JP2003053743A - Method for producing partially pad-integrated molding - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method for producing a partially pad-integrated molding which can prevent the falling and deformation of the tip side of a skin side part by a simple structure and obtain a product with stable quality easily and economically. SOLUTION: A magnet M is embedded in a place of a lower mold surface 12, where the skin 30 is arranged, and a side part support member 50 to be attracted/fixed by the magnet is arranged on the fringe back of the design surface part 31 of the skin. The side of the skin is supported from the back side by the contact between the support member 50 and the back of the side 32 of the skin, and a foaming raw material P1 is expanded between a pad housing recessed part 22 and the design surface of the skin while the side of the skin is supported by the support member 50.

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 article having a partial pad.

[0002]

2. Description of the Related Art For example, in an automobile interior part or the like, in order to have a decorative property and a shock absorbing property at the time of collision like an instrument panel of an automobile, a space between a panel main body and a skin is used. A foam molded article having a foam interposed is preferably used. Further, recently, in order to further reduce the weight and the cost, a partial pad integrated molded product in which a pad made of a foam and a skin is provided only in a necessary portion of the panel body is preferably used.

FIG. 6 and FIG. 7 showing a 7-7 cross section thereof show an example of a conventional partial pad integrally molded product 60. The partial pad integrated molded product 60 shown in the figure is used as an instrument panel, and a pad housing recess 62 is formed in a predetermined surface portion of a panel body 61 having a predetermined shape made of hard plastic or the like. 6
2 is provided with a pad 75 composed of the foam P and a skin 70 covering the foam. The skin 70 has a design surface portion 71 that is visible to the user of the molded article 60 and the like, and a side surface portion 72 that is formed by bending so as to stand from the edge of the design surface portion 71 to the back side of the skin. The portion 72 is accommodated in the pad accommodating recess 62 of the panel body 61 and abuts on the side wall inner surface 63 of the pad accommodating recess 62.

Conventionally, as a simple manufacturing method for this type of partial pad integrated molding, an upper die 81 as shown in FIG.
And a lower mold 85, a molding mold 80 is used,
Is disposed on the mold surface 86 so that the design surface front surface 71a is the lower mold surface 86 side, and the side surface 72a of the outer skin 70 faces the panel main body 61 to the side wall inner surface 63 of the pad accommodating recess 62. The upper mold surface 82
, The foaming material P1 is injected between the skin 70 and the panel body 61, and the foaming material P1 is foamed so that the pad 75 in which the foam P and the skin 70 are integrated is accommodated in the pad of the panel body 61. There is a method of forming the recess 62.

However, in the method of manufacturing the partial pad integrated molded article, the skin 7 is arranged when the skin 70 is arranged.
Since the side surface portion 72 of 0 is erected upward, and the side surface portion tip 72b is a free end and is easily deformed, the skin side surface portion tip 72b side may fall inside the skin 70 or undulate. A gap may be formed between the skin side surface portion 72 and the side wall inner surface 63 of the pad accommodating recess 62, and the foaming raw material P1 may leak to the design surface portion front side 71a of the skin through the gap. Foaming raw material P1 leaked in this way
Foams and forms burrs that adhere to the design surface portion 71 of the skin 70 or to the surface of the panel body 61. Therefore, it is necessary to remove burrs after the partial pad integrated molded product 60 is demolded. The partial pad-integrated molded product 60 has no commercial value. Further, the leakage of the foaming raw material P1 causes the quality of the partial pad integrated molded product 60 to vary,
There is also a problem of wasting raw materials.

[0006]

SUMMARY OF THE INVENTION The present invention has been made in view of the above points, and has a simple structure capable of preventing the side surface of the epidermis from collapsing or deforming, and having a stable quality and a good appearance. The present invention provides a method for manufacturing a partially pad-integrated molded product, which can be obtained easily and economically.

