JP2009119755A - Skin molded article, method for molding skin molded article, and method for molding foamed molded member with skin - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a skin molded article capable of preventing appearance and quality of a foamed molded member with a skin as a product from decreasing by improving handling properties of the skin applied to the foamed molded member with the skin, a method for molding the skin molded article, and a method for molding the foamed molded member with the skin. <P>SOLUTION: The skin molded article 20 is used when the foamed molded member 10 with the skin having a core material 11, the skin 12 facing to the core material, and a foamed body 14 filled into a space 13 between the core material and the skin, is molded. This skin molded article has a skin part 30 forming the skin of the foamed molded member with the skin and an insert part 40 arranged around the skin part and being a frame shape for holding the skin part. The skin part and the insert part are integrated by a RIM molding. <P>COPYRIGHT: (C)2009,JPO&INPIT

Description

  The present invention relates to a skin molded product, a method for molding a skin molded product, and a method for molding a foam-molded member with a skin.

Interior parts used in automobiles and homes include a resin single-layer molded body type and a skin-molded molded body type. In recent years, among the latter, a foam-formed member with a skin having a three-layer structure of skin layer-foam layer-core material layer has been frequently used (see Patent Document 1). A flexible skin formed by RIM molding (reaction injection molding) is used for the skin layer.
JP 2001-145926 A

  Since the skin is very soft, the skin may be broken when the skin is handled or when the skin is set in a molding die for a foamed molded member with a skin. In such a case, there is a problem that creases remain on the surface of the foam-formed member with a skin as a product, and the appearance quality is deteriorated.

  The object of the present invention is to improve the handleability of the skin applied to the foam-formed member with skin, thereby preventing the deterioration of the appearance quality of the foam-formed member with skin as a product, and a method for molding the skin-molded product Another object of the present invention is to provide a method for forming a foamed molded member with a skin.

  In order to achieve the above object, a skin molded product of the present invention comprises a skin-molded foam-molded member having a core material, a skin facing the core material, and a foam filled in a space between the core material and the skin. A skin molded product used when molding, an skin part forming the skin of the foamed molded member with skin, and an insert part having a frame shape arranged around the skin part and holding the skin part, have. The skin portion and the insert part are integrated by RIM molding.

  In order to achieve the above object, a method for molding a skin molded product of the present invention comprises a core material, a skin facing the core material, and a foam with a skin that has a foam filled in a space between the core material and the skin. A method of molding a skin molded product used when molding a molded member, wherein a frame shape is formed on a RIM mold in which a cavity having an inner surface shape that matches the outer shape of the skin of the foamed molded member with the skin is formed. A step of setting an insert part to be formed, and a RIM molding using a RIM molding material for forming the skin, and a skin part forming the skin of the foamed molded member with the skin and the insert part holding the skin part. And integrating them.

  In order to achieve the above object, a method for molding a foamed molded member with a skin of the present invention comprises a core material, a skin facing the core material, and a foam filled in a space between the core material and the skin. A method for forming a foam-molded member with a skin, wherein a skin part forming the skin of the foam-molded member with skin is formed on a molding die in which a cavity having an inner surface shape that matches the outer shape of the foam-molded member with skin is formed, and A step of setting a skin molded product in which an insert part having a frame shape arranged around the skin portion and holding the skin portion is integrated by RIM molding, and a core so as to face the skin molded product in the mold A step of setting a material, and a step of filling a space between the skin molded product and the core material with a foam.

  According to the skin molded product of the present invention, when the skin molded product is handled or when the skin molded product is set in the molding die of the foamed molded member with the skin, the insert part can be gripped to perform the work. The problem that the skin part breaks does not occur. Therefore, according to the skin molded product of the present invention, the handleability of the skin applied to the foamed molded member with a skin can be improved, and the appearance quality of the foamed molded member with a skin as a product can be prevented from being deteriorated.

  According to the method for molding a skin molded product of the present invention, by obtaining the above skin molded product, the handleability of the skin applied to the foamed molded member with a skin can be improved, and the foamed molded member with a skin as a product. It is possible to prevent deterioration of the appearance quality.

