JP2009226889A - Injection foaming molded article, injection foaming mold, and manufacturing method of injection foaming molded article - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide an injection foaming molded article composed to be easily and surely molded to have good appearance of end edges with simple configuration, and an injection foaming mold and a manufacturing method of the injection foaming molded article with good appearance of the end edges. <P>SOLUTION: A base material 1 having a protrusion 5 at the corner part of the surface 1a of an end part is molded, a cavity 18 is formed by a second mold 12 and a third mold 13 holding the base material 1, and materials of a facing and a foaming material 4 are injected and filled into the cavity at given pressure. Part of the materials of the facing and foaming material 4 in contact with the third mold 13 is solidified to form a facing layer 2 and the third mold 13 is subjected to core-back to form a foaming layer 3 to the integrated part 4b. A winding part 4a is molded relatively thin only by the facing layer 2. Thus, the winding part 4a can be wound and joined to an end part rear face 1b of the base material 1 with good appearance. <P>COPYRIGHT: (C)2010,JPO&INPIT

Description

  The present invention relates to an injection foam molded product, an injection foam molding die, and a method for manufacturing an injection foam molded product. More specifically, the present invention includes a base material, a skin layer and a foam layer, and is integrally molded with the base material by injection foam molding. The enveloping part formed by extending and forming the edge of the epidermis / foaming material from the end part of the base material is entrained and joined to the back surface of the base material. The present invention relates to an injection foam molded article, an injection foam mold for molding such an injection foam molded article, and a method for producing such an injection foam molded article.

  Conventionally, a base material and a skin material are integrally formed and the skin material is wound around an end portion of the base material (for example, Patent Document 1). Patent Document 1 relates to an apparatus for integrally forming a skin that eliminates an appearance defect that occurs when a base material terminal formed by simultaneously molding a base material made of a resin and a skin material with the skin material.

  In Patent Document 1, a skin is integrally formed by forming a cavity with opposing first and second molds, placing a skin material between the opposing molds, and then injecting molten resin and clamping the mold. An apparatus, wherein the first mold and the second mold are clamped to form a shear edge at the outer peripheral contact portion of the first mold and the second mold, and the cavity is formed Of the first and second molds, the end of the male mold has a predetermined angle from the abutting surface that forms the cavity by abutting with the other mold when clamping, and is directed toward the other mold facing the mold. A skin integrated molding apparatus is disclosed, in which a step of about 0.5 to 1.0 mm is provided, and a round-shaped recess is formed from the step.

  Further, Patent Document 1 discloses a skin integral molding in which a cavity is formed by opposed male and female molds, and a skin material is placed between the opposed molds, and then a molten resin is injected and clamped. In the apparatus, a slide mold is formed on the outer periphery of the male mold, and the slide mold has a support portion for holding the skin material outside the cavity of the female mold when the mold is clamped, and a protrusion protruding from the support portion toward the cavity side. A skin integrated molding apparatus is disclosed, in which a step having a height of about 0.5 to 1.0 mm and a concave portion including at least a rounded top from the step are provided.

  Furthermore, for example, in an interior product such as an instrument panel or a door trim of an automobile, a foam layer serving as a cushioning material is provided on the surface of a base material that retains its shape by having a predetermined rigidity (having shape retention). An injection foam molded product is used in which the skin layers constituting the design surface are integrally laminated. In addition, in order to improve the appearance of such an injection-foamed molded product used as an interior product, in the conventional technology, the skin / foam material composed of the skin layer and the foam layer is projected from the end of the base material. In such a case, the rolled portion is formed into an entrained portion, and the entrained portion is wound around the back surface of the base material and joined by welding or the like.

