JP2001187411A - Method for manufacturing foam molded product - Google Patents

Abstract

PROBLEM TO BE SOLVED: To prevent urethane foam from leaking out from near an edge in addition to prevention of flexure or slippage of the edge part by providing a slide core which advances or retreats in a horizontal direction not generating friction to the edge part when a top force is clamped. SOLUTION: A core material Xb is set to a top force 5, and a skin material Xa is set to a bottom force 3. In this state a slide core 21 advancing or retreating almost horizontally is advanced, and an outside face of an edge part 9 is positioned by being held by abutting against an abutting surface. Then, a raw material for urethane foam Xc is poured onto a rear face side of the skin material. Thereafter, the top force is lowered, and slide core is retreated to clamp a mold. The edge part is held by a projected part 13 of the core material thereby and positioned. Thereafter, the raw material of urethane foam is foamed by a temperature of the mold between the core material and the skin material, and an instrument panel X having partly a pad part 7 wherein the urethane foam is allowed to intervene between the core material and the skin material, is integrally molded.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for producing a foamed molded product by foaming a foamed material between a core material and a skin and integrally molding the foamed molded product. And foaming a foamed raw material between them to obtain a foamed molded product.

[0002]

2. Description of the Related Art In general, among interior parts for automobiles, a sunshade or the like is configured such that the surface of a core material is entirely covered by a skin through a foam material. Such a sunshade is sandwiched between an upper mold having a core material, a lower mold having a skin set thereon, and the upper mold and the lower mold, as disclosed in, for example, Japanese Patent Application Laid-Open No. 5-228943. And an intermediate mold for forming an end face of the foam layer.

[0003] However, such a method for producing a foamed molded article is suitable for a method in which the surface of a core material is entirely covered by a skin, but it has a decorative property such as an instrument panel and a function of cushioning impact upon collision. Is required,
In some cases, the surface of the core material is partially covered by the skin via the foam layer. In this case, a method of manufacturing a foam molded product such as a sunshade that entirely covers the surface of the core material with the skin as described above is a method of manufacturing a foam molded product such as an instrument panel that partially covers the surface of the core material with the skin. Can not be applied as.

[0004] Therefore, conventionally, when manufacturing a foam molded product such as an instrument panel, for example, as disclosed in JP-A-7-329077, an edge portion provided at an end portion of a skin is upward. The upper skin is set in the lower mold so as to protrude to the mold side, and the core material is set in the upper mold so that the protrusions of the core material correspond to the edges of the skin, and the upper mold is While the support member protruding and retracting substantially parallel to the moving direction is projected to hold and position the edge portion of the skin from the outside, the support member is slid with respect to the outside surface of the edge portion during mold clamping. With the member immersed below, the positioning of the edge is released, and when the mold is clamped, the edge of the skin is held from the outside with the protrusion of the core instead of the support member, and the core and the skin are positioned. Foaming material injected during By bubbling, the method in which the surface of the core material to produce a foamed molded article having a pad portion which is partially covered is taken by the skin.

[0005]

However, in the above-mentioned method of manufacturing a foam molded product in which the surface of the core material is partially covered with the skin, the support member slides into the outer surface of the edge portion and sinks. The edge portion is dragged in the falling direction with the immersion of the support member due to the friction at the time of sliding (at the time of immersion). In this case, since the edge portion itself is soft and flexible, if the edge portion is dragged in the falling direction by the support member, the edge portion may be bent or shifted. For this reason, inaccuracy arises in positioning when the convex portion of the core material is brought into contact with the outer side of the edge portion in place of the immersed support member, thereby causing an inaccuracy in positioning. It is feared that the foamed raw material leaks out from the vicinity of the edge portion due to such a problem that the foamed material cannot be formed.