  According to the method for molding a foam-formed member with a skin of the present invention, by integrating the core material, the skin-molded product and the foam, the handleability of the skin applied to the foam-formed member with a skin can be improved, It is possible to prevent deterioration of the appearance quality of the foamed molded member with a skin as a product.

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

  FIG. 1 (A) is a cross-sectional view showing a foam-formed member 10 with a skin formed by applying the present invention, and FIG. 1 (B) is an integrated core 11 and skin-molded product before a trimming step. It is sectional drawing which shows 20 and the foam 14.

  With reference to FIG. 1 (A), the foamed molded member 10 with a skin is applied to automotive interior parts such as a door trim, for example. The foam-equipped molded member 10 has a core material 11, a skin 12 facing the core material 11, and a foam 14 filled in a space 13 between the core material 11 and the skin 12. The inner surface of the core 11 is integrated with the skin 12 by the foam 14. The skin 12 forms the surface of an automobile interior part. A known material can be appropriately selected for each of the core material 11 and the foam 14. For example, as the material of the core material 11, polypropylene resin (PP), acrylonitrile / butadiene / styrene resin (ABS), or the like can be used. For example, a foamed polyurethane resin can be used for the foam 14. Although the skin 12 can be applied with RIM molding or vacuum molding, in this embodiment, the skin 12 is formed by RIM molding using a polyurethane resin (corresponding to a RIM molding material). The RIM molding material in the present invention is not intended to be limited to the polyurethane resin, and other molding materials may be used.

  FIG. 1B is a cross-sectional view showing a state in which the process of filling the foam 14 is completed and the integrated core material 11, the skin molded product 20 and the foam 14 are taken out from the mold 200 (see FIG. 8). FIG. As shown in the figure, in the present embodiment, a skin molded product 20 is used when the foamed molded member with skin 10 is molded.

  2A is a perspective view showing a skin molded product 20 used when molding the foamed molded member 10 with skin, and FIG. 2B is a cross-sectional view taken along line 2B-2B of FIG. 2A. It is. 3A is a perspective view showing the insert part 40 of the skin molded product 20, and FIG. 3B is a cross-sectional view taken along line 3B-3B of FIG. 3A. 4 is a cross-sectional view conceptually showing a state in which the skin molded product 20 is housed in the rack 61, and FIG. 5 is a cross-sectional view conceptually showing a state in which the skin molded product 20 is stacked and stocked. 6 is a perspective view showing a state in which the insert part 40 is set in the RIM mold 100 for molding the skin molded product 20, and FIG. 7 shows a state in which the upper and lower molds 101 and 102 are closed from the state shown in FIG. It is sectional drawing.

  Referring to FIGS. 2 and 3, skin molded product 20 is used when molding foamed molded member 10 with skin, and skin part 30 that forms skin 12 of foamed molded member 10 with skin, And an insert part 40 having a frame shape that is arranged around and holds the skin part 30, and the skin part 30 and the insert part 40 are integrated by RIM molding.

  The insert part 40 has a plate shape with an opening 41 formed in the center. A step portion 42 is formed around the opening 41. A passage portion 43 that communicates with the gate 106 and introduces the RIM molding material when the RIM molding die 100 (see FIG. 6) is set is formed in a part of the insert part 40. In the illustrated example, the insert part 40 has a rectangular frame shape such as a frame. However, the insert part 40 only needs to have a shape that can hold the skin portion 30, and is not limited to a closed shape such as a rectangular frame shape. For example, if the skin portion 30 has a rectangular shape, a frame shape that holds at least three sides around the skin portion 30, that is, a “U” shape may be used.

  The insert part 40 has a protrusion 44 that determines a position when the insert part 40 is set in the mold 200 of the foamed molded member 10 with a skin. One surface 45a (the upper surface in the figure) on the side where the RIM molding material flows out of both surfaces of the insert part 40 is formed as a flat surface. The protrusions 44 are provided on the other surface 45b (the lower surface in the drawing) of the both sides of the insert part 40 on the side where the RIM molding material does not flow. In the following description, for convenience of explanation, one surface of the both sides of the insert part 40 on the side on which the RIM molding material flows is also referred to as “surface 45a”. The other surface is also referred to as “back surface 45b”.