[0007]

According to a first aspect of the present invention, there is provided a skin having a side surface portion which is bent toward the back surface of the skin at an edge of the design surface portion, and the front surface side of the design surface portion of the skin is a mold surface side of the lower mold. In this manner, the panel main body having the pad accommodating concave portion capable of accommodating at least the tip side of the side surface portion of the outer skin formed on the surface while being arranged on the mold surface of the lower mold, at least the side surface portion of the epidermis in the pad accommodating concave portion. Arranged so that the tip side is accommodated and the back side of the panel body is in contact with the mold surface of the upper mold, and by foaming the foaming raw material between the pad accommodating recess of the panel body and the design surface portion of the skin. In the method of manufacturing a partial pad integrated molded article, a magnet is embedded in a portion of the mold surface of the lower die where the edge of the design surface portion of the skin is arranged, and when the skin is arranged, the magnet is embedded on the back surface of the edge of the design surface portion. Attracted by magnet The side surface supporting member to be fixed is arranged so as to contact the back surface of the side surface of the skin, and the side surface supporting member supports the side surface of the skin from the back side. It is characterized in that the raw material is foamed between the pad accommodating concave portion and the design surface portion of the skin.

According to a second aspect of the present invention, in the first aspect, the side surface support member has a side surface contact surface that abuts a rear surface of the side surface of the skin, and a side surface contact surface that abuts a rear surface of the design surface of the skin. And a dent forming a gap for entering the foam body between the contact surface of the design surface portion and the back surface of the design surface portion of the epidermis is partially formed.

Further, the invention of claim 3 is the invention according to claim 1 or 2, wherein the side surface supporting member abuts on the side surface abutting surface abutting on the side surface rear surface of the skin and the design surface abutting abutting on the design surface portion back of the skin. It is characterized in that it is formed in a substantially L-shaped cross section constituted by the contact surface.

[0010]

DETAILED DESCRIPTION OF THE INVENTION The present invention will be described in detail below with reference to the accompanying drawings. 1 is a partial sectional view of a molding die showing a manufacturing method according to an embodiment of a method for manufacturing a partial pad integrated molded article of the present invention, FIG. 2 is a sectional view taken along line 2-2 of FIG. 1, and FIG. 3 is a sectional view, FIG. 4 is a perspective view showing an embodiment of the side surface supporting member, and FIG. 5 is a perspective view showing another embodiment of the side surface supporting member.

1 and 2, which is a sectional view taken along line 2-2 of FIG.
The molding die 10 shown in FIG. 3, which is a 3-3 cross section, is for manufacturing a partial pad integrated molded product 20 for an instrument panel, which has the same outer shape as that of FIG. And is composed of a lower mold 11 and an upper mold 15. The partial pad integrated molded article 20 has a pad 35 formed in the pad accommodating recess 22 of the panel body 21 and including the foam P and the skin 30 covering the foam P.

The lower mold 11 is a molded product 2 of the partial pad.
0 has a skin disposing mold surface 12 on which the skin 30 of the pad 35 is disposed at a predetermined portion. The surface arranging mold surface 12 of this example is adapted to the shape of the pad 35 in the partial pad integrated molded product 20, is a low surface having a step with respect to the periphery thereof, and has an edge of the mold surface 12. Is an inclined surface 12a inclined upward. A magnet M is embedded in the vicinity of the slope 12a of the skin disposing mold surface 12 so that an attractive magnetic force is generated near the edge of the skin disposing mold surface 12. Note that the magnet M is embedded with a plate-like object which is continuous in a required direction at least corresponding to a position where a side surface supporting member 50 described later is arranged, or an object which is made of small pieces is embedded at appropriate intervals.

The upper mold 15 is a molded product 2 of the partial pad.
0 has a panel body placement mold surface 16 on which the panel body 21 is placed. This panel body placement mold surface 16
Is conformed to the shape of the panel body 21, and the portion 17 corresponding to the pad accommodating recess 22 has a recessed shape. The lower mold 11 and the upper mold 15 may be openably and closably connected by a hinge member or the like (not shown).