SUMMARY OF THE INVENTION The present invention has been made in view of the above circumstances, and an object thereof is to provide a slide core in a lower mold and to move the upper mold in the mold clamping direction with respect to an outer surface of an edge portion. The sliding core is retracted in a direction that does not cause friction to reliably prevent deflection and displacement of the edge portion, and also to surely prevent leakage of the foamed material from near the edge portion.

[0007]

Means for Solving the Problems In order to achieve the above object, a solution taken by the invention according to claim 1 is to form a foam molded article integrally by foaming a foaming material between a core material and a skin. As a method of manufacturing a foamed molded product, the skin is set on the lower mold so that the edge provided at the end of the skin protrudes toward the upper mold, and the slide core is moved forward and backward in a substantially horizontal direction. The contact portion is positioned by being brought into contact with the edge portion of the skin in a substantially vertical direction from the outside in the vertical direction, and the core material is set on the upper mold so that the projection of the core material corresponds to the edge portion of the skin. Next, while lowering the upper mold,
The slide core is retracted and mold-clamped, and the edge of the skin is abutted from the outside by the convex portion of the core material and positioned. Thereafter, the foamed raw material injected in the mold opened state or after the mold is closed is foamed to obtain a foam molded article in which the foam layer is integrally molded between the core material and the skin.

According to the first aspect of the present invention, the contact portion of the slide core, which abuts the edge portion of the skin from the outside in a substantially vertical direction at the forward position, moves in the horizontal direction when the upper mold is clamped. As a result, the contact portion does not cause friction or the like to the edge portion (outer surface) when the slide core is retracted. Therefore, the soft and flexible edge portion is not dragged in the falling direction with the retraction of the slide core, and the edge portion is effectively prevented from being bent or shifted. In addition, when the mold is clamped, the accuracy of positioning the edge portion by contacting the convex portion of the core material with the edge portion instead of the contact portion is secured, and the convex portion accurately contacts the outside of the edge portion, Leakage of the foam material from the vicinity of the edge is reliably prevented.

The solution taken by the invention according to claim 2 is as follows.
In addition to the constituent features of the first aspect of the present invention, the upper mold is lowered so that the convex portion of the core material comes into contact with the edge portion of the skin from obliquely upward facing the edge portion of the skin during mold clamping.

According to the second aspect of the present invention, the convex portion of the core material contacts the edge portion from an obliquely upper surface facing the edge portion at the time of mold clamping. Even if there is a slight time difference in the timing of positioning the abutting part of the core material in contact with the part, the edge part may be bent or displaced in the falling direction,
The protruding portion of the core material reliably contacts the edge portion to correct the deflection or displacement of the edge portion, and leakage of the foam material from near the edge portion is more reliably prevented.

[0011]

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

FIGS. 1 to 3 show a molding die as a molding die used for molding an instrument panel (foam molded product) of an automobile. Here, as shown in FIG. 4, the molding die 1 (which is entirely shown in FIG. 2) is used to form a core Xb and a skin Xa (skin) partially covering the surface of the core Xb. An example of manufacturing an instrument panel X having a pad portion 7 having a cushioning property with an urethane foam Xc (foam layer) interposed therebetween as an integral part is illustrated. The molding die 1 includes a fixed lower mold 3 and a mold opening direction with respect to the lower mold 3 (arrow a shown in FIG. 2).
The movable upper die 5 which can be moved up and down in the mold clamping direction (the direction of the arrow a shown in FIG. 2) and the lower die 3 can move horizontally in one side (the left side in the figure). An example of a method for manufacturing an instrument panel X using the molding die 1 will be described below with reference to FIGS. 1 to 3.

First, as a first step, as shown in FIG. 1, the skin material Xa is provided such that an edge portion 9 provided at one end (left side in the figure) of the skin material Xa projects toward the upper mold 5 side.
Is set on the lower mold 3 with its front surface facing downward, and the skin material Xa is brought into close contact with the lower mold 3 by negative pressure from a vacuum suction hole (not shown). On the other hand, as shown in FIG. 2, the core material Xb is set on the upper die 5 with its back surface facing upward such that the protrusions 13 of the core material Xb correspond to the edge portions 9 of the skin material Xa. Here, as the skin material Xa, one preformed by vacuum forming or slash molding, which is a general manufacturing method, is used, and also, the core material Xb, which is preformed by conventional compression molding or injection molding, is used. .

