JP2005014370A - Foamed molded member with skin - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To avoid a decrease in quality feeling even if a first region and a second region different in touch feeling from each other are provided. <P>SOLUTION: A skin 16 is constituted of the thin-walled first skin part 42 closely bonded to the outside surface of a foam 14 and the thick-walled second skin part 44 set to a thickness dimension larger than that of the first skin part 42 and closely bonded to the outside surface of a base material 12. By this constitution, the touch feeling of the outside design surface formed from the skin 16 is changed respectively between the first region 20 comprising the foam 14 and the first skin part 42 and the second region 22 comprising the second skin part 44. Concretely, the first region 20 is set to a "soft region" developing the physical properties of the foam 14 and rich in flexibility and the second region 22 is set to a "hard region" developing the physical properties of the skin 16 and rich in elasticity. <P>COPYRIGHT: (C)2005,JPO&NCIPI

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a foam-molded member with a skin, and more specifically, a base material molded into a required shape, a foam adhered to the outer surface of the base material, and the outer surface of the base material and the foam The present invention relates to a foam-molded member with a skin comprising a skin to be applied to the skin.
[0002]
[Prior art]
For example, a foam-molded member with a skin is composed of a base material molded into a required shape, a foam attached to the outer surface of the base material, and a skin attached to the outer surface of the base material and the foam. The three-layer structure is as follows. The base material has a required strength using a relatively hard synthetic resin such as ASG, and the foam interposed between the base material and the skin is a flexible urethane foam or the like. The skin that contributes to improving the tactile sensation as a material and is exposed to the outside contributes to the improvement in the appearance of the material using a synthetic resin as described later. Examples of such foam-formed members with a skin include various vehicle interior members (instrument panels, floor consoles, console lids, door panels, etc.) installed in the vehicle passenger compartment, various furniture (chairs, sofas, etc.), and the like. It is done.
[0003]
FIG. 10 is a schematic perspective view showing an instrument panel which is a vehicle interior member as an example of a foam-formed member with a skin, and FIG. 11 is a cross-sectional view taken along line XX of FIG. As illustrated in FIG. 11, the instrument panel 10 is assembled in front of the vehicle passenger compartment and positioned below the windshield 24, and therefore, the external design surface of the instrument panel 10 has a passenger seat. In the region from the center of the upper surface to the center of the front surface (region facing the passenger seat side), high quality and high touch are required, and in the region behind the upper surface that is exposed to heat and ultraviolet rays from the direct sunlight transmitted through the windshield 24. Weather resistance is required. Therefore, in the base material 12 constituting the instrument panel 10, the foam 14 and the skin 16 are attached to the adherent portion 18 with the adherent portion 18 provided from the center of the upper surface to the center of the front surface on the outer surface. The base material 12 is exposed from the center of the upper surface to the rear of the upper surface. That is, the instrument panel 10 is divided into a first region 20 where the foam 14 and the skin 16 are attached and a second region 22 where the base material 12 is exposed. The tactile feeling is improved and the weather resistance is improved by the second region 22. In addition, the technique relevant to this is disclosed by patent document 1, for example.
[0004]
[Patent Document 1]
Japanese Patent Laid-Open No. 11-020509
[Problems to be solved by the invention]
By the way, when the skin 16 is classified on the basis of the molding technique, (a) the resin sheet material is vacuum-molded based on the vacuum molding technique, and (b) the resin powder is slush molded based on the powder slush molding technique. And (c) those molded by spraying from urethane based on the spray molding technique are suitably implemented, and are made of an elastomer such as TPO, PVC, TPU, PU, or a soft resin. Although the skin 16 molded by such a molding technique can be faithfully reversed and reproduced with respect to the shape and pattern of the molding surface in the molding die, it is impossible to control the thickness and the back surface shape. It is used for implementation under a uniform molding to a thickness of about 1.5 mm. However, such a thin skin 16 has a problem that it tends to be deformed and deteriorated due to heat history when exposed to heat, ultraviolet rays, and the like due to direct sunlight.
[0006]
Therefore, as described above, the skin 16 does not extend to the second region 22 that receives direct sunlight, but only covers the first region 20 that is less affected by direct sunlight. . For this reason, the first region 20 to which the skin 16 is applied and the second region 22 to which the base material 12 is exposed are completely separated, and a boundary line is formed between the regions 20 and 22. At the same time, since the “soft feeling” and “moist feeling” of the skin 16 are not visually expressed in the second region 22, there is a problem that the deterioration of the texture of the instrument panel 10 cannot be avoided. Further, for example, when the area ratio of the second region 22 is increased, the exposed portion of the base material 12 is widened at the same time as the adherence portion of the skin 16 is narrowed, which causes further deterioration of the texture of the instrument panel 10. It will be.
[0007]
OBJECT OF THE INVENTION
The present invention has been proposed to suitably solve the above-described problems, and even if the first region and the second region having different tactile sensations are provided by adopting a skin formed based on the reaction injection molding technology. It is an object of the present invention to provide a foam-formed member with a skin that can avoid deterioration in texture.
[0008]
[Means for Solving the Problems]
In order to solve the above-mentioned problems and achieve the intended object, the present invention provides a base material molded into a required shape, a foam adhered to the outer surface of the base material, and the base material and the foam. In a foam-formed member with a skin consisting of a skin to be deposited on the outer surface of
A thin first skin portion that is in close contact with the outer surface of the foam, and a thick second skin that is set to have a larger thickness dimension than the first skin portion and is in close contact with the outer surface of the substrate. Composed of parts and
The tactile sensation of the external design surface formed by the skin is configured to change between a first region composed of a foam and the first skin portion and a second region composed of the second skin portion, respectively. To do.
[0009]
In order to solve the above-mentioned problem and achieve the intended purpose, another invention includes a base material molded into a required shape, a foam to be applied to the outer surface of the base material, In a foam-formed member with a skin consisting of a skin to be applied to the outer surface of the foam,
The skin is composed of a thin first skin part and a thick second skin part set to a thickness dimension larger than the first skin part,
The foam is formed with a thick first foamed portion interposed between the base material and the first skin portion, and a thickness dimension smaller than the first foamed portion. Consists of a thin second foamed portion interposed between the skin portion,
The tactile sensation of the external design surface formed by the skin is changed between a first region composed of the first foamed portion and the first skin portion and a second region composed of the second foamed portion and the second skin portion, respectively. It is characterized by having comprised as follows.
[0010]
DETAILED DESCRIPTION OF THE INVENTION
Next, a foamed molded member with a skin according to the present invention will be described below with reference to the accompanying drawings by giving preferred examples. In addition, in an Example, an instrument panel is illustrated as a foaming molding member with a skin. Therefore, the same members / parts as those of the instrument panel 10 illustrated in FIGS. 10 and 11 will be described with the same reference numerals.
[0011]
[First embodiment]
FIG. 1 is a schematic perspective view of an instrument panel as a foamed molded member with a skin according to the first embodiment, FIG. 2 is a cross-sectional view taken along the line II-II of FIG. 1, and FIG. is there. The instrument panel 30 of the first embodiment includes a base material 12 molded into a required shape, a foam 14 to be applied to the outer surface of the base material 12, and the outer surfaces of the base material 12 and the foam body 14. And basically has the same structure as the conventional instrument panel 10 illustrated in FIG. For convenience of explanation, the right side (passenger seat side) in FIG. 2 is the “front side” of the instrument panel 30 and the left side (front glass 24 side) is the “rear side”.
[0012]
The base material 12 is a large synthetic resin molded body formed from a synthetic resin material such as ASG based on an injection molding technique using an injection mold (not shown), for example. Various positions for installing the instrument unit 32, the glove box 34, the air-conditioning operation panel 36, the audio device 38, the air outlet 40, and the like are formed at the required position of the base material 12. No. 12 has sufficient strength to withstand these weights. And the whole outer surface of the base material 12 becomes the adherence part 18 to which the foam 14 and the skin 16 are adhered, and the upper surface rear side close to the windshield 24 is the conventional example illustrated in FIG. A step like the base material 12 in the instrument panel 30 is not formed and is flat. In the vicinity of the rear end of the base material 12, a base material opening 48 that functions as an air outlet 41 described later is formed.
[0013]
The foam 14 is a urethane foam formed by, for example, subjecting a urethane raw material to a foaming reaction. The thickness U is about 5 to 10 mm although there are some differences in each part, and the physical properties rich in flexibility. Have. Therefore, when an appropriate portion of the skin 16 attached to the foam 14 is pressed with a fingertip or the like, the pressed foam 14 is compressed and the pressed portion is deformed in a concave manner. This contributes to improving the tactile sensation of the ment panel 30. In the event of a collision, if an occupant is thrown forward and collides with the instrument panel 30, the impact will be absorbed and the injury will be reduced.
[0014]
The said skin 16 implemented in the instrument panel 30 of an Example is a urethane molded object shape | molded based on the reaction injection molding (Reaction Injection Molding shaping | molding) technique which is a well-known technique. In this reaction injection molding technology, polyol and isocyanate are injected into the cavity of the required shape defined in the mold while stirring, and these are reacted in the cavity, so that urethane molding with the same shape as the cavity is formed. This is a method of forming a body. Therefore, for example, a sheet-like member having a different thickness for each part, a member having a complicated outer surface uneven shape, and the like, as long as it is a shape that can be removed from the mold, as in a general injection molding technique. It has a feature that makes it possible to form a shaped urethane molded body. Moreover, unlike the injection molding of thermoplastic resin, there is no inconvenience that “sinking” occurs even when the thickness is different for each part.
[0015]
As shown in FIGS. 2 and 3, the skin 16 of the embodiment molded based on the reaction injection molding technique described above includes a thin first skin portion 42 that is in close contact with the outer surface of the foam 14, and this The thickness is set to be larger than that of the first skin portion 42, and is formed of a thick second skin portion 44 that is in close contact with the outer surface (the adherend portion 18) of the substrate 12. In the first embodiment, the thickness P1 of the first skin portion 42 is about 1 mm, and the thickness P2 of the second skin portion 44 is about 5 to 10 mm. That is, the thickness P2 of the second skin portion 44 is the sum of the thickness P1 of the first skin portion 42 and the thickness U of the foam 14. Therefore, in the skin 16 of the embodiment, the first skin portion 42 exhibits moderate flexibility and is easily deformed, but the second skin portion 44 is difficult to deform. It should be noted that the outer surface of the skin 16 is uniformly textured from the first skin portion 42 to the second skin portion 44, and when viewed from the outer surface side, these first The boundary portion between the skin portion 42 and the second skin portion 44 is not recognized at all.
[0016]
FIG. 4 is a partial cross-sectional view showing a state in which the skin 16 is molded by the skin molding die 50 for molding the skin 16. The skin mold 50 is composed of a first mold 52 and a second mold 54 that can be closed with each other. By closing the first mold 52 and the second mold 54, the skin mold 50 is closed. A cavity 56 having the same shape as the skin 16 is defined inside. The second mold 54 is provided with an injection port 58 with which an injection nozzle N for injecting a foaming raw material into the cavity 56 is aligned.
[0017]
The first mold 52 is provided with a protrusion 52A that can come into contact with the molding surface of the second mold 54 so that the skin 16 is opened in the second skin portion 44 when the skin 16 is molded. The part 46 can be opened. Accordingly, as illustrated in FIGS. 2 and 3, if the skin opening 46 is formed so as to be aligned with the base material opening 48 provided in the base material 12, the base material openings 48 communicated with each other. Further, the air outlet 41 can be opened by the skin opening 46. Moreover, since the second skin portion 44 is formed to be thick, the peripheral portion of the skin opening 46 is not easily deformed even when exposed to heat, ultraviolet rays, or the like due to direct sunlight, and a separately formed garnish member or the like Is not required to be attached to the skin opening 46.
[0018]
FIG. 5 shows the foam between the skin 16 set in the first mold 62 and the base material 12 set in the second mold 64 by the foam mold 60 for foam-molding the foam 14. It is explanatory sectional drawing which showed the state which shape | molds 14. FIG. When the foam molding die 60 is closed, the second skin portion 44 of the skin 16 is brought into close contact with the outer surface of the substrate 12 by the clamping force of the first molding die 62 and the second molding die 64. Thus, a sealed state is formed, and the foam 14 during the foaming reaction can be prevented from leaking from between the second skin portion 44 and the substrate 12. However, it is desirable that the second skin portion 44 and the base material 12 are bonded simultaneously with the molding of the foam 14 with an adhesive or the like applied prior to mold closing.
[0019]
Note that, as illustrated in FIG. 6, the second skin portion 44 and the base material 12 may be bonded to each other using a part of the foam 14. That is, when the foaming mold 60 is closed, several gaps 66 (for example, a thickness of about 0.5 mm and a width of about 10 mm) are appropriately defined between the second skin portion 44 and the base material 12. If the second skin portion 44 is molded, a part of the foam 14 enters the gap 66 and hardens. Therefore, the second skin portion 44 and the base material 44 can be cured using the foam 14. Adhesion with the material 12 is achieved. When it does in this way, there exists an advantage which can abbreviate | omit the application | coating operation | work of the adhesive agent before foaming molding of the foam 14.
[0020]
In the instrument panel 30 of the first embodiment employing the above-described skin 16, the external design surface formed by the skin 16 is formed from the foam 14 and the first skin portion 42 as illustrated in FIG. The second region 22, which is composed of only the first region 20 extending from the center of the upper surface of the instrument panel 30 to the center of the front surface and the second skin portion 44, is located at the rear of the upper surface of the instrument panel 30. It is divided into and. However, since the skin 16 is applied to the entire outer surface of the base material 12 from the first region 20 to the second region 22, the boundary between the first region 20 and the second region 22 in appearance. The line is not visible at all (FIG. 1).
[0021]
As described above, the foam 14 has physical properties rich in flexibility, and the skin 16 has physical properties rich in elasticity (rebound). Accordingly, when the first region 20 and the second region 22 are compared, the first region 20 is a so-called “soft region” in which flexibility is suitably exhibited, and the second region 22 is elastic. This is a so-called “hard region” in which (repellency) is suitably exhibited. In other words, the instrument panel 30 of the first embodiment is configured by forming the skin 16 from the first skin portion 42 and the second skin portion 44 having different thicknesses, and the formation range of the foam 14 is defined as the first region 20. By limiting to only the first region 20 having high flexibility and the second region 22 having high elasticity, the tactile sensation of the external design surface formed by the skin 16 is changed. .
[0022]
As described above, the instrument panel 30 according to the first embodiment employs the skin 16 formed based on the reaction injection molding technique, so that both the first region 20 and the second region 22 having different tactile sensations are provided. Since the boundary portion between the regions 20 and 22 is not visually recognized from the outside, it is possible to suitably avoid the deterioration of the texture. Moreover, since the epidermis 16 is deposited from the first region 20 to the second region 22, the “soft feeling” and “moist feeling” of the epidermis 16 are visually expressed on the entire external design surface. Thus, the texture of the instrument panel 30 can be improved suitably. Furthermore, even if the area ratio of the second region 22 is increased, only the second skin portion 44 is increased, and no change occurs on the external design surface formed by the skin 16, so that the instrument The deterioration of the texture of the ment panel 30 is not caused.
[0023]
[Second embodiment]
FIG. 7 is a side sectional view of an instrument panel as a foamed molded member with a skin according to the second embodiment, and FIG. 8 is an enlarged sectional view of a main part of FIG. In the instrument panel 70 according to the second embodiment, the skin 16 is divided into a thin first skin portion 72 and a thick second skin portion 74 set to a thickness dimension larger than the first skin portion 72. It is composed of Further, the foam 14 is formed to have a thick first foam portion 76 interposed between the base material 12 and the first skin portion 72 and a thickness dimension smaller than the first foam portion 76, A thin second foamed portion 78 is interposed between the base material 12 and the second skin portion 74.
[0024]
In the skin 16, since the thickness P1 of the first skin portion 72 is about 1 mm and the thickness P2 of the second skin portion 74 is about 5 to 9 mm, the first skin portion 72 is moderately flexible. The second skin portion 74 is difficult to be deformed due to its performance. Moreover, in the said foam 14, since the thickness U1 of the said 1st foam part 76 shall be about 5-7 mm and the thickness U2 of the said 2nd foam part 78 shall be about 2-4 mm, the said 1st foam part 76 is rich in flexibility and easily deformed, and the second foamed portion 78 is less flexible and difficult to deform.
[0025]
Accordingly, when the first region 20 and the second region 22 are compared, the first region 20 is a so-called “soft region” in which flexibility is suitably exhibited, and the second region 22 is elastic. This is a so-called “hard region” in which (repellency) is suitably exhibited. In other words, the instrument panel 70 of the second embodiment comprises the skin 16 from the first skin portion 72 and the second skin portion 74 having different thicknesses, whereby the foam 14 has the first thickness different from each other. By being formed in the foamed portion 76 and the second foamed portion 78, the external design formed by the skin 16 is divided into the first region 20 having high flexibility and the second region 22 having high elasticity. The tactile sensation of the surface has been changed.
[0026]
Therefore, the instrument panel 70 according to the second embodiment can obtain the same effects as those of the instrument panel 30 of the first embodiment. However, the second region 22 of the instrument panel 70 according to the second embodiment has a second foamed portion 78, so that it is slightly more flexible than the second region 22 in the instrument panel 30 according to the first embodiment. Will have.
[0027]
[Example of change]
FIG. 9 is a side sectional view of an instrument panel according to a modified example. In the instrument panel 80 of this modified example, the thickness gradually increases from the first skin portion 42 to the second skin portion 44 at the boundary portion between the first skin portion 42 and the second skin portion 44 in the skin 16. A wall thickness gradually changing portion 82 is provided. Therefore, since the ratio of the thickness of the epidermis 16 and the thickness of the foam 14 gradually changes from the first region 20 toward the second region 22 in the gradually changing thickness portion 82, the first region The elasticity gradually increases from 20 toward the second region 22 and the flexibility gradually decreases. Thereby, it is possible to avoid a sense of incongruity due to a sudden change in elasticity and flexibility at the boundary between the first region 20 and the second region 22.
[0028]
Although FIG. 9 illustrates a modification based on the first embodiment, it can also be applied to the second embodiment.
[0029]
In each of the above-described embodiments, the instrument panel which is a vehicle interior member is exemplified as the foam-formed member with a skin. However, the foam-formed member with a skin targeted by the present application is not limited to this, and the floor console is not limited thereto. Various vehicle interior members such as console lids and door panels and various furniture (chairs, sofas, etc.) are also targeted.
[0030]
【The invention's effect】
As described above, according to the foam-molded member with a skin according to the present invention, even if the first region and the second region having different tactile sensations are provided by adopting the skin molded based on the reaction injection molding technology, both are provided. Since the boundary portion of the region is not visually recognized from the outside, there is a beneficial effect that it is possible to suitably avoid the deterioration of the texture. Moreover, since the epidermis is applied from the first region to the second region, the “soft feeling” and “moist feeling” of the epidermis are visually expressed on the entire external design surface, and the epidermis is attached. There is an advantage that it is possible to suitably improve the texture of the foam molded member. Furthermore, even if the area ratio between the first region and the second region is changed, no change occurs on the external design surface formed by the skin, so that the texture of the foamed molded member with the skin is not deteriorated. There are also advantages.
[Brief description of the drawings]
FIG. 1 is a schematic perspective view of an instrument panel as a foam-formed member with a skin according to a first embodiment.
FIG. 2 is a cross-sectional view taken along the line II-II in FIG.
3 is an enlarged cross-sectional view of a main part of FIG.
FIG. 4 is a partial cross-sectional view showing a state in which the skin is molded by a skin molding die for molding the skin based on the reaction injection molding technique.
FIG. 5 shows a foam molding die for foam molding, in which the first molding die with the outer skin set and the second molding die with the substrate set are closed, and the foam is molded. It is explanatory sectional drawing which showed the state which has shown, Comprising: The 2nd skin part of an outer_skin | epidermis closely_contact | adheres to the outer surface of a base material, and has shown that the leakage of a foam is prevented.
FIG. 6 shows a foam molding die for foam molding, in which the first molding die set with the skin and the second molding die set with the base material were closed, and the foam was molded. Is an explanatory cross-sectional view showing a state in which the second skin portion is formed so that an appropriate number of gaps are defined between the outer surface of the substrate and the second skin portion of the skin, This indicates that a part of the foam is allowed to enter the gap, and the foam and the base material are bonded to the second skin portion by the foam.
FIG. 7 is a side sectional view of an instrument panel as a foamed molded member with a skin according to a second embodiment.
8 is an enlarged cross-sectional view of a main part of FIG.
FIG. 9 is a side sectional view of an instrument panel as a foamed molded member with a skin according to a modified example.
FIG. 10 is a schematic perspective view of an instrument panel as a conventional foamed molded member with a skin.
11 is a cross-sectional view taken along line XX in FIG.
[Explanation of symbols]
12 Base material 14 Foam 16 Skin 20 First region 22 Second region 42, 72 First skin portion 44, 74 Second skin portion 76 First foam portion 78 Second foam portion 82 Thickness gradually changing portion

Claims (4)

A base material (12) molded into a required shape, a foam (14) to be applied to the outer surface of the base material (12), and an outer surface of the base material (12) and the foam (14). In the foamed molded member with the skin consisting of the skin (16) to be deposited,
The skin (16) is set to have a thin first skin portion (42) that is in close contact with the outer surface of the foam (14) and a thickness dimension larger than the first skin portion (42), and the base material A thick second skin portion (44) that is in close contact with the outer surface of (12),
The tactile sensation of the external design surface formed by the skin (16) consists of a first region (20) composed of a foam (14) and the first skin portion (42), and a second skin portion (44). A foam-molded member with a skin, characterized in that it is configured to vary with the second region (22). A base material (12) molded into a required shape, a foam (14) to be applied to the outer surface of the base material (12), and an outer surface of the base material (12) and the foam (14). In the foamed molded member with the skin consisting of the skin (16) to be deposited,
The skin (16) comprises a thin first skin portion (72) and a thick second skin portion (74) set to a thickness dimension larger than the first skin portion (72),
From the first foamed part (76), the thick foamed part (76) interposed between the base material (12) and the first skin part (72). A thin second foamed portion (78) formed between the base material (12) and the second skin portion (74), having a small thickness dimension;
The tactile sensation of the external design surface formed by the skin (16) is divided into a first region (20) composed of the first foam portion (76) and the first skin portion (72), and the second foam portion (78). And a foam-molded member with a skin, characterized in that it is configured to change in each of the second region (22) comprising the second skin portion (74). In the boundary portion between the first skin portion (42/72) and the second skin portion (44/74) in the skin (16), the first skin portion (42/72) to the second skin portion (44 / 74. The foamed molded member with a skin according to claim 1 or 2, further comprising a wall thickness gradually changing portion (82) whose thickness gradually increases over 74). The foamed molded member with a skin according to any one of claims 1 to 3, wherein the skin (16) is a urethane molded body molded based on a reaction injection molding technique.

Images