At the time of manufacturing the partial pad integrated molding, a skin 30 is arranged on the skin disposing mold surface 12 of the lower mold 11. The outer skin 30 constitutes the surface of the pad 35 portion in the partial pad integrated molded product 20, and is made of soft vinyl chloride resin (PVC) or thermoplastic polyurethane resin (T.
PU) or a thermoplastic polyolefin-based elastomer (TPO) or the like, which is formed into a predetermined pad surface shape by known powder slush molding or vacuum molding. The skin 30 is the pad 35.
Is formed on the edge of the design surface portion 31 that constitutes the design surface of the lower surface of the lower surface of the outer surface of the lower surface of the lower die 11. And is placed on the mold surface 12. At that time, the base portion 32a of the side surface portion 32 of the outer skin 30 and the inclined surface 12a of the mold surface 12 are brought into contact with each other, and the outer skin 30 is positioned.

A side surface supporting member 50 made of a material such as iron attracted by the magnet M of the lower mold 11 is disposed on the back surface of the design surface portion 31 where the side surface portion 32 of the skin 30 is present. The side surface supporting member 50 is the mold surface 1 of the lower mold.
The outer skin 30 is sucked and fixed by the magnet M of No. 2 and abuts on the side surface back surface 32b of the outer skin 30 to contact the outer skin 3
The side surface 32 of 0 is supported in a correct shape without waviness or collapse.

The side surface supporting member 50 of this embodiment is also used.
Is defined in claim 2, and as can be easily understood from the perspective view of FIG. 4, the side surface contact surface 51 that contacts the side surface rear surface 32b of the outer skin 30, and the design surface rear surface 3 of the outer skin 30.
1b and the design surface part contact surface 52 which contact | abuts. The presence of the side surface contact surface 51 makes it possible to reliably support the side surface portion 32 of the skin 30 from the back surface 32b side, and the existence of the design surface portion contact surface 52 enables the side surface support member 50 to be supported. Can be more securely fixed to the predetermined position. The side surface contact surface 5
1 is an inclination angle that matches the side surface portion 32 of the skin 30, and the height is also preferably set according to the height of the side surface portion 32 of the skin 30. Further, the design surface contact surface 5
2 is preferably an article in which a dent 54 that forms a gap 53 for entering the foam body is partially formed between the skin 30 and the design surface back surface 31b. By doing so, the foaming raw material P1 enters the foam intrusion gap 53 at the time of forming a foam, which will be described later, and the side surface supporting member 50 and the design surface back surface 31 of the skin 30 are formed.
Since the edge of the design surface portion 31 of the outer skin 30 is bonded to the side surface supporting member 50 through the foam P1 formed in the gap 53 for entering the foam, the design surface portion 3 of the outer skin 30 is foamed.
It is possible to prevent the edge of 1 from rising or becoming wrinkled, and the edge of the design surface portion 31 of the outer skin 30 is covered with the outer skin 30.
Since the foam P partially intervenes between the side surface supporting member 50 and the side surface supporting member 50, the contact feeling of the pad can be improved.

Further, the side surface supporting member 50 is formed in a substantially L-shaped cross section composed of the side surface contacting surface 51 and the design surface contacting surface 52, as defined in claim 3. Those are preferable. By doing so, it is possible to realize weight reduction and cost reduction as compared with the case where the side surface supporting member 50 is a solid member such as a rod.

Further, as the side surface supporting member, as shown in FIG.
Like the side surface supporting member 50A shown in FIG. 5, a plurality of pieces each having a substantially L-shaped cross section having a side surface contact surface 51a and a design surface contact surface 52a may be arranged at appropriate intervals. . With this configuration, the side surface supporting member 5
The space portion where 0A is not arranged is the side surface supporting member 5
The same effect as that of the 0 recess 54 is exhibited.

