JP2007296752A - Method and apparatus for manufacturing foamed molding member - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method for manufacturing a foamed molding member capable of preventing a foamed body from leaking while opening is prevented from occurring without generating face difference between a substrate and a surface skin. <P>SOLUTION: The method for manufacturing the foamed molding member including the steps of arranging the surface skin 3 and an inserting member 5 in a mold 6 for molding and filling the foamed body 4 to mold so that the surface skin 3 and the inserting member 5 at least partially form the surface comprises a sealing process wherein while the surface skin 3 is pinched between the outer surface of the inserting member 5 and the mold 6 for molding, an overlapping site of the surface skin 3 to the inserting member 5 is elastically deformed by a pressing means 10 to seal a space between the surface skin 3 and the inserting member 5, and a filling process wherein the foamed body 4 is filled in the mold 6 for molding. <P>COPYRIGHT: (C)2008,JPO&INPIT

Description

  The present invention relates to a method and an apparatus for manufacturing a foam molded member.

  2. Description of the Related Art Conventionally, as a method for manufacturing vehicle interior members, furniture, and the like, a method has been used in which a base material and an outer skin are provided in a foam cavity and a foam is formed by filling the gap with foam. (See Patent Document 1). In this method, a spare space formed so as to cover the boundary portion by the skin is provided at the boundary portion between the base material and the skin, and even when the foam leaks from the boundary portion, the foam is not contained in the spare space. It has a feature that it stays at the outside and is not exposed to the outside.

  However, in this method, a surface difference occurs between the base material and the skin to provide a spare space, and there is no sense of unity. Also, unless the spare space is completely filled with foam, the base material and the skin are completely bonded. Therefore, opening of the mouth occurs at the boundary between the base material and the skin.

Further, for example, when there is an insert member that is inserted to be combined with a foam in foam molding, a gap is generated between the insert member and the foaming die due to the insert member being hard or due to deformation due to molding. The foam leaks into the gap between the levers, and the work of removing the leaked foam occurs.
JP 2005-1311 A

  The present invention has been made to solve the problems associated with the above-described prior art, and is a foam-molded member capable of preventing leakage of a foam while preventing mouth opening without causing a surface difference between the base material and the skin. It aims at providing the manufacturing method of.

  The manufacturing method of a foam molded member according to the present invention that achieves the above object includes disposing a skin and an insert member on a mold, and filling the foam so that the skin and the insert member at least partially form a surface. A method of manufacturing a foam molded member to be molded, wherein a skin is sandwiched between an outer surface of the insert member and a molding die, and a portion overlapping the insert member of the skin is elastically deformed by a pressing means, whereby the skin and the insert It has a sealing step for sealing between the members, and a filling step for filling the mold with a foam.

  An apparatus for manufacturing a foam molded member according to the present invention that achieves the above object comprises arranging a skin and an insert member in a mold, and filling the foam so that the skin and the insert member at least partially form a surface. An apparatus for manufacturing a foam molded member to be molded, comprising: a pressing unit that elastically deforms the sandwiched portion when the skin is sandwiched between an outer surface of the insert member and a molding die.

  The foamed molded member manufacturing method and manufacturing apparatus according to the present invention configured as described above do not have a step space unlike the conventional method, so that no step is generated and the opening of the mouth can be prevented. In addition, since the skin is pressed against the insert member while elastically deforming the portion of the skin that overlaps with the insert member by the pressing means, the skin is strongly struck against the insert member, so that no gap is generated, and leakage of the foam can be prevented.

  Since the foam molding member manufacturing apparatus according to the present invention configured as described above has a pressing means that elastically deforms a portion of the skin that overlaps with the insert member, the skin strongly hits the insert member and no gap is formed. , Foam leakage can be prevented.

  Embodiments of the present invention will be described with reference to the drawings.

<First Embodiment>
FIG. 1 is a perspective view showing an instrument panel as a foam molded member manufactured by the method of manufacturing a foam molded member according to the first embodiment, and FIG. 2 is a partial cross section of the foam molded member along the line II-II in FIG. FIG. In addition, the braille pattern in FIG. 1 represents a skin, and the oblique line represents the insert member.

