JP2003001740A - Skin-integrated foam molded article and method for molding it - Google Patents

Abstract

PROBLEM TO BE SOLVED: To improve sealing properties and appearance of a boundary between the folded part of a skin and a core material. SOLUTION: A folded part 19 which is projected to the back side of the skin 5 and in which the front side of the skin 5 is brought into contact with the inner peripheral face of the standing wall 17 of the core material 3 is formed on the peripheral edge of the skin 5. A projected part 21 which has the same projected length and projected thickness as the thickness of the folded part 19 and the apex of which is brought into contact with the inner peripheral face of the standing wall 17 is formed on the end edge of the folded part 19. A channel part 21a into which a holding tool for holding the folded part 19 is inserted when an instrument panel 1 is molded is formed on the surface side of the instrument panel 1 of the projected part 21.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a skin-integrated foam-molded article in which a foam layer is integrally molded between a core material and a skin, and an improvement in the molding method thereof, and more particularly to a measure for sealing at the time of molding and a measure for appearance. It is a thing.

[0002]

2. Description of the Related Art Japanese Patent Application Laid-Open No. 7-314469 discloses an instrument panel as a skin-integrated foam-molded article in which a foam layer is integrally molded between a core material and a skin. In this instrument panel, a bent portion projecting to the back surface side of the skin is formed on the peripheral edge of the skin, and a projecting portion having a groove opening to the front surface side of the instrument panel is formed at the edge of the bent portion. The tip of the protruding portion is in contact with the inner peripheral surface of the standing wall of the core member so that the foaming raw material does not leak when the instrument panel is molded. The bent portion is in contact with the standing wall so that the groove portion cannot be seen from the outside due to foaming pressure at the time of molding the instrument panel, and the skin (folded portion) and the core material (standing wall) are separated from each other. There is no gap between them.

When the instrument panel is molded, the holder is projected from the lower mold side and inserted into the groove of the protrusion to hold the bent portion and position the skin.

[0004]

By the way, from the viewpoint of improving the sealing property at the time of molding and preventing a gap between the skin and the core material after the molding, the bent portion of the skin has a foaming pressure. It is desirable that the core member be easily bent toward the standing wall by the action. For that purpose, it is necessary to shorten the projecting length of the projecting portion and thin the wall thickness of the projecting portion on the bottom surface side of the groove portion.

However, in the above-mentioned conventional example, as shown in FIG. 2B, the bent portion b and the protruding portion c of the outer skin a are formed by bending the periphery of one outer skin a into a U shape. Therefore, the protrusion length L1 of the protrusion c is the sum of the thickness T1 of the bent portion b and the groove width W of the groove d, and moreover, the thickness T2 of the protrusion c on the bottom surface side of the groove d. Is equal to the wall thickness T1 of the bent portion b, and there is a limit to shortening the protruding length L1 of the protruding portion c and reducing the wall thickness T2 of the protruding portion c on the bottom surface side of the groove d.

The present invention has been made in view of the above points, and an object thereof is to improve the sealing property and appearance of the boundary between the bent portion of the skin and the core material.

[0007]

In order to achieve the above-mentioned object, the present invention is characterized in that the shape of the protruding portion protruding from the edge portion of the peripheral edge of the skin and abutting against the standing wall of the core material is devised. To do.

Specifically, the present invention is directed to a skin-integrated foam-molded article in which a foam layer is integrally molded between a core material and a skin and a molding method therefor, and the following means for solving the problems have been taken.

That is, the invention according to claim 1 relates to the former skin-integrated foam-molded article, wherein the core material is provided with a standing wall constituting a foam layer accommodating recess corresponding to the skin-forming region. The outer peripheral edge is formed with a bent portion that protrudes toward the back surface of the outer surface and the outer surface of the outer surface abuts the inner peripheral surface of the standing wall, and the edge of the bent portion has a wall thickness of the bent portion. A protrusion having the same protrusion length and protrusion and having a tip abutting against the inner peripheral surface of the standing wall is formed, and the skin-integrated foam molded product is molded on the surface side of the skin-integrated foam molded product of the protrusion. A groove is formed so that a holder for holding the bent portion can be inserted.

With the above structure, in the invention according to claim 1, the protrusion length of the protrusion is shorter than that of the conventional example, and the thickness of the protrusion on the bottom surface side of the groove is thinner than that of the conventional example. Therefore, the bent portion of the skin easily bends toward the standing wall of the core material due to the action of foaming pressure, the sealing property at the time of molding is improved, and the foaming raw material does not leak. In addition, no gap is formed between the skin and the core material after molding, and the appearance is improved.

The second aspect of the present invention relates to the latter method for forming a foam-integrated skin-molded article, in which the bent portion formed on the peripheral edge of the skin so as to project to the back side of the skin projects to the upper mold side. The outer skin is placed on the lower mold, and the surface of the foam-integrated molded article of the protruding portion is formed with a protruding length and a protruding thickness that are equal to the wall thickness of the bent portion at the edge of the bent portion. The outer skin is set in the lower mold by inserting the groove formed on the side into the holder and holding and positioning the bent portion so that the standing wall of the core material corresponds to the bent portion of the skin. Then, the core material is set in an upper mold, and then the molding die is closed by the upper mold and the lower mold to bring the tip of the protruding portion of the skin into contact with the inner peripheral surface of the standing wall of the core material, and thereafter During the foaming of the foam raw material injected into the cavity in the mold open state or after the mold is closed, the holder is pushed The outer surface of the bent portion is brought into contact with the inner peripheral surface of the standing wall by the foaming pressure due to further foaming expansion of the foaming raw material, and the foam layer corresponds to the skin forming region by the standing wall. It is characterized in that a foam-integrated foam-molded article which is housed in the foamed-layer housing recess formed as described above and integrally molded between the core material and the skin is obtained.

With the above structure, in the invention according to the second aspect, the simple operation of putting the holder in and out of the epidermis allows
It is possible to obtain a skin-integrated foam-molded article that exhibits the effects of the first aspect.

[0013]

BEST MODE FOR CARRYING OUT THE INVENTION Embodiments of the present invention will be described below with reference to the drawings.

FIG. 1 shows a vehicle instrument panel 1 as a skin material-integral foam-molded article according to an embodiment of the present invention. However, the invention is not limited to this. It can also be applied to.

The instrument panel 1 includes a core member 3
The upper panel portion 9 has a three-layer structure in which the foam layer 7 is integrally formed between the outer skin 5 and the outer skin 5, and the lower panel portion 11 has a single-layer structure including only the core material 3. In FIG. 1, reference numeral 3a denotes an air outlet opened in the core member 3 of the lower panel portion 11, and a grill 13 is attached to the air outlet 3a. Reference numeral 15 is a steering wheel.

In the vicinity of the edge portion 3b of the core material 3, a standing wall 17 which constitutes a foam layer accommodating concave portion 3c is formed corresponding to the skin forming region. On the other hand, as shown in an enlarged view in FIG. 2A, a bent portion 19 is formed on the peripheral edge of the outer skin 5 so as to project to the back surface side of the outer skin 5 and the front surface side of the outer skin 5 contacts the inner peripheral surface of the standing wall 17. Has been done. In addition, a projecting portion having a projecting length L2 and a projecting thickness T3 which are equal to the wall thickness T1 of the bent portion 19 at the end edge of the bent portion 19 and the tip of which is in contact with the inner peripheral surface of the standing wall 17 21 is formed. Further, on the front surface side of the instrument panel 1 of the projecting portion 21, there is provided a groove portion 21a into which a holder 109 (see FIGS. 3 to 6) described later that holds the bent portion 19 when the instrument panel 1 is molded is inserted. Has been formed. The wall thickness T4 of the protruding portion 21 on the bottom surface side of the groove portion 21a is reduced by the depth D of the groove portion 21a. The bent portion 19 is in contact with the standing wall 17 due to the foaming pressure during molding of the instrument panel 1, covers the groove portion 21a so as not to be seen from the outside, and covers the skin 5 (folded portion 19). And core material 3 (standing wall 1
No gap is created between this and 7). Such a skin 5 can be formed by the powder slush molding method.

The instrument panel 1 constructed as described above has a lower mold 101 and an upper mold 10 as shown in FIGS.
It is molded in the following manner using the molding die 105 provided with 3.

(1) As shown in FIG. 3, the upper mold 103
(Appearing in FIGS. 4 to 6) is lifted to open the molding die 105, and the skin 5 is formed on the surface material setting surface 101a of the lower mold 101 so that the bent portion 19 projects toward the upper mold 103. 5 Place with the front side in contact.

(2) The fluid pressure cylinder 107 installed on one end side (the left end side in FIG. 3) of the lower mold 101 is extended to advance the holder 109 connected to the tip of the piston rod 107a thereof to advance the holder. Projection 21 at the tip of the tool 109
The outer skin 5 is set on the surface material setting surface 101a of the lower die 101 by inserting the groove portion 21a of the above and holding and positioning the bent portion 19 so as not to fall outward. In this state, the skin 5 is brought into close contact with the lower mold 101 by negative pressure from a vacuum suction hole (not shown) formed in the lower mold 101.

(3) On the other hand, as shown in FIG.
Of the core material 3 so that the standing wall 17 of the upper mold 103 corresponds to the bent portion 19 of the skin 5.
Set so that the back side of the core material 3 contacts. that time,
A core material holding device (not shown) installed substantially in the center of the upper mold 103 holds the core material 3 so as not to drop from the upper mold 103.

(4) The upper die 103 is lowered obliquely from above as shown by the arrow A in FIG. 4 to close the forming die 105 (see FIG. 5). Thereby, the protruding portion 2 of the skin 5
One tip is brought into contact with the inner peripheral surface of the standing wall 17 of the core material 3, and both are pressed in a surface contact state to seal the location.

At other points, the peripheral edge of the skin 5 is formed by the molding die 10.
By pressing the ridge (not shown) protruding from the core material 3 in a line contact state by the mold closing force of 5, the location is sealed.

As described above, the upper mold 103 and the lower mold 101 are
By closing the molding die 105 and sealing the peripheral edge of the skin 5 over the entire circumference, the leakage of the foaming raw material to the outside of the cavity is prevented.

(5) A foaming material (not shown) is injected into the cavity 111 between the skin 5 and the core 3 from an injection head (not shown) provided on the upper mold 103.

(6) During the foaming of the foaming raw material injected into the cavity 111, the fluid pressure cylinder 107 is contracted to cause the holder 109 to move into the groove 2 of the protrusion 21.
Remove from 1a (see FIG. 6). It is preferable that the holding tool 109 is pulled out while the foaming raw material reaches the bent portion 19 of the skin 5 and the foaming is continued. As a result, after the holder 109 is pulled out, the standing wall 17 is formed by the foaming pressure.
It is possible to completely eliminate the gap between the bent portion 19 and the bent portion 19.

(7) When the foaming raw material further expands and expands, the foaming pressure causes the surface 5 surface side of the bent portion 19 to contact the inner peripheral surface of the standing wall 17, and the foaming layer 7
Are accommodated in the foam layer accommodating recess 3c, and the core material 3 and the skin 5 are
The instrument panel 1 which is integrally molded between and is molded.

At this time, the projecting length L2 of the projecting portion 21 of the skin 5 is set shorter than that of the conventional example, and the wall thickness T4 of the projecting portion 21 on the bottom side of the groove 21a is thinner than that of the conventional example. Since it is set, the bent portion 19 of the skin 5 can be easily bent toward the standing wall 17 side of the core material 3 by the action of the foaming pressure, and the sealing property at the time of molding can be improved, and the foam raw material can be obtained. Can be prevented from leaking. Further, it is possible to prevent a gap from being formed between the skin 5 and the core material 3 after the molding, so that the appearance and appearance can be improved. Furthermore, the instrument panel 1 having the above-described effects can be formed by a simple operation of putting the holder 109 in and out of the skin 5.

(8) As shown in FIG. 6, the instrument panel 1 in which the foaming raw material is cured in the cavity 111 and the foam layer 7 is integrally molded between the skin 5 and the core material 3 in the upper panel section 9. Is molded.

(9) The core holding device is operated to move the core 3
After releasing the holding by the core material holding device, the upper die 103 is lifted to open the molding die 105, and then the molded instrument panel 1 is released from the lower die 101.

In the above embodiment, after placing the skin 5 on the surface material setting surface 101a of the lower die 101, the holder 109 is moved forward, and the groove 21a of the protrusion 21 is formed at the tip of the holder 109. Although the bending portion 19 was inserted and the bending portion 19 was positioned, on the contrary, the outer skin 5 is placed on the surface material setting surface 101a of the lower mold 101 with the holder 109 advanced, and thereafter,
The bent portion 19 may be positioned by inserting the groove portion 21a of the protruding portion 21 into the tip of the holder 109.

Further, in the above embodiment, the molding die 1 is used.
Instrument panel 1 by the closed injection method in which the foaming raw material is injected into cavity 111 in the mold closed state of 05.
However, the present invention can also be applied to the case where the instrument panel 1 is molded by the open pouring method in which the foaming raw material is injected into the cavity 111 with the molding die 105 opened.

Further, although the case where the skin 5 is a single layer is shown in the above-mentioned embodiment, a multi-layer structure having a solid skin surface layer and a soft foam layer integrally molded on the back surface of the skin surface layer is adopted. It may be epidermis.

[0033]

As described above, according to the first aspect of the invention, a bent portion is formed on the peripheral edge of the skin so as to project to the back surface side of the skin and the front surface side of the skin contacts the inner peripheral surface of the standing wall of the core material. Forming a protrusion on the edge of the bent portion that has a protrusion length and a protrusion thickness equivalent to the wall thickness of the bent portion, the tip of which is in contact with the inner circumferential surface of the standing wall, On the surface side of the foamed molded product, a groove portion into which a holder for holding the bent portion is inserted when the skin-integrated foamed molded product is molded is formed. Therefore, the bent portion of the skin can be easily bent to the standing wall side of the core material by the action of foaming pressure,
It is possible to improve the sealing property so that the foaming raw material does not leak, and it is possible to improve the appearance by preventing a gap from being formed between the skin and the core material after molding.

According to the method of the second aspect of the present invention, it is possible to obtain the foam-integrated body with integrated skin having the effect of the invention of the first aspect by a simple operation of putting the holder in and out of the outer skin. .

[Brief description of drawings]

FIG. 1 is a perspective view showing a driver seat side of an instrument panel as a skin-integrated foam-molded product according to an embodiment.

FIG. 2A is an enlarged cross-sectional view showing a projecting portion formed on a bent portion of a skin edge in the embodiment, and FIG. 2B shows a projecting portion formed on a bent portion of a skin edge in a conventional example. It is sectional drawing which expands and shows.

FIG. 3 is a molding process diagram showing a state in which the epidermis is set in a lower mold in the embodiment.

FIG. 4 is a molding process diagram showing a state immediately before the upper mold set with the core material descends and shifts to a mold closed state in the embodiment.

FIG. 5 is a molding process diagram showing a mold closed state in the embodiment.

FIG. 6 is a forming process diagram showing a state where the instrument panel is formed in the embodiment.

[Explanation of symbols]

DESCRIPTION OF SYMBOLS 1 Instrument panel (foam-molded product integrated with skin) 3 Core material 3c Foam layer accommodating recess 5 Skin 7 Foam layer 17 Standing wall 19 Bent portion 21 Projection 21a Groove 101 Lower die 103 Upper die 105 Mold 109 Retainer 111 Cavity L2 protrusion length T1 protrusion thickness T3 protrusion protrusion thickness

   ─────────────────────────────────────────────────── ─── Continued front page    F term (reference) 3D044 BA11 BB01 BC03 BC30                 4F100 BA03 BA10A BA10B DB07B                       DD05A DJ01C EH312 EJ022                       GB33 JL00                 4F204 AD08 AD23 AG03 AG20 AG21                       AH25 EA01 EB01 EB13 EF05                       EF27 EL25 EL26

Claims (2)

[Claims] 1. A skin-integrated foam-molded article in which a foam layer is integrally molded between a core material and a skin, wherein the core material has a standing layer that forms a foam layer accommodating recess corresponding to a skin formation region. A wall is formed, a bent portion is formed on the peripheral edge of the skin so as to project toward the back surface side of the skin, and the front surface side of the skin contacts the inner circumferential surface of the standing wall. A protrusion having a protrusion length and a protrusion thickness equal to the wall thickness, the tip of which is in contact with the inner peripheral surface of the upright wall, is formed. A skin-integrated foam-molded article, characterized in that a groove into which a holder for holding the bent portion is inserted is formed when the article is molded. 2. A method for molding a foam-in-one-in-situ molded product in which a foam layer is integrally molded between a core material and a skin, wherein a bent portion formed on the periphery of the skin and protruding toward the back surface of the skin is an upper mold. The outer skin is placed on the lower mold so as to project to the side, and the outer skin of the protruding portion formed at the end edge of the bent portion with a protruding length and a protruding thickness equivalent to the wall thickness of the bent portion. The outer skin is set in the lower mold by inserting the groove formed on the surface side of the integrated foam molded product into the holder to position and hold the bent portion, and the standing wall of the core material bends the skin. Set the core material to the upper mold so as to correspond to the portion, and then close the molding die by the upper mold and the lower mold to make the tip of the protruding portion of the skin on the inner peripheral surface of the standing wall of the core material. Then, in the mold open state or after the mold is closed, the above holder is held in the middle of foaming of the foam raw material injected into the cavity. Withdrawing from the groove of the protruding portion, the outer skin surface side of the bent portion is brought into contact with the inner peripheral surface of the standing wall by the foaming pressure due to further foaming expansion of the foaming raw material, and the foamed layer becomes the skin forming region by the standing wall. A method for molding a skin-integrated foam-molded product, comprising: obtaining a skin-integrated foam-molded product which is housed in a foam layer-containing recess formed correspondingly and integrally molded between the core material and the skin.