The panel body 21 is disposed on the upper die 15 such that the back surface 21a side of the panel body 21 abuts on the panel body placement die surface 16. The panel body 21 is made of a hard plastic molded product or the like formed by injection molding or the like in accordance with the shape of the partial pad integrated molded product 20, and the side surface portion 32 of the outer skin 30 is provided at a predetermined portion of the surface. The pad accommodating recess 22 capable of accommodating at least the tip side 32c is formed such that the side wall inner surface 23 thereof is aligned with the inclination of the side surface portion 32 of the outer skin 30, and the molding die 1
When the mold 0 is closed, the side surface 32
Is arranged in the upper mold 15 so that at least the front end side 32c thereof is accommodated. Then, the upper mold 15 and the lower mold 11 are closed, whereby the side surface 32d of the outer skin 30 is opposed to the side wall inner surface 23 of the pad housing recess 22, and the side surface 32 of the outer skin 30 is held in the pad housing recess 22. Side wall inner surface 2
3 and the side surface support member 50 are sandwiched. Depending on the structure of the molding die 10 and the like, the lower die 11
The panel body 21 is placed on the lower mold 11 so as to cover the outer skin 30 placed on the lower mold 11 and the lower mold 11 and the upper mold 1 in that state.
In some cases, the closed mold of 5 is performed.

Next, an injection port formed in the pad accommodating recess 22 of the panel body 21 and an injection head mounting port formed in the upper mold 15 so as to communicate with the injection port (neither is shown). A foaming raw material P1 such as a urethane foam raw material is injected between the pad accommodating concave portion 22 of the panel body 21 and the design surface portion 31 of the outer skin 30 through the foaming to form a foamed body P. At that time, since the side surface portion 32 of the skin 30 is correctly supported by the side surface supporting member 50, the skin side surface portion 32 does not collapse or deform,
Due to the pressure at the time of foaming of the foaming raw material P1, the skin side surface part 3
Since 2 adheres closely to the side wall inner surface 23 of the pad accommodating recess 22, the foaming raw material P1 is prevented from leaking out of the skin 30 through the space between the skin side surface part 32 and the side wall inner surface 23 of the pad accommodating recess 22. The pad 35 including the body P and the epidermis 30 is favorably formed with a constant quality. Moreover, the gap 5 for entering the foam is formed by the recess 54 of the side surface supporting member 50.
3, the foam P is also formed by infiltration, and the design surface portion 3 of the skin 30 is formed.
Since the edge of No. 1 is bonded to the side surface supporting member 50 through the foam P, the skin 30 does not wrinkle or float at the edge of the pad 35. Then, the mold is opened by a known method and the mold is released to obtain a desired partial pad integrated molded product 20.

In the above-mentioned embodiment, the example of the closed molding in which the foaming raw material is injected with the molding die closed is shown. However, in the present invention, the foaming raw material is injected with the molding die opened and then closed. It is also appropriately applied to open molding in which the material is molded and foamed.

Further, the side surface portion of the skin is preferably provided over the entire circumference of the design surface portion, but may be provided only in a part thereof. Furthermore, the side surface supporting member does not necessarily have to be provided on all the portions of the epidermis where the side surface portion exists, and may be provided only on a portion where the side surface portion is easily deformed or collapsed.

Further, since the feel of the pad surface is apt to be harder in the part where the side surface supporting member is present than in other parts, it is far from the user when the partial pad integrated molded product is used, or is opposite to the user. The side part is preferable.
That is, in the partial pad integrated molded product 20 for the instrument panel in the above-described embodiment, the side surface supporting member is provided at the pad edge portion (the portion indicated by the symbol F in FIG. 6) on the front windshield side far from the occupant who is the user. Therefore, the side surface support member is not used in the region close to the occupant even if the side surface portion of the skin exists. Of course, the present invention is not limited to the manufacture of instrument panels, but is also applicable to the manufacture of automobile interior parts and molded articles for other uses.

[0024]

As shown and described above, according to the method of manufacturing a partial pad integrated molded article of the present invention, a magnet is embedded in the lower die surface portion where the edge of the design surface portion of the skin is arranged. , A side surface supporting member attracted and fixed by the magnet is arranged on the back surface of the design surface portion of the skin, and the side surface portion of the skin is supported from the back side by contact between the side surface supporting member and the back surface of the side surface of the skin. However, since the foaming raw material is foamed between the pad accommodating recess and the design surface portion of the skin under the supported state, it is possible to prevent the side surface portion formed at the edge of the design surface portion of the skin from falling down or deforming, The sealing effect between the side surface of the skin and the pad accommodating recess of the panel body is improved, and a good quality partial pad integrated product can be easily obtained economically with less waste of raw materials.