  As shown in FIGS. 1 and 2, the foam molded member 1 (instrument panel) is formed by filling a foam 4 between the base material 2 and the skin 3. Further, an insert member 5 inserted so as to be coupled to the foam 4 is overlapped with an end portion of the skin 3, and the foam 4 is filled between the insert member 5 and the base material 2.

  Next, the manufacturing method of a foam molding member is demonstrated.

  FIG. 3 is a partial cross-sectional view in the mold showing a state in which the skin and the base material are arranged in the mold in the method for manufacturing a foam molded member according to the first embodiment, and FIG. 4 is a diagram in which an insert member is further arranged in the mold. FIG. 5 is a partial cross-sectional view inside the mold showing when the mold is closed, and FIG. 6 is a partial cross-sectional view inside the mold showing when the foam is filled. 7 is a partial cross-sectional view showing a state where the mold is opened, and FIG. 8 is a partial cross-sectional view of the foam-molded member showing a state where the molded foam-formed member is taken out from the mold.

  The foam molded member 1 described above is formed by filling the foam 4 after placing the base material 2, the skin 3 and the insert member 5 in the cavity 7 of the mold 6. The foam 4 is, for example, foamed urethane.

  First, as shown in FIG. 3, the upper mold 6A and the lower mold 6B which are the molds 6 are opened, the skin 3 is installed in contact with the cavity 7 of one mold 6 such as the lower mold 6B, and the other The substrate 2 is placed in contact with the cavity 7 of the upper die 6A, which is the molding die 6, for example.

  The skin 3 is provided with a stepped portion 8 that protrudes to the side in contact with the mold 6 at the end in contact with the insert member 5 by a process described later.

  The lower mold 6 </ b> B is provided with a recess 9 that accommodates the stepped portion 8 corresponding to the stepped portion 8 of the skin 3. In the concave portion 9, an in-mold protruding portion 10 (pressing means) protruding so as to be in contact with the stepped portion 8 is formed, and a vacuum cup 11 is provided. Further, the lower mold 6B is provided with a cutting blade 14 that protrudes into the cavity 7 and can cut the skin 3 corresponding to the position of the base portion 12 that is the base of the step portion 8. The cutting blade 14 is normally housed in the lower mold 6B, and can be moved back and forth into the cavity 7 by a driving source such as a hydraulic cylinder (not shown). The cutting blade 14 is provided corresponding to the extending shape of the base portion 12 to be cut, but may be provided as a plurality of divided blades as necessary.

  Next, as shown in FIG. 4, the insert member 5 is installed inside the step portion 8 corresponding to the step portion 8 of the skin 3. The insert member 5 is sucked by the vacuum cup 11 and pressed against the step portion 8, whereby elastic deformation occurs at a portion of the step portion 8 sandwiched between the insert member 5 and the in-mold protruding portion 10, and the step portion 8. Is strongly pressed against the insert member 5 to seal between the skin 3 and the insert member 5 (sealing process). Here, the inner surface 16 of the stepped portion in contact with the insert member 5 of the stepped portion 8 is formed in the same plane as the outer surface 17 of the skin. That is, the depth of the concave portion 9 is equal to the thickness of the stepped portion 8, and therefore, the outer surface 17 of the skin and the outer surface 18 of the insert member 5 are arranged in the same plane.

  Next, the mold 6 is closed as shown in FIG.

  Thereafter, as shown in FIG. 6, the foam 4 is injected from the outside of the mold 6 and filled between the skin 3 and the base 2 and between the insert member 5 and the base 2 (filling step). . At this time, since the stepped portion 8 of the skin 3 is elastically deformed and strongly pressed against the insert member 5, the foam 4 is not leaked from the gap between the skin 3 and the insert member 5. Therefore, for example, even if the insert member 5 is hard, the skin 3 and the insert member 5 can be brought into close contact with each other, and leakage of the foam 4 can be prevented. Further, since the insert member 5 contacts the step portion 8 of the skin 3 and does not contact the cavity 7, damage due to contact between the cavity 7 and the insert member 5 can be prevented. For this reason, it is not necessary to affix the protective seal for preventing the insert member 5 from being damaged.

