JP2005297307A - Method for producing expanded material with skin, method for producing instrument panel, and mold - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To well demold an expanded material with a skin by solving the problem of an undercut when a mold forming the undercut is used. <P>SOLUTION: With the use of a foaming mold 120 forming the undercut in a molding, in the production of an instrument panel 10, a skin material is applied on the inner surface 120a of the foaming mold 120 to mold the skin 22. Next, a foamed material is sealed in the foaming mold 120 in which the skin 22 is molded and a substrate 30 is set to mold the instrument panel 10. Next, an extrusion core 52 and a deformed core 54 are elevated integrally, and the instrument panel 10 is deformed elastically so that the undercut 26 of the instrument panel 10 is eliminated. The instrument panel 10 with the undercut 26 eliminated is removed from the foaming mold 120. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

  The present invention relates to a technique for manufacturing a foam with a skin. In particular, the present invention relates to a technique for manufacturing a foam with a skin using a mold that causes an undercut in a molded product.

  A foam with a skin covering a soft foam with a hard skin has been put into practical use. The foam with a skin is used, for example, for an instrument panel disposed in front of a driver's seat or a passenger seat of an automobile. The skin of the foam with skin used in the instrument panel improves the appearance of the instrument panel. Moreover, the foam of the foam with a skin absorbs a collision force. The instrument panel is configured by joining a base material for storing instruments and a foam with a skin while maintaining its shape.

The following methods are widely used as a method for producing a foam with a skin. In this method, first, the skin is formed using a slush molding method. In the slush molding method, powder or paste-like skin material is put into a slush mold heated to a high temperature (about 230 ° C) to melt the skin material, and then the slush mold is cooled to form the skin. It is a method to do. When the skin is slush-molded, the skin is set in a foaming mold. Then, the foam material is sealed and foamed in a foaming mold in which the skin is set. Thereby, the foam with a skin in which the foam is joined to the skin is formed. Finally, the foaming mold is opened and the foam with skin is released from the foaming mold.
For example, a foam with a skin used for a complicated shape such as an instrument panel has to be complicated in its own shape. For example, if an attempt is made to form a foam with a skin having a complex shape using a foam mold composed of two cores, a fixed core and a movable core, the foam mold is interfered with the foam with a skin, and the foam is molded. If the shape remains unchanged, the foam with skin cannot be released. That is, if a mold having a simple core configuration is used, an undercut occurs in the foam with a skin. Therefore, the foam with a skin is often molded using a molding die divided into a large number of cores so that undercut does not occur. Patent Document 1 discloses a mold that is divided into a large number of cores.

In recent years, liquid skin materials have been developed. If a liquid skin material is used, the skin can be molded in the foam mold by directly applying the skin material to the inner surface of the foam mold. When a foam material is sealed in a foaming mold in which a skin is molded and foamed, a foam (foam with a skin) joined to the skin can be molded. If the skin is molded in the foam mold, the slush mold for molding the skin can be eliminated. Patent Document 2 discloses a technique for manufacturing an instrument panel using this technique.
JP-A-4-133706 Japanese National Patent Publication No. 7-508939

  In the technique of Patent Document 2, in order to solve the problem of undercut, a foam with a skin is manufactured using a foaming mold divided into a plurality of cores. Since the foaming mold divided into a plurality of cores is used, the skin material is applied across two or more cores (see FIGS. 4 and 5 of Patent Document 2). In this case, in the process in which the applied skin material is solidified and the skin is molded, the parting line (the shape between the cores) is transferred to the skin. For example, in the case of a foam with a skin used for an instrument panel, if a parting line is formed in a skin part that can be visually recognized from a driver's seat or a passenger seat, the appearance is poor. However, if a mold having a structure (simple core structure) in which the parting line is not transferred to the visible portion of the skin is used, an undercut problem arises.

  The present inventors are developing products with the goal of producing a high-quality foam with a skin. In order to produce a high-quality foam with a skin, it is necessary to avoid the formation of a parting line in the visible portion of the skin. Therefore, it was decided to employ a method of manufacturing a foam with a skin using a mold that causes an undercut so that the parting line is not transferred to the visible portion of the skin. And when the mold which an undercut produces is used, it came to develop the technique which eliminates the problem of an undercut and can release a foam with a skin well. The development of this technology has made it possible to eliminate the need for a slush mold and to produce a high-quality foam with a skin in which a parting line is not substantially formed.