That is, when molding such an injection foam molded article, first, as shown in FIG. 7, the cavity 14 ′ is formed by the first molds 11 ′ and 12 ′, and the melted base material 1 ′ is formed.
The material 1 is injected and filled into the cavity 14 'to form the substrate 1'. Then, the mold 11 ′ is released from the front surface 1a ′ side of the base material 1 ′, the back surface 1b ′ side is held by the mold 12 ′, and the mold 12 ′ and the mold 13 ′ are brought into contact with each other. At this time, the cavity 18 ′ includes an integral part molding portion 18b ′ for integrally molding the skin / foaming material 4 ′ with the base material 1 ′ by the mold 12 ′ and the mold 13 ′ holding the base material 1 ′. And a winding portion molding portion 18a ′ for molding the winding portion 4a ′ so as to extend from the end portion of the substrate 1 ′. When the melted skin / foam material is injected and filled at a predetermined pressure in the cavity 18 ′, as shown in FIG. 8, it contacts the mold 13 ′ of the material of the skin / foam 4 ′. The portion is cooled and solidified to form a skin layer (also called a skin layer) 2 ′ having a predetermined thickness. On the other hand, the portion between the portion of the skin / foaming material 4 ′ where the skin layer 2 ′ is formed and the mold 12 ′ holding the base material 1 is not yet solidified and remains in a molten state. ing. In this state, as shown by the arrows in FIG. 9, when the molds 12 'and 13' are slightly opened and the core is backed, the portion where the skin layer 2 'of the material of the skin / foam 4' is formed and the substrate 1 In the portion between the mold 12 and the 'holding mold 12', the pressure at the time of injection filling is released and foamed to form the foamed layer 3 '. The skin / foaming material 4 ′ includes an integrated part 4 b ′ laminated and integrated with the base material 1 ′, and a winding part 4 a ′ extended from the end of the base material 1 ′. As shown in FIG. 10, the winding portion 4 a ′ is wound on the back surface 1 b ′ side of the base material 1 ′ and joined to the base material 1 ′ in a later step.

JP-A-8-183063

  However, among the above conventional techniques, in Patent Document 1, a skin material is disposed in a cavity and a base material is integrally formed with the skin material. The material is not integrally molded, and the skin material is not foamed.

  Further, in the prior art shown in FIGS. 7 to 10, the skin / foaming material 4 ′ includes not only the integral part 4b ′ but also the entrained part 4a ′, and the foam layer 3 ′ is formed on the whole. The winding portion 4a 'was thick ((a) of FIG. 10). For this reason, as shown in FIG. 10 (b), the radius of the portion (part corresponding to the end surface of the base material 1 ′) that is bent to be wound around the back surface 1b ′ of the base material 1 ′ is increased, and the end surface of the base material 1 ′ is increased. There is a problem that it is difficult to form the edge of the injection foam molded article with good appearance and to reliably entrain and join it, such as forming a gap without being in close contact with the adhesive. In the conventional technique, it is necessary to attach another member such as a cover in order to cover the edge that does not look good, and there is a problem that it takes time and cost.

The present invention has been made in view of the above-described problems, and an object of the present invention is to provide an injection foam molded article that can be easily and surely molded with a simple configuration with good appearance. .
In addition, the present invention has been made in view of the above-described problems, and provides an injection foam molding die capable of easily and reliably molding an injection foam molded product having a good edge appearance with a simple configuration. With the goal.
Furthermore, the present invention has been made in view of the above-described problems, and provides an injection foam molded product manufacturing method capable of easily and surely forming an edge of an injection foam molded product with a simple configuration with good appearance. The purpose is to do.

  In order to solve the above-mentioned problems, the invention relating to the injection foam molded article according to claim 1 is a skin / foam material comprising a base material, a skin layer and a foam layer, and integrally molded with the base material by injection foam molding. An injection foam molded product in which a winding portion formed by extending the edge of the skin / foam material from the end portion of the base material is wound around and joined to the back surface of the base material. And the processus | protrusion is formed in the surface side corner | angular part of the edge part of the said base material, It is characterized by the above-mentioned.

