JP2002052548A - Skin seal structure of foamed molded product with skin - Google Patents

Abstract

PROBLEM TO BE SOLVED: To enable the rationalization of molding work and the reduction of molding cost by dispensing with a molding preparation process for preventing the leak of urethane foam. SOLUTION: A first joining piece 32 is formed to the end edge of a first skin 14, and the second joining piece 34 mutually overlapped with the first joining piece 32 is formed to the end edge of a second skin 16. The contact part with the first and second joining pieces 32 and 34 overlapped with each other is provided to the inner wall surface 12a of a base material 12. When a first foaming mold 42, to which the base material 12 is set, and a second foaming mold 44, to which the first and second skins 14 and 16 are set, are clamped, the first and second joining pieces 32 and 34 are closely bonded and sealed by the pressing of the contact 36 to prevent the leak of urethane foam 18 from the gap between both joining pieces 32 and 34.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a skin seal structure for a foam molded article with a skin, and more particularly, to a base molded into a required shape in a first foam molding die.
The first skin and the second skin formed into a required shape are set in a second foaming mold, and urethane foam is formed in a foaming space defined between the base material and the both skins by closing both molds. The present invention relates to a skin seal structure for preventing the urethane foam from leaking from a joint end portion between the first skin and the second skin when the foamed article is molded by foaming.

[0002]

2. Description of the Related Art As a foam molded article with a skin formed by foaming urethane foam in a foaming space defined between a base material formed into a required shape and a skin formed into a required shape, for example, a passenger car There is an instrument panel, a floor console, a door panel, etc. installed in the passenger compartment of the vehicle. Such a foamed molded article with the skin obtains the overall rigidity by the base material, improves the texture of the appearance of the foamed molded article by the skin, and further utilizes the elasticity of the urethane foam or the like. It is designed to improve tactile sensation and absorb shock.

FIG. 2 is a perspective view showing an instrument panel as an example of the above-mentioned foam molded article with a skin. In this instrument panel 10, two kinds of skins (first skin 14 and first skin 14) having different color tones and the like are used. By using the two skins 16), the texture of the appearance is further improved. That is, by using the first skin 14 in the upper half and the second skin 16 in the lower half with the upper and lower middle part of the instrument panel 10 as a boundary, the whole is color-coded in a two-tone color, and a single skin is formed. A higher quality can be obtained as compared with a single color tone using.

[0004]

When the first skin 14 and the second skin 16 are used as in the instrument panel 10, the base material 12 and the first skin are used.
When the urethane foam 18 is formed in the foaming space 20 defined between the skin 14 and the second skin 16, the urethane foam 18 is prevented from leaking from the gap between the joint ends of the two skins 14, 16. It is necessary to take measures.
Here, as a skin seal structure for preventing leakage of the urethane foam 18, for example, an adhesive tape 26 is attached to the joint end portion 22 of the first skin 14 and the joint end portion 24 of the second skin 16 which are in contact with each other. A seal structure (FIG. 9) for covering and joining the joint, a concave portion 28 is provided at the joint end portion 22 of the first skin 14, and a convex portion 30 is provided at the joint end portion 24 of the second skin 16. A seal structure (FIG. 10) using a fastener form for engaging the convex portion 30 is provided for implementation.

[0005] However, the above-mentioned skin seal structure requires a molding preparation step for applying the adhesive tape 26 in a state of straddling both the joint ends 22 and 24.
In addition, in the above-mentioned skin seal structure, a molding preparation step for engaging the concave portion 28 and the convex portion 30 is required. Therefore, in any case, the number of working steps is increased and the molding cost is increased. Was. Moreover, in the skin seal structure, the adhesive tape 2 as a separate member is used.
It was pointed out that the cost was increased due to the increase in the number of parts because the number of components was 6.