  The protrusion 44 is also used as a protrusion that determines the position of the insert part 40 when it is set in the RIM mold 100 (see FIG. 7). The structure of the insert part 40 can be simplified by using the RIM mold 100 and the member for determining the position of the insert part 40 with respect to the mold 200 of the foamed molding member 10 with the skin.

  The skin molded product 20 has a stopper portion 50 that joins the skin portion 30 and the insert part 40. In the insert part 40, a large number of through holes 46 penetrating from the front surface 45a to the back surface 45b are formed. The through hole 46 is formed in the step portion 42. The stopper part 50 is formed by the RIM molding material flowing out through the through hole 46 to the back surface 45b side. The stopper portion 50 has a size larger than that of the through hole 46. The insert part 40 has a non-adhesive configuration with respect to the RIM molding material. For example, the insert part 40 is made of polypropylene or a metal whose outer surface is coated with fluorine resin or silicon. By providing the stopper part 50, the skin part 30 and the insert part 40 can be joined even if the insert part 40 is a non-adhesive structure with respect to the RIM molding material.

  The skin part 30 and the insert part 40 are separable by removing the stopper part 50 (refer FIG. 13 mentioned later). The stopper 50 can be easily removed by cutting. The insert part 40 separated from the skin part 30 is configured to be reusable. Since the insert part 40 has a non-adhesive structure with respect to the RIM molding material, the skin part 30 can be easily peeled off and separated from the insert part 40, and the separated insert part 40 can be easily reused.

  Referring to FIG. 4, when the skin molded product 20 is stored in the rack 61, the periphery of the insert part 40 can function as a guide when stored in the rack 61. The skin molded product 20 can be easily stored in the rack 61 and can be easily taken out. Moreover, since the skin parts 30 do not adhere to each other, damage to the skin parts 30 can be prevented.

  With reference to FIG. 5, when stacking and stocking the skin molded product 20, the protrusions 44 of the insert part 40 function as spacers that prevent the skin portions 30 adjacent in the stacking direction from adhering to each other. Can do. Since the skin portions 30 do not adhere to each other, the skin portion 30 can be prevented from being damaged, and the skin molded product 20 can be easily taken out. Reference numeral 62 in the figure indicates a collar for adjusting a gap between the projection 44 having a low height shown on the right side in the figure and the insert component 40 on the lower side.

  Next, the manufacturing method of the skin molded product 20 will be described.

  Referring to FIGS. 6 and 7, when RIM molding of skin molded product 20, RIM mold 100 in which cavity 103 having an inner surface shape that matches the outer shape of skin 12 of foam molded member 10 with a skin is formed. Is used. The RIM mold 100 has an upper mold 101 and a lower mold 102 that are relatively close to and away from each other. By closing the upper mold 101 and the lower mold 102, a cavity 103 that matches the shape of the skin 12 is formed. The insert part 40 is set on the lower mold 102. The lower mold 102 is formed with an engagement hole 104 into which the protrusion 44 of the insert part 40 is fitted. The lower mold 102 is formed with a concave portion 105 having an inner surface shape that matches the outer shape of the stopper portion 50 in accordance with the position of the through hole 46 of the insert part 40.

  First, as shown in FIG. 6, the upper mold 101 and the lower mold 102 are relatively opened. The insert part 40 having a frame shape is set on the lower mold 102 (setting step). The insert part 40 is set on the lower mold 102 so that the passage portion 43 communicates with the gate 106.

  In the setting step, the position when setting in the RIM mold 100 is determined by using the protrusion 44 that is provided in the insert part 40 and determines the position when setting in the mold 200 of the foamed molded member 10 with skin. That is, the protrusion 44 is also used as a protrusion that determines the position of the insert part 40 when it is set in the RIM mold 100. The structure of the insert part 40 can be simplified by using the RIM mold 100 and the member for determining the position of the insert part 40 with respect to the mold 200 of the foamed molding member 10 with the skin. In the insert part 40, the surface 45a on the side on which the RIM molding material flows is formed as a flat surface, and the protrusion 44 is provided on the back surface 45b on the side on which the RIM molding material does not flow.