  In order to solve the above-mentioned problems, the invention according to the injection foaming mold of claim 2 is a skin / foaming material comprising a base material, a skin layer and a foam layer, and formed integrally with the base material by injection foam molding. An injection foam molded article in which a winding part for winding and joining to the back surface of the base material is formed by extending the edge of the skin / foaming material from the end part of the base material. A first mold for molding at least the front surface side of the base material, and a second mold for molding at least the back surface side of the base material and holding the base material A cavity formed by the first mold and the second mold, and a third mold for molding the skin / foam material between the second mold and the base material held by the second mold Is a recess for forming protrusions at the corners on the surface side of the end of the substrate. Has the second mold and the third mold is characterized in that the skin layer of the skin - foam and forms the anchoring portions.

  In order to solve the above-mentioned problem, the invention according to the method for manufacturing an injection foam molded article of claim 3 is to inject and fill the skin / foam material with a predetermined pressure in the mold in which the base material is disposed, A skin layer is formed on a portion of the skin / foaming material that is in contact with the mold, and a portion between the base material and the skin layer of the skin / foaming material is held in a melted state. The base material and the skin / foam material composed of the skin layer and foam layer are integrally formed by foaming the melted portion between the base material and the skin layer of the skin / foam material. In addition, an injection foam molded product in which an end portion of the skin / foaming material is extended from an end portion of the base material to form an entrainment portion, and the entrainment portion is entrained and joined to the back surface of the base material. A method for manufacturing a foam molded article, wherein a cavity is formed by a first mold and a second mold. Forming a base having protrusions on the surface side corners of the end, holding the base on the second mold, and moving the base to the surface side of the base by the second mold and the third mold A cavity is formed and the material of the skin / foaming material is injected and filled, and the skin layer is formed by contacting the third mold, and the entrainment portion is formed by the skin layer, and then the second mold and Forming an injection foam molded article in which a foam layer is formed between the base material and the skin layer by core-backing the third mold, and taking out the injection foam molded article from the mold and entraining the skin layer. The portion is wound around and joined to the back surface of the end portion of the base material.

  According to the first aspect of the present invention, the protrusions are formed at the corners on the surface side of the end of the base material, so that the integral part laminated with the base material has a foam layer. The winding part that wraps around the back surface of the base material from the part corresponding to the projection of the base material to the end is thin because it is formed only by the skin layer, and this wrapping part is wound around the back surface of the base material. Even so, it is possible to provide an injection-foamed molded article having a nicely configured edge.

  According to the second aspect of the present invention, since the cavity formed by the first mold and the second mold has the recess, when the substrate is molded with the first and second molds, Protrusions are formed on the surface side corners of the part. Then, the substrate is released from the first mold and left on the second mold, and then the mold is opened, and then the second mold and the third mold are closed to form the skin / foam material Inject and fill the material. The material of the skin / foaming material is cooled and solidified to form the skin layer, including the entrained part extended so as to protrude from the end of the base material, and the part in contact with the third mold is cooled and solidified. Since protrusions are formed at the surface side corners of the end portions of the material, the portion between the skin layer and the base material in the integral part integrally formed with the base material is maintained in a molten state without solidifying. In this state, when the second mold and the third mold are slightly opened and the core is backed, the melted portion of the integral part of the skin / foam material is released and foamed. Injection foam molded products are thinly formed so that the entrainment part that is extended so as to protrude from the edge of the base material of the skin / foam material is almost only the skin layer, and the foam layer is formed in the integral part that is integrally molded with the base material. It is molded in the state. Therefore, it is possible to provide an injection foam molding die capable of manufacturing an injection foam molded article having a beautifully wound edge even when the entrained portion of the skin / foaming material is wound around and joined to the back surface of the base material.

  According to the invention of claim 3, a cavity is formed by the first mold and the second mold, and a base material having protrusions on the surface side corners of the end portion is formed, and the base material is left. By forming a cavity on the surface side of the substrate with the second and third molds and injection-filling the material of the skin / foaming material, it is extended to protrude from the substrate edge of the skin / foaming material The entangled portion is formed thinly only with the skin layer, and the portion between the base material and the skin layer of the integral part integrally formed with the base material is maintained in a molten state. In this state, when the second mold and the third mold are slightly opened and the core is backed, the melted portion of the integral part of the skin / foam material is released from the pressure and foamed. That is, in the injection foam molded product, the integral part that overlaps the base material of the skin / foam material has a foam layer formed between the base material and the skin layer, and the entrained part that is extended from the end of the base material has It is formed thin only on the skin layer. For this reason, the injection foam molded article is taken out from the second and third molds, and the entrained portion of the skin layer is wound around and joined to the back of the end of the base material to produce an injection foam molded article having a good edge appearance. Possible methods can be provided.