  Next, the cutting blade 14 is protruded from the lower mold 6B into the cavity 7, and the step portion 8 of the skin 3 is cut at the root portion 12 (cutting step).

  Thereafter, the mold 6 is opened as shown in FIG. 7 to stop the suction of the vacuum cup 11, and as shown in FIG. 8, the foamed molded member 1 with the stepped portion 8 cut off is taken out.

  In the molded foam molded member 1, the outer surface 17 of the skin and the outer surface 18 of the insert member 5 are arranged in the same plane, so that no surface difference occurs on the surface at the boundary between the skin 3 and the insert member 5. It is formed.

  FIG. 9 is a partial cross-sectional view showing the boundary between the skin of the foam molded member and the insert member. FIG. 9A shows an example of the shape of the insert member, and FIG. 9B shows another example of the shape of the insert member.

  The end of the insert member 5 at the boundary with the skin 3 can be processed with a predetermined curvature (see FIG. 9A) or chamfered (see FIG. 9B).

  According to the present embodiment, the foam 4 can be prevented from leaking due to elastic deformation of the skin 3, so that it is not necessary to provide a spare space in the skin 3 as in the prior art, for example, and the surface difference of the foam molded member 1 is eliminated. be able to. Moreover, since it is not necessary to affix a protective seal on the insert member 5 as described above, it is possible to prevent occurrence of a surface difference caused by affixing the protective seal.

  Further, since it is not necessary to provide a spare space, it is possible to prevent the mouth opening from occurring at the boundary portion between the insert member 5 and the skin 3.

  Further, since the foam 4 can be prevented from leaking from between the skin 3 and the insert member 5 due to the elastic deformation by the skin 3, the foam 4 to the vacuum cup 11 provided in the mold 6 or a vacuum drawing hole (not shown). Inflow, and the work for removing the foam 4 when the foam 4 flows into the vacuum cup 11 or the like does not occur, thereby preventing an increase in man-hours.

Second Embodiment
FIG. 10 is a partial cross-sectional view in the mold before the insert member is stacked on the skin in the foam molded member manufacturing method according to the second embodiment, and FIG. 11 is an insert member on the skin in the foam molded member manufacturing method. It is a fragmentary sectional view in the shaping | molding die at the time of overlapping. In addition, about the site | part which has the same function as 1st Embodiment, the same code | symbol is used and in order to avoid duplication, the description is abbreviate | omitted.

  In the second embodiment, as shown in FIG. 10, unlike the first embodiment, the in-mold protrusion 10 is not formed in the recess 9 of the lower mold 6 </ b> B, and the skin contacting the mold 6 is formed on the step 8 of the skin 3. A protruding portion 15 (pressing means) is formed. Thereby, as shown in FIG. 11, when the insert member 5 is overlaid on the stepped portion 8 of the skin 3, the stepped portion 8 is sandwiched between the insert member 5 and the lower mold 6B, and the skin protruding portion is elastically deformed. Note that the effects of this elastic deformation and the subsequent steps are the same as those in the first embodiment, and thus description thereof is omitted.

  The present invention is not limited to the above-described embodiment, and various modifications can be made within the scope of the claims. For example, the present invention may be applied to the boundary portion between the base material 2 and the skin by causing the base material 2 to act as the insert member 5. Further, the upper mold 6A and the lower mold 6B may have opposite configurations.

It is a perspective view which shows the instrument panel as a foaming molding member manufactured with the manufacturing method of the foaming molding member which concerns on 1st Embodiment. It is a fragmentary sectional view of the foaming molding member which follows the II-II line of FIG. It is a fragmentary sectional view in a shaping | molding die which shows the time of arrange | positioning a skin and a base material in a shaping | molding die in the manufacturing method of the foaming molding member which concerns on 1st Embodiment. It is a fragmentary sectional view in a shaping | molding die which shows the time of arrange | positioning an insert member further to a shaping | molding die. It is a fragmentary sectional view in a shaping | molding die which shows the time of closing a shaping | molding die. It is a fragmentary sectional view in a shaping | molding die which shows the time of filling with a foam. It is a fragmentary sectional view which shows the time of opening a shaping | molding die. It is a fragmentary sectional view of the foam molding member showing the time of taking out the molded foam molding member from the mold. It is a fragmentary sectional view which shows the boundary of the skin of a foaming molding member, and an insert member, (A) shows an example of the shape of an insert member, (B) shows the other example of the shape of an insert member. In the manufacturing method of the foaming molding member concerning a 2nd embodiment, it is a fragmentary sectional view in a forming die before putting an insert member on a skin. It is a fragmentary sectional view in a shaping | molding die at the time of stacking an insert member on the skin in the manufacturing method of the foaming molding member.

