed in advance on at least a part of the exposed surface of the formed in-mold foamed product by melting and pressing the foamed beads by sliding the foamed beads toward the surface.

According to a fourth aspect of the present invention, foamed beads are filled in a mold formed of two molds, and the foamed beads are foamed by steam heating and fused to each other. After forming the body, open the mold and then
A method of manufacturing an in-mold foam molded article with a skin, in which a skin material is arranged in one of the two molds and clamped, and the foam molded article and the skin material are fused and integrated by steam heating. There is provided on the surface of the other mold a pressing portion which is slidable inward and outward and which can be heated, simultaneously with or after fusion-integration of the in-mold foam molded body and the skin material. By pressing the heated pressing portion inward to melt and press the in-mold foam molded product, a reinforcing layer is formed on at least a part of the exposed surface of the in-mold foam molded product. is there.

According to a fifth aspect of the present invention, a foaming bead is filled in a molding die comprising two molds, and these foaming beads are foamed by steam heating and fused to each other. After forming the body, open the mold and then
A method of manufacturing an in-mold foam molded article with a skin, in which a skin material is arranged in one of the two molds and clamped, and the foam molded article and the skin material are fused and integrated by steam heating. A pressing portion which is slidable inward and outward and which can be heated is provided on the surface of the other mold, and heating is performed before the fusion molding of the in-mold foam molded body and the skin material. By sliding the pressing portion in the state inward to melt and press the in-mold foam molded product, a reinforcing layer is formed in advance on at least a part of the exposed surface of the in-mold foam molded product. It is in.

According to a sixth aspect of the present invention, before forming the reinforcing layer, the pressing portion is slid in advance outward from other portions to form a concave portion, and the pressing portion is formed in the concave portion. The present invention is to form a reinforcing layer by melting and pressing the protruding portion of the in-mold foam molded article or the filled foam beads by sliding the pressing portion in a heated state inward.

According to a seventh aspect of the present invention, a skin material is placed on one of two molds constituting a molding die, the mold is clamped, foamed beads are filled in the mold, and steam is charged. In a method for producing an in-mold foamed molded article with a skin, wherein the foamed beads are foamed by heating and fused with each other, and the foamed beads and the skin material are fused and integrated, an inner surface is formed on the surface of the one mold. And a pressing portion that is slidable outward is provided, and a heating portion that can be heated is provided on the surface of the other mold to fuse the foam beads with each other and fuse the foam beads with the skin material. Simultaneously with or after the integration, the pressing portion is slid inward, and the formed in-mold foam molded product is pressed and melted by the heated portion in a heated state, thereby forming the in-mold foam molded product. A reinforcing layer on at least part of the exposed surface of the It is to.

According to another aspect of the present invention, a skin material is placed on one of two molds constituting a molding die, the mold is clamped, and then the foamed beads are filled in the mold. In a method for producing an in-mold foamed molded article with a skin, wherein the foamed beads are foamed by heating and fused with each other, and the foamed beads and the skin material are fused and integrated, an inner surface is formed on the surface of the one mold. And a pressing portion that is slidable outward is provided, and a heating portion that can be heated is provided on the surface of the other mold to fuse the foam beads with each other and fuse the foam beads with the skin material. Before the integration, the pressing portion is slid inward, and the foam beads are pressed against the heating portion in a heated state and melted, so that at least the exposed surface of the in-mold foam molded body formed. Forming a reinforcing layer in advance in part In the Kukoto.

According to a ninth aspect of the present invention, a foaming bead is filled in a mold formed of two molds, and these foamed beads are foamed by steam heating, and are fused to each other. After forming the body, open the mold and then
A method of manufacturing an in-mold foam molded article with a skin, in which a skin material is arranged in one of the two molds and clamped, and the foam molded article and the skin material are fused and integrated by steam heating. There is provided a pressing portion which is slidable inward and outward on the surface of the one mold, and a heating portion which can be heated on the surface of the other mold, and the foaming in the mold is provided. Simultaneously with or after the fusion integration of the molded body and the skin material, the pressing portion is slid inward, and the in-mold foam molded body is pressed against the heating portion in a heated state, thereby melting. The object is to form a reinforcing layer on at least a part of the exposed surface of the in-mold foam molded article.

According to a tenth aspect of the present invention, foamed beads are filled in a mold formed of two molds, and these foamed beads are foamed by steam heating and fused to each other. After forming the body, open the mold, place the skin material on one of the two molds, close the mold, and fuse the in-mold foam molded body and the skin material together by steam heating. A method for producing an in-mold foam molded article with a skin, wherein a pressing portion slidable inward and outward is provided on the surface of the one mold, and the surface of the other mold is heated. A possible heating unit is provided, and before the fusion-integration of the in-mold foam molded body and the skin material, the pressing unit is slid inward to bring the in-mold foam molded body into a heated state. By pressing and melting the heating section, the exposed surface of the in-mold foam molded article is reduced. And also to advance forming the reinforcing layer in a part.

[0017]

Embodiments of the present invention will be described below with reference to the drawings. In the following first, second, and fifth embodiments, in the case where the in-mold foam molded body is formed after the skin material is disposed on the molding die, in the third and fourth embodiments,
The case where the skin material is arranged after the in-mold foam molded body is formed by the molding die will be described.

As shown in FIG. 1, the manufacturing method according to the first embodiment includes an in-mold foam molding 2 and a skin material 3 fused and integrated with the in-mold foam molding 2. Inner foam molding 2
Production of the in-mold foam molded article 1 with a skin provided with a reinforcing layer 4 formed by melting and pressing the in-mold foam molded article 2 at, for example, the central portion of the exposed surface 2a not covered with the skin material 3 It is related to.

As shown in FIGS. 2 to 6, this manufacturing method includes, for example, the female mold (one mold) 6 and the male mold (the other mold) 7 of the mold 5 as described above. 6 is the skin material 3
After placing and closing the mold, the inside of the mold 8 is filled with foam beads 9,
The foam beads 9 are foamed by steam heating and fused to each other, and the foam beads 9 and the skin material 3
Are fused and integrated.

At the center of the surface 7a of the male mold 7, for example, a pressing portion 10 slidable inward and outward and heatable is provided to fuse the foam beads 9 with each other and to form the foam beads. After the fusion and integration of the skin material 9 and the skin material 3, the pressed portion 10 in a heated state is slid inward to melt and press the formed in-mold foam molded body 2, thereby forming the inside of the mold. The reinforcing layer 4 is formed at, for example, a central portion of the exposed surface 2a of the foam molded article 2.

As shown in FIG. 2, the molding die 5 can be closed and opened, for example, in the vertical direction. The female die 6 as an upper die and the male die 7 as a lower die. 2
It consists of two molds.

Below the female mold 6, a middle mold 11 having, for example, a concave cross section is fixed, and a chamber 11b is formed therein. Further, a plurality of decompression holes 11c communicating with the chamber 11b are formed in the middle die 11.

Above the male mold 7, a middle mold 12 having, for example, a convex cross section is fixed, and a chamber 12b is formed therein.
Is also provided. The middle mold 12 has a plurality of steam holes 12c communicating with the chamber 12b.

The pressing portion 10 is provided on the surface 7 of the male mold 7.
a, for example, slidably provided in the center of the middle mold 12 inward and outward by sliding means (not shown),
For example, it can be heated to a predetermined temperature by a heating means such as an electric heater 14. In this embodiment,
Although the heating can be performed by embedding the electric heater 14 in the pressing portion 10, the heating is not limited to this, and the electric heater 14 may be fixed to the back surface 10 b side of the pressing portion 10, or may be, for example, heat. Other heating means such as a medium heater may be used.

In order to manufacture the in-mold foam molded article 1 with a skin, as shown in FIG. 3, first, the skin material 3 is placed on the female mold 6 by vacuum molding or the like, and the mold is closed. Is filled with foam beads 9.

Examples of the skin material 3 include a sheet made of a vinyl chloride resin or a polyolefin resin such as a polyethylene resin or a polypropylene resin.

Examples of the synthetic resin constituting the expanded beads 9 include a polyolefin resin and a polystyrene resin.

Next, as shown in FIGS. 4 and 5, a steam valve (not shown) connected to the chamber 12b of the male mold 7 is opened to supply steam S from the steam hole 12c into the mold 8, thereby forming the foam beads. The foamed beads 9 and the skin material 3 are fused and integrated with each other while the foamed beads 9 and the skin material 3 are fused together to form the in-mold foam molded body 2. In addition, at the time of this heating and foaming, the steam S at a temperature lower than the temperature at which they are fused to each other, if necessary, so that a fusion defect does not occur.
May be performed in advance, or the steam may be kept for a predetermined time in that state, and the drain may be removed by evacuation or the like after the steam.

Thereafter, the pressing portion 10 is kept in a heating state at a predetermined temperature, and as shown in FIGS. 5 and 6, the pressing portion 10 is slid inward to melt the in-mold foam molded body 2. By pressing, the reinforcing layer 4 is formed, for example, at the center of the exposed surface 2a of the in-mold foam molded body 2.

Then, after cooling as required, the mold is opened and removed from the mold.
If a is cut off or the like, the in-mold foam molded article 1 having a predetermined shape shown in FIG. 1 can be obtained.

As described above, the pressing portion 1 in the heated state
By melting and pressing the in-mold foam molded body 2 at 0,
Since the reinforcing layer 4 is formed on the exposed surface 2a of the in-mold foam molded article 2, there is an advantage that the foaming structure of the foam beads 9 hardly remains in the reinforcing layer 4, and the foaming structure can be further enhanced. Also, since the in-mold foam molded article 1 with the skin and the reinforcing layer 4 can be formed by the same molding die 5, there is an advantage that the number of steps can be reduced and the cost can be reduced. Further, the obtained in-mold foam molded article 1 with the skin has the advantage that the rigidity is higher because the reinforcing layer 4 is further enhanced as described above.

In addition, as in this embodiment, before forming the reinforcing layer 4, the pressing portion 10 is slid outward from the other portion 12 d in advance to form the concave portion 15. When the reinforcing layer 4 is formed by melting and pressing the protruding portion 16 of the in-mold foam molded body 2 formed in the concave portion 15 by the pressing portion 10 in a heated state, the in-mold foam molded body 2 Thus, the reinforcing layer 4 and the other portion 2d on the exposed surface 2a can be finished flat without any step. For this reason, there is an advantage that stress concentration due to a step when an external force acts on the in-mold foam molded article 1 with the skin can be prevented, and the rigidity can be further increased.

In this embodiment, the melting and pressing by the pressing portion 10 are performed after the in-mold foam molded body 2 is formed. However, the present invention is not limited to this. Therefore, it may be performed during the formation of the in-mold foam molded body 2, that is, simultaneously with the fusion of the foam beads 9 to each other and the fusion of the foam beads 9 and the skin material 3.

As shown in FIG. 7, the method of manufacturing the in-mold foam molded article 1 with a skin according to the second embodiment is the same as that of the first embodiment except that the foam beads 9 are filled into the mold 8 in the first embodiment.
Before the reinforcing layer 4 is formed, the heated pressing portion 10 is slid inward to melt and press the foam beads 9, thereby forming an in-mold foam formed by subsequent heat foaming. The reinforcing layer 4 is formed in advance, for example, in the central portion of the exposed surface 2a of the substrate 2, for example.

After the formation of the reinforcing layer 4, if the steam S is supplied from the steam holes 12 c to heat-foam the other foam beads 9, the in-mold foam molded article 1 with a skin can be obtained. .

As described above, since the foamed beads 9 before heating and foaming are melted and pressed by the pressing portion 10, the foamed beads 9 can be melted while being foamed, so that the reinforcing layer 4 can be more effectively formed. There is an advantage that it can be enhanced.

Also in this embodiment, the pressing portion 10 is slid out of the other portion 12d in advance to form the recess 15, and the foam beads 9 filled in the recess 15 are removed. The reinforcing layer 4 may be formed by melting and pressing at the pressing portion 10 in a heated state,
In this case, the reinforcing layer 4 and the other portion 2d on the exposed surface 2a can be finished in a flat state with no steps.

As shown in FIG. 8, the method of manufacturing the foamed molded article 1 with a skin according to the third embodiment is the same as that of the first embodiment, except that the foamed beads 9 are filled in the mold 8 and steam-heated. These foam beads 9 are foamed and fused together to form an in-mold foam molded body 2, then the mold is opened, the skin material 3 is placed on the female mold 6, and the mold is clamped. The in-mold foam molded body 2 and the skin material 3 are fused and integrated.

Then, the in-mold foam molded body 2 and the skin material 3
Simultaneously with or after the fusion integration, the pressing portion 10 in the heated state is slid inward to melt and press the in-mold foam molded body 2, as shown in FIG. The reinforcing layer 4 is formed at, for example, a central portion of the exposed surface 2a of the inner foam molded body 2.

As described above, after the in-mold foam molded body 2 is formed by in-mold foam molding, the skin material 3 can be fused and integrated with the same molding die 5 and the reinforcing layer 4 can also be formed. There is an advantage that the cost can be reduced and the cost can be reduced. Further, the foamed structure hardly remains in the reinforcing layer 4 formed by the pressing of the pressing portion 10,
There is an advantage that it can be further enhanced.

As shown in FIG. 9, the method for manufacturing the in-mold foam molded article 1 according to the fourth embodiment is the same as that of the third embodiment except that the in-mold foam molded article 2 and the skin material 3 are fused. Before the integration, the pressurized portion 10 in the heated state is slid inward to melt and press the in-mold foam molded body 2, as shown in FIG. The reinforcing layer 4 is previously formed, for example, at the center of the exposed surface 2a.

As described above, after the in-mold foam molded body 2 is formed, the skin material 3 is fused and integrated with the same molding die 5 and the reinforcing layer 4 can also be formed. This has the advantage that the number of steps can be reduced and the cost can be reduced. In addition, there is an advantage that the foamed structure hardly remains in the reinforcing layer 4 formed by the pressing of the pressing portion 10 and can be further enhanced.

In the third and fourth embodiments, after the in-mold foam molded body 2 is formed, the skin material 3 is integrated with the skin material 3 using the same molding die 5. It is desirable to use a relatively thin material of the skin material 3 of about 1 mm or less so that the mold can be smoothly clamped after the arrangement.

As shown in FIG. 10, the method of manufacturing the in-mold foam molded product 1 with a skin according to the fifth embodiment is the same as that of the first embodiment, except that, for example, a middle mold 11 fixed to the female mold 6 is used.
As a pressing portion 20 slidable inward and outward, and a heating portion 21 capable of heating the entire surface 7a of the male mold 7, for example, is provided to fuse and foam the foam beads 9 with each other. After the fusion of the beads 9 and the skin material 3, the pressing portion 20 is slid inward, and the formed in-mold foam molded body 2 is pressed and melted by the heating portion 21 in a heated state. By doing so, the reinforcing layer 4 is formed on, for example, the entire exposed surface 2a of the in-mold foam molded article 2.

As described above, the heating unit 21 provided on the male mold 7
Alternatively, the in-mold foam molded body 2 may be pressed and melted by the pressing portion 20 provided on the female mold 6 to form the in-mold foam molded body 2.
The reinforcing layer 4 can be formed on the exposed surface 2a.

In this embodiment, similarly to the second embodiment, after filling the foam beads 9 into the mold 8,
Before the reinforcing layer 4 is formed, the pressing portion 20 is slid inward, and the foam beads 9 are pressed and melted by the heating portion 21 in a heated state, thereby being formed by subsequent heating and foaming. The reinforcing layer 4 may be previously formed on the exposed surface 2a of the in-mold foam molded article 2. In this case, the heating unit 21 may be partially provided on the surface 7a of the male mold 7 so that the steam S can be supplied to the mold 8 even after the formation of the reinforcing layer 4.

Further, as in the third and fourth embodiments, the reinforcing layer 4 may be formed after the in-mold foam molded body 2 is formed in advance.

Further, as in the first to fourth embodiments, the heating unit 21 may be slidable inward and outward, and the heating unit 21 may be pressed.

In the first to fifth embodiments,
Although the case where the reinforcing layer 4 is formed at the central portion or the entirety of the exposed surface 2a of the in-mold foam molded body 2 has been described, the forming place, number, shape, and the like are not particularly limited, and the exposed surface 2a is not limited. A predetermined number may be formed as necessary in at least a part of. Further, the pressing portions 10 and 20 and the heating portion 21 are formed by a middle mold 1 fixed to a mold such as a female mold 6 or a male mold 7.
In addition to 1 and 12, it can be provided at a predetermined position on the surface of various molds. In addition, in order to increase the adhesive strength between the in-mold foam molded body 2 and the skin material 3 to be formed, an adhesive is applied to the skin material 3 arranged in the mold such as the female mold 6 or the like. ,
If necessary, an adhesive may be interposed between them.

[0050]

Next, the present invention will be described in more detail with reference to examples, but the present invention is not limited to these examples.

[Example 1] Of the two molds constituting a molding die, one mold was a female mold having a design pattern irregularity formed on the surface thereof, and the other mold was a female mold having an irregular surface. A male type having a pressing portion 10 slidable inward and outward and heatable at the center is provided.

A TPO sheet (thermoplastic polyolefin sheet, thickness: 0.5 mm) was used as a skin material, and after softening by heating, placed in the female mold and shaped (vacuum formed) using a vacuum pump. .

As expanded beads, Eperan PP (trade name,
(Kanebuchi Chemical Industry Co., Ltd., foaming ratio: 15 times, internal pressure of 2 kg / cm ² was previously applied by air pressure in a pressure vessel), the mold was clamped, and then filled into the mold. in this case,
Prior to filling the foam beads, the depression was previously slid outward from the other portions to form a recess.

Next, steam (steam pressure: 0.7 kg / cm ² · G) is supplied into the mold from the steam holes formed in the male mold, preheated, and the foamed beads are steamed for 5 seconds. The drain and water vapor were sucked and removed using a vacuum pump so that the pressure in the mold was 500 mmHg or less.

After that, steam (steam pressure 3.2 to 3.7 kg / cm ² · G) is again supplied from the steam hole into the mold, and 3 to 5 kg.
After holding for 2 seconds and performing main heating, an in-mold foam molded body having a protruding portion in the concave portion is formed, and then the pressing portion is heated to 230 ° C. to melt the protruding portion of the in-mold foam molded body. And pressed. Next, when the mold was opened after being cooled with water and allowed to cool, a reinforcing layer was formed at the center of the exposed surface of the in-mold foam molded article, and there was a stepless skin between the reinforcing layer and other parts. An in-mold foam molded article was obtained.

Example 2 Example 1 was repeated except that the expanded beads were melted and pressed while the pressing portion of the male mold was heated to 230 ° C. before filling the expanded beads into the mold and preheating. As a result, an in-mold foam molded article having a skin having a reinforcing layer on the exposed surface of the formed in-mold foam molded article was obtained.

[Example 3] In parallel with the steaming and the subsequent suction and removal of the drain and water vapor by a vacuum pump,
The same procedure as in Example 1 was carried out except that the male pressing portion was heated to 230 ° C. to melt and press the foam beads, with a skin having a reinforcing layer on the exposed surface of the formed in-mold foam. An in-mold foam molded article was obtained.

[0058]

As described above, according to the first aspect of the present invention, since the more solid reinforcing layer is formed on the in-mold foam molded article with the skin, there is an advantage that the rigidity is higher.

According to the second and seventh aspects of the present invention, the in-mold foam molded product is melted and pressed by the pressing portion in a heated state, or the heating portion in a heated state. The reinforcing layer is formed on the exposed surface of the in-mold foam molded article by being pressed and melted by the pressing portion, so that the foamed structure of the expanded beads hardly remains in this reinforcing layer, and it can be further enriched. There are advantages. Further, since the in-mold foam molded article with the skin and the reinforcing layer can be formed by the same mold, there is an advantage that the number of steps can be reduced and the cost can be reduced.

According to the third and eighth aspects of the present invention, the expanded beads before heating and foaming are melted and pressed by the pressing portion in the heated state, or are pressed by the pressing portion in the heated state. Since the beads are pressed and melted, the beads can be melted while being foamed, so that there is an advantage that the reinforcing layer can be more effectively enriched.

According to the fourth, fifth, ninth, and tenth aspects of the present invention, after the in-mold foam molded article is formed by the in-mold foam molding, the skin material is integrally fused with the same molding die. In addition, since a reinforcing layer can also be formed, there is an advantage that man-hours can be reduced and cost can be reduced. Further, there is an advantage that a foamed structure hardly remains in the formed reinforcing layer, and it can be further enriched.

According to the sixth aspect of the present invention, before forming the reinforcing layer, the pressing portion is slid out of other portions in advance to form a recess, and the recess is formed in the recess. The protruding part of the in-mold foam molded article or the foam beads to be filled,
Since the reinforcing layer is formed by sliding the pressing portion in the heated state inward to melt and press, the reinforcing layer on the exposed surface of the in-mold foam molded body and other portions are flat with no steps. It can be finished in a state. Therefore, there is an advantage that stress concentration due to a step when an external force acts on the inner foam molded article with the skin can be prevented, and the rigidity can be further increased.

[Brief description of the drawings]

FIG. 1 is a cross-sectional view of an in-mold foam molded article with a skin obtained by the manufacturing method according to the first to fourth embodiments.

FIG. 2 is a schematic cross-sectional view of a molding die used in the method for manufacturing the in-mold foam molded article with a skin according to the first embodiment.

FIG. 3 is a schematic cross-sectional view showing a state in which a skin material is arranged on the female mold shown in FIG. 2, the mold is clamped, and then foam beads are filled into the mold.

FIG. 4 is a schematic cross-sectional view showing a state in which foam beads are heated and foamed in a mold.

FIG. 5 is a schematic cross-sectional view showing a state in which a pressing portion in a heated state is slid inward.

FIG. 6 is a schematic cross-sectional view showing a state in which a reinforcing layer is formed by melting and pressing an in-mold foam molded product at a pressing portion.

FIG. 7 shows a method for producing an in-mold foamed article with a skin according to a second embodiment, in which after filling with foamed beads, the foamed beads are melted and pressed by a pressing portion in a heated state, so that a reinforcing layer is previously formed. FIG. 4 is a schematic cross-sectional view showing a formed state.

FIG. 8 is a schematic cross-sectional view showing a state in which an in-mold foam molded article is formed without disposing a skin material in the method for producing an in-mold foam molded article with a skin according to the third embodiment.

FIG. 9 is a cross-sectional view illustrating a method for manufacturing an in-mold foam molded article with a skin according to a fourth embodiment. FIG. 4 is a schematic cross-sectional view showing a state in which a reinforcing layer is formed by pressing.

FIG. 10 is a schematic diagram showing a state in which a reinforcing layer is formed by pressing and melting an in-mold foam molded body to a heating unit with a pressing unit in the method for manufacturing an in-mold foam molded body with a skin according to the fifth embodiment. Sectional view.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 In-mold foam molding with skin 2 In-mold foam molding 2a Exposed surface 3 Skin material 4 Reinforcement layer 5 Mold 6 Female mold (one mold) 6a surface 7 Male mold (the other mold) 7a Surface 8 mold Inside 9 Expanded beads 10, 20 Pressing part 12d Other parts 15 Concave part 16 Projecting part 21 Heating part

Claims (10)

[Claims] 1. An in-mold foam molded article with a skin, comprising: an in-mold foam molded article; and a skin material fused and integrated with the in-mold foam molded article, wherein an exposed surface of the in-mold foam molded article is provided. An in-mold foam molded article with a skin, wherein at least a part thereof is provided with a reinforcing layer formed by melting and pressing the in-mold foam molded article or foam beads constituting the in-mold foam molded article. 2. A skin material is placed on one of two molds constituting a molding die, and after clamping, the foamed beads are filled in the mold, and these foamed beads are foamed by steam heating. The foam beads and the skin material are fused and integrated with each other, and the foamed bead and the skin material are fused and integrated with each other. A pressable portion that can be heated is provided, and simultaneously with or after the fusion of the foam beads and the fusion and integration of the foam beads and the skin material, the press portion in a heated state is slid inward,
A method for producing an in-mold foam molded article with a skin, wherein a reinforcing layer is formed on at least a part of an exposed surface of the in-mold foam molded article by melting and pressing the formed in-mold foam molded article. . 3. A skin material is placed on one of two molds constituting a molding die, and after clamping, the foamed beads are filled in the mold, and these foamed beads are foamed by steam heating. The foam beads and the skin material are fused and integrated with each other, and the foamed bead and the skin material are fused and integrated with each other. A heating pressable portion is provided, and before the fusion of the foam beads to each other and the fusion of the foam beads and the skin material, the press portion in the heated state is slid inward to form the foam beads. Melting and pressing to form a reinforcing layer in advance on at least a part of the exposed surface of the in-mold foam molded article to be formed. 4. A foamed bead is filled into a mold of a mold composed of two molds, and the foamed beads are foamed by steam heating and fused together to form an in-mold foam molded article. After that, the skin material is placed in one of the two molds and the mold is clamped, and the foam molding in the mold and the skin material are fused and integrated by steam heating. A method for manufacturing a body, wherein a pressing portion which is slidable inward and outward and which can be heated is provided on the surface of the other mold, and the in-mold foam molded body and a skin material are fused and integrated. Simultaneously with or after that, the pressing portion in the heated state is slid inward to melt and press the in-mold foam molded body, thereby forming a reinforcing layer on at least a part of the exposed surface of the in-mold foam molded body. A method for producing an in-mold foamed article with a skin, comprising: 5. A foamed bead is filled in a mold of a mold composed of two molds, and the foamed beads are foamed by steam heating and fused together to form an in-mold foam molded article. After that, the skin material is placed in one of the two molds and the mold is clamped, and the foam molding in the mold and the skin material are fused and integrated by steam heating. A method for manufacturing a body, wherein a pressing portion which is slidable inward and outward and which can be heated is provided on the surface of the other mold, and the in-mold foam molded body and a skin material are fused and integrated. Before, the pressurized portion in a heated state is slid inward to melt and press the in-mold foam molded body, thereby forming a reinforcing layer on at least a part of the exposed surface of the in-mold foam molded body in advance. A method for producing an in-mold foam molded article with a skin, characterized by being formed. 6. Before forming the reinforcing layer, the pressing portion is slid outward from other portions in advance to form a concave portion, and the in-mold foam molded body formed in the concave portion projects. The reinforcing layer is formed by melting and pressing the pressing portion in a heated state, by pressing the pressing portion in a heated state, or by pressing the foamed beads filled therein. A method for producing an in-mold foam molded article with a skin. 7. A skin material is placed in one of two molds constituting a molding die, and after clamping, the foamed beads are filled in the mold, and these foamed beads are foamed by steam heating. A method for producing an in-mold foamed molded article with a skin in which these foam beads and the skin material are fused and integrated together with each other, and wherein the foamed beads and the skin material are slidable inward and outward on the surface of the one mold. Along with the pressing portion, a heating portion that can be heated is provided on the surface of the other mold, and simultaneously or after the fusion of the foam beads and the fusion of the foam beads and the skin material, or The pressing portion is slid inward, and the formed in-mold foam molded body is pressed against the heated portion in a heated state, and is melted, so that at least a part of the exposed surface of the in-mold foam molded body is formed. With a skin characterized by forming a reinforcing layer Method for producing a mold expanded molded product. 8. A skin material is placed in one of two molds constituting a molding die, and after clamping, the foamed beads are filled in the mold, and the foamed beads are foamed by steam heating. A method for producing an in-mold foamed molded article with a skin in which these foam beads and the skin material are fused and integrated together with each other, and wherein the foamed beads and the skin material are slidable inward and outward on the surface of the one mold. A pressing portion is provided, and a heating portion capable of heating is provided on the surface of the other mold, and the pressing is performed before the fusion of the foam beads and the fusion of the foam beads and the skin material. Part is slid inward, and the foamed beads are pressed and melted by the heating part in a heated state, thereby forming a reinforcing layer on at least a part of the exposed surface of the in-mold foam molded article to be formed in advance. With a skin characterized by leaving Method of manufacturing an inner foamed molded. 9. A foamed bead is filled in a mold of a mold composed of two molds, these foamed beads are foamed by steam heating, and they are fused to each other to form a foamed molded article in a mold. After that, the skin material is placed in one of the two molds and the mold is clamped, and the foam molding in the mold and the skin material are fused and integrated by steam heating. A method of manufacturing a body, wherein a pressing portion slidable inward and outward is provided on a surface of the one mold, and a heating portion capable of heating is provided on a surface of the other mold. Simultaneously with or after the fusion integration of the in-mold foam molded article and the skin material, the pressing section is slid inward, and the in-mold foam molded article is pressed against the heating section in a heated state, By melting, a reinforcing layer is formed on at least a part of the exposed surface of the in-mold foam molded article. Method for manufacturing a skin-integrated type foamed articles, characterized by forming. 10. A foamed bead is filled in a mold of a mold composed of two molds, these foamed beads are foamed by steam heating, and are fused together to form an in-mold foam molded body. After that, the skin material is placed in one of the two molds and the mold is clamped, and the foam molding in the mold and the skin material are fused and integrated by steam heating. A method of manufacturing a body, wherein a pressing portion slidable inward and outward is provided on a surface of the one mold, and a heating portion capable of heating is provided on a surface of the other mold. Before the fusion-integration of the in-mold foam molded product and the skin material, the pressing portion is slid inward, and the in-mold foam molded product is pressed and melted by the heating portion in a heated state. Thereby, a reinforcing layer is previously formed on at least a part of the exposed surface of the in-mold foam molded article. Method for manufacturing a skin-integrated type foamed articles, characterized in that to be formed.