[0006]

SUMMARY OF THE INVENTION The present invention has been proposed to solve the above-mentioned problems suitably. A first foaming mold in which a base material is set and a second foaming mold in which a first skin and a second skin are set. When the mold is closed, the first joining piece and the second joining piece of both skins overlapping each other are forcibly attached to the wall surface of the second foaming mold at the contact portion provided on the base material. A skin seal structure of a foam molded article with a skin is provided in which a pressing preparation step for preventing leakage of urethane foam is made unnecessary by forming the two joining pieces so as to be in close contact with each other by pressing. The purpose is to:

[0007]

SUMMARY OF THE INVENTION In order to solve the above-mentioned problems and to achieve the desired object, the present invention sets a base material formed into a required shape in a first foaming mold and forms the substrate into a required shape. The first skin and the second skin are set in a second foaming mold, and urethane foam is foamed in a foaming space defined between the base material and the two skins by closing both molds. A skin seal structure for preventing the urethane foam from leaking from a joint end portion between the first skin and the second skin when forming a foamed molded product,
A first joint piece integrally formed on an edge of the first skin and a second joint integrally formed on an edge of the second skin and overlapping the first joint; One part, formed on the inner wall surface of the substrate facing the foaming space side,
The first and second foaming molds are brought into contact with the first joining piece and the second joining piece that overlap when the mold is clamped, and both joining pieces are forcibly pressed against the wall surface of the second foaming mold. The urethane foam is prevented from leaking from a gap between the two joining pieces under the sealing action of the first joining piece and the second joining piece by pressing the contacting part. It is characterized in that it is configured to obtain.

[0008]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Next, a skin seal structure of a foam molded article with a skin according to the present invention will be described below with reference to the accompanying drawings by way of preferred embodiments. In the embodiment, the instrument panel 10 shown in FIG. 1 is exemplified as a foam molded article with a skin, and the same members as those shown in FIGS. 9 and 10 are described with the same reference numerals.

FIG. 1 is a sectional view taken along the line II of FIG.
1 shows a skin seal structure of a foam molded article with a skin according to a preferred embodiment of the present invention. The instrument panel 10 as a foam molded article with a skin includes a base material 12 formed into a required shape, a first skin 14 and a second skin 16 formed into a required shape, and the base material 12, the first skin 14 and Urethane foam 1 with foam interposed between second skins 16
And 8. As shown in FIG. 1, the skin seal structure of the present embodiment based on this premise is the first skin 1 shown in FIG.
A first joining piece 32 formed integrally with an end of the fourth joining piece;
A second joining piece 34 formed integrally with the edge of the second skin 16 and overlapping the first joining piece 32.
And a contact portion 36 formed on the inner wall surface 12a of the base material 12 facing the side of the foaming space 20, and abutting on the first joint piece 32 and the second joint piece 34. .

The base material 12 is formed by integrally injection-molding an olefin resin material such as polyethylene or polypropylene by using, for example, an injection mold (not shown). As shown in FIG. The shape is based on the design shape. Then, an instrument unit, a glove box, an air-conditioning operation panel, which is installed on the instrument panel 10,
Various installation sections for installing audio equipment, air outlets, and the like are formed and have sufficient strength to allow installation of these apparatuses and equipment.

As shown in FIGS. 1, 3 and 4, the contact portion 36 formed on the inner wall surface 12a of the base material 12 is provided with the first joint piece portion of the first skin 14 overlapping each other. 32 and a plurality of abutting rib pieces 38 erected at required intervals and directed toward the second joint piece 34 of the second skin 16. Each of these contact rib pieces 38
Are arranged at required intervals along the extending direction of the first joint piece 32 and the second joint piece 34, and thus are arranged in the horizontal direction in the left-right horizontal direction substantially at the center of the inner wall surface 12 a of the base material 12. It is formed for each required interval. Then, as described later, the base material 12 is set in a first foaming mold 42 of a foaming mold 40, and the first skin 14 and the second skin 16 are set in a second foaming mold of the foaming mold 40. With the setting at 44, the first and second foaming molds 42 and 44 are closed (closed) to form the urethane foam 18.
Then, the first joining piece 32 and the second joining piece 34 overlapping each other are attached to the tip 3 of each contact rib piece 38.
8a is set so as to abut. Therefore, the first joining piece 32 and the second joining piece 34 are held in close contact with each other by being sandwiched between the tip 38a of each contact rib piece 38 and the set surface 44a of the second foam molding die 44. Is to be achieved. The interval between the contact rib pieces 38 is such that the expansion movement of the urethane foam 18 foaming in the foaming space 20 is not hindered.
And when it comes into contact with the second joining piece 34, the two joining pieces 3
It is set on the premise that each of the conditions is satisfied to prevent the urethane foam 18 from leaking out by making the entire surfaces 2 and 34 adhere to each other.