(Aspect of the Invention)
In the following, the invention that is claimed to be claimable in the present application (hereinafter referred to as “claimable invention”. The claimable invention is at least the “present invention” to the invention described in the claims. Some aspects of the present invention, including subordinate concept inventions of the present invention, superordinate concepts of the present invention, or inventions of different concepts) will be illustrated and described. As with the claims, each aspect is divided into sections, each section is numbered, and is described in a form that cites the numbers of other sections as necessary. This is for the purpose of facilitating the understanding of the claimable invention, and is not intended to limit the combinations of the constituent elements constituting the claimable invention to those described in the following sections. In other words, the claimable invention should be construed in consideration of the description accompanying each section, the description of the embodiments, etc., and as long as the interpretation is followed, another aspect is added to the form of each section. In addition, an aspect in which constituent elements are deleted from the aspect of each item can be an aspect of the claimable invention. In each of the following items, item (1) corresponds to claim 1, item (3) corresponds to claim 2, and item (5) corresponds to claim 3.

(1) It is composed of a base material and a skin / foam material integrally formed with the base material by injection foam molding comprising a skin layer and a foam layer, and an edge of the skin / foam material is defined as the base material An injection foam molded product in which the entrainment portion formed by extending from the end of the substrate is entrained and joined to the back surface of the substrate,
An injection foam molded product, wherein protrusions are formed on the corners on the surface side of the end of the substrate.

  In the invention of item (1), the protrusions are formed at the corners on the surface side of the end of the base material, so that the integral part laminated with the base material has a foam layer. In addition, the entrainment part that wraps around the back surface of the base material from the portion corresponding to the protrusion of the base material to the end is formed by only the skin layer, so that it is thin. Therefore, even if the entraining part is entrained and joined to the back surface of the base material, the end edge of the injection foam molded product has a good appearance.

(2) It is composed of a base material, and a skin / foaming material that is integrally formed with the base material by injection foam molding, which is composed of a skin layer and a foam layer, and an edge of the skin / foaming material is defined as the base material An injection foam molded product in which the entrainment portion formed by extending from the end of the substrate is entrained and joined to the back surface of the substrate,
An injection foam molded product, wherein the enveloping part of the skin / foaming material is formed by the skin layer.

  In the invention of the item (2), since the entrainment part is formed by the skin layer, it is possible to realize an injection foam molded article having a structure in which the entrainment part can be thinly formed and the edge can be configured with a good appearance. it can.

(3) Consists of a base material, and a skin / foaming material that is integrally formed with the base material by injection foam molding, which is composed of a skin layer and a foamed layer. An injection foam molding die for molding an injection foam molded product, wherein the part is formed by extending the edge of the skin / foam material from the end of the base material,
A first mold for molding at least the surface side of the substrate;
A second mold for shaping at least the back side of the substrate and holding the substrate;
A third mold for molding the skin / foaming material with the base material held by the second mold,
The cavity formed by the first mold and the second mold has a recess for forming a protrusion on the surface side corner of the end of the base material,
An injection foaming mold characterized in that the second mold and the third mold form the entrainment portion by a skin layer of the skin / foaming material.

