JP2006015633A - Injection foaming mold, injection foam molding method and skinned foamed resin member - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To suppress a phenomenon that a resin skin is deformed so as to be peeled from a molding surface when a mold is finely opened in order to integrally mold a foamed resin core body along with the resin skin by vacuum foaming after the resin skin is molded in a closed mold. <P>SOLUTION: A foamable resin material is injected in a fixed mold 40 and a movable mold 50 both of which are closed to fill the molds 40 and 50 and the foamable resin material coming into contact with a molding surface 41 for molding a skin is cooled and solidified on the molding surface 41 to mold the resin skin 3. After the fixed mold 40 and the movable mold 50 are finely opened, the foamable resin material is subjected to vacuum foaming in the finely opened molds 40 and 50 and cooled and solidified to integrally mold the foamed resin core 2 on the resin skin 3. At that time, the resin skin 3 of the part corresponding to a protruded excess part 12 is deformed so as to be peeled from the recessed step part 42 of the molding surface 41 for molding the skin to suppress the deformation of the part corresponding to the design surface 11a of a molded product part 11. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

  The present invention relates to an injection foam molding die, an injection foam molding method, and a foamed resin member with a skin. More specifically, for example, a foamed resin member with a skin that can be applied to vehicle interior parts such as an instrument panel, and the like are molded. The present invention relates to an injection foam molding die and an injection foam molding method.

  Since interior parts such as automotive instrument panels need to have both strength and soft touch, they are generally composed of a hard resin base material and a soft resin skin layered on the base material surface. Yes. As the resin skin, those made of soft PVC or TPO are the mainstream, and in order to give a soft touch, a foamed resin core made of the same material as the resin skin or a different material such as urethane is used as the resin skin. Many are interposed between the resin and the resin base material.

  In order to produce a foamed resin member with a skin comprising such a resin base material and a foamed resin core and a resin skin made of the same kind of material, the resin skin is first formed by injection molding in a mold that has been closed. To do. Thereafter, the mold is slightly opened to open the micro mold, and the foamed resin core is integrally formed on the resin skin. Next, there is a method in which a resin base material is injection-molded in a state where an integral body of the resin skin and the foamed resin core is disposed in a mold (see, for example, Patent Document 1).

Specifically, a foamed resin material made of TPO or the like to which a chemical foaming agent has been added is injected and filled into a closed mold, and the foamed resin material in contact with the mold surface is cooled and solidified on the mold surface to form a resin skin. Is molded. After that, with the resin skin adhered to the mold surface, the mold is slightly opened to open the micro mold, and the foamed resin material inside the molten state is foamed under reduced pressure and cooled and solidified. The foamed resin core is molded integrally. Then, in a state where the resin skin and the foamed resin core are integrated in the mold, the molten resin is injected into the mold, filled, and cooled and solidified to integrate the resin base material. The foamed resin member with a skin is manufactured.
JP 2001-239544 A

  However, the conventional method for producing a foamed resin member with a skin has the following disadvantages.

  That is, when the micro mold is opened for foaming under reduced pressure, the resin skin molded in the previous process is basically attached to the mold surface. There is no problem if the resin skin adhering to the mold surface grows as much as the amount of movement of the mold opening when the mold is opened, but the elongation of the resin skin is less than the amount of movement of the mold opening and the elongation of the resin skin However, if it cannot follow the mold opening, it may be deformed so that the resin skin is partially peeled off from the surface of the skin molding die. If the deformation of the resin skin due to the peeling from the mold surface occurs on the design surface, a problem occurs in the molding quality.

  The present invention has been made in view of the above circumstances, and after forming a resin skin in a closed mold, when opening a micro mold to form a foamed resin core integrally with the resin skin by foaming under reduced pressure Furthermore, it is a technical problem to be solved to eliminate such a disadvantage that the resin surface is deformed so as to be peeled off from the mold surface and the molding quality on the design surface is deteriorated.

  (1) The injection foam molding die according to claim 1 is integrally provided on the surface of the foamed resin core so as to continuously surround at least the top surface and the side surface of the foamed resin core and the foamed resin core. A molded product part having a desired molded product shape with the surface of the resin skin corresponding to the top surface of the foamed resin core as a design surface, and the foamed resin core. An injection foaming mold for integrally molding the foamed resin core and the resin skin of a foamed resin member with a skin having a convex excess portion provided on the side surface of the molded part corresponding to the side surface. A movable mold that can be closed or opened by a predetermined amount by moving in a direction approaching or separating from the fixed mold and at least one of the fixed mold and the movable mold. One skin for molding the resin skin into a predetermined outer shape A mold surface for molding, the mold surface for skin molding is a design surface molding die surface for molding the resin skin of the design surface portion, and the resin at a portion corresponding to the side surface of the foamed resin core A side molding die surface for molding a skin, and the side molding die surface has a mold surface shape corresponding to the convex extra portion, and the resin in a portion corresponding to the convex extra portion A concave step for molding the skin is provided.

  The injection foam molding mold is a movable mold that can be closed or opened by a predetermined amount by moving in a direction close to or away from the fixed mold and the fixed mold. The fixed mold and the movable mold At least one of them has a surface having a skin forming mold surface for forming the resin skin into a predetermined outer shape. And by this fixed mold and movable mold, at least a foamed resin core body and a resin skin integrally provided on the surface of the foamed resin core body so as to continuously surround at least the top surface and the side surface of the foamed resin core body A molded product part having a desired molded product shape with the surface of the resin skin corresponding to the top surface of the foamed resin core as a design surface, and a side surface of the molded product part corresponding to the side surface of the foamed resin core The foamed resin core body and the resin skin of the foamed resin member with a skin having a protruding extra portion provided on the substrate are integrally molded.

  That is, in this injection foaming mold, the foamed resin material is injected and filled into the fixed mold and the movable mold in the closed state. The foamed resin material in contact with the skin molding die surface is cooled and solidified on the mold surface, thereby forming the resin skin into a shape along the skin molding die surface. Thereafter, the movable mold is moved by a predetermined amount in the direction away from the fixed mold to open the micro mold, and the foamed resin material is foamed under reduced pressure and cooled and solidified in the fixed mold and the movable mold which are opened by the micro mold. Thus, the foamed resin core is integrally formed on the resin skin to form the foamed resin member with the skin.

  Here, when the mold is opened for foaming under reduced pressure, the resin skin molded in the previous step is basically attached to the surface of the skin molding. There is no problem if the resin skin adhering to the surface of the mold for molding the skin follows the mold opening at the time of micro mold opening and extends by the same amount as the mold opening amount, but the elongation amount of the resin skin is less than the mold opening amount. If the elongation of the resin skin does not fully follow the mold opening, the resin skin may be deformed so as to be partially peeled off from the surface of the skin molding die. When the deformation of the resin skin due to the peeling from the skin molding die surface occurs on the design surface, a problem occurs in the molding quality.

  In this respect, this injection foam molding die is for integrally molding a foamed resin core and a resin skin of a foamed resin member with a skin having a molded product part and a convex extra part provided on a side surface of the molded product part. The mold surface for molding a resin skin into a predetermined outer shape has a design surface mold surface and a side surface mold surface, and the side surface mold surface A concave step portion is provided which has a mold surface shape corresponding to the convex extra portion and molds the resin skin of the portion corresponding to the convex extra portion.

  For this reason, when the movable mold is moved with respect to the fixed mold to open the micro mold in order to foam the foamed resin material under reduced pressure after molding the resin skin on the surface molding mold surface, the portion corresponding to the convex extra part The resin skin of the part corresponding to the design surface of the molded product part is peeled off from the design surface molding die surface by deforming so that the resin skin of is peeled off from the mold surface for skin molding (mold surface of the concave step portion) It can suppress that it deform | transforms. Therefore, it is possible to ensure good quality in the design surface of the molded product portion.

  (2) The injection foam molding die according to claim 2 is the injection foam molding die according to claim 1, wherein the concave step portion is in a mold opening direction as a moving direction of the movable mold with respect to the fixed mold. An orthogonal mold surface extending in a substantially orthogonal direction is provided on the design surface molding mold surface side.

  In this injection foam molding die, when the mold is opened, the resin skin of the part corresponding to the design surface of the molded product part is molded to the design surface by deforming so that the resin skin is peeled off from the orthogonal mold surface of the concave step part. It can suppress that it deform | transforms so that it may peel from a mold surface. For this reason, by sufficiently securing the length that the orthogonal mold surface extends in the direction substantially orthogonal to the mold opening direction in relation to the mold opening amount and the skin resin elongation amount at the time of micro mold opening. It is possible to reliably suppress the deformation so that the resin skin of the portion corresponding to the design surface is peeled off with a margin.

  (3) The injection foam molding die according to claim 3 is the injection foam molding die according to claim 1 or 2, wherein the foamed resin member with skin is fixed in a laminated state on the bottom surface of the foamed resin core. In addition, a resin base in which an end portion of the resin skin that is integrally provided on the surface of the foamed resin core so as to continuously surround a top surface and a side surface of the foamed resin core is fixed to its own edge portion. A shape in which one of the fixed mold and the movable mold has the skin forming mold surface, and the other of the fixed mold and the movable mold corresponds to the outer shape of the resin base material. It has the base-material type | mold surface which has.

  This injection foam molding mold is provided integrally on the surface of the foamed resin core so that the bottom surface of the foamed resin core is fixed in a laminated state and continuously surrounds the top and side surfaces of the foamed resin core. An injection foaming mold for integrally molding the foamed resin core and the resin skin of a foamed resin member with a skin, further comprising a resin base material in which the end of the resin skin is fixed to the edge of the resin skin A shape in which one of the fixed mold and the movable mold has the skin molding mold surface, and the other of the fixed mold and the movable mold corresponds to the outer shape of the resin base material. The base surface has a mold surface.

  In this injection foaming mold, the resin base material is placed on the base material mold surface, and the foamed resin material is injected and filled into the closed mold and the movable mold that are closed, and contacts the skin molding mold surface. By cooling and solidifying the foamed resin material to be formed on the mold surface, the resin skin is formed into a shape along the mold surface for skin molding. At this time, the edge part of the resin skin is fixed to the edge part of the resin base material. Thereafter, the movable mold is moved by a predetermined amount in the direction away from the fixed mold to open the micro mold, and the foamed resin material is foamed under reduced pressure and cooled and solidified in the fixed mold and the movable mold which are opened by the micro mold. Thus, the foamed resin core is integrally formed on the resin skin. At this time, the bottom of the foamed resin core is fixed in a state of being laminated on the resin base material. Thus, the resin base material, the foamed resin core body whose own bottom surface is fixed in a laminated state on the resin base material, and the foam resin core body so as to continuously surround the top surface and the side surface of the foam resin core body A foamed resin member with a skin provided with a resin base material, which is formed integrally with the surface of the resin base material and has a resin skin whose end is fixed to the edge of the resin base material, can be molded. It becomes possible to ensure favorable quality in the design surface of the molded product part of the foamed resin member.

  (4) The injection foam molding method according to claim 4 is integrally provided on the surface of the foamed resin core so as to continuously surround at least the top surface and the side surface of the foamed resin core and the foamed resin core. A molded product part having a desired molded product shape having at least a resin skin and a design surface of the surface of the resin skin corresponding to the top surface of the foamed resin core, and a side surface of the foamed resin core An injection foam molding method for integrally molding the foamed resin core and the resin skin of the foamed resin member with a skin having a convex excess portion provided on the side surface of the molded product part corresponding to A movable mold capable of closing a mold or opening a predetermined amount by moving in a direction close to or away from the fixed mold and at least one of the fixed mold and the movable mold Is a table for molding the resin skin into a predetermined outer shape An injection step of injecting and filling a foamed resin material into the first cavity formed in the movable mold and the fixed mold closed using a mold having a molding die surface, and in the first cavity The foamed resin material that is in contact with the skin molding mold surface is cooled and solidified on the mold surface to mold the resin skin, and the movable mold is separated from the fixed mold. By opening the micro mold by moving a predetermined amount to the fixed mold and the second cavity formed in the movable mold, the foamed resin material is foamed under reduced pressure and cooled and solidified. A foam molding step of molding the foamed resin core body integrally with the resin skin and molding the foamed resin member with the skin, and corresponding to the convex extra part when the micro mold is opened in the foam molding step The deformation of the resin skin of the portion corresponding to the design surface of the molded product portion is suppressed by deforming the resin skin of the portion to be peeled off from the surface of the skin molding die. .

  In this injection foam molding method, a fixed mold and a movable mold which can be closed or opened by a predetermined amount by moving in a direction approaching or separating from the fixed mold, the fixed mold and the movable mold Using at least one of which has a skin molding mold surface for molding the resin skin into a predetermined outer shape, the foamed resin core and at least the top surface and the side surface of the foamed resin core are continuously provided. A desired molded product shape having at least a resin skin integrally provided on the surface of the foamed resin core so as to surround, and having the surface of the resin skin corresponding to the top surface of the foamed resin core as a design surface The foamed resin core and the resin skin are integrally molded of a foamed resin member with a skin having a molded product part having a protrusion and a convex excess provided on the side of the molded part corresponding to the side of the foamed resin core To do.

  That is, in this injection foam molding method, the foamed resin material is injected and filled into the first cavities formed in the closed mold and the movable mold (injection process). Then, the foamed resin material in contact with the skin molding mold surface in the first cavity is cooled and solidified on the mold surface to mold the resin skin into a shape along the skin molding mold surface (skin skin). Molding process). Thereafter, the micro mold is opened by moving the movable mold by a predetermined amount in the direction away from the fixed mold, and the foamed resin is formed in the second cavity formed in the fixed mold and the movable mold that are opened. By foaming the material under reduced pressure and solidifying by cooling, a foamed resin core is integrally formed on the resin skin to form a foamed resin member with a skin (foam molding process).

  Here, when the micro mold is opened for foaming under reduced pressure in the foam molding process, the resin skin molded in the skin molding process is basically attached to the surface of the skin molding. There is no problem if the resin skin adhering to the surface of the mold for molding the skin follows the mold opening at the time of micro mold opening and extends by the same amount as the mold opening amount, but the elongation amount of the resin skin is less than the mold opening amount. If the elongation of the resin skin does not fully follow the mold opening, the resin skin may be deformed so as to be partially peeled off from the surface of the skin molding die. When the deformation of the resin skin due to the peeling from the skin molding die surface occurs on the design surface, a problem occurs in the molding quality.

  In this regard, this injection foam molding method is for integrally molding a foamed resin core and a resin skin of a foamed resin member with a skin having a molded product portion and a convex extra portion provided on the side surface of the molded product portion. In the injection foam molding method, when the mold is opened in the foam molding step, the molded product part is deformed so as to peel off the resin skin of the part corresponding to the convex extra part from the surface of the skin molding die It can suppress that the resin skin of the part corresponding to the design surface of this deform | transforms so that it may peel from the mold surface for skin shaping | molding. Therefore, it is possible to ensure good quality in the design surface of the molded product part.

  (5) An injection foam molding method according to claim 5 is the injection foam molding method according to claim 4, wherein the skin molding mold surface molds the resin skin of the design surface portion. And a side surface mold surface for molding the resin skin of the portion corresponding to the side surface of the foamed resin core, the mold surface corresponding to the convex extra portion on the side surface mold surface A concave step portion for forming the resin skin of a portion corresponding to the convex extra portion is provided, and the concave step portion is a mold opening direction as a moving direction of the movable mold with respect to the fixed mold It has the orthogonal type | mold surface extended in the direction substantially orthogonal with respect to the said design surface shaping | molding die surface side, It is characterized by the above-mentioned.

  In this injection foam molding method, the mold surface for molding the skin is designed to mold the design surface molding die surface for molding the resin skin of the design surface portion and the resin skin of the portion corresponding to the side surface of the foamed resin core. A fixed mold and a movable mold having a side mold surface are used. The side molding die surface is provided with a concave step portion that has a mold surface shape corresponding to the convex extra portion and molds the resin skin of the portion corresponding to the convex extra portion. The step portion has, on the design surface molding die surface side, an orthogonal mold surface extending in a direction substantially orthogonal to a mold opening direction as a moving direction of the movable mold with respect to the fixed mold.

  For this reason, when opening the micro mold in the foam molding process, by deforming so that the resin skin of the part corresponding to the convex extra part is peeled off from the mold surface for skin molding (orthogonal mold surface of the concave stepped portion), It can suppress that the resin skin of the part corresponding to the said design surface of the said molded product part deform | transforms so that it may peel from a design surface molding die surface. Therefore, by sufficiently securing the length that the orthogonal mold surface extends in the direction substantially perpendicular to the mold opening direction in relation to the mold opening amount and the resin skin elongation amount in the case of micro mold opening, It is possible to reliably suppress the deformation so that the resin skin of the portion corresponding to the design surface is peeled off with a margin.

  (6) The injection foam molding method according to claim 6 is the injection foam molding method according to claim 4 or 5, wherein the foamed resin member with skin is fixed in a laminated state on the bottom surface of the foamed resin core. A resin base material in which an end portion of the resin skin, which is integrally provided on the surface of the foamed resin core so as to continuously surround a top surface and a side surface of the foamed resin core, is fixed to an edge portion of the resin core. In addition, one of the fixed mold and the movable mold has the skin molding mold surface, and the other of the fixed mold and the movable mold has a shape corresponding to the outer shape of the resin base material. It has the base surface for base materials, It is characterized by the above-mentioned.

  In this injection foam molding method, the bottom surface of the foamed resin core is fixed in a laminated state and is integrally provided on the surface of the foamed resin core so as to continuously surround the top surface and the side surface of the foamed resin core. The foamed resin core and the resin skin of a foamed resin member with a skin further provided with a resin base material in which the end of the resin skin is fixed to the edge of the resin skin are integrally molded. Therefore, one of the fixed mold and the movable mold has the skin molding mold surface, while the other of the fixed mold and the movable mold has a shape corresponding to the outer shape of the resin substrate. Has a surface.

  That is, in this injection foam molding method, a foamed resin material is injected and filled into a first cavity formed in a fixed mold and a movable mold that are closed while a resin base material is placed on the base mold surface. (Injection step), the resin foam is formed into a shape along the skin molding die surface by cooling and solidifying the foamed resin material in contact with the skin molding die surface in the first cavity. (Skin forming step). At this time, the edge part of the resin skin is fixed to the edge part of the resin base material. Thereafter, the movable mold is moved away from the fixed mold by a predetermined amount to open the micro mold, and the foamed resin material is placed in the second cavity formed in the micro mold open fixed mold and the movable mold. By foaming under reduced pressure and solidifying by cooling, a foamed resin core is integrally formed on the resin skin (reduced pressure foaming step). At this time, the bottom of the foamed resin core is fixed in a state of being laminated on the resin base material. Thus, the resin base material, the foamed resin core body whose own bottom surface is fixed in a laminated state on the resin base material, and the foam resin core body so as to continuously surround the top surface and the side surface of the foam resin core body A foamed resin member with a skin provided with a resin base material, which is formed integrally with the surface of the resin base material and has a resin skin whose end is fixed to the edge of the resin base material, can be molded. It becomes possible to ensure favorable quality in the design surface of the molded product part of the foamed resin member.

  (7) The foamed resin member with a skin according to claim 7 is integrally provided on the surface of the foamed resin core body so as to continuously surround the foamed resin core body and at least the top surface and the side surface of the foamed resin core body. The resin skin is molded by cooling and solidifying the foamed resin material that is filled in the molds of the fixed mold and the movable mold that are closed and is in contact with the mold surface. Thereafter, the foamed resin material is foamed under reduced pressure and cooled and solidified in the fixed mold and the movable mold which are opened by moving the movable mold by a predetermined amount relative to the fixed mold. A foamed resin member with a skin formed by integrally molding the foamed resin core on the resin skin, and the design surface is the surface of the resin skin corresponding to the top surface of the foamed resin core. A molded product part having a desired molded product shape, and And it is characterized in that it has a said molded article portion projecting extra portion provided on a side surface of the corresponding to the side surface of the resin core member.

  The foamed resin member with a skin includes at least a foamed resin core and a resin skin integrally provided on the surface of the foamed resin core so as to continuously surround at least the top surface and the side surface of the foamed resin core. The molded resin surface is molded by cooling and solidifying the foamed resin material filled in the mold of the closed mold and the movable mold, which is in contact with the mold surface, and then movable with respect to the fixed mold. The foamed resin core is integrally molded on the resin skin by foaming the foamed resin material under reduced pressure in the fixed mold and the movable mold that are moved by a predetermined amount in the separating direction and by cooling and solidifying in the mold. It is made.

  Here, when the micro mold is opened for foaming under reduced pressure, the resin skin molded in the previous step is basically attached to the mold surface. There is no problem if the resin skin adhering to the mold surface follows the mold opening when the mold opens and extends as much as the mold opening amount. However, the resin skin elongation amount is less than the mold opening amount and the resin skin If the elongation of the resin cannot follow the mold opening, the resin skin may be deformed so as to be partially peeled off from the mold surface. If the deformation of the resin skin due to the peeling from the mold surface occurs on the design surface, a problem occurs in the molding quality.

  In this respect, the foamed resin member with a skin has a molded product part having a desired molded product shape with the surface of the resin skin corresponding to the top surface of the foamed resin core as a design surface, and a foamed resin core. And a convex extra portion provided on the side surface of the molded product portion corresponding to the side surface. Therefore, when the movable mold is moved with respect to the fixed mold and the micro mold is opened to form the foamed resin material under reduced pressure after molding the resin skin, the resin skin of the portion corresponding to the convex extra part is the mold surface. It can suppress that the resin skin of the part corresponding to the design surface of the said molded product part deform | transforms so that it may peel from a mold surface. Therefore, it is possible to ensure good quality in the design surface of the molded product part.

  (8) The foamed resin member with skin according to claim 8 is the foamed resin member with skin according to claim 7, wherein the bottom surface of the foamed resin core is fixed in a laminated state, and the top of the foamed resin core. A resin base material in which an end portion of the resin skin integrally provided on the surface of the foamed resin core so as to continuously surround the surface and the side surface is fixed to the end edge portion thereof; It is what.

  The foamed resin member with a skin is provided integrally on the surface of the foamed resin core so that the bottom surface of the foamed resin core is fixed in a laminated state and continuously surrounds the top and side surfaces of the foamed resin core. The resin base material is further provided with a resin base material with the end of the resin skin fixed to its own edge, and foaming is performed in the molds of the fixed mold and the movable mold which are closed while the resin base material is placed on the mold surface. It can be obtained in the same manner as the foamed resin member with a skin according to claim 7, except that the resin material is injected and filled. For this reason, it becomes possible to ensure the quality in the design surface of the molded product part of this foamed resin member with a skin well.

  (9) The injection foam molding die according to claim 9 is integrally provided on the surface of the foamed resin core so as to continuously surround at least the top surface and the side surface of the foamed resin core and the foamed resin core. A molded product part having a desired molded product shape with the surface of the resin skin corresponding to the top surface of the foamed resin core as a design surface, and the foamed resin core. An injection foaming mold for integrally molding the foamed resin core and the resin skin of a foamed resin member with a skin having a concave notch provided on the side of the molded product corresponding to the side. A movable mold that can be closed or opened by a predetermined amount by moving in a direction approaching or separating from the fixed mold and at least one of the fixed mold and the movable mold. One skin for molding the resin skin into a predetermined outer shape A mold surface for molding, the mold surface for skin molding is a design surface molding die surface for molding the resin skin of the design surface portion, and the resin at a portion corresponding to the side surface of the foamed resin core A side molding die surface for molding the skin, and the side molding die surface has a mold surface shape corresponding to the concave notch, and the resin corresponding to the concave notch A convex step for forming the skin is provided.

  The injection foam molding mold is a movable mold that can be closed or opened by a predetermined amount by moving in a direction close to or away from the fixed mold and the fixed mold. The fixed mold and the movable mold At least one of them has a surface having a skin forming mold surface for forming the resin skin into a predetermined outer shape. And by this fixed mold and movable mold, at least a foamed resin core body and a resin skin integrally provided on the surface of the foamed resin core body so as to continuously surround at least the top surface and the side surface of the foamed resin core body A molded product part having a desired molded product shape with the surface of the resin skin corresponding to the top surface of the foamed resin core as a design surface, and a side surface of the molded product part corresponding to the side surface of the foamed resin core The foamed resin core body and the resin skin of the foamed resin member with a skin having a concave notched portion provided in are integrally molded.

  That is, in this injection foaming mold, the foamed resin material is injected and filled into the fixed mold and the movable mold in the closed state. The foamed resin material in contact with the skin molding die surface is cooled and solidified on the mold surface, thereby forming the resin skin into a shape along the skin molding die surface. Thereafter, the movable mold is moved by a predetermined amount in the direction away from the fixed mold to open the micro mold, and the foamed resin material is foamed under reduced pressure and cooled and solidified in the fixed mold and the movable mold which are opened by the micro mold. Thus, the foamed resin core is integrally formed on the resin skin to form the foamed resin member with the skin.

  Here, when the mold is opened for foaming under reduced pressure, the resin skin molded in the previous step is basically attached to the surface of the skin molding. There is no problem if the resin skin adhering to the surface of the mold for molding the skin follows the mold opening at the time of micro mold opening and extends by the same amount as the mold opening amount, but the elongation amount of the resin skin is less than the mold opening amount. If the elongation of the resin skin does not fully follow the mold opening, the resin skin may be deformed so as to be partially peeled off from the surface of the skin molding die. When the deformation of the resin skin due to the peeling from the skin molding die surface occurs on the design surface, a problem occurs in the molding quality.

  In this respect, this injection foam molding die is for integrally molding the foamed resin core and the resin skin of the foamed resin member with a skin having a molded part and a concave notch provided on the side surface of the molded part. The mold surface for molding a resin skin into a predetermined outer shape has a design surface mold surface and a side surface mold surface, and the side surface mold surface A convex step portion is provided which has a mold surface shape corresponding to the concave cutout portion and molds the resin skin of the portion corresponding to the concave cutout portion.

  For this reason, when the movable mold is moved with respect to the fixed mold and the micro mold is opened so that the foamed resin material is decompressed and foamed after molding the resin skin on the surface molding mold surface, the portion corresponding to the concave notch It is possible to suppress the resin skin of the part corresponding to the design surface of the molded product part from being deformed so as to be peeled off from the design surface molding die surface by hooking and supporting the resin skin of the resin skin on the surface molding die surface. it can. Therefore, it is possible to ensure good quality in the design surface of the molded product part.

  (10) The injection foam molding die according to claim 10 is the injection foam molding die according to claim 9, wherein the convex step portion is in a mold opening direction as a moving direction of the movable mold with respect to the fixed mold. An inclined mold surface extending in a negative angle direction is provided on the design surface mold surface side.

  In this injection foam molding mold, when the mold is opened, the resin skin is hooked and supported by the inclined mold surface of the convex step portion, so that the resin skin of the portion corresponding to the design surface of the molded product portion is the design surface. It can suppress that it deform | transforms so that it may peel from a shaping | molding die surface.

  Here, the inclined mold surface of this convex step portion extending in a direction that forms a negative angle with respect to the mold opening direction, which is the moving direction of the movable mold relative to the fixed mold, demolds the molded foamed resin member with skin. Regardless of the presence of the portion that becomes the undercut portion, the angle is set so that the mold can be removed.

  (11) The injection foam molding die according to claim 11 is the injection foam molding die according to claim 9 or 10, wherein the foamed resin member with skin is fixed in a laminated state on the bottom surface of the foamed resin core. In addition, a resin base in which an end portion of the resin skin that is integrally provided on the surface of the foamed resin core so as to continuously surround a top surface and a side surface of the foamed resin core is fixed to its own edge portion. A shape in which one of the fixed mold and the movable mold has the skin forming mold surface, and the other of the fixed mold and the movable mold corresponds to the outer shape of the resin base material. It has the base-material type | mold surface which has.

  This injection foam molding mold is provided integrally on the surface of the foamed resin core so that the bottom surface of the foamed resin core is fixed in a laminated state and continuously surrounds the top and side surfaces of the foamed resin core. An injection foaming mold for integrally molding the foamed resin core and the resin skin of a foamed resin member with a skin, further comprising a resin base material in which the end of the resin skin is fixed to the edge of the resin skin A shape in which one of the fixed mold and the movable mold has the skin molding mold surface, and the other of the fixed mold and the movable mold corresponds to the outer shape of the resin base material. The base surface has a mold surface.

  In this injection foaming mold, the resin base material is placed on the base material mold surface, and the foamed resin material is injected and filled into the closed mold and the movable mold that are closed, and contacts the skin molding mold surface. By cooling and solidifying the foamed resin material to be formed on the mold surface, the resin skin is formed into a shape along the mold surface for skin molding. At this time, the edge part of the resin skin is fixed to the edge part of the resin base material. Thereafter, the movable mold is moved by a predetermined amount in the direction away from the fixed mold to open the micro mold, and the foamed resin material is foamed under reduced pressure and cooled and solidified in the fixed mold and the movable mold which are opened by the micro mold. Thus, the foamed resin core is integrally formed on the resin skin. At this time, the bottom of the foamed resin core is fixed in a state of being laminated on the resin base material. Thus, the resin base material, the foamed resin core body whose own bottom surface is fixed in a laminated state on the resin base material, and the foam resin core body so as to continuously surround the top surface and the side surface of the foam resin core body A foamed resin member with a skin provided with a resin base material, which is formed integrally with the surface of the resin base material and has a resin skin whose end is fixed to the edge of the resin base material, can be molded. It becomes possible to ensure favorable quality in the design surface of the molded product part of the foamed resin member.

  (12) The injection foam molding method according to claim 12 is integrally provided on the surface of the foamed resin core so as to continuously surround at least the top surface and the side surface of the foamed resin core and the foamed resin core. A molded product part having a desired molded product shape having at least a resin skin and a design surface of the surface of the resin skin corresponding to the top surface of the foamed resin core, and a side surface of the foamed resin core An injection foam molding method for integrally molding the foamed resin core and the resin skin of a foamed resin member with a skin having a concave notch provided on the side surface of the molded product part corresponding to A movable mold capable of closing a mold or opening a predetermined amount by moving in a direction close to or away from the fixed mold and at least one of the fixed mold and the movable mold For molding the resin skin into a predetermined outer shape An injection step of injecting and filling a foamed resin material into the first cavity formed in the fixed mold and the movable mold that are closed using a mold surface for skin molding, and in the first cavity The foamed resin material in contact with the skin molding mold surface is cooled and solidified on the mold surface, thereby separating the movable mold from the stationary mold and the skin molding process for molding the resin skin. By opening a micro mold by moving a predetermined amount in the direction, and by foaming the foamed resin material under reduced pressure and cooling and solidifying in the second cavity formed in the fixed mold and the movable mold that are micro mold opened A foam molding step of molding the foamed resin core body integrally with the resin skin to mold the foamed resin member with the skin, and when opening the micro mold in the foam molding step, the concave notch The resin skin of the part corresponding to the design surface of the molded product part is suppressed by hooking and supporting the resin skin of the corresponding part on the surface of the mold for molding the skin. .

  In this injection foam molding method, a fixed mold and a movable mold which can be closed or opened by a predetermined amount by moving in a direction approaching or separating from the fixed mold, the fixed mold and the movable mold Using at least one of which has a skin molding mold surface for molding the resin skin into a predetermined outer shape, the foamed resin core and at least the top surface and the side surface of the foamed resin core are continuously provided. A desired molded product shape having at least a resin skin integrally provided on the surface of the foamed resin core so as to surround, and having the surface of the resin skin corresponding to the top surface of the foamed resin core as a design surface The foamed resin core and the resin skin are integrally molded of a foamed resin member with a skin having a molded product part having a surface and a concave notch provided on the side of the molded product part corresponding to the side of the foamed resin core. To do.

  That is, in this injection foam molding method, the foamed resin material is injected and filled into the first cavities formed in the closed mold and the movable mold (injection process). Then, the foamed resin material in contact with the skin molding mold surface in the first cavity is cooled and solidified on the mold surface to mold the resin skin into a shape along the skin molding mold surface (skin skin). Molding process). Thereafter, the micro mold is opened by moving the movable mold by a predetermined amount in the direction away from the fixed mold, and the foamed resin is formed in the second cavity formed in the fixed mold and the movable mold that are opened. By foaming the material under reduced pressure and solidifying by cooling, a foamed resin core is integrally formed on the resin skin to form a foamed resin member with a skin (foam molding process).

  Here, when the micro mold is opened for foaming under reduced pressure in the foam molding process, the resin skin molded in the skin molding process is basically attached to the surface of the skin molding. There is no problem if the resin skin adhering to the surface of the mold for molding the skin follows the mold opening at the time of micro mold opening and extends by the same amount as the mold opening amount, but the elongation amount of the resin skin is less than the mold opening amount. If the elongation of the resin skin does not fully follow the mold opening, the resin skin may be deformed so as to be partially peeled off from the surface of the skin molding die. When the deformation of the resin skin due to the peeling from the skin molding die surface occurs on the design surface, a problem occurs in the molding quality.

  In this respect, this injection foam molding method is for integrally molding a foamed resin core body and a resin skin of a foamed resin member with a skin having a molded product portion and a concave notched portion provided on a side surface of the molded product portion. In the injection foam molding method, when the micro mold is opened in the foam molding step, the resin skin of the portion corresponding to the concave notch is hooked and supported on the skin molding die surface to It can suppress that the resin skin of the part corresponding to a design surface deform | transforms so that it may peel from the mold surface for skin molding. Therefore, it is possible to ensure good quality in the design surface of the molded product part.

  (13) The injection foam molding method according to claim 13 is the injection foam molding method according to claim 12, wherein the skin molding mold surface molds the resin skin of the design surface portion. And a side surface mold surface for molding the resin skin of the portion corresponding to the side surface of the foamed resin core, and the side surface mold surface has a mold surface corresponding to the concave notch A convex step for forming the resin skin of a portion corresponding to the concave notch is provided, and the convex step is a mold opening direction as a moving direction of the movable mold with respect to the fixed mold It has the inclined type | mold surface extended in the direction used as a negative angle in the said design surface shaping | molding die surface side, It is characterized by the above-mentioned.

  In this injection foam molding method, the mold surface for molding the skin is designed to mold the design surface molding die surface for molding the resin skin of the design surface portion and the resin skin of the portion corresponding to the side surface of the foamed resin core. A fixed mold and a movable mold having a side mold surface are used. The side surface molding die surface is provided with a convex step portion that has a mold surface shape corresponding to the concave cutout portion and molds the resin skin of the portion corresponding to the concave cutout portion. The step portion has an inclined mold surface on the side of the design surface mold that extends in a direction that forms a negative angle with respect to the mold opening direction that is the moving direction of the movable mold relative to the fixed mold.

  For this reason, when opening the micro mold in the foam molding process, the resin skin of the part corresponding to the concave notch is hooked and supported by the skin molding mold surface (inclined mold surface of the convex step), thereby forming It can suppress that the resin skin of the part corresponding to the design surface of a product part deform | transforms so that it may peel from the mold surface for skin molding.

  Here, the inclined mold surface of this convex step portion extending in a direction that forms a negative angle with respect to the mold opening direction, which is the moving direction of the movable mold relative to the fixed mold, demolds the molded foamed resin member with skin. Regardless of the presence of the portion that becomes the undercut portion, the angle is set so that the mold can be removed.

  (14) The injection foam molding method according to claim 14 is the injection foam molding method according to claim 12 or 13, wherein the foamed resin member with skin is fixed in a laminated state on the bottom surface of the foamed resin core. A resin base material in which an end portion of the resin skin, which is integrally provided on the surface of the foamed resin core so as to continuously surround a top surface and a side surface of the foamed resin core, is fixed to an edge portion of the resin core. In addition, one of the fixed mold and the movable mold has the skin molding mold surface, and the other of the fixed mold and the movable mold has a shape corresponding to the outer shape of the resin base material. It has the base surface for base materials, It is characterized by the above-mentioned.

  In this injection foam molding method, the bottom surface of the foamed resin core is fixed in a laminated state and is integrally provided on the surface of the foamed resin core so as to continuously surround the top surface and the side surface of the foamed resin core. The foamed resin core and the resin skin of a foamed resin member with a skin further provided with a resin base material in which the end of the resin skin is fixed to the edge of the resin skin are integrally molded. Therefore, one of the fixed mold and the movable mold has the skin forming mold surface, while the other of the fixed mold and the movable mold has a shape corresponding to the outer shape of the resin base material. It has a material mold surface.

  That is, in this injection foam molding method, a foamed resin material is injected and filled into a first cavity formed in a fixed mold and a movable mold that are closed while a resin base material is placed on the base mold surface. (Injection step), the resin foam is formed into a shape along the skin molding die surface by cooling and solidifying the foamed resin material in contact with the skin molding die surface in the first cavity. (Skin forming step). At this time, the edge part of the resin skin is fixed to the edge part of the resin base material. Thereafter, the movable mold is moved away from the fixed mold by a predetermined amount to open the micro mold, and the foamed resin material is placed in the second cavity formed in the micro mold open fixed mold and the movable mold. By foaming under reduced pressure and solidifying by cooling, a foamed resin core is integrally formed on the resin skin (reduced pressure foaming step). At this time, the bottom of the foamed resin core is fixed in a state of being laminated on the resin base material. Thus, the resin base material, the foamed resin core body whose own bottom surface is fixed in a laminated state on the resin base material, and the foam resin core body so as to continuously surround the top surface and the side surface of the foam resin core body A foamed resin member with a skin provided with a resin base material, which is formed integrally with the surface of the resin base material and has a resin skin whose end is fixed to the edge of the resin base material, can be molded. It becomes possible to ensure favorable quality in the design surface of the molded product part of the foamed resin member.

  (15) The foamed resin member with skin according to claim 15 is provided integrally on the surface of the foamed resin core body so as to continuously surround the foamed resin core body and at least the top surface and the side surface of the foamed resin core body. The resin skin is molded by cooling and solidifying the foamed resin material that is filled in the molds of the fixed mold and the movable mold that are closed and is in contact with the mold surface. Thereafter, the foamed resin material is foamed under reduced pressure and cooled and solidified in the fixed mold and the movable mold which are opened by moving the movable mold by a predetermined amount relative to the fixed mold. A foamed resin member with a skin formed by integrally molding the foamed resin core on the resin skin, and the design surface is the surface of the resin skin corresponding to the top surface of the foamed resin core. A molded part with the desired molded part shape and the front And is characterized in that it has a said molded article portion recessed cutout portion provided on a side surface of the corresponding to the side surface of the foamed resin core body.

  The foamed resin member with a skin includes at least a foamed resin core and a resin skin integrally provided on the surface of the foamed resin core so as to continuously surround at least the top surface and the side surface of the foamed resin core. The molded resin surface is molded by cooling and solidifying the foamed resin material filled in the mold of the closed mold and the movable mold, which is in contact with the mold surface, and then movable with respect to the fixed mold. The foamed resin core is integrally molded on the resin skin by foaming the foamed resin material under reduced pressure in the fixed mold and the movable mold that are moved by a predetermined amount in the separating direction and by cooling and solidifying in the mold. It is made.

  Here, when the micro mold is opened for foaming under reduced pressure, the resin skin molded in the previous step is basically attached to the mold surface. There is no problem if the resin skin adhering to the mold surface follows the mold opening when the mold opens and extends as much as the mold opening amount. However, the resin skin elongation amount is less than the mold opening amount and the resin skin If the elongation of the resin cannot follow the mold opening, the resin skin may be deformed so as to be partially peeled off from the mold surface. If the deformation of the resin skin due to the peeling from the mold surface occurs on the design surface, a problem occurs in the molding quality.

  In this respect, the foamed resin member with a skin has a molded product part having a desired molded product shape with the surface of the resin skin corresponding to the top surface of the foamed resin core as a design surface, and a foamed resin core. And a concave cutout portion provided on the side surface of the molded product portion corresponding to the side surface. For this reason, when the micro mold is opened by moving the movable mold relative to the fixed mold in order to foam the foamed resin material under reduced pressure after molding the resin skin, the portion of the resin skin corresponding to the concave notch is formed on the mold surface. By being hooked and supported, it is possible to suppress deformation of the resin skin corresponding to the design surface of the molded product part so as to be peeled off from the skin molding die surface. Therefore, it is possible to ensure good quality in the design surface of the molded product part.

  (16) The foamed resin member with skin according to claim 16 is the foamed resin member with skin according to claim 15, wherein the bottom surface of the foamed resin core is fixed in a laminated state, and the top of the foamed resin core. A resin base material in which an end portion of the resin skin integrally provided on the surface of the foamed resin core so as to continuously surround the surface and the side surface is fixed to the end edge portion thereof; It is what.

  The foamed resin member with a skin is provided integrally on the surface of the foamed resin core so that the bottom surface of the foamed resin core is fixed in a laminated state and continuously surrounds the top and side surfaces of the foamed resin core. The resin base material is further provided with a resin base material with the end of the resin skin fixed to its own edge, and foaming is performed in the molds of the fixed mold and the movable mold which are closed while the resin base material is placed on the mold surface. It can be obtained in the same manner as the foamed resin member with a skin according to claim 15 except that the resin material is injected and filled. For this reason, it becomes possible to ensure the quality in the design surface of the molded product part of this foamed resin member with a skin well.

  Hereinafter, embodiments of the present invention will be specifically described.

(Embodiment 1)
In this embodiment, the present invention is applied to an instrument panel (hereinafter referred to as an instrument panel) of an automobile, and the invention according to claims 1 to 8 is embodied.

  FIG. 1 shows a cross-sectional view of a main part of an instrument panel 10 as a foamed resin member with a skin molded by the injection foam molding method according to the present embodiment.

  The instrument panel 10 includes a resin base material 1 made of PP (polypropylene), a foamed resin core 2 made of TPO (thermoplastic olefin) having its bottom surface fixed in a laminated state on the resin base material 1, The foamed resin core 2 is integrally provided on the surface of the foamed resin core 2 so as to continuously surround the top surface 2a and the side surface 2b, and its own end is fixed to the edge of the resin substrate 1. It is composed of a foamed resin core 2 and a TPO resin skin 3 made of the same material.

  The instrument panel 10 includes a molded product portion 11 having a desired molded product shape in which the surface of the resin skin 3 corresponding to the top surface 2a of the foamed resin core 2 is a design surface 11a, and a foamed resin core. And a convex extra portion 12 integrally provided on the side surface 11b of the molded product portion 11 corresponding to the second side surface 2b. The molded product portion 11 of the instrument panel 10 has a corner portion 11c at a boundary portion between the design surface 11a and the side surface 11b (an end edge portion of the design surface 11a). It becomes a design surface part matching part with an adjacent counterpart material when assembled to the surface. In addition, the shape shown with a dashed-two dotted line in FIG. 1 is the original molded product shape of the molded product part 11, and this instrument panel 10 has the convex excess part 12 for the part which protruded from this dashed-two dotted line.

  The instrument panel 10 having the above configuration was molded as follows.

  First, a resin base material 1 having a predetermined shape was obtained by injection molding using a base metal mold (not shown).

  On the other hand, an injection foaming mold according to this embodiment was prepared. This injection foaming mold is composed of a fixed mold 40 and a movable mold 50 that can be closed or opened by a predetermined amount by moving in a direction approaching or separating from the fixed mold 40. Yes. The fixed mold 40 has a skin molding die surface 41 for molding the resin skin 3 into a predetermined outer shape. The movable mold 50 has a substrate mold surface 51 having a shape corresponding to the outer shape of the resin substrate 1.

  Then, as shown in FIG. 2, the skin molding die surface 41 of the fixed mold 40 includes a design surface molding die surface 41 a for molding the resin skin 3 of the design surface 11 a portion, and a side surface of the foamed resin core 2. 2b, and a side molding die surface 41b for molding the portion of the resin skin 3 corresponding to 2b. The side molding die surface 41b has a die surface shape corresponding to the convex extra portion 12, and this A concave step portion 42 for forming the resin skin 3 at a portion corresponding to the convex extra portion 12 is provided. The concave step 42 is a direction (in FIG. 3 and FIG. 4) substantially orthogonal to the mold opening direction (the downward direction in FIGS. 3 and 4, the same applies hereinafter), which is the moving direction of the movable mold 50 relative to the fixed mold 40. An orthogonal die surface 42a extending in the horizontal direction (hereinafter the same) is provided on the design surface molding die surface 41a side (the upper side in FIGS. 3 and 4; the same applies hereinafter).

  The length that the orthogonal mold surface 42a of the concave step portion 42 extends in a direction substantially orthogonal to the mold opening direction corresponds to the design surface 11a when the micro mold is opened in the foam molding process, as will be described later. In order to prevent the resin skin 3 of the portion to be deformed from being peeled off from the design surface molding die surface 41a, a sufficiently long length is secured in relation to the mold opening amount and the resin skin elongation amount when the micro mold is opened. Yes. Specifically, in this embodiment, the length in which the orthogonal mold surface 42a of the recessed step portion 42 extends in a direction substantially orthogonal to the mold opening direction is set to about 2 to 4 mm. In addition, the mold opening amount at the time of micro mold opening in the foaming molding process mentioned later is about 4-6 mm.

<Injection process>
In a state where the resin base material 1 is disposed on the base mold surface 51 of the movable mold 50 (see FIG. 3), the movable mold 50 is moved in the direction of approaching the fixed mold 40, so that the fixed mold 40 and The movable mold 50 was closed. The foamed resin material (TPO added with CO ₂ as a chemical foaming agent) was injected and filled into the first cavities formed in the molds of the fixed mold 40 and the movable mold 50 that were closed.

<Skin molding process>
The foamed resin material that contacts the skin molding mold surface 41 in the first cavity is cooled and solidified by the mold surface 41, so that the resin skin 3 is shaped along the skin molding mold surface 41. Molded (state of FIG. 3). At this time, the end portion of the resin skin 3 was fixed to the end edge portion of the resin base material 1.

  Strictly speaking, the resin skin 3 after the skin molding step is in a semi-solidified state that has not yet been completely solidified, and is basically attached to the skin molding die surface 41.

<Foam molding process>
After that, the fixed mold 40 and the movable mold 50 were micro-opened by moving the movable mold 50 by a predetermined amount with respect to the fixed mold 40 in the direction of separating. Thereby, the foamed resin material in the molten state in the resin skin 3 is foamed under reduced pressure and cooled and solidified in the second cavity formed in the fixed mold 40 and the movable mold 50 which are micro-opened. The foamed resin core 2 was molded integrally with the resin skin 3 (state shown in FIG. 4). At this time, the bottom surface of the foamed resin core 2 was fixed in a state of being laminated on the resin base material 1.

<Demolding process>
Then, the fixed mold 40 and the movable mold 50 were further opened by further moving the movable mold 50 away from the fixed mold 40, and the molded product was demolded.

  Thus, the resin base material 1, the foamed resin core body 2 with its bottom surface fixed in a laminated state on the resin base material 1, and the top surface 2a and the side surface 2b of the foam resin core body 2 are continuously surrounded. In this way, the foamed resin with the skin provided with the resin base material 1, which is provided integrally with the surface of the foamed resin core body 2 and has the resin skin 3 with its own end fixed to the edge of the resin base material 1. An instrument panel 10 as a member was molded.

  Here, when the micro mold is opened for foaming under reduced pressure in the foam molding process, the elongation of the resin skin 3 molded in the skin molding process is less than the mold opening, and the elongation of the resin skin 3 can follow the mold opening. Otherwise, the resin skin 3 may be deformed so as to be partially peeled from the skin molding die surface 41. When the deformation of the resin skin 3 due to the peeling from the skin molding die surface 41 occurs on the design surface 11a, and the resin skin 3 is deformed so that the corner portion 11c, which is the edge of the design surface 11a, is rounded. A problem arises because the molding quality in the design surface component matching portion is deteriorated.

  In this regard, in the present embodiment, the instrument panel 10 has a convex extra portion 12 on the side surface 11b of the molded product portion 11, and the concave step portion 42 for molding the convex extra portion 12 is used for skin molding. The mold surface 41 is provided on the side molding surface 41b. For this reason, when the micro mold is opened in the foam molding process, the resin skin 3 corresponding to the convex excess portion 12 is deformed so as to be peeled off from the orthogonal mold surface 42a of the concave step portion 42 of the skin molding die surface 41. Therefore, it can suppress that the resin skin 3 of the part corresponding to the design surface 11a of the molded article part 11 deform | transforms so that it may peel from the design surface shaping | molding die surface 41a. In addition, the resin skin 3 of the part corresponding to the design surface 11a is not peeled off from the design surface molding die surface 41a in this way, and the resin skin 3 of the part corresponding to the convex extra part 12 is the orthogonal surface of the concave step part 42. The reason why it is peeled off preferentially from 42a is that it is close to the micro mold opening position.

  Therefore, according to this embodiment, the molding quality in the design surface 11a of the molded product part 11 can be ensured satisfactorily, and the molding quality in the design surface part matching part can also be satisfactorily secured.

(Embodiment 2)
In the present embodiment, the present invention is applied to an instrument panel of an automobile in the same manner as in the first embodiment, and the invention according to claims 9 to 16 is embodied.

  As shown in FIG. 5, a cross-sectional view of the main part of the instrument panel 10 as a foamed resin member with a skin formed by the injection foam molding method according to the present embodiment, the instrument panel 10 is provided on the side surface 11 b of the molded product part 11. The configuration is the same as that of the first embodiment except that the concave notched portion 13 is provided. In addition, the shape shown with a dashed-two dotted line in FIG. 5 is the original molded product shape of the molded product part 11, and this instrument panel 10 has the concave notch part 13 for the amount retracted | retracted from this dashed-two dotted line.

  The instrument panel 10 having the above configuration was molded as follows.

  First, a resin base material 1 having a predetermined shape was obtained by injection molding using a base metal mold (not shown).

  On the other hand, an injection foaming mold according to this embodiment was prepared. As shown in FIG. 6, this injection foaming mold has a mold surface shape corresponding to the concave notch 13 on the side molding surface 41 b of the skin molding mold surface 41 of the fixed mold 40. A convex step 43 is provided for molding the resin skin 3 at a portion corresponding to the concave cutout 13. And this convex step part 43 is a direction (FIG. 7, FIG. An inclined mold surface 43a extending in the diagonally upper right direction in FIG. 8 (hereinafter the same) is provided on the design surface molding mold surface 41a side (the upper side in FIGS. 7 and 8; the same applies hereinafter).

  Here, the inclined mold surface 43a of the convex step portion 43, which extends in a direction that forms a negative angle with respect to the mold opening direction, which is the moving direction of the movable mold 50 with respect to the fixed mold 40, is a molded foamed resin member with a skin. Regardless of the presence of a portion that becomes an undercut portion when demolding, an angle (about 10 to 20 degrees) at which the demolding is possible is set.

  Other configurations of the injection foam molding die are the same as those of the first embodiment.

<Injection process>
In a state where the resin substrate 1 is disposed on the substrate mold surface 51 of the movable mold 50 (see FIG. 7), the movable mold 50 is moved in the direction of approaching the fixed mold 40, so that the fixed mold 40 and The movable mold 50 was closed. The foamed resin material (TPO added with CO ₂ as a chemical foaming agent) was injected and filled into the first cavities formed in the molds of the fixed mold 40 and the movable mold 50 that were closed.

<Skin molding process>
The foamed resin material that contacts the skin molding mold surface 41 in the first cavity is cooled and solidified by the mold surface 41, so that the resin skin 3 is shaped along the skin molding mold surface 41. Molded (state of FIG. 7). At this time, the end portion of the resin skin 3 was fixed to the end edge portion of the resin base material 1.

  Strictly speaking, the resin skin 3 after the skin molding step is in a semi-solidified state that has not yet been completely solidified, and is basically attached to the skin molding die surface 41.

<Foam molding process>
After that, the fixed mold 40 and the movable mold 50 were micro-opened by moving the movable mold 50 by a predetermined amount with respect to the fixed mold 40 in the direction of separating. Thereby, the foamed resin material in the molten state in the resin skin 3 is foamed under reduced pressure and cooled and solidified in the second cavity formed in the fixed mold 40 and the movable mold 50 which are micro-opened. The foamed resin core body 2 was integrally formed on the resin skin 3 (state shown in FIG. 8). At this time, the bottom surface of the foamed resin core 2 was fixed in a state of being laminated on the resin base material 1.

<Demolding process>
Then, the fixed mold 40 and the movable mold 50 were further opened by further moving the movable mold 50 away from the fixed mold 40, and the molded product was demolded.

  Thus, the resin base material 1, the foamed resin core body 2 with its bottom surface fixed in a laminated state on the resin base material 1, and the top surface 2a and the side surface 2b of the foam resin core body 2 are continuously surrounded. In this way, the foamed resin with the skin provided with the resin base material 1, which is provided integrally with the surface of the foamed resin core body 2 and has the resin skin 3 with its own end fixed to the edge of the resin base material 1. An instrument panel 10 as a member was molded.

  Here, when the micro mold is opened for foaming under reduced pressure in the foam molding process, the elongation of the resin skin 3 molded in the skin molding process is less than the mold opening, and the elongation of the resin skin 3 can follow the mold opening. Otherwise, the resin skin 3 may be deformed so as to be partially peeled from the skin molding die surface 41. When the deformation of the resin skin 3 due to the peeling from the skin molding die surface 41 occurs on the design surface 11a, and the resin skin 3 is deformed so that the corner portion 11c, which is the edge of the design surface 11a, is rounded. A problem arises because the molding quality in the design surface component matching portion is deteriorated.

  In this respect, in this embodiment, the instrument panel 10 has a concave notch 13 on the side surface 11b of the molded product part 11, and the convex step 43 for molding the concave notch 13 is a skin molding die. The surface 41 is provided on the side molding surface 41b. For this reason, when opening the micro mold in the foam molding step, the resin skin 3 corresponding to the concave notch 13 is hooked and supported by the inclined mold surface 43a of the convex step portion 43 of the skin molding die surface 41. It can suppress that the resin skin 3 of the part corresponding to the design surface 11a of the molded article part 11 deform | transforms so that it may peel from the design surface shaping | molding die surface 41a.

  Therefore, according to this embodiment, the molding quality in the design surface 11a of the molded product part 11 can be ensured satisfactorily, and the molding quality in the design surface part matching part can also be satisfactorily secured.

(Other embodiments)
In the first embodiment described above, an example in which one convex excess portion 12 is provided on the side surface 11b of the molded product portion 11 and one concave step portion 42 is provided on the side surface molding die surface 41b of the skin molding die surface 41 will be described. However, the number, shape, and size of the extra convex portion 12 and the concave step portion 42 are not particularly limited, and can be appropriately set within a range where the effects of the present invention can be achieved.

  Similarly, in the above-described second embodiment, the number, shape, and size of the concave notch 13 and the convex stepped portion 43 are not particularly limited, and can be appropriately set within a range in which the effects of the present invention can be achieved. is there.

  Further, a mode in which the first embodiment and the second embodiment are combined, that is, for example, in the first embodiment, the concave notch 13 is continuously provided on the upper side of the convex extra portion 12, and the convex step portion is provided on the upper side of the concave step portion 42. 43 can also be provided continuously.

  Furthermore, in the first embodiment and the second embodiment described above, the resin base material 1 is formed in advance using a base material mold different from the fixed mold 40 and the movable mold 50, and the resin base material 1 is movable. Although the example which sets to the base-material type | mold surface 51 of the type | mold 50 was demonstrated, the said movable mold | type 50 is a part of base-material mold | die (the movable type | mold of the fixed type | mold and movable type | mold which comprise a base-material mold | die) ) Can be used together. That is, the resin base material 1 is injection-molded using the base material fixed mold and the movable mold 50, and the movable mold 50 while holding the molded resin base material 1 is moved to the fixed mold 40 side. The injection process may be performed with the fixed mold 40 and the movable mold 50 closed.

  In addition, in Embodiment 1 and Embodiment 2 described above, the foamed resin member with a skin provided with the resin base material 1 has been described. However, the foamed resin member with a skin without the resin base material 1, that is, the resin skin 3 and A foamed resin member with a skin composed of the foamed resin core 2 enclosed in the resin skin 3 may be used.

  Moreover, the resin material which comprises the resin base material 1 is not specifically limited, Olefin materials, such as PE other than above-mentioned PP, can be employ | adopted. Similarly, the resin material constituting the foamed resin core 2 and the resin skin 3 made of the same material is not particularly limited, and an all-orphein material or the like can be employed in addition to the above-mentioned TPO.

It is principal part sectional drawing of the instrument panel as Embodiment 1 of this invention as a foamed resin member with a skin. 1 is a cross-sectional view of a main part of a fixed mold according to Embodiment 1 of the present invention. It is principal part sectional drawing which concerns on Embodiment 1 of this invention and shows the mode of a skin molding process. It is principal part sectional drawing which concerns on Embodiment 1 of this invention and shows the mode of a foam molding process. It is principal part sectional drawing of the instrument panel as Embodiment 2 of this invention as a foamed resin member with a skin. FIG. 10 is a cross-sectional view of a main part of a fixed mold according to the second embodiment of the present invention. It is principal part sectional drawing which concerns on Embodiment 2 of this invention and shows the mode of a skin molding process. It is principal part sectional drawing which concerns on Embodiment 2 of this invention, and shows the mode of a foam molding process.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 ... Resin base material 2 ... Foamed resin core body 2a ... Top surface 2b ... Side surface 3 ... Resin skin 11 ... Molded part 11a ... Design surface 11b ... Side surface 12 ... Convex part 13 ... Concave notch part 40 ... Fixed mold DESCRIPTION OF SYMBOLS 41 ... Mold surface for skin molding 41a ... Design surface molding die surface 41b ... Side surface molding die surface 42 ... Concave step part 42a ... Orthogonal mold surface 43 ... Convex step part 43a ... Inclined mold surface 50 ... Movable mold 51 ... Base material type | mold surface

Claims (16)

At least a foamed resin core and a resin skin integrally provided on the surface of the foamed resin core so as to continuously surround at least a top surface and a side surface of the foamed resin core, and the foamed resin core And a convex portion provided on the side surface of the molded product portion corresponding to the side surface of the foamed resin core, and having a molded product portion having a design surface as the surface of the resin skin of the portion corresponding to the top surface of the molded resin. An injection foam molding die for integrally molding the foamed resin core body and the resin skin of the foamed resin member with a skin having an extra portion,
A fixed mold and a movable mold capable of closing or opening a predetermined amount by moving in a direction approaching or separating from the fixed mold, and at least one of the fixed mold and the movable mold is Having a skin molding mold surface for molding the resin skin into a predetermined outer shape;
The skin molding mold surface is a side surface molding for molding a design surface molding die surface for molding the resin skin of the design surface portion and a portion of the resin skin corresponding to the side surface of the foamed resin core. A mold surface,
The side surface molding die surface has a mold surface shape corresponding to the convex extra portion, and is provided with a concave step portion for molding the resin skin of a portion corresponding to the convex extra portion. And injection foam mold.   The concave step portion has an orthogonal mold surface extending in a direction substantially orthogonal to a mold opening direction, which is a moving direction of the movable mold with respect to the fixed mold, on the design surface molding mold surface side. 2. The injection foam molding die according to claim 1. The foamed resin member with skin is integrated with the surface of the foamed resin core so that the bottom surface of the foamed resin core is fixed in a laminated state and continuously surrounds the top and side surfaces of the foamed resin core. A resin base material in which an end portion of the provided resin skin is fixed to an edge portion of the self;
One of the fixed mold and the movable mold has the skin molding mold surface, while the other of the fixed mold and the movable mold has a shape corresponding to the outer shape of the resin substrate. The injection foam molding die according to claim 1 or 2, further comprising a mold surface. At least a foamed resin core and a resin skin integrally provided on the surface of the foamed resin core so as to continuously surround at least a top surface and a side surface of the foamed resin core, and the foamed resin core And a convex portion provided on the side surface of the molded product portion corresponding to the side surface of the foamed resin core, and having a molded product portion having a design surface as the surface of the resin skin of the portion corresponding to the top surface of the molded resin. An injection foam molding method for integrally molding the foamed resin core body and the resin skin of a foamed resin member with a skin having an extra portion,
A movable mold capable of closing a mold or opening a predetermined amount by moving in a direction close to or away from the fixed mold and at least one of the fixed mold and the movable mold Is used having a mold surface for skin molding for molding the resin skin into a predetermined outer shape,
An injection step of injecting and filling a foamed resin material into the first cavity formed in the movable mold and the fixed mold that are closed;
A skin molding step of molding the resin skin by cooling and solidifying the foamed resin material in contact with the skin molding mold surface in the first cavity;
A micro mold is opened by moving the movable mold by a predetermined amount in a direction in which the movable mold is separated from the fixed mold, and the foaming is performed in the fixed mold opened by the micro mold and the second cavity formed in the movable mold. A foam molding step of molding the foamed resin member with the skin by integrally molding the foamed resin core on the resin skin by foaming the resin material under reduced pressure and cooling and solidifying,
When opening the micro mold in the foam molding step, by deforming the resin skin of the portion corresponding to the convex extra part so as to be peeled off from the skin molding mold surface, the design surface of the molded product part An injection foam molding method characterized by suppressing deformation of the resin skin of a corresponding part. The skin molding mold surface is a side surface molding for molding a design surface molding die surface for molding the resin skin of the design surface portion and a portion of the resin skin corresponding to the side surface of the foamed resin core. A concave step portion that has a mold surface shape corresponding to the convex extra portion and molds the resin skin of a portion corresponding to the convex extra portion. Provided,
The concave step portion has an orthogonal mold surface extending in a direction substantially orthogonal to a mold opening direction, which is a moving direction of the movable mold with respect to the fixed mold, on the design surface molding mold surface side. 5. The injection foam molding method according to claim 4. The foamed resin member with skin is integrated with the surface of the foamed resin core so that the bottom surface of the foamed resin core is fixed in a laminated state and continuously surrounds the top and side surfaces of the foamed resin core. A resin base material in which an end portion of the provided resin skin is fixed to an edge portion of the self;
One of the fixed mold and the movable mold has the skin molding mold surface, while the other of the fixed mold and the movable mold has a shape corresponding to the outer shape of the resin substrate. 6. The injection foam molding method according to claim 4, further comprising a mold surface. A fixed mold comprising at least a foamed resin core and a resin skin integrally provided on the surface of the foamed resin core so as to continuously surround at least a top surface and a side surface of the foamed resin core. A direction in which the movable mold is separated from the fixed mold after the resin skin is molded by cooling and solidifying the foamed resin material filled in the movable mold and contacting the mold surface. The foamed resin core is integrally molded on the resin skin by foaming the foamed resin material under reduced pressure in the fixed mold and the movable mold which are moved by a predetermined amount to the mold and cooled and solidified. A foamed resin member with an outer skin,
A molded product part having a desired molded product shape, with the surface of the resin skin corresponding to the top surface of the foamed resin core as a design surface;
A foamed resin member with a skin, comprising a convex excess provided on a side surface of the molded part corresponding to a side surface of the foamed resin core.   The bottom surface of the foamed resin core is fixed in a laminated state, and the resin skin is integrally provided on the surface of the foamed resin core so as to continuously surround the top surface and the side surface of the foamed resin core. 8. The foamed resin member with a skin according to claim 7, further comprising a resin base material having an end portion fixed to its own edge portion. At least a foamed resin core and a resin skin integrally provided on the surface of the foamed resin core so as to continuously surround at least a top surface and a side surface of the foamed resin core, and the foamed resin core A molded product part having a desired molded product shape with the surface of the resin skin corresponding to the top surface of the resin as a design surface, and a concave shape provided on the side surface of the molded product part corresponding to the side surface of the foamed resin core An injection foam mold for integrally molding the foamed resin core and the resin skin of the foamed resin member with a skin having a notch,
A fixed mold and a movable mold capable of closing or opening a predetermined amount by moving in a direction approaching or separating from the fixed mold, and at least one of the fixed mold and the movable mold is Having a skin molding mold surface for molding the resin skin into a predetermined outer shape;
The skin molding mold surface is a side surface molding for molding a design surface molding die surface for molding the resin skin of the design surface portion and a portion of the resin skin corresponding to the side surface of the foamed resin core. A mold surface,
The side molding die surface is provided with a convex step portion that has a mold surface shape corresponding to the concave cutout portion and molds the resin skin of a portion corresponding to the concave cutout portion. And injection foam mold.   The convex step portion has an inclined mold surface on the design surface mold surface side that extends in a direction that forms a negative angle with respect to a mold opening direction that is a moving direction of the movable mold with respect to the fixed mold. The injection foam molding die according to claim 9. The foamed resin member with skin is integrated with the surface of the foamed resin core so that the bottom surface of the foamed resin core is fixed in a laminated state and continuously surrounds the top and side surfaces of the foamed resin core. A resin base material in which an end portion of the provided resin skin is fixed to an edge portion of the self;
One of the fixed mold and the movable mold has the skin molding mold surface, while the other of the fixed mold and the movable mold has a shape corresponding to the outer shape of the resin substrate. The injection-foaming mold according to claim 9 or 10, which has a mold surface. At least a foamed resin core and a resin skin integrally provided on the surface of the foamed resin core so as to continuously surround at least a top surface and a side surface of the foamed resin core, and the foamed resin core A molded product part having a desired molded product shape with the surface of the resin skin corresponding to the top surface of the resin as a design surface, and a concave shape provided on the side surface of the molded product part corresponding to the side surface of the foamed resin core An injection foam molding method for integrally molding the foamed resin core body and the resin skin of the foamed resin member with a skin having a notch,
A movable mold capable of closing a mold or opening a predetermined amount by moving in a direction close to or away from the fixed mold and at least one of the fixed mold and the movable mold Is used having a mold surface for skin molding for molding the resin skin into a predetermined outer shape,
An injection step of injecting and filling a foamed resin material into the first cavity formed in the fixed mold and the movable mold which are closed; and
A skin molding step of molding the resin skin by cooling and solidifying the foamed resin material in contact with the skin molding mold surface in the first cavity;
A micro mold is opened by moving the movable mold by a predetermined amount in a direction in which the movable mold is separated from the fixed mold, and the foaming is performed in the fixed mold opened by the micro mold and the second cavity formed in the movable mold. A foam molding step of molding the foamed resin member with the skin by integrally molding the foamed resin core on the resin skin by foaming the resin material under reduced pressure and cooling and solidifying,
Corresponding to the design surface of the molded part by hooking and supporting the resin skin of the part corresponding to the concave notch when the micro mold is opened in the foam molding process An injection foam molding method characterized by suppressing deformation of the resin skin of a portion to be performed. The skin molding mold surface is a side surface molding for molding a design surface molding die surface for molding the resin skin of the design surface portion and a portion of the resin skin corresponding to the side surface of the foamed resin core. A convex step for forming the resin skin of the portion corresponding to the concave notch and having a shape corresponding to the concave notch. Provided,
The convex step portion has an inclined mold surface on the design surface mold surface side that extends in a direction that forms a negative angle with respect to a mold opening direction that is a moving direction of the movable mold with respect to the fixed mold. The injection foam molding method according to claim 12. The foamed resin member with skin is integrated with the surface of the foamed resin core so that the bottom surface of the foamed resin core is fixed in a laminated state and continuously surrounds the top and side surfaces of the foamed resin core. A resin base material in which an end portion of the provided resin skin is fixed to an edge portion of the self;
One of the fixed mold and the movable mold has the skin molding mold surface, while the other of the fixed mold and the movable mold has a shape corresponding to the outer shape of the resin substrate. The injection foam molding method according to claim 12 or 13, characterized by having a mold surface. A fixed mold comprising at least a foamed resin core and a resin skin integrally provided on the surface of the foamed resin core so as to continuously surround at least a top surface and a side surface of the foamed resin core. A direction in which the movable mold is separated from the fixed mold after the resin skin is molded by cooling and solidifying the foamed resin material filled in the movable mold and contacting the mold surface. The foamed resin core body is integrally formed on the resin skin by foaming the foamed resin material under reduced pressure in the fixed mold and the movable mold, which are moved by a predetermined amount to the mold and cooled and solidified. A foamed resin member with an outer skin,
A molded product part having a desired molded product shape, with the surface of the resin skin corresponding to the top surface of the foamed resin core as a design surface;
A foamed resin member with a skin, comprising: a concave notch provided on a side surface of the molded product portion corresponding to a side surface of the foamed resin core.   The bottom surface of the foamed resin core is fixed in a laminated state, and the resin skin is integrally provided on the surface of the foamed resin core so as to continuously surround the top surface and the side surface of the foamed resin core. The foamed resin member with a skin according to claim 15, further comprising a resin base material having an end portion fixed to its own edge portion.

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