JP2008273052A - Foam molding member, and method for manufacturing the same - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method for manufacturing a foam molding member which forms a surface member with a skin and an insert member, reduces the gap and a surface difference between the skin and the insert member, and improves appearance quality. <P>SOLUTION: An instrument panel 11 (foam molding member) includes a skin 20, a decorative panel 40 (insert member) which is formed from a harder material than the skin, is adjacent to the skin and forms the surface member 30 together with the skin, a core material 50 opposing to the surface member, and a foam 60 filled in a space between the surface member and the core material. The decorative panel is provided with a tip end part 41 which is overlapped with the skin back surface 21 side opposing to the core material side. A rib 54 for attaching the tip end part to the skin back surface side by contacting with the tip end part is projectingly provided on the core material toward the surface member. <P>COPYRIGHT: (C)2009,JPO&INPIT

Description

  The present invention relates to a foam molded member and a method for producing a foam molded member.

The interior parts used in automobiles and homes are usually configured by combining a plurality of parts. For example, an instrument assembly disposed in the front of a vehicle interior is configured by combining components such as an instrument panel, a decorative panel for enhancing decorativeness, a ventilator serving as a conditioned air outlet, and a meter hood. The instrument panel is formed from, for example, a foam molded member in which a foam is filled between the skin and the core material (see Patent Document 1). In Patent Literature 1, the surface of the skin of the instrument panel is solidified by filling and solidifying the foam in a state where the concave formed on the skin of the instrument panel and the convex formed on the storage component are fitted together, A technique for forming the surface of the storage component substantially flush is described.
Japanese Patent Laid-Open No. 2002-172756

  In order to improve the appearance quality of interior parts, it is important to reduce gaps and surface differences between the combined parts.

  The technique described in Patent Literature 1 is a technique based on an instrument panel having an opening for storing storage components. For this reason, the surface and the insert member such as a decorative panel are combined to form a surface member, and a foam molded member formed by filling a foam between the surface member and the core material is patented. The technique described in Document 1 cannot be applied.

  Even in the foam molded member in which the skin and the insert member are combined to form the surface member, it is necessary to reduce the gap and surface difference between the skin and the insert member in order to improve the appearance quality. .

  Therefore, the present invention is a foam-molded member in which the skin and the insert member are combined to form a surface member, and the gap and surface difference between the skin and the insert member are reduced to improve the appearance quality. An object is to provide a foam molded member. Another object of the present invention is to provide a method for producing such a foam molded member.

The invention according to claim 1 for achieving the above object comprises an epidermis,
An insert member formed of a material harder than the skin and forming a surface member with the skin adjacent to the skin;
A core material facing the surface member;
A foam filled in a space between the surface member and the core;
Provided on the insert member, a tip portion overlapping the back side of the skin facing the core side,
It is a foam-molded member having ribs that are provided on the core member so as to protrude toward the surface member, and that bring the tip portion into close contact with the back side of the skin by contacting the tip portion.

The invention according to claim 9 includes an open mold, an outer skin, and an insert member that is formed of a material harder than the outer skin and forms a surface member together with the outer skin adjacent to the outer skin. A step of disposing a core member provided with protruding ribs such that the core member faces the surface member;
By closing the mold and moving the surface member and the core material relatively close to each other, the rib is formed on the tip portion that is provided on the insert member and overlaps the back side of the skin facing the core material side. A sealing step for bringing the tip portion into close contact with the back side of the epidermis,
And filling the space between the surface member and the core material with a foam.

  According to the foam molded member and the foam molded member manufacturing method according to the present invention, a foam molded member in which the skin and the insert member together form a surface member, and a gap between the skin and the insert member, The surface difference can be reduced and the appearance quality can be improved.

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

(First embodiment)
FIG. 1 is a perspective view showing an instrument assembly 10 including an instrument panel 11 to which a foam molded member of the present invention is applied, and FIG. 2 is a cross-sectional view showing a main part of the instrument panel 11 according to the first embodiment. It is.

  Referring to FIG. 1, an instrument assembly 10 is configured by combining parts such as an instrument panel 11, a ventilator 17, and a meter hood 18.