  Next, as shown in FIG. 7, the upper mold 101 and the lower mold 102 are relatively closed. The gate 106 communicates with the cavity 103 through the passage portion 43. RIM molding is performed using a RIM molding material for forming the skin 12. The RIM molding material is injected into the cavity 103 through the gate 106 and the passage portion 43. Thereby, the skin part 30 which forms the skin 12 of the foam-molded member 10 with skin and the insert part 40 which holds the skin part 30 are integrated (RIM process).

  As described above, the insert part 40 has the front surface 45a formed on a flat surface and the protrusion 44 provided on the back surface 45b. In the case where the insert part 40 is not used as in the present embodiment, an uneven shape for determining the position of the foamed molded member 10 with the skin relative to the molding die 200 must be imparted to the skin itself. The flow of the RIM molding material is disturbed by the uneven shape of the mold, and there is a possibility that voids are generated by entraining air. Generation | occurrence | production of a void will cause the fall of the external appearance quality of an epidermis.

  On the other hand, in this embodiment, since the protrusion 44 for positioning is formed in the insert part 40, it is not necessary to give the uneven | corrugated shape for positioning to the skin part 30 itself which makes the skin 12. FIG. Therefore, the surface 45a of the insert part 40 can be formed into a flat surface so that the flow of the RIM molding material is not disturbed. Thereby, generation | occurrence | production of a void can be prevented and the fall of the external appearance quality of the skin 12 can be prevented.

  In the RIM process, the RIM molding material flows out through the through hole 46 penetrating from the front surface 45 a to the back surface 45 b of the insert part 40 to the back surface 45 b side and flows into the recess 105 of the lower mold 102. Thus, the stopper portion 50 having a size larger than the through hole 46 is formed. Although the insert part 40 is a non-adhesive structure with respect to the RIM molding material, the skin part 30 and the insert part 40 can be joined together by the stopper part 50.

  The skin part 30 and the insert part 40 can be separated by removing the stopper part 50. Since the insert part 40 has a non-adhesive structure with respect to the RIM molding material, the skin part 30 can be easily peeled off and separated from the insert part 40, and the separated insert part 40 can be easily reused. For this reason, the insert part 40 set this time uses an insert part provided for reuse.

  Next, the manufacturing method of the foam-formed member 10 with the skin using the skin molded product 20 will be described.

  FIG. 8 is a perspective view showing a molding die 200, a core material 11, and a skin molding product 20 for molding the foamed molded member 10 with a skin, and FIG. 9 shows that the core material 11 and the skin molding product 20 are set in the molding die 200. 10 is a cross-sectional view showing a state in which the space 13 between the skin molded product 20 and the core material 11 is filled with the foam 14, and FIG. 11 is an integrated core material 11 and skin. 12A is a cross-sectional view showing a state in which the molded product 20 and the foamed body 14 are trimmed, FIG. 12A is a perspective view showing an end material 70 removed from the foamed molded member 10 with a skin as a product, and FIG. 12A is a cross-sectional view taken along the line 12B-12B in FIG. 12A, and FIG. 13 is a cross-sectional view showing a state in which the peripheral portion 31 of the skin portion 30 and the insert part 40 in the end material 70 are separated.

  With reference to FIGS. 8 and 9, when molding the foamed molded member 10 with skin, a molding die 200 in which a cavity having an inner surface shape that matches the outer shape of the foamed molded member 10 with skin is used. The mold 200 includes an upper mold 201 and a lower mold 202 that are relatively close to and away from each other. By closing the upper mold 201 and the lower mold 202, a cavity 203 that matches the shape of the foamed molded member with skin 10 is formed. The core material 11 is set on the upper mold 201. The skin molded product 20 is set in the lower mold 202. The lower mold 202 is formed with an engagement hole 204 into which the protrusion 44 of the insert part 40 of the skin molded product 20 is fitted.

  First, as shown in FIG. 8, the upper mold 201 and the lower mold 202 are relatively opened. The core material 11 is set on the upper mold 201, and the skin molded product 20 is set on the lower mold 202 (set process of the skin molded product 20). As described above, the skin molded product 20 includes the skin part 30 that forms the skin 12 of the foamed molded member 10 with skin, and the insert part 40 that is arranged around the skin part 30 and has a frame shape that holds the skin part 30 is RIM. It is integrated by molding.

  In the setting process of the skin molded product 20, the position for setting the molding die 200 is determined using the protrusions 44 provided on the insert part 40.

  In the skin molded product 20, a frame-shaped insert part 40 holds the skin portion 30 that forms the skin 12. For this reason, when the skin molded product 20 is handled or when the skin molded product 20 is set in the molding die 200, the insert part 40 can be gripped and the work can be performed, and the skin 12 is broken. It does not occur. Therefore, the handleability of the skin 12 applied to the foam-formed member with skin 10 can be improved, and the appearance quality of the foam-formed member 10 with skin as a product can be prevented from being deteriorated.

  Furthermore, the position of the skin molded product 20 when set in the mold 200 is determined by the protrusion 44 of the insert part 40. For this reason, the position of the skin portion 30 with respect to the molding die 200, and hence the position of the skin 12 does not vary from shot to shot, and the occurrence of wrinkles and bumps on the skin 12 after molding can be prevented.

  Next, the core material 11 is set on the molding die 200 so as to face the skin molded product 20 (step of setting the core material 11).

  Next, as shown in FIG. 9, the upper mold 201 and the lower mold 202 are relatively closed. Next, as shown in FIG. 10, the foam 14 is filled into the space 13 between the skin molded product 20 and the core material 11 (filling step). Thereby, the core material 11, the skin molded product 20, and the foam 14 are integrated. For convenience of explanation, the core material 11, the skin molded product 20, and the foam 14 that are integrated are also referred to as “intermediate molded product”.

  Next, as shown in FIGS. 11 and 12, the intermediate molded product is taken out from the molding die 200 (see FIG. 1), the periphery of the skin portion 30 of the skin molded product 20 is trimmed, and the foamed molded member 10 with the skin as a product is obtained. The end material 70 in which the peripheral remaining portion 31 of the skin portion 30 and the insert part 40 are integrated is removed (trimming step). Trimming is performed by setting it on a dedicated trimming jig 300. As the trimming jig 300, for example, a hot blade punching jig provided with a hot blade 301 is used. As another trimming method, it is also possible to apply a water jet.

  Next, as shown in FIG. 13, the stopper portion 50 that detachably joins the peripheral portion 31 of the skin portion 30 and the insert part 40 in the end material 70 is removed. The stopper 50 is removed using a cutting tool such as a nipper. The peripheral part 31 of the skin part 30 can be easily peeled off and separated from the insert part 40, and the separated insert part 40 can be easily reused for molding another skin molded product 20. The skin molded product 20 set this time uses insert parts that have been reused.

  As described above, the skin molded product 20 of the present embodiment has a skin portion 30 that forms the skin 12 of the foamed molded member 10 with a skin, and a frame shape that is disposed around the skin portion 30 and holds the skin portion 30. Since the skin part 30 and the insert part 40 are integrated by RIM molding, when the skin molded product 20 is handled or the skin molded product 20 is molded into the foamed molded member 10 with the skin. When setting to 200, etc., the insert part 40 can be grasped and work can be performed, and the trouble that the skin part 30 is broken does not occur. Therefore, according to said skin molded product 20, the handleability of the skin 12 applied to the foamed molded member 10 with a skin can be improved, and the deterioration of the appearance quality of the foamed molded member 10 with a skin as a product can be prevented. Can do.