Then, in a state where the skin material Xa and the core material Xb are set in the molding die 1, respectively, the first contact surface 23 as the first contact portion and the second contact portion as the second contact portion are provided. The slide core 21 having the two contact surfaces 25 is advanced (the state shown in FIG. 1), and the outer surface of the edge portion 9 of the skin material Xa abuts on the first contact surface 23 from the outside in a substantially vertical direction. And the edge portion 9 is prevented from falling outward by the first contact surface 23.

Next, as a second step, an injection device (injection) is applied to the exposed surface (back surface) of the skin material Xa in the molding die 1 in an open state, that is, between the core material Xb and the skin material Xa. (Not shown), a raw material (foaming raw material) of urethane foam Xc as a foam layer is injected. Here, the raw material of the urethane foam Xc is injected by a so-called open injection method, but the raw material of the urethane foam may be injected by a closed injection method in which the upper die 5 is closed with respect to the lower die 3.

Thereafter, as a third step, the upper die 5 is lowered from diagonally above in the direction of arrow a shown in FIG. 2, and the slide core 21 is retracted as shown in FIG. 2 to clamp the mold (the state shown in FIG. 3). Then, instead of the first contact surface 23, the edge portion 9 of the skin material Xa is abutted from outside by the convex portion 13 of the core material Xb and positioned, and the slide core 2 is positioned.
A rubber sheet 27 as an elastic material provided on the first second contact surface 25 and the upper die 5 elastically clamp the outer end edge of the core Xb outside the projection 13.

In this case, in the third step, the first contact surface 23 of the slide core 21 for holding the edge 9 of the skin material Xa.
However, when the upper die 5 is clamped, the upper die 5 is separated from the edge portion 9 in a direction substantially perpendicular to the edge portion 9. Therefore, when the slide core 21 is retracted, the first contact surface 23 generates friction against the outer surface of the edge portion 9. As the slide core 21 retreats, the soft and flexible edge portion 9 is not dragged in the falling direction, so that the bending and displacement of the edge portion 9 can be effectively prevented. Moreover, in the third step, the convex portion 13 of the core member Xb comes into contact with the outer surface of the edge portion 9 from an obliquely upper position facing the outer surface of the edge portion 9 at the time of mold clamping. Instead, there is a slight time difference in the timing at which the inner surface of the projection 13 of the core member Xb abuts on the outer surface of the edge 9, and the edge 9 is bent or displaced in the falling direction. Also, the convex portion 1 of the core material Xb
The inner side surface 3 reliably abuts against the outer side surface of the edge portion 9 to correct the deflection and displacement of the edge portion 9, and it is possible to reliably prevent the urethane foam Xc from leaking from the vicinity of the edge portion 9.

In the third step, the rubber sheet 27 elastically slides the outer end edge of the core member Xb from the obliquely upper side with respect to the second contact surface 25 of the slide core 21 at the time of mold clamping. In addition, it is possible to reliably prevent the core member Xb, which is the front side of the instrument panel X, from being damaged by sliding contact with the outer edge, thereby improving the quality of the instrument panel X. Further, in the third step, the second contact surface 25 is brought into contact with the upper die 5 via the core Xb at the retracted position of the slide core 21, so that the holding of the core Xb is ensured. For this reason, the single slide core 21 moves the skin material X at the advanced position.
The function of holding the edge portion 9a from the outside and the function of holding the core Xb at the retracted position are provided, so that the slide core 21 can be used effectively.