Explanation of symbols

1 Foam molding member (instrument panel),
2 base material,
3 epidermis,
4 Foam,
5 Insert member,
6 Mold,
6A Upper mold,
6B Lower mold,
7 cavities,
8 steps,
9 recess,
10 In-mold protrusion (pressing means),
11 vacuum cups,
12 Root,
14 cutting blade,
15 skin protrusion (pressing means),
16 Inside surface of the step,
17 outer surface of the epidermis,
18 Insert member outer surface.

Claims (13)

A method for producing a foam molded member, wherein a skin and an insert member are arranged in a mold, and the foam and the insert member are filled with a foam so as to form a surface at least partially.
While sandwiching the skin between the outer surface of the insert member and the mold, the sealing step of sealing the space between the skin and the insert member by elastically deforming the portion overlapping the insert member of the skin by pressing means;
And a filling step of filling the molding die with a foam.   2. The foam molding member according to claim 1, wherein the pressing means is an in-mold projecting portion provided in the molding die so as to be in contact with the skin corresponding to a portion where the skin and the insert member overlap each other. Manufacturing method.   2. The foam molded member according to claim 1, wherein the pressing means is a skin protruding portion provided on the skin so as to be in contact with the mold corresponding to a portion where the skin and the insert member overlap each other. Production method.   A step portion that protrudes from the outer surface of the skin toward the outside of the mold is formed in a portion that overlaps with the insert member of the skin, and elastic deformation of the skin by the pressing means is caused at the step portion. The manufacturing method of the foaming molding member of any one of Claims 1-3 to do.   After the filling step, the method includes a cutting step of cutting the stepped portion with a cutting blade that is embedded in the mold and protrudes into the cavity of the mold while holding the foam molded member by the mold. The manufacturing method of the foaming molding member of Claim 4 characterized by the above-mentioned.   The method of manufacturing a foam molded member according to claim 4 or 5, wherein a surface of the step portion that contacts the insert member is formed in the same plane as the outer skin surface.   The foam molded member according to claim 6, wherein a corner portion of the insert member provided adjacent to the skin from which the stepped portion is cut is curved or chamfered by a predetermined curvature. Production method. An apparatus for producing a foam molded member, in which a skin and an insert member are disposed in a mold, and the foam and the insert member are filled with a foam so as to form a surface at least partially.
An apparatus for manufacturing a foam molded member, comprising pressing means for elastically deforming the sandwiched portion when the skin is sandwiched between an outer surface of the insert member and a molding die.   9. The foam molding according to claim 8, wherein the pressing means is an in-mold projecting portion provided in the mold so as to be in contact with the skin corresponding to a portion where the skin and the insert member overlap each other. Manufacturing equipment for members.   9. The foam molding member according to claim 8, wherein the pressing means is a skin protrusion provided on the skin so as to be in contact with the molding die corresponding to a portion where the skin and the insert member overlap each other. Manufacturing equipment.   11. The concave portion for accommodating a step portion formed by projecting from the outer surface of the outer skin to the outside of the molding die is formed at a portion of the molding die that sandwiches the outer skin. The manufacturing apparatus of the foaming molding member of Claim 1.   12. The apparatus for manufacturing a foam molded member according to claim 11, further comprising a cutting blade embedded in a mold for cutting the stepped portion and capable of moving back and forth into a cavity of the mold.   The depth of the said recessed part corresponds with the thickness of the said level | step-difference part, The manufacturing apparatus of the foaming molding member of Claim 11 or 12 characterized by the above-mentioned.

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