  The insert part 40 has a protrusion 44 that determines a position when the foam-molded member 10 with a skin is set in the mold 200, the surface 45 a of the insert part 40 is formed on a flat surface, and the protrusion 44 is formed on the insert part 40. Since it is provided on the back surface 45b, it is not necessary to give the uneven shape for positioning to the skin portion 30 itself forming the skin 12. Therefore, the surface 45a of the insert part 40 can be formed into a flat surface so that the flow of the RIM molding material is not disturbed. Thereby, generation | occurrence | production of a void can be prevented and the fall of the external appearance quality of the skin part 30 and by extension, the skin 12 can be prevented.

  Since the projecting portion 44 of the insert component 40 is also used as the projecting portion 44 that determines the position of the insert component 40 when the insert component 40 is set in the RIM mold 100, the insert portion 40 is inserted in comparison with the case where a member for positioning is provided separately. The configuration of the component 40 can be simplified.

  The skin molded product 20 is formed by inserting a through hole 46 formed in the insert part 40 from the front surface 45a to the back surface 45b and flowing out of the RIM molding material to the back surface 45b through the through hole 46, and is larger than the through hole 46. Since the stopper part 50 having a size and joining the skin part 30 and the insert part 40 is provided, even if the insert part 40 is configured to be non-adhesive to the RIM molding material, the stopper part 50 is provided. Thus, the skin portion 30 and the insert part 40 can be joined together.

  The skin part 30 and the insert part 40 are separable by removing the stopper part 50, and the insert part 40 is configured to be reusable. Therefore, the skin part 30 is easily peeled off from the insert part 40 and separated. The separated insert part 40 can be easily reused.

  The periphery of the insert part 40 functions as a guide when the rack 61 is accommodated, or when the protrusions 44 of the insert part 40 stack and stock the skin molded product 20, the skin parts 30 adjacent in the stacking direction are adjacent to each other. Since it functions as a spacer for preventing adhesion, the skin molded product 20 can be easily stored, and the skin portions 30 do not adhere to each other, so that damage to the skin portion 30 can be prevented.

  In addition, the molding method of the skin molded product 20 of the present embodiment is the insert component having a frame shape in the RIM mold 100 in which the cavity of the inner surface shape that matches the outer shape of the skin 12 of the foam molded member 10 with the skin is formed. 40, the RIM molding using the RIM molding material for forming the skin 12, and the skin part 30 forming the skin 12 of the foamed molded member 10 with the skin and the insert part 40 for holding the skin part 30 are integrated. Therefore, it is possible to obtain the skin molded product 20 having the above-described characteristic actions and effects. By obtaining the skin molded product 20, it is possible to improve the handleability of the skin 12 applied to the foamed molded member 10 with a skin, and to prevent the appearance quality of the foamed molded member 10 with a skin from being deteriorated.

  In the step of setting the insert part 40 in the RIM mold 100, the protrusion part 44 that is provided in the insert part 40 and determines the position when being set in the mold 200 of the foamed molded member 10 with the skin is used for the RIM mold 100. Since the position for setting is determined, the configuration of the insert part 40 can be simplified as described above. In addition, since the insert part 40 is formed with a flat surface 45a and a projection 44 on the back surface 45b, the skin part 30 forming the skin 12 itself has an uneven shape for positioning as described above. Therefore, it is possible to prevent the flow of the RIM molding material from being disturbed. Thereby, generation | occurrence | production of a void can be prevented and the fall of the external appearance quality of the skin part 30 and by extension, the skin 12 can be prevented.

  In addition, the molding method of the skin-equipped foam-molded member 10 of the present embodiment includes a step of setting the skin-molded product 20 in the molding die 200 of the skin-molded foam-molded member 10 and a mold 200 facing the skin-molded product 20. Since it has the process of setting the core material 11, and the process of filling the space 14 between the skin molded product 20 and the core material 11 with the foam 14, the core material 11, the skin molded product 20 and the foam 14 are Integrate. At this time, in the skin molded product 20, the frame-shaped insert part 40 holds the skin portion 30 forming the skin 12, and therefore, when the skin molded product 20 is handled or the skin molded product 20 is set in the molding die 200. In some cases, the work can be performed by holding the insert part 40, and the problem that the skin 12 is broken does not occur. Therefore, the handleability of the skin 12 applied to the foam-formed member with skin 10 can be improved, and deterioration of the appearance quality of the foam-formed member 10 with skin as a product can be prevented.