The technology according to the present invention is a method of manufacturing a foam with a skin using a mold that causes an undercut in a molded product. In this method, a skin material is formed by applying a skin material to the inner surface of the mold. Moreover, the process of shape | molding a foam with a skin by sealing a foaming material in the shaping | molding die in which the skin is shape | molded is implemented. Moreover, the process which eliminates the undercut of a foam with a skin is implemented by moving at least one part of a shaping | molding die and elastically deforming a foam with a skin. And the process of releasing the foam with a skin from which the undercut was eliminated from a shaping | molding die is implemented.
This method eliminates the need for a slush mold because the skin material is applied to the inner surface of the mold to mold the skin. Further, in order to eliminate the undercut by moving the mold and elastically deforming the foam with skin, the foam with skin can be successfully released from the mold. When the foam with skin is released, the foam with skin that has been elastically deformed returns to its original shape. A foam with a skin having a desired shape can be obtained.
By adopting this method, the dividing line is not substantially transferred to the skin, and a high-quality foam with a skin can be produced.

The present invention also provides a method for producing an instrument panel in which a skin, a foam and a base material are joined using a mold that causes an undercut in a molded product. This method implements the step of forming a substrate. Moreover, the process of apply | coating a skin material to a shaping | molding die inner surface and shape | molding a skin is implemented. In addition, the foaming material is sealed in a molding die in which the skin is molded and the base material is set, and a process of molding an instrument panel in which the skin, the foam and the base material are joined is performed. Moreover, the process which eliminates the undercut of an instrument panel is implemented by moving at least one part of a shaping | molding die and elastically deforming an instrument panel. And the process which releases the instrument panel from which the undercut was eliminated from the shaping | molding die is implemented.
In this method, the undercut is eliminated by elastically deforming the skin, foam and substrate together. By adopting this method, the parting line is not substantially transferred to the epidermis, and a high-quality instrument panel can be manufactured.
The base material may be molded in the above-described mold, or may be set in the mold after being molded outside the above-described mold.

Integral skin foam, a foam-molded product, has been put into practical use. The raw material of the integral skin foam is foamed so that the surface layer portion is low foamed and the inside is highly foamed. The surface layer is smooth with almost no bubbles remaining, and the inside is soft. The nature of the surface layer of the integral skin foam is a property necessary for the skin of the instrument panel, and the internal property is a property necessary for the foam of the instrument panel. For this purpose, an instrument panel may be constructed using an integral skin foam. If an integral skin foam material is used, a skin and a foam can be shape | molded simultaneously, and a foam with a skin can be shape | molded with few processes.
In the present invention, when manufacturing a foam with a skin by sealing an integral skin foam material in a mold that causes an undercut in the molded product, a technology is provided that can successfully release the foam with a skin by eliminating the undercut. To do. This method includes the step of sealing the integral skin foam material in a mold and molding the foam with a skin. Moreover, the process of eliminating the undercut of a foam with a skin is provided by moving at least one part of a shaping | molding die and elastically deforming a foam with a skin. And the process with the mold release of the foam with a skin from which the undercut was eliminated is provided.
In this method, the undercut is eliminated by elastically deforming the foam with a skin formed from the integral skin foam material. By adopting this method, the parting line is not substantially transferred to the skin, and a high-quality foam with skin can be produced.

Moreover, in this invention, the shaping | molding die which an undercut produces in a molded article is provided. The mold includes a pair of cores that elastically deform the molded product by moving integrally with the molded product sandwiched therebetween to eliminate the undercut and release the sandwiched product by moving relative to each other. . A dual-purpose actuator that also serves as an actuator that moves the pair of cores integrally with an actuator that moves the pair of cores integrally is provided.
This molding die elastically deforms the molded product so that the undercut is eliminated by moving integrally with the pair of cores sandwiching the molded product. Since the molded product is sandwiched between the pair of cores, it can be accurately elastically deformed in the direction in which the undercut is eliminated. When the undercut is eliminated, the molded product can be easily released. Moreover, a pair of core moves relatively so that the state which pinched | interposed the molded article may be cancelled | released. Since the state where the molded product is sandwiched is released, the molded product can be easily taken out from the pair of cores.
In the present invention, since the integral movement and the relative movement of the pair of cores are realized by one actuator, the configuration of the mold can be simplified.

The technique described here is also a creation of the present invention.
(Embodiment 1) The technology of the present embodiment is a method for manufacturing an instrument panel in which an integral skin foam (foam with skin) is bonded to a base material using a mold that causes an undercut in a molded product. This method comprises the step of forming a substrate. Further, the method includes a step of sealing an integral skin foam material in a molding die on which the base material is set, and molding an instrument panel in which the integral skin foam is bonded to the base material. Moreover, the process of eliminating the undercut of an instrument panel is provided by moving at least one part of a shaping | molding die and elastically deforming an instrument panel. And the process which releases the instrument panel from which the undercut was eliminated from a shaping | molding die is provided.
If this method is used, a high quality instrument panel can be manufactured.

(Form 2) The technique of this form is a shaping | molding die which an undercut produces in a molded article. The molding die includes a pair of cores that elastically deform the molded product to eliminate the undercut by moving integrally with the molded product sandwiched therebetween, and an actuator that integrally moves the pair of cores.
If this mold is used, the molded product can be accurately elastically deformed in a direction in which the undercut is eliminated.

Here, the main features of the techniques described in the following examples are described.
(Mode 3) The foaming mold includes a fixed core and three movable cores. The movable core is a main movable core, an extruded core, and a deformed core. The extruded core and the deformed core (a pair of cores) move integrally with the molded product sandwiched therebetween to elastically deform the molded product.
(Form 4) A guide groove is formed in the main movable core. The deformable core has a guide pin. The deformable core displaces its height position by moving the guide pin along the guide groove of the main movable core.
(Mode 5) A rod is fixed to the extruded core. An actuator for applying an urging force (a combined actuator) is connected to the rod. A rod is disposed so as to penetrate a long hole provided in the deformable core. The rod can be displaced in the slot.

First Embodiment An embodiment of the present invention will be described with reference to the drawings. FIG. 1 shows a perspective view of the instrument panel 10. The instrument panel 10 is disposed in front of the driver's seat and the passenger seat of the automobile.
FIG. 2 is a sectional view taken along line II-II in FIG. As shown in FIG. 2, the instrument panel 10 is configured by joining a foam with skin 20 and a base material 30. The foam with skin 20 is composed of a skin 22 and a foam 24. The instrument panel 10 has a configuration in which a foam 24 is interposed between the skin 22 and the base material 30. The base material 30 maintains the shape of the instrument panel 10 and houses instruments. The foam 24 of the foam with skin 20 absorbs a collision force. The skin 22 covers the surface of the foam 24 to improve the appearance of the instrument panel 10. In this embodiment, the skin 22 covers a part of the base material 30 without the foam 24 (the lower part in FIG. 2).

Next, the structure of the foam mold for manufacturing the instrument panel 10 will be described. FIG. 3 shows a cross-sectional view of the foam mold 120. The foam mold 120 has a fixed core 40 and three movable cores 50, 52, 54. In the state where the mold is closed (the state shown in FIG. 3), the cavity 120 a is defined by these cores 40, 50, 52 and 54. Precisely, the pin 80 is embedded in the core 50, and the end surface of the pin 80 on the fixed core side also functions as a surface that defines the cavity 120a.
The fixed core 40 constitutes the left part of the foam molding die 120. The fixed core 40 has a large width in the left-right direction in FIG. 3 and also has a large width in the direction perpendicular to the plane of FIG. The fixed core 40 is immovable. The right part of the foam mold 120 is constituted by three movable cores 50, 52, 54 and a pin 80. Each movable core 50, 52, 54 is movable with respect to the fixed core 40. Hereinafter, the core 50 is referred to as a main movable core, the core 52 is referred to as an extruded core, and the core 54 is referred to as a deformed core.

The main movable core 50 has a large width in the left-right direction in FIG. 3, and also has a large width in the direction perpendicular to the paper surface in FIG. The main movable core 50 is provided with holes 50b and 50c penetrating in the left-right direction. The hole 50b of the main movable core 50 extends straight from the right end to the upper left direction. The hole 50c extends in a straight line substantially horizontally.
The main movable core 50 can move independently in the left-right direction. The main movable core 50 is connected to an actuator 100 that moves the main movable core 50.
A rod 56 is fixed to the extruded core 52. The rod 56 is slidably fitted in a hole 50b provided in the main movable core 50. An actuator 104 that integrally moves the extruded core 52 and the rod 56 is connected to the rod 56. As will be described in detail later, the extruded core 52 moves integrally with the deformable core 54 when the positional relationship with the main movable core 50 is in a predetermined relationship, and the positional relationship with respect to the main movable core 50 is other than the predetermined relationship. Moves relative to the deformable core 54.
An actuator is not connected to the deformable core 54. The deformable core 54 can move as the actuator 104 moves the extruded core 52. The actuator 104 is an actuator for the extruded core 52 and an actuator for the deformable core 54. The configuration of the deformable core 54 will be described in detail later.
The pin 80 is slidably fitted in a hole 50 c provided in the main movable core 50. An actuator 102 that moves the pin 80 is connected thereto.
As each actuator 100, 102, 104 described above, for example, a hydraulic cylinder can be adopted.

Next, the configuration of the deformable core 54 will be described in detail with reference to FIG. FIG. 4 is a schematic perspective view of the deformable core 54. In FIG. 4, since the deformed core 54 is shown in a very simplified manner, there is a portion whose shape does not match the cross-sectional view of FIG.
The deformable core 54 has a first portion 54c extending in the up-down direction and a second portion 54d extending leftward from the lower portion of the first portion 54. The upper part of the first portion 54c is formed in a curved surface shape. In the first portion 54c, two long holes 54a and 54a penetrating the first portion 54c to the left and right are formed. The long holes 54a and 54a are long in the vertical direction. Rods 56 and 56 pass through the long holes 54a and 54a, respectively. The lengths of the long holes 54 a and 54 a in the vertical direction are longer than the diameters of the rods 56 and 56. Accordingly, the rods 56, 56 can move in the vertical direction in the long holes 54a, 54a.
The end surfaces 56a, 56a of the rods 56, 56 are fixed to the extruded core 52 (see FIG. 3) (only one rod 56 is visible in FIG. 3). Two rods 56, 56 pass through the main movable core 50, and both the rods 56, 56 are connected to the actuator 104.

As shown in FIG. 4, guide pins 54 b and 54 b are fixed to the side surface of the first portion 54 c of the deformable core 54. Each of the guide pins 54b and 54b is a cylindrical member and extends by the same length at the same height position.
Reference numerals 50 a and 50 a in FIG. 4 are guide grooves provided in the main movable core 50. Also in FIG. 3, the guide groove 50a is indicated by a broken line. Each guide groove 50a, 50a is formed in the same shape. Guide pins 54b and 54b of the deformable core 54 are slidably fitted in the guide grooves 50a and 50a, respectively. The deformed core 54 is supported by fitting the guide pins 54 b and 54 b into the guide grooves 50 a and 50 a of the main movable core 50. As shown in FIG. 3, the guide groove 50a extends in the upper left direction from the right end to the intermediate position, and extends in the lower left direction from the intermediate position to the left end. The inclination angle of the guide groove 50a in the upper left direction is substantially equal to the inclination angle of the hole 50b of the main movable core 50. In the state of FIG. 3 (mold closed state), the guide pin 54b is positioned at the right end of the guide groove 50a.

As shown in FIG. 3, the deformable core 54 is arranged so as to face slightly to the upper left. In the mold closed state, the rod 56 is in contact with the lower surface of the elongated hole 54 a of the deformable core 54. A gap is formed between the upper surface of the long hole 54 a and the rod 56.
A ring member 58 is fixed to the rod 56. The ring member 58 prohibits the deformable core 54 from moving toward the non-extrusion core 52 along the rod 56. The ring member 58 is also fixed to the other rod 56 (see FIG. 3). By the ring member 58, the extruded core 52 and the deformable core 54 are kept in close contact in the left-right direction. However, a gap is provided between the extruded core 52 and the deformable core 54 in the vertical direction. In this gap, the skin 22 and the base material 24 of the instrument panel 10 are sandwiched (the situation can be clearly seen in FIG. 3).

  Since the lower part 26 interferes with the fixed core 40, the instrument panel 10 cannot be released while maintaining the state of FIG. That is, the instrument panel 10 has an undercut 26. In the present embodiment, the undercut 26 is eliminated and the instrument panel 10 is released. This point will be described in detail later.

Next, a method for manufacturing the instrument panel 10 will be described. FIG. 5 shows a flowchart of the manufacturing method of this embodiment.
First, the process of shape | molding the base material 30 is implemented (step S2). The base material 30 is formed by injection molding using a resin such as PP, ASG, or PC / ABS. The injection mold is separate from the foam mold 120.
Subsequently, the molded base material 30 is set in the foam molding die 120 (step S4). As shown in FIG. 3, the base material 30 is set so as to contact the main movable core 50 and the extruded core 52.
When the base material 30 is set in the foam mold 120, a liquid skin material is applied to the foam mold 120 (step S6). A polyurethane material is used as the skin material. This polyurethane material has a low-foaming property and does not leave bubbles, resulting in a smooth surface. The skin 22 is formed by applying the skin material to the entire inner surface of the fixed core 40 and a part of the base material 30 (the portion between the extruded core 52 and the deformable core 54). At this time, since the skin material is applied across the fixed core 40 and the deformable core 54, the dividing line is transferred to the molded skin 22. However, this parting line exists at the position (namely, the back side) indicated by reference numeral 70 in FIG. 1 when the instrument panel 10 is placed in the automobile. The parting line 70 cannot be seen from the driver's seat or the passenger seat, and the appearance of the instrument panel 10 is not impaired by the presence of the parting line 70.
When the skin 22 is molded in step S6, the foam material is poured into the foaming mold 120 in which the base material 30 is set and the skin 22 is molded (step S8). The foam material used here is a polyurethane material. This polyurethane material has a high foaming property, and when it is foamed and cured, a soft foam is formed. By this step, the foam 24 bonded to the skin 22 and the base material 30 is molded. That is, the instrument panel 10 is molded.

As described above, the molded instrument panel 10 has the undercut 26. In step S <b> 10, the undercut 26 is eliminated, and the instrument panel 10 is released from the foaming mold 120. In the following, how this step is performed will be described in detail.
First, the actuator 100 (see FIG. 3) moves the main movable core 50 in the right direction. At this time, the pin 80 is biased leftward by the actuator 102 so that the pin 80 does not move rightward integrally with the main movable core 50. In addition, the rod 56 is biased leftward by the actuator 104 so that the extruded core 52 and the deformable core 54 are integrated with the main movable core 50 and do not move rightward.
As a result, as shown in FIG. 6, only the main movable core 50 moves in the right direction. In the process in which only the main movable core 50 moves to the right, the position of the guide pin 54b in the guide groove 50a changes. That is, the position of the guide pin 54b in the guide groove 50a is displaced leftward from the right end of the guide groove 50a. As described above, the guide groove 50a extends in the upper left direction from the right end to the intermediate position. For this reason, as the guide pin 54b is displaced to the intermediate position of the guide groove 50a, the guide pin 54b gradually rises. When the guide pin 54b is raised, the deformable core 54 fixed thereto is also raised.
The extruded core 52 gradually moves upward as the rod 56 protrudes from the main movable core 50. As described above, the inclination angle of the rod 56 (hole 50b; see FIG. 3) and the inclination angle in the upper left direction of the guide groove 50a are substantially equal. Accordingly, the extruded core 52 and the deformed core 54 rise at substantially the same speed. That is, when the main movable core 50 moves to the right, the extruded core 52 and the deformable core 54 rise together. Between the extruded core 52 and the deformed core 54, the skin 22 and the base material 30 of the instrument panel 10 are sandwiched. Therefore, when the extruded core 52 and the deformable core 54 are raised, the lower part of the instrument panel 10 is elastically deformed as shown in FIG. Thereby, the lower part of the instrument panel 10 does not interfere with the fixed core 40. That is, the undercut 26 (see FIG. 3) of the instrument panel 10 is eliminated.
Since it is the actuator 104 that directly applies force to the extruded core 52 and the deformable core 54, it is the actuator 104 that raises the extruded core 52 and the deformable core 54 integrally. I can say that.

When the main movable core 50 is moved rightward to the state shown in FIG. 6, the actuator 102 stops urging the pin 80 leftward and the actuator 104 stops urging the rod 56 leftward. However, the main movable core 50 continues to move rightward. Then, the pin 80 having friction with respect to the main movable core 50 moves rightward together with the main movable core 50. Further, the rod 56 is arranged to be inclined with respect to the main movable core 50 and has a large friction with respect to the main movable core 50. Accordingly, the rod 56 and the extruded core 52 move in the right direction together with the main movable core 50. At this time, when the extruded core 52 moves in the right direction, the deformed core 54 in contact with the right surface of the extruded core 52 also moves in the right direction.
After all, the main movable core 50, the extruded core 52, the deformable core 54, and the pin 80 move together in the right direction. FIG. 7 shows the result of such movement. Comparing FIG. 6 and FIG. 7, it can be seen that the position of the pin 54b in the guide groove 50a of the main movable core 50 is not displaced.
Since the instrument panel 10 is sandwiched between the extruded core 52 and the deformable core 54, when the extruded core 52 and the deformable core 54 move in the right direction, the instrument 10 also moves in the right direction. Since the undercut 26 (see FIG. 3) of the instrument panel 10 is eliminated, the instrument panel 10 moves to the right without interfering with the fixed core 40.

When the main movable core 50, the push-out core 52, the deformable core 54, and the pin 80 move together to a predetermined position, the actuator 100 is stopped. The actuator 102 urges the pin 80 in the left direction and the actuator 104 urges the rod 56 in the left direction. As a result, the pin 80 moves in the left direction, and the rod 56 and the pushing core 52 move in the left direction (more precisely, in the upper left direction). When the rod 56 moves in the left direction, the ring member 58 fixed to the rod 56 pushes the deformed core 54, so that the deformed core 54 also moves in the left direction. The actuator 102 and the actuator 104 are controlled so that the amount of movement of the pin 80 per time and the amount of movement of the rod 56 (extruded core 54) in the left direction coincide with each other.
Since the deformable core 54 moves to the left with respect to the main movable core 50, the position of the guide pin 54b in the guide groove 50a of the main movable core 50 is displaced to the left. Since the guide groove 50a extends in the lower left direction from the intermediate position toward the left end, the guide pin 54b is displaced in the lower left direction. For this reason, the deformable core 54 moves in the lower left direction. At this time, the rod 56 does not interfere with the movement of the deformable core 54 in the lower left direction. The position of the rod 56 in the elongated hole 54a of the deformable core 54 changes. FIG. 8 shows a view in which the guide pin 54b is located at the left end of the guide groove 50a. As shown in FIG. 8, the upper surface of the rod 56 is in contact with the upper surface of the long hole 54 a of the deformable core 54, and a gap is formed between the lower surface of the long hole 54 a and the lower surface of the rod 56.

  Until the guide pin 54b of the deformable core 54 is positioned at the left end of the guide groove 50a (until the state shown in FIG. 8), the extruded core 52, the deformable core 54, and the pin 80 move leftward. In this process, the extruded core 52 and the deformable core 54 move relative to each other in the direction of separating vertically. For this reason, the sandwiching of the instrument panel 10 between the extruded core 52 and the deformed core 54 is released. At this time, the elastic deformation of the instrument panel 10 is released, and the instrument panel 10 is restored to the same shape as in the state of FIG. Since the holding of the instrument panel 10 by the extruded core 52 and the deformable core 54 is released, the instrument panel 10 can be easily removed.

According to the first embodiment, since the skin material is directly applied to the foam mold 120 and the skin 22 is molded, the slush mold can be eliminated. Moreover, in order to eliminate the undercut 26 (refer FIG. 3) by moving the extruded core 52 and the deformation | transformation core 54 integrally, and elastically deforming the instrument panel 10, the instrument panel 10 can be released successfully. . If the method of 1st Example is employ | adopted, a parting line will not be substantially transcribe | transferred to the skin 22, but the quality instrument panel 10 can be manufactured.
Moreover, in order to apply a deformation force to the instrument panel 10 while being sandwiched between the extruded core 52 and the deformable core 54, the instrument panel 10 can be accurately elastically deformed in a direction to eliminate the undercut. When the instrument panel 10 is released from the fixed core 40, the extruded core 52 and the deformable core 54 release the instrument panel 10 from being pinched. For this reason, the instrument panel 10 can be easily taken out between the extruded core 52 and the deformed core 54.
The actuator 104 of this embodiment serves as both an actuator that moves the extruded core 52 and the deformable core 54 integrally and an actuator that moves the same. A foam molding die 120 having a simple configuration with a small number of actuators is realized.

Second Embodiment Here, a description will be given focusing on differences from the first embodiment. In the present embodiment, the method for manufacturing the instrument panel 10 is different from that in the first embodiment. FIG. 9 shows a flowchart of the manufacturing method of this embodiment. Steps S12 and S14 are the same as steps S2 and S4 (see FIG. 5) of the first embodiment, and thus description thereof is omitted.
In step S16, the integral skin foam material is injected into the foaming mold 120 (see FIG. 3 and the like) on which the base material 30 is set. This integral skin foam material is a polyurethane material. The integral skin foam material has the property that the surface portion is low foamed and the inside is highly foamed. The nature of the surface layer of the integral skin foam is a property necessary for the skin of the instrument panel, and the internal property is a property necessary for the foam of the instrument panel. When the integral skin foam material is used, the skin 22 and the foam 24 (foam with skin 20) can be molded simultaneously. By performing the process of step S16, the instrument panel 10 in which the foam with skin 20 is joined to the base material 30 is molded.
Since the process of step S18 is the same as that of step S10 (refer FIG. 5) of 1st Example, description is abbreviate | omitted.

  According to the present embodiment, the step of molding the skin 22 and the step of molding the foam 24 can be performed simultaneously. For this reason, the instrument panel 10 can be manufactured with a fewer number of steps than in the first embodiment.

Specific examples of the present invention have been described in detail above, but these are merely examples and do not limit the scope of the claims. The technology described in the claims includes various modifications and changes of the specific examples illustrated above.
In the first embodiment, the foam 30 and the base material 30 are joined simultaneously with the molding of the foam 24 by setting the base material 30 in the foam mold 120. However, only the foam with skin 20 may be molded in the foaming mold, and the foam with skin 20 taken out from the mold and the substrate 30 may be joined.
-You may shape | mold the base material 30 by methods other than injection molding. The base material may be molded in the foam mold 120.

  Further, the technical elements described in the present specification or drawings exhibit technical usefulness alone or in various combinations, and are not limited to the combinations described in the claims at the time of filing. In addition, the technology illustrated in the present specification or the drawings achieves a plurality of objects at the same time, and has technical utility by achieving one of the objects.

It is a perspective view of an instrument panel. It is the II-II sectional view taken on the line of FIG. It is sectional drawing of a foaming mold. It is a schematic perspective view of a deformation | transformation core. It is the figure which showed the manufacturing method of the instrument panel with the flowchart. It is a figure when a foaming mold is opened to the predetermined position from the state of FIG. It is a figure when the foaming mold is further opened from the state of FIG. It is a figure when a foaming mold is further opened from the state of FIG. It is the figure which showed the manufacturing method of the instrument panel with the flowchart (2nd Example).

Explanation of symbols

10: instrument panel 20: foam with skin 22: skin 24: foam 26: undercut portion 30: base material 40: fixed core 50: main movable core 50a: guide groove 52: extruded core 54: deformed core 54a: Long hole 54b: Guide pin 56: Rod 58: Ring member 80: Pins 100, 102, 104: Actuator 120: Foaming mold

Claims (4)

It is a method of producing a foam with a skin using a mold that causes an undercut in a molded product,
Applying a skin material to the inner surface of the mold and molding the skin;
Sealing the foam material in a mold in which the skin is molded and molding the foam with the skin;
Removing the undercut of the foam with skin by moving at least a part of the mold and elastically deforming the foam with skin;
The manufacturing method of the foam with a skin provided with the process of releasing the foam with a skin from which the undercut was eliminated from a shaping | molding die. It is a method of manufacturing an instrument panel in which a skin, a foam and a base material are joined using a mold that causes an undercut in a molded product,
Forming a substrate;
Applying a skin material to the inner surface of the mold and molding the skin;
Sealing the foamed material in a mold in which the skin is molded and the base is set, and molding an instrument panel in which the skin, the foam and the base are joined;
Removing the undercut of the instrument panel by moving at least a part of the mold and elastically deforming the instrument panel;
A method for manufacturing an instrument panel, comprising a step of releasing the instrument panel from which the undercut has been eliminated from the mold. It is a method of producing a foam with a skin using a mold that causes an undercut in a molded product,
Sealing the integral skin foam material in the mold and molding the foam with skin;
Removing the undercut of the foam with skin by moving at least a part of the mold and elastically deforming the foam with skin;
The manufacturing method of the foam with a skin provided with the process of releasing the foam with a skin from which the undercut was eliminated from a shaping | molding die. A mold that causes undercuts in the molded product.
A pair of cores that elastically deform the molded product by moving integrally with the molded product sandwiched therebetween to eliminate the undercut, and release the sandwiched molded product by moving relative to each other,
A molding die comprising a dual-purpose actuator that doubles as an actuator that moves a pair of cores integrally and an actuator that moves relative to each other.

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