  Referring to FIG. 2, an instrument panel 11 (corresponding to a foam molding member) is formed of a skin 20 and a material harder than the skin 20, and forms a surface member 30 together with the skin 20 adjacent to the skin 20. A decorative panel 40 (corresponding to an insert member), a core member 50 facing the surface member 30, and a foam 60 filled in a space between the surface member 30 and the core member 50. . The decorative panel 40 is provided with a tip 41 that overlaps the back surface 21 side of the skin 20 facing the core material 50 side. The core member 50 is provided with ribs 51 projecting toward the surface member 30 so that the tip portion 41 is brought into close contact with the back surface 21 side of the skin 20 by contacting the tip portion 41.

  The ribs 51 of the core member 50 are in contact with the tip portion 41 of the decorative panel 40, and the tip portion 41 is in close contact with the back surface 21 side of the skin 20. By filling the foam 60 in this state, the foam 60 can be sealed. The foam 60 can be prevented from leaking to the surfaces 22 and 43 through the gap between the skin 20 and the decorative panel 40, and as a result, the gap or surface difference between the skin 20 and the decorative panel 40. Can be reduced. The rib 51 may be dimensioned so long as the front end 41 that is in close contact with the back surface 21 side of the skin 20 can sufficiently exert the function of sealing the foam 60, and excessively presses the back surface 21 side of the skin 20. It is preferable to set the dimensions so as not to occur. This is because, when the front end portion 41 excessively presses the back surface 21 side of the skin 20, wrinkles or the like accompanying the pressing appear on the surface 22 of the skin 20, and there is a concern that the appearance quality may be deteriorated.

  It is preferable that the area of the end face of the front end portion 41 that the rib 51 contacts is larger than the cross-sectional area of the rib 51. The relative positional deviation between the tip 41 and the rib 51 can be allowed, and the rib 51 can be brought into contact with the tip 41 so that the tip 41 can be securely adhered to the back surface 21 side of the skin 20. It is.

  The decorating panel 40 preferably has a side end face 42 that contacts the skin 20 at an acute angle with respect to the surface 22 of the adjacent skin 20. Due to the inclined shape of the side end face 42, as shown by the arrow 31 in the figure, the force when the epidermis 20 is pressed does not work in the direction of expanding the gap between the epidermis 20 and the decorative panel 40. It is converted into a force that presses the end against the side end face 42. This is because the converted force does not generate a gap at the mating portion between the skin 20 and the decorative panel 40, and the appearance quality can be improved.

  The skin 20 has a flange portion 23 provided at the end adjacent to the decorative panel 40 so as to protrude toward the core member 50. The front end portion 41 of the decorative panel 40 has a shape that extends along the flange portion 23. In the illustrated example, the decorative panel 40 includes a surface portion 44 that forms the surface 43, an inclined portion 45 that extends from the end portion of the surface portion 44 adjacent to the skin 20 toward the core member 50 and includes the side end face 42, It includes a tip portion 41 extending from the end portion of the inclined portion 45 so as to be substantially parallel to the surface portion 44.

  It is preferable that the flange part 23 of the skin 20 has a cross-sectional shape along the contour formed by the inclined part 45 and the tip part 41 of the decorative panel 40 (see FIGS. 3 and 4 which are process drawings). . Since the decorative panel 40 is formed of a material harder than the skin 20, the flange portion 23 can be deformed by pressing against the contour of the decorative panel 40. However, when the flange portion 23 is excessively deformed, wrinkles and the like accompanying the deformation appear on the surface 22 of the skin 20 and there is a possibility that the appearance quality is deteriorated. Therefore, it is preferable that the flange portion 23 of the skin 20 has a cross-sectional shape along the contour of the decorative panel 40.

  A known material can be appropriately selected for each of the skin 20, the decorative panel 40, the core member 50, and the foamed body 60. For example, as the material of the skin 20, a vinyl chloride resin (PVC), an olefin thermoplastic elastomer (TPO), a polyurethane thermoplastic elastomer (TPU), or the like can be used. The skin 20 is formed into a shape determined by vacuum forming or the like. The material of the decorative panel 40 can be appropriately selected as long as the material is harder than the skin 20, and for example, acrylonitrile / butadiene / styrene resin (ABS) can be used. As a material of the core material 50, polypropylene resin (PP), acrylonitrile / butadiene / styrene resin (ABS), or the like can be used. For example, urethane foam can be used for the foam 60.