Thereafter, as a fourth step, the core material Xb and the skin material Xa are controlled in the state shown in FIG.
Between the core material Xb and the skin material Xa to partially form the pad portion 7 having the urethane foam Xc interposed between the core material Xb and the skin material Xa (the instrument panel after final molding shown in FIG. 4). (In the case of X, the upper part) is integrally formed.

It should be noted that the present invention is not limited to the above embodiment, but includes various other modifications. For example, in the above embodiment, the skin material Xa is
The slide core 21 is moved forward in the state of being set to, and the first contact surface 23 is brought into substantially vertical contact with the outer surface of the edge portion 9 of the skin material Xa from the outside to position the edge portion 9. First, the skin material is set in the lower mold in a state in which the slide core is advanced and positioned at the advanced position, and the first contact surface is brought into substantially vertical contact with the outer surface of the edge portion of the skin material from the outside. Alternatively, the edge portion may be positioned.

Further, in the above embodiment, the instrument panel X is applied as a foam molded product, but it is needless to say that the instrument panel X may be applied to interior components such as a door trim and a console box.

[0022]

As described above, according to the method for manufacturing a foamed molded product according to the first aspect of the present invention, the contact portion of the slide core is separated from the edge portion in a direction substantially perpendicular to the edge portion during mold clamping. In addition to effectively preventing flexing and displacement of the edge in the falling direction due to friction when the contact part separates, foam material leaks from near the edge by accurately positioning the edge with the convex part Can be reliably prevented.

According to the method for manufacturing a foamed molded product according to the second aspect of the present invention, the convex portion of the core material is brought into contact with the edge portion from obliquely above the edge portion when clamping the mold. Instead, the edge part can be reliably positioned by the convex part while correcting the deflection and displacement of the edge part in the falling direction due to a slight time difference when positioning the edge part with the convex part of the core material, and from the vicinity of the edge part Leakage of the foaming material can be more reliably prevented.

[Brief description of the drawings]

FIG. 1 is a vertical sectional front view of a lower mold showing a mold opening state of a molding die.

FIG. 2 is a vertical sectional front view showing a state immediately before a molding die according to an embodiment of the present invention shifts to a mold clamping state.

FIG. 3 is a vertical cross-sectional front view showing a closed state of a molding die.

FIG. 4 is a perspective view showing a state where an instrument panel is partially in a longitudinal section.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Mold (mold) 3 Lower mold 5 Upper mold 9 Edge part 13 Convex part 21 Slide core 23 First contact surface (contact part) 27 Rubber sheet (elastic material) X Instrument panel (foam molded product) ) Xa skin material (skin) Xb core material Xc urethane foam (foam layer)

──────────────────────────────────────────────────続 き Continued on the front page (51) Int.Cl. ⁷ Identification symbol FI theme coat ゛ (Reference) B29L 31:30 B29L 31:30

Claims (2)

[Claims] 1. A method for producing a foamed molded product by foaming a foamed raw material between a core material and a skin and integrally molding the foamed molded product, wherein an edge provided at an end of the skin is an upper mold. The above-mentioned outer skin is set on the lower mold so as to protrude to the side, and the abutting portion is positioned so as to abut on the edge portion of the outer skin in a substantially vertical direction from the outer side at the forward position of the slide core which can be advanced and retracted in a substantially horizontal direction. At the same time, the core material is set on the upper mold so that the protrusions of the core material correspond to the edge portions of the skin, and then the upper mold is lowered, and the slide core is retracted to clamp the mold. The edge of the skin is positioned in contact with the outside from the convex portion of the outer surface, and then the foaming material injected in the mold opened state or after the mold is closed is foamed, so that the foam layer is formed between the core material and the skin. Is to obtain a foam molded product integrally molded Method for producing a foam molded article. 2. The foam according to claim 1, wherein the upper mold is lowered so as to abut the convex portion of the core material from an obliquely upper side facing the edge portion of the skin when the mold is clamped. Manufacturing method of molded article.