The first skin 14 and the second skin 16 are
A resin sheet material made of polyethylene, polypropylene, or the like is vacuum-molded using a vacuum molding die (not shown), or a resin sheet is formed by powder slush molding using a powder slush molding die (not shown), The instrument panel 10 is integrally formed into a shape that conforms to the outer shape of the instrument panel 10, and has a different color tone, texture, and the like. The first skin 14 is attached to the upper half of the base material 12 with the upper and lower middle portions of the instrument panel 10 as boundaries, and the first joint piece 32 is integrally formed at the front lower end edge. Have been. On the other hand, the second skin 16 is attached to the lower half of the base material 12 with the upper and lower middle portions of the instrument panel 10 as boundaries, and the second joining piece 34
Are integrally formed. As shown in FIG. 1, the first skin 14 and the second skin 16 thus formed are
The first joint piece 3 of the first skin 14 is attached to the
2 overlaps the outside of the second joining piece 34 of the second skin 16 in an overlapping state. The first joining piece 3
Since the edge of 2 is exposed outside the instrument panel 10, it is preferable to perform a shaping process in order to improve the texture.

As shown in FIG. 7, the urethane foam 18 sets the base material 12 on the setting surface 42a of the first foaming mold 42 in the foaming mold 40 and the second foaming mold 40 in the mold 40. With the first skin 14 and the second skin 16 set on the setting surface 44a of the foaming mold 44, the base material 12 and the foaming space 20 defined by the first skin 14 and the second skin 16 are formed. It is formed by foaming and solidifying a urethane stock solution. Then, the foamed and solidified urethane foam 18 is completely adhered to the base material 12 and the first skin 14 and the second skin 16 to form the instrument panel 10 as a foam molded article with a skin. Since the urethane foam 18 has appropriate elasticity, when it is pressed from outside the first skin 14 or the second skin 16 with a fingertip or the like, the urethane foam 18 is appropriately elastically deformed into a concave shape, thereby improving the tactile sensation. I have.

Next, assuming the skin sealing structure of the foam molding apparatus with a skin according to the present embodiment, a molding mode of the instrument panel 10 will be schematically described. The base material 12
And the first skin 14 and the second skin 16 are preliminarily formed into a required shape in the previous step, and the inner wall surface 12a of the base material 12 is formed.
Each of the contact rib pieces 38 of the contact portion 36 is integrally formed, the first joint piece 32 is integrally formed with the first skin 14, and the second joint piece 32 is formed with the second skin 16. The part 34 is integrally formed.

Prior to the foam molding of the urethane foam 18, the preformed base material 12, the first skin 14 and the second skin 16 are set in a foam molding die 40 for foam molding the urethane foam 18. I do. That is, as shown in FIG. 5, in the first foaming mold 42 of the foaming mold 40, the base material 12 is set at a required position on the setting surface 42a. In the second foaming mold 44, first, the first skin 14 is set at a required position on the setting surface 44a, and then the second skin 16 is placed at a required position on the setting surface 44a.
Is set. As a result, the first joint piece 32 of the first skin 14 and the second joint piece 34 of the second skin 16 overlap each other. Note that an adhesive may be applied to the back surface of the first joint piece 32 or the surface of the second joint piece 34 as necessary.

When the setting of the first skin 14, the second skin 16, and the base material 12 is completed, as shown in FIG. Tighten (close). At this time, the respective contact rib pieces 38 formed on the base material 12 are close to the first joint piece part 32 of the first skin 14 and the second joint piece part 34 of the second skin 16 overlapping each other. When the clamping of the first foaming mold 42 with respect to the second foaming mold 44 is completed, the distal end 38a of each contact rib piece 38 comes into contact with the second joining piece 34, and the second joining piece 34 The portion 34 and the first joining piece 32 are forcibly pressed against the set surface 44 a of the second foaming mold 44. Thereby, the first joint piece 32 and the second
The joining piece 34 is sandwiched between the tip 38a of each contact rib piece 38 and the set surface 44a of the second foaming mold 44,
Maintained in a sealed state with full contact with each other
(FIG. 7).

It should be noted that the first foaming mold 42 and the second
By injecting a required amount of a urethane raw material prior to the closing of the foaming mold 44, the base material 12, the first skin 14, and the second skin 16 are defined after the closing of the two dies 42, 44. The foaming reaction of the urethane raw material starts in the formed foaming space 20. Then, as shown in FIG. 7, the urethane raw material moves in the foaming space 20 while foaming and expanding between the contact rib pieces 38, and eventually fills the entire inside of the foaming space 20. However, the urethane foam 18 which expands and expands under the sealing action by the close contact of the first joint piece 32 and the second joint piece 34 with both joint pieces 3.
It is prevented from entering into the gap between 2, 34, and the urethane foam 18 is suitably prevented from leaking to the front (outer surface) side of the instrument panel 10.

As described above, in the skin sealing structure of the foam molded article with the skin according to the present embodiment, the base material 12 integrally formed with the respective contact rib pieces 38 is set in the first foam molding die 42 and 1st skin 1 in which 1 joining piece 32 is integrally formed
The second skin 36 in which the fourth and second joint pieces 34 are integrally formed.
Is set in the second foaming mold 44, and the normal operation of clamping both foaming molds 42, 44 is simply performed, and the entire surface of the first joining piece 32 and the second joining piece 34 is A sealing state is formed by the close contact. That is, as in the conventional skin seal structure shown in FIGS. 9 and 10, the first joint piece 32 and the second skin 1 of the first skin 14 are formed.
6, a preliminary molding step for sealing the second joining piece portion 34 is unnecessary, and simplification, rationalization, and cost reduction of the molding operation can be achieved by reducing the number of operation steps. Further, in sealing the first joint piece 32 and the second joint piece 34, no other members other than the base material 12 and the skins 14, 16 are used, so that cost reduction can be expected.

The contact portions 36 for bringing the first and second joining pieces 32 and 34 into close contact with each other are a plurality of contact rib pieces 38 erected at required intervals. While ensuring the overall close contact between the joining pieces 32, 34, it does not become an obstacle when the foaming urethane foam 18 fills the foaming space 20.

FIG. 8 shows an instrument panel 10 as a foam molded product with a skin of a type in which accessory parts 46 such as decorative parts are retrofitted on the outer surface of the skin. The first joint piece 32, the second joint piece 34, and the contact rib piece 38 are arranged in the installation portion 48 of the accessory 46. Thus, when the accessory 46 is mounted on the installation scheduled portion 48, the edge of the first joining piece 32 is completely covered and is not exposed to the outside, and the edge of the first joining piece 32 is shaped. There is an advantage that the processing can be omitted.

[0021]

As described above, according to the skin sealing structure of the foam molded article with the skin according to the present invention, the base material integrally formed with the respective contact rib pieces is set in the first foam molding die, and The usual work of clamping both foaming molds under the condition that the first skin in which one joining piece is integrally molded and the second skin in which the second joining piece is integrally molded is set in the second foaming mold. Only by performing this, a sealing state is formed by the close contact between the first joining piece and the second joining piece. That is,
There is no need for a preliminary molding step for sealing the joint between the first skin and the second skin, and there is an advantageous effect that simplification, rationalization, cost reduction, and the like can be achieved by reducing the number of work steps. Further, when the first joint piece and the second joint piece are sealed, no other members other than the base material and the respective skins are used, so that cost reduction can be expected.

The contact portions for bringing the first and second joint pieces into close contact with each other are a plurality of contact rib pieces formed upright at required intervals. While ensuring full adhesion, it does not become an obstacle when the foaming urethane foam fills the foaming space.

[Brief description of the drawings]

FIG. 1 is a cross-sectional view taken along the line II of FIG. 2, and shows a skin seal structure of a foam molded article with a skin according to an embodiment of the present invention.

FIG. 2 is a perspective view of an instrument panel exemplified as a foam molded article with a skin.

FIG. 3 is a front view of a base material in which a contact portion formed of a plurality of contact rib pieces is integrally formed.

FIG. 4 is a perspective view of an abutting portion including a plurality of abutting rib pieces formed upright at required intervals on an inner wall surface of a base material.

FIG. 5 is a view showing a state in which a base material integrally formed with a contact portion is set in a first foaming mold, and a first skin formed integrally with a first joint piece and a second skin integrally formed with a second joint piece. It is principal part sectional drawing which shows the state set to a 2nd foaming mold.

FIG. 6 is a cross-sectional view of a main part showing a state where the first foaming mold on which the base material is set is clamped to the second foaming mold on which the first skin and the second skin are set.

FIG. 7 is a perspective view of a first foaming mold and a second foaming mold, in which the contact portions formed on the base material are pressed against the mutually overlapping first joining piece and second joining piece by clamping the mold; FIG. 4 is a cross-sectional view of a main part showing a state in which urethane foam is molded in a foaming space with the entire surface in close contact.

FIG. 8 is a diagram showing an example in which the first joint piece, the second joint piece, and the contacting part are arranged in the part where the accessory is to be installed; FIG. 4 is a cross-sectional view showing an example of an embodiment in which the cover is provided.

FIG. 9 is a cross-sectional view showing an example of a conventional skin seal structure, in which a joint end of a first skin and a joint end of a second skin are sealed with an adhesive tape.

FIG. 10 is a cross-sectional view showing another example of the conventional skin seal structure, in which a seal is formed by engagement of a concave portion provided at a joint end portion of a first skin and a convex portion provided at a joint end portion of a second skin. It is something to do.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 10 Instrument panel (foam molded product with skin) 12 Base material 12a Inner wall surface 14 First skin 16 Second skin 18 Urethane foam 20 Foaming space 32 First joint piece 34 Second joint piece 36 Contact part 38 Contact Rib piece 38a Tip 42 First foaming mold 44 Second foaming mold 44a Set surface

 ──────────────────────────────────────────────────続 き Continued on the front page F term (reference) 4F204 AA31 AA42 AB02 AD05 AD08 AD18 AD35 AG03 AG20 AG21 AH25 AM32 EA01 EB01 EB13 EF05 EF27 EF37 EF49 EK21 EL21

Claims (2)

[Claims] 1. A base material (12) formed in a required shape is set in a first foaming mold (42), and a first skin (14) and a second skin (16) formed in a required shape are formed on a second foam mold (42). Set in a foaming mold (44), the base material (12) by closing both molds (42, 44)
A foam molded product with a skin by foaming a urethane foam (18) in a foaming space (20) defined between the skin and both skins (14, 16).
When molding (10), the first skin (14) and the second skin
A skin seal structure for preventing the urethane foam (18) from leaking from a joint end portion with the (16), and a first skin (14) integrally formed on an edge portion of the first skin (14). 1 joint piece part (32), and a second joint piece part (34) formed integrally with an edge of the second skin (16) and overlapping the first joint piece part (32).
And the inner wall surface of the base material (12) facing the foaming space (20).
(12a), the first and second foaming molds (42, 4
4) is brought into contact with the first joining piece (32) and the second joining piece (34) which are overlapped when the mold is clamped, and the two joining pieces (32, 34) are attached to the second foaming mold (44). A contact portion (36) forcibly pressed against the wall surface of the first joint piece (32) and the second joint piece (34) under the action of pressing the contact portion (36). And both joint pieces (3
A skin seal structure for a foam molded article with a skin, which is configured to prevent the urethane foam (18) from leaking from the gap (2, 34). 2. The contact portion (36) is connected to the first joint piece (3).
2) and a plurality of abutting rib pieces (38) formed at required intervals along the extending direction of the second joining piece (34), and the tip (38a) of each abutting rib piece (38) ) And the second foaming mold (4
The skin sealing structure for a foam-molded article with a skin according to claim 1, wherein the set surface (44a) of (4) achieves close contact between the two joint pieces (32, 34).