  Next, a method for manufacturing the instrument panel 11 will be described.

  3 is a cross-sectional view showing a state in which the skin 20 and the core material 50 are arranged on the opened mold 100. FIG. 4 further shows a decorative panel 40 as an insert member on the opened mold 100. It is sectional drawing which shows the state arrange | positioned. FIG. 5 is a cross-sectional view showing a sealing process in which the mold 100 is closed and the front end portion 41 of the decorative panel 40 is brought into close contact with the back surface 21 side of the skin 20, and FIG. 6 is a cross-sectional view showing the process of filling the foam 60. FIG.

  Referring to FIG. 3, the mold 100 includes upper and lower molds 101 and 102 that are relatively close to and away from each other. In the illustrated example, the upper mold 101 moves toward and away from the lower mold 102. The upper die 101 has an inner shape cavity that matches the outer shape of the core member 50, and the lower die 102 has an inner shape that matches the outer shape of the surface member 30 (the skin 20 and the decorative panel 40). A shaped cavity is formed.

  First, as shown in FIG. 3, the upper and lower molds 101 and 102 of the mold 100 are opened, the core material 50 is disposed on the upper mold 101, and the skin 20 is disposed on the lower mold 102. The skin 20 has a flange portion 23 provided so as to protrude toward the core member 50.

  Next, as shown in FIG. 4, the decorative panel 40 is further arranged on the lower mold 102 (arrangement step). The front end portion 41 of the decorative panel 40 has a shape that extends along the flange portion 23. The decorative panel 40 includes a surface portion 44, an inclined portion 45, and a tip portion 41 extending from the end portion of the inclined portion 45 so as to be substantially parallel to the surface portion 44. As described above, the flange portion 23 of the skin 20 has a cross-sectional shape along the contour formed by the inclined portion 45 and the tip portion 41 of the decorative panel 40.

  Next, as shown in FIG. 5, the mold 100 is closed, and the surface member 30 and the core material 50 are moved relatively close to each other. With this approaching movement, the rib 51 of the core member 50 comes into contact with the front end portion 41 of the decorative panel 40, and the front end portion 41 comes into close contact with the back surface 21 side of the skin 20 (sealing process). Since the area of the end face with which the rib 51 contacts is larger than the cross-sectional area of the rib 51 in the front end portion 41, the front end portion 41 can be reliably adhered to the back surface 21 side of the skin 20.

  Next, as shown in FIG. 6, the space between the surface member 30 and the core member 50 is filled with the foam 60 (filling step). In this filling step, the ribs 51 of the core member 50 are in contact with the tip portion 41 of the decorative panel 40, and the tip portion 41 is in close contact with the back surface 21 side of the skin 20. By filling the foam body 60 in this state, the foam body 60 can be sealed even if variations in the dimensional accuracy of the skin 20 and the decorative panel 40 and variations upon setting in the mold 100 occur. . The foam 60 can be prevented from leaking to the surfaces 22 and 43 through the gap between the skin 20 and the decorative panel 40, and as a result, the gap or surface difference between the skin 20 and the decorative panel 40. Is reduced.

  As described above, according to the first embodiment of the present invention, the instrument panel 11 (foam molded member) in which the outer skin 20 and the decorative panel 40 (insert member) together form the surface member 30. And the seal between the skin 20 and the decorative panel 40 is good, the leakage of the foam 60 does not occur, the gap and the surface difference between the skin 20 and the decorative panel 40 are small, Even if the skin 20 near the mating portion between the skin 20 and the decorative panel 40 is pressed, no gap is generated at the mating portion between the skin 20 and the decorative panel 40. Thus, the instrument panel which improved the external appearance quality by reducing the clearance gap and surface difference between the outer skin 20 and the decorating panel 40 by having improved the precision of part alignment with the epidermis 20 and the decorating panel 40. 11 can be provided. Moreover, the manufacturing method of such an instrument panel 11 can be provided. Since a plurality of parts are insert-molded in the foam molding process, the manufacturing cost of the instrument panel 11 can be reduced without assembly in the subsequent process.

(Second Embodiment)
FIG. 7 is a cross-sectional view showing a main part of the instrument panel 12 according to the second embodiment. Members common to those in the first embodiment are denoted by the same reference numerals, and description thereof is partially omitted.

  The distal end portion 41 and the skin 20 in the second embodiment are different from the first embodiment in that an uneven portion 70 that fits into each other is provided.

  In the illustrated example, a convex portion 71 projecting toward the skin 20 is formed at the front end portion 41 of the decorative panel 40, and a concave portion 72 into which the convex portion 71 is fitted on the top surface of the flange portion 23 of the skin 20, that is, the back surface 21. Is formed. When the convex portion 71 and the concave portion 72 are fitted to each other, the decorative panel 40 and the skin 20 are difficult to move in a direction perpendicular to the paper surface of FIG. 7, and the decorative panel 40 and the skin are formed during or after molding. The positioning accuracy with respect to 20 is improved. The dimensional accuracy defect of the decorating panel 40 and the skin 20 and the set variation of the decorating panel 40 and the skin 20 at the time of insertion can be absorbed. As a result, the surface difference between the skin 20 and the decorating panel 40 is reduced.

  Since the decorative panel 40 is made of a material harder than the skin 20, a concave portion is formed in the skin 20 by pressing the convex portion 71 of the tip 41 against the skin 20. However, when the skin 20 is deformed excessively, wrinkles and the like accompanying the deformation appear on the surface 22 of the skin 20 and there is a possibility that the appearance quality is deteriorated. Therefore, it is preferable to previously form a concave portion 72 into which the convex portion 71 of the distal end portion 41 is fitted in the skin 20.

(Third embodiment)
FIG. 8 is a cross-sectional view showing a main part of the instrument panel 13 according to the third embodiment. Members common to the first and second embodiments are denoted by the same reference numerals, and description thereof is partially omitted.

  The distal end portion 46 in the third embodiment is different from the first and second embodiments in that it is rotatably connected to the decorative panel 40 via a hinge portion 47.

  The skin 20 has a flange portion 23 provided at the end adjacent to the decorative panel 40 so as to protrude toward the core member 50. The front end portion 46 of the decorative panel 40 has a shape that is wound around the flange portion 23 by being pushed by the rib 52 and turning. In the illustrated example, the decorative panel 40 includes a surface portion 44, an inclined portion 45, a top portion 48 extending from the end portion of the inclined portion 45 so as to be substantially parallel to the surface portion 44, and a hinge portion at the end portion of the top portion 48. And a distal end portion 46 that is pivotably connected via 47.

  It is preferable that the flange part 23 of the skin 20 has a cross-sectional shape along the contour formed by the inclined part 45, the top part 48, and the tip part 46 of the decorative panel 40 (FIGS. 9 and 10 which are process drawings). See). As described in the first embodiment, it is for preventing wrinkles and the like accompanying deformation of the flange portion 23 from appearing on the surface 22 of the skin 20 and preventing deterioration in appearance quality.

  The flange portion 23 of the skin 20 is formed with end faces 24 and 25 that form a pair facing each other. The inclined portion 45 of the decorative panel 40 faces one end surface 24 of the flange portion 23, and the front end portion 46 of the decorative panel 40 faces the other end surface 25 of the flange portion 23. The pivotable tip 46 has a triangular cross section, and the rib 52 is in contact with one of the two surfaces 46a, 46b adjacent to the hinge 47 (referred to as the bottom surface) and the other surface 46b. (The contact surface) faces the other end surface 25 of the flange portion 23. The distal end portion 46 is pushed by the rib 52 and rotates, whereby the contact surface 46 b comes into close contact with the other end surface 25 of the flange portion 23 on the back surface 21 side of the skin 20. Thereby, the flange part 23 is pinched | interposed by the inclination part 45 of the decorating panel 40, the top part 48, and the contact surface 46b of the front-end | tip part 46. FIG.

  The rib 52 and the tip 46 are in contact with each other with an arbitrary angle α (see FIG. 11). When the distal end 46 rotates counterclockwise in FIG. 11 about the hinge 47 until the angle α becomes 0 degree, the contact surface 46b comes into close contact with the back surface 21 side (end surface 25) of the skin 20. It is set to do. Regardless of the position at which the rib 52 contacts the bottom surface 46a of the tip 46, the tip 46 always rotates until the angle α is 0 degrees. Thereby, the clearance gap between the skin 20 and the front-end | tip part 46 is always stabilized, the foam 60 can be sealed reliably, and the clearance gap and surface difference between the skin 20 and the decorating panel 40 reduce.

  A method for manufacturing the instrument panel 13 according to the third embodiment will be described.

  FIG. 9 is a cross-sectional view showing a state in which the skin 20 and the core material 50 are arranged on the opened mold 100. FIG. 10 further shows the decorative panel 40 as an insert member on the opened mold 100. It is sectional drawing which shows the state arrange | positioned. 11 is a cross-sectional view showing a state in which the rib 52 of the core member 50 is in contact with the bottom surface 46a of the front end portion 46 of the decorative panel 40. FIG. FIG. 13 is a perspective view showing the decorating panel 40 and the core member 50 in a mold-closed state, and FIG. 14 is a foam 60. It is sectional drawing which shows the process of filling.

  First, as shown in FIG. 9, the upper and lower molds 101 and 102 of the mold 100 are opened, the core material 50 is disposed on the upper mold 101, and the skin 20 is disposed on the lower mold 102. The skin 20 has a flange portion 23 provided so as to protrude toward the core member 50.

  Next, as shown in FIG. 10, the decorative panel 40 is further arranged on the lower mold 102 (arrangement step). The front end portion 46 of the decorative panel 40 has a shape that is wound around the flange portion 23 by being pushed by the rib 52 and turning. The decorative panel 40 includes a surface portion 44, an inclined portion 45, a top portion 48, and a tip portion 46 that is rotatably connected to an end portion of the top portion 48 via a hinge portion 47. As described above, the flange portion 23 of the skin 20 has a cross-sectional shape along the contour formed by the inclined portion 45, the top portion 48 and the tip portion 46 of the decorative panel 40.

  Next, as shown in FIG. 11, the mold 100 is closed, and the surface member 30 and the core material 50 are moved relatively close to each other. With this approaching movement, the ribs 52 of the core member 50 come into contact with the bottom surface 46 a of the front end portion 46 of the decorative panel 40. As shown in FIG. 12, when the upper mold 101 is further lowered, the rib 52 rotates the distal end portion 46 about the hinge portion 47, and the contact surface 46 b of the distal end portion 46 is the back surface 21 side (end surface) of the skin 20. 25) (sealing process). Thus, the lowering operation in which the rib 52 pushes down the distal end portion 46 is converted into the rotational operation of the distal end portion 46 with the hinge portion 47 as a fulcrum, and the contact surface 46b of the distal end portion 46 is changed to the back surface 21 side (end surface) 25). Thereby, the foam 60 can be reliably sealed, and the clearance gap and surface difference between the skin 20 and the decorating panel 40 reduce. As shown in FIG. 13, since the area of the end surface (bottom surface 46 a) with which the rib 52 contacts is larger than the cross-sectional area of the rib 52, the distal end portion 46 is placed on the back surface 21 side of the skin 20. It is possible to ensure close contact.

  Next, as shown in FIG. 14, the space between the surface member 30 and the core material 50 is filled with the foam 60 (filling step). In this filling step, the ribs 52 of the core member 50 are in contact with the front end portion 46 of the decorative panel 40, and the front end portion 46 is rotated and is in close contact with the back surface 21 side of the skin 20. By filling the foam 60 in this state, the foam 60 can be sealed. The foam 60 can be prevented from leaking to the surface 22 side through the gap between the skin 20 and the decorative panel 40, and as a result, the gap and surface difference between the skin 20 and the decorative panel 40 are reduced. To do.

  In the third embodiment, during the mold closing operation, the rib 52 has a mechanism that pushes down the distal end portion 46 so that the distal end portion 46 and the skin 20 are brought into close contact with each other. The setting is completed simply by placing 40 on the lower mold 102, so that the trouble of setting the parts can be saved and the variation of the parts set can be reduced.

(Fourth embodiment)
FIGS. 15A and 15B are cross-sectional views showing the main parts of the instrument panel 14 according to the fourth embodiment. Members common to the first to third embodiments are denoted by the same reference numerals, and description thereof is partially omitted.

  The distal end portion 46 and the skin 20 in the fourth embodiment are different from the third embodiment in that an uneven portion 70 that fits into each other is provided. The point which provides the uneven | corrugated | grooved part 70 is the same as that of 2nd Embodiment.

  In the example of illustration, the convex part 73 which protrudes toward the skin 20 is formed in the front-end | tip part 46 of the decorating panel 40, and the recessed part 74 in which the convex part 73 fits in the end surface 25 of the flange part 23 of the skin 20 is formed. Yes. By fitting the convex portion 73 and the concave portion 74 to each other, the decorative panel 40 and the skin 20 are difficult to move in a direction perpendicular to the paper surface of FIG. 15B, and the decorative panel is formed during or after molding. The positioning accuracy between 40 and the skin 20 is improved. The dimensional accuracy defect of the decorating panel 40 and the skin 20 and the set variation of the decorating panel 40 and the skin 20 at the time of insertion can be absorbed. As a result, the surface difference between the skin 20 and the decorating panel 40 is reduced.

  In addition, it is preferable to form the recessed part 74 in which the convex part 73 of the front-end | tip part 46 fits in the skin 20. As shown in FIG. This is because, as described in the second embodiment, wrinkles or the like accompanying deformation of the skin 20 are prevented from appearing on the surface 22 of the skin 20 and deterioration in appearance quality is prevented.

(Fifth embodiment)
FIG. 16 is a cross-sectional view showing a main part of the instrument panel 15 according to the fifth embodiment. Members common to the first to fourth embodiments are denoted by the same reference numerals, and description thereof is partially omitted.

  In 5th Embodiment, in addition to the rib 52 which adheres the front-end | tip part 46 to the back surface 21 side of the skin 20 by contacting the front-end | tip part 46 of the decorating panel 40, it contacts the top part 48 of the decorating panel 40. Thus, the fourth embodiment is different from the fourth embodiment in that a rib 53 is also provided to bring the top portion 48 into close contact with the back surface 21 side of the skin 20.

  Since the top 48 is brought into close contact with the back surface 21 side of the skin 20 by the rib 53 as well as the front end portion 46, the foam 60 leaks to the surface 22 side through the gap between the skin 20 and the decorative panel 40. As a result, the gap and surface difference between the skin 20 and the decorative panel 40 are further reduced.

(Sixth embodiment)
FIGS. 17A and 17B are cross-sectional views showing the main parts of the instrument panel 16 according to the sixth embodiment. Members common to the first to fifth embodiments are denoted by the same reference numerals, and description thereof is partially omitted.

  The rib 54 in the sixth embodiment is different from the fourth embodiment in that a small protrusion 55 is provided that is crushed when it contacts the tip 46 in an overloaded state. FIG. 17A shows a state before the small protrusion 55 is crushed, and FIG. 17B shows a state in which the small protrusion 55 is crushed because the rib 54 contacts the tip 46 in an overloaded state. .

  For the small protrusion 55, an appropriate shape material can be selected as long as it can be crushed when the rib 54 comes into contact with the tip 46 in an overloaded state. For example, a hook-like or loop widely used in a hook-and-loop fastener A protrusion raised in a shape can be applied.

  By providing the small protrusion 55 at the tip of the rib 54, an anti-slip effect between the rib 54 and the tip 46 is exhibited. Further, when the gap 56 is generated between the core material 50 and the upper mold 101 due to the deformation of the core material 50, the outer skin 20 and the distal end portion 46 are pressed against each other, causing strong interference. I may receive it. When such strong interference is applied, the small protrusion 55 is crushed so that the strong interference can be mitigated and an appearance abnormality can be prevented.

  When the core member 50 is set at a specified position and no gap 56 is formed between the core member 50 and the upper mold 101, the rib 54 pushes down the tip 46 without breaking the small protrusion 55. Rotate.

It is a perspective view which shows the instrument assembly provided with the instrument panel to which the foaming molding member of this invention is applied. It is sectional drawing which shows the principal part of the instrument panel which concerns on 1st Embodiment. It is sectional drawing which shows the state which has arrange | positioned the skin and the core material in the open mold. It is sectional drawing which shows the state which has further arrange | positioned the decoration panel which is an insert member to the open mold. It is sectional drawing which shows the sealing process which closes a shaping | molding die and adheres the front-end | tip part of a decorating panel to the back side of an outer skin. It is sectional drawing which shows the process of filling a foam. It is sectional drawing which shows the principal part of the instrument panel which concerns on 2nd Embodiment. It is sectional drawing which shows the principal part of the instrument panel which concerns on 3rd Embodiment. It is sectional drawing which shows the state which has arrange | positioned the skin and the core material in the open mold. It is sectional drawing which shows the state which has further arrange | positioned the decoration panel which is an insert member to the open mold. It is sectional drawing which shows the state which the rib of the core material contacted the bottom face of the front-end | tip part of a decorating panel. It is sectional drawing which shows the sealing process which closes a shaping | molding die and rotates the front-end | tip part of a decorating panel to the back side of an outer skin, and makes it closely_contact | adhere. It is a perspective view which shows the decorating panel and core material in a mold closed state. It is sectional drawing which shows the process of filling a foam. 15A and 15B are cross-sectional views showing the main parts of an instrument panel according to the fourth embodiment. It is sectional drawing which shows the principal part of the instrument panel which concerns on 5th Embodiment. FIGS. 17A and 17B are cross-sectional views showing the main parts of an instrument panel according to the sixth embodiment.

Explanation of symbols

10 Instrument assembly,
11-16 Instrument panel (foam molding member),
20 epidermis,
21 The back of the epidermis,
22 The surface of the epidermis,
23 flange part,
24 End face of flange,
25 End face of flange (back of skin),
30 Surface members (skin and insert members),
40 decorative panel (insert member),
41 tip,
42 side end face,
43 Surface of decorative panel,
44 Surface part,
45 Inclined part,
46 Tip,
46a The bottom of the tip,
46b The contact surface of the tip,
47 Hinge part,
48 Top,
50 core material,
51, 52, 53, 54 ribs,
55 Small protrusions,
60 foam,
70 Concavity and convexity,
71, 73 convex part,
72, 74 recess,
100 mold,
101 Upper mold,
102 Lower mold.

Claims (10)

The epidermis,
An insert member formed of a material harder than the skin and forming a surface member with the skin adjacent to the skin;
A core material facing the surface member;
A foam filled in a space between the surface member and the core;
Provided on the insert member, a tip portion overlapping the back side of the skin facing the core side,
A foam-molded member, comprising: a rib provided on the core member so as to project toward the surface member, and contacting the tip portion to bring the tip portion into close contact with the back side of the skin.   2. The foam molded member according to claim 1, wherein the distal end portion is rotatably connected to the insert member via a hinge portion, and is in close contact with the back side of the skin by being pushed and rotated by the rib.   The foam-molded member according to claim 1, wherein the distal end portion and the skin are provided with uneven portions that fit into each other.   The foam-molded member according to claim 1 or 2, wherein an area of an end face of the tip portion that contacts the rib is larger than a cross-sectional area of the rib.   The foam-molded member according to claim 1, wherein the insert member has a side end surface that contacts the skin at an acute angle with respect to the surface of the adjacent skin.   The foamed molded member according to claim 1 or 2, wherein the rib is provided with a small protrusion that is crushed when it contacts the tip end in an overloaded state. The skin has a flange portion provided to protrude toward the core material,
The foam-molded member according to claim 1, wherein the distal end portion has a shape extending along the flange portion. The skin has a flange portion provided to protrude toward the core material,
The foam molded member according to claim 2, wherein the distal end portion has a shape that is wound around the flange portion by being pushed and rotated by the rib. In an opened mold, an outer skin, an insert member formed of a material harder than the outer skin and forming a surface member with the outer skin adjacent to the outer skin, and a core material provided with ribs protruding therefrom A step of arranging the core material so as to face the surface member;
By closing the mold and moving the surface member and the core material relatively close to each other, the rib is formed on the tip portion that is provided on the insert member and overlaps the back side of the skin facing the core material side. A sealing step for bringing the tip portion into close contact with the back side of the epidermis,
Filling the space between the surface member and the core material with a foam.   The foaming according to claim 9, wherein, in the sealing step, the tip portion that is rotatably connected to the insert member via a hinge portion is pressed by the rib to be rotated, thereby being brought into close contact with the back side of the skin. Manufacturing method of molded member.

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