  In the invention of (3), since the cavity formed by the first mold and the second mold has a recess, when the substrate is molded with the first and second molds, the end portion Protrusions are formed at the surface side corners. Then, the substrate is released from the first mold and left on the second mold, and then the mold is opened, and then the second mold and the third mold are closed to form the skin / foam material Inject and fill the material. The cavity formed by the second mold and the third mold inevitably has a thin entrainment part forming part as a result of the protrusion formed at the surface side corner of the end part of the base material, and corresponds to the base material. The integral part forming part is thick. Therefore, the skin / foam material injected and filled into the cavity formed by the second mold and the third mold is cooled at the portion in contact with the third mold to solidify to form a skin layer. And since the entrainment part molding part is thin, the entrainment part is composed only of the skin layer, but since the integral part molding part is thick, the part between the skin and the substrate in the integral part melts without solidifying. Maintain the state. In this state, when the second mold and the third mold are slightly opened and the core is backed, the melted portion of the integral part of the skin / foam material is released and foamed. Injection foam molded products are thinly formed so that the entrainment part that is extended so as to protrude from the edge of the base material of the skin / foam material is almost only the skin layer, and the foam layer is formed in the integral part that is integrally molded with the base material. It is molded in the state. Therefore, even if the entrained portion of the skin / foaming material is entrained and joined to the back surface of the base material, an injection foam molded product can be manufactured in which the edge is enviably encased.

  (4) The cavity formed by the second mold and the third mold holding the base material is formed with a protrusion at the corner on the surface side of the end portion of the base material. However, even if the core is backed up later, the thickness of the skin / foaming material will not foam, and the thickness of the integral part will allow the skin / foaming material to foam by making the core back later. The injection foaming mold according to item (3), which is formed.

  In the invention of the item (4), in the invention described in the item (3), the projection is formed at the corner portion on the surface side of the end portion of the substrate, whereby the second mold holding the substrate. The cavity formed by the third part has a thickness that does not cause the material of the skin / foam material to foam even if the entrained part molding part later cores back with the projection as a boundary. It is formed to a thickness that allows the material of the skin / foaming material to be foamed by core back later. Therefore, it is possible to realize an injection foaming mold having a structure in which the integral part can be surely foamed, and the entrainment part can be formed thin to form the edge with a good appearance.

(5) Injecting and filling the skin / foam material with a predetermined pressure into the mold in which the base material is disposed, and forming a skin layer on the part of the skin / foam material in contact with the mold; -Hold the portion between the base material and the skin layer of the foam material in a molten state, and make the mold core back between the base material and the skin layer of the skin / foam material. Foam the melted part,
An injection foam in which a base material and a skin / foam material composed of a skin layer and a foam layer are integrally formed, and an edge of the skin / foam material is extended from the end of the base material to form a entangled portion. A method for producing an injection-foamed molded article in which a molded article is molded, and the entrainment part is entrained and joined to the back surface of the substrate,
A cavity is formed by the first mold and the second mold, and a base material having protrusions on the surface side corners of the end is formed,
Holding the base material in the second mold, forming a cavity on the surface side of the base material by the second mold and the third mold, and injecting and filling the skin / foaming material, and contacting the third mold And forming the skin layer, and forming the entrainment portion by the skin layer,
Thereafter, the second mold and the third mold are core-backed to mold an injection foam molded product in which a foam layer is formed between the base material and the skin layer,
A method for producing an injection foam molded article, comprising: taking out the injection foam molded article from a mold, and entraining and joining the entrained portion made of the skin layer to the back surface of the end of the substrate.

  In the invention of (5), a cavity is formed by the first mold and the second mold, a base material having protrusions on the surface side corners of the end portion is formed, and the second base material in which the base material is left. By forming a cavity on the surface side of the base material with the mold of the mold and the third mold and injecting and filling the material of the skin / foaming material, it is extended so as to protrude from the edge of the skin / foaming material base material The part is formed thinly only with the skin layer, and the part between the base material and the skin layer of the integral part integrally molded with the base material is maintained in a molten state. In this state, when the second mold and the third mold are slightly opened and the core is backed, the melted portion of the integral part of the skin / foam material is released from the pressure and foamed. That is, in the injection foam molded product, the integral part that overlaps the base material of the skin / foam material has a foam layer formed between the base material and the skin layer, and the entrained part that is extended from the end of the base material has It is formed thin only on the skin layer. Therefore, this injection foam molded product