  In the step of setting the skin molding product 20 on the molding die 200, the position when setting on the molding die 200 is determined by using the projections 44 provided on the insert part 40, so the skin portion 30 with respect to the molding die 200 is determined. Thus, the position of the skin 12 does not vary from shot to shot, and the formation of wrinkles and bumps on the skin 12 after molding can be prevented.

  The core 11, the skin molded product 20 and the foam 14 that are integrated are taken out from the molding die 200, the periphery of the skin portion 30 of the skin molded product 20 is trimmed, and the foamed molded member 10 with the skin as the product is left. The trimming step of removing the end material 70 in which the peripheral remaining portion 31 of the skin portion 30 and the insert part 40 are integrated is further provided. Thereby, the foam-formed member 10 with a skin as a product is obtained.

  The peripheral portion 31 of the skin portion 30 and the insert component 40 in the end material 70 are removed so as to be separable, and the peripheral portion 31 of the skin portion 30 can be easily peeled off and separated from the insert component 40. The separated insert part 40 can be easily reused for molding other skin molded products 20. Since only the peripheral portion 31 around the skin portion 30 is trimmed and becomes waste, compared to the case where the reusable insert part 40 is not used, the waste of the material forming the skin 12 is reduced, and the material Yield can be increased.

FIG. 1 (A) is a cross-sectional view showing a foam-formed member with a skin formed by applying the present invention, and FIG. 1 (B) is an integrated core, skin-formed product, and foam before the trimming step. It is sectional drawing which shows a body. FIG. 2A is a perspective view showing a skin-molded product used when molding a foam-formed member with a skin, and FIG. 2B is a cross-sectional view taken along line 2B-2B in FIG. . FIG. 3A is a perspective view showing an insert part of a skin molded product, and FIG. 3B is a cross-sectional view taken along line 3B-3B in FIG. It is sectional drawing which shows notionally the state which accommodated the skin molded product in the rack. It is sectional drawing which shows notionally the state which laminated | stacked and stocked the skin molded product. It is a perspective view which shows the state which set the insert components to the RIM shaping | molding die which shape | molds a skin molded product. It is sectional drawing which shows the state which closed the up-and-down type | mold from the state shown in FIG. It is a perspective view which shows the shaping | molding die which shape | molds a foaming molding member with a skin, a core material, and a skin molded product. It is sectional drawing which shows the state which set the core material and the skin molded product to the shaping | molding die. It is sectional drawing which shows the state which filled the space between a skin molded product and a core material with the foam. It is sectional drawing which shows the state which trims the core material, skin molded product, and foam which were united. FIG. 12A is a perspective view showing an end material removed from a foam-formed member with a skin as a product, and FIG. 12B is a cross-sectional view taken along the line 12B-12B in FIG. It is sectional drawing which shows the state which isolate | separated the circumference | surroundings remainder of the skin part in an end material, and insert components.

Explanation of symbols

10 Foam molded member with skin,
11 Core material,
12 epidermis,
13 space,
14 foam,
20 skin molded product,
30 epidermis,
31 The remainder around the epidermis,
40 insert parts,
41 opening,
42 steps,
43 passage part,
44 protrusions,
45a surface (one surface on which the RIM molding material flows),
45b Back side (the other side where the RIM molding material does not flow),
46 Through hole,
50 stopper,
61 racks,
62 colors,
70 mill ends,
100 RIM mold,
101 Upper mold,
102 Lower mold,
103 cavities,
104 engagement hole,
105 recess,
106 gates,
200 Mold for foamed molded member with skin,
201 Upper mold,
202 Lower mold,
203 cavity,
204 engagement hole,
300 Trimming jig,
301 Hot blade.

Claims (15)

A skin molded product used when molding a foamed molded member with a skin having a core material, a skin facing the core material, and a foam filled in a space between the core material and the skin,
A skin part forming the skin of the foamed molded member with the skin;
An insert part having a frame shape arranged around the skin part and holding the skin part,
A skin molded product in which the skin portion and the insert part are integrated by RIM molding. The insert part has a protrusion that determines the position when set in a molding die of the foamed molded member with skin,
One of the surfaces of the insert part on which the RIM molding material flows is formed as a flat surface,
The skin-molded product according to claim 1, wherein the protrusion is provided on the other surface of the insert part on the side where the RIM molding material does not flow.   The skin-molded product according to claim 2, wherein the protrusion is also used as a protrusion that determines the position of the insert part when the protrusion is set in a RIM mold. A through-hole formed in the insert part and penetrating from one surface where the RIM molding material flows to the other surface where the RIM molding material does not flow;
A stopper part that is formed by the RIM molding material flowing out to the other surface through the through hole and has a size larger than the through hole and that joins the skin part and the insert part; ,
The skin molded article according to any one of claims 1 to 3, wherein the insert part has a non-adhesive configuration with respect to the RIM molding material. The skin part and the insert part are separable by removing the stopper part,
The skin molded product according to claim 4, wherein the insert part is configured to be reusable.   The skin molded product according to any one of claims 1 to 5, wherein a periphery of the insert part functions as a guide when stored in a rack.   The skin molded product according to claim 2, wherein the protrusion of the insert part functions as a spacer that prevents the skin portions adjacent in the stacking direction from adhering to each other when the skin molded product is stacked and stocked. . A method for molding a skin molded product used when molding a foam-formed member with a skin having a core material, a skin facing the core material, and a foam filled in a space between the core material and the skin. ,
A step of setting an insert part having a frame shape in a RIM mold in which a cavity having an inner surface shape that matches the outer shape of the skin of the foamed molded member with the skin is formed;
RIM molding using the RIM molding material for forming the skin, and integrating the skin part forming the skin of the foamed molded member with the skin and the insert part holding the skin part, Molding method for molded products. In the step of setting the insert part in the RIM mold, when the insert part is set in the RIM mold using a protrusion provided on the insert part and defining a position when the insert part is set in the foam mold member with skin The position of
One of the surfaces of the insert part on which the RIM molding material flows is formed as a flat surface,
The method for molding a skin molded product according to claim 8, wherein the protrusion is provided on the other surface of the insert part on the side where the RIM molding material does not flow. The RIM molding material flows out to the side of the other surface through a through hole formed in the insert part that penetrates from one surface where the RIM molding material flows to the other surface where the RIM molding material does not flow. By forming a stopper portion having a size larger than the through hole, joining the skin portion and the insert component,
The method for molding a skin molded product according to claim 8 or 9, wherein the insert part has a non-adhesive configuration with respect to the RIM molding material. The skin part and the insert part are separable by removing the stopper part,
The method for molding a skin molded article according to claim 10, wherein the insert part is an insert part that has been reused. A molding method for a foam-formed member with a skin, comprising a core material, a skin facing the core material, and a foam filled in a space between the core material and the skin,
In a mold in which a cavity having an inner surface shape that matches the outer shape of the foam-formed member with skin is formed, the skin part forming the skin of the foam-formed member with skin and the skin part disposed around the skin part A step of setting a skin molded product in which an insert part having a frame shape to be held is integrated by RIM molding;
A step of setting a core material to face the skin molded product in the mold;
And a step of filling the space between the skin molded product and the core material with a foam.   The foam-molding with a skin according to claim 12, wherein in the step of setting the skin-molded product on the molding die, a position when the skin-molding product is set on the molding die is determined using a protrusion provided on the insert part. A method for forming a member.   Taking out the core material, the skin molded product and the foamed body from the mold, trimming the periphery of the skin portion of the skin molded product, leaving a foamed molded member with a skin as a product, The molding method of the foam-molded member with a skin according to claim 12 or 13, further comprising a trimming step of removing an end material in which a peripheral remaining portion of the skin portion and the insert part are integrated.   15. The stopper part which detachably joins the peripheral part of the skin part and the insert part in the end material is removed, and the insert part is reused for molding another skin molded product. The molding method of the foaming molding member with a description of description.

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