Further, according to the invention of claim 2, the side surface support member has a side surface contact surface that contacts the rear surface of the side surface of the skin and a design surface contact surface that contacts the rear surface of the design surface of the skin. ,
Since a recess that forms a foam intrusion gap between the design surface contacting surface and the back surface of the design surface of the skin is partially formed, the side surface of the skin and the pad accommodating recess of the panel body are formed. Not only can the seal between the seals be more reliable, the product quality can be more stable, and the economical efficiency due to the reduction of waste of raw materials can be further improved, but the outer skin is adhered to the side surface support member via the foam at the edge of the pad. It is possible to manufacture a partial pad-integrated molded product in which the pad does not float or wrinkle and the surface feeling of the edge of the pad is good.

Further, according to the third aspect of the present invention, since the side surface supporting member is formed to have a substantially L-shaped cross section composed of the side surface abutting surface and the design surface abutting surface, the skin side surface portion Can be supported more reliably, and an increase in weight due to the side surface supporting member can be reduced.

[Brief description of drawings]

FIG. 1 is a partial cross-sectional view showing a molding die at the time of manufacturing according to one manufacturing embodiment of a partial pad integrated molded article of the present invention.

2 is a sectional view taken along line 2-2 of FIG.

3 is a sectional view taken along line 3-3 of FIG.

FIG. 4 is a perspective view showing an embodiment of a side surface support member.

FIG. 5 is a perspective view showing another embodiment of the side surface supporting member.

FIG. 6 is a perspective view showing a general instrument panel as a partial pad integrated molded product.

7 is a sectional view taken along line 7-7 of FIG.

FIG. 8 is a partial cross-sectional view of a molding die at the time of manufacturing a conventional partial pad integrated molded product.

[Explanation of symbols]

10 Mold 11 Lower mold 12 Lower mold surface for skin placement 15 Upper mold 16 Upper die surface placement surface 20 Partial pad integrated molding 21 panel body 22 Pad receiving recess 30 epidermis 31 Skin design surface 32 Side of epidermis 50 Side support member 51 Side contact surface 52 Design surface contact surface 54 Cavity M magnet P1 foaming raw material P foam

Claims (3)

[Claims] 1. A skin having a side surface bent to the back side of the skin at the edge of the design surface is arranged on the mold surface of the lower mold with the front surface of the design surface of the skin facing the mold surface of the lower mold. on the other hand,
A panel main body having a pad accommodating recess formed on the surface capable of accommodating at least the tip side of the side surface of the skin is formed so that at least the tip end of the side surface of the epidermis is accommodated in the pad accommodating recess. A method for producing a partial pad integrated molded article by arranging so that the back side is in contact with the mold surface of the upper mold, and foaming a foaming raw material between the pad accommodating recess of the panel body and the design surface portion of the skin, wherein the skin is A magnet is embedded in a portion of the lower die surface where the edge of the design surface portion is arranged, and at the time of arranging the skin, the side surface support member attracted and fixed to the edge back surface of the design surface portion by the magnet The side surface of the skin is supported by the side surface supporting member from the back side by being arranged so as to contact the back surface of the side surface, and the foaming raw material is exposed to the pad accommodating recess under the supporting state of the side surface of the skin. Partial pad producing method of the single piece, wherein the foaming between the design surface of the. 2. The side surface support member has a side surface contact surface that contacts the rear surface of the side surface of the skin and a design surface contact surface that contacts the back surface of the design surface of the skin, and the surface contact surface has a skin. 2. The method for manufacturing a partial pad integrated molded article according to claim 1, wherein a dent that forms a foam entry gap is formed between the dent and the back surface of the design surface portion. 3. The side surface support member is formed in a substantially L-shaped cross section composed of a side surface contact surface that contacts the back surface of the side surface of the skin and a design surface contact surface that contacts the back surface of the design surface of the skin. The method for producing a partially pad-integrated molded product according to claim 1 or 2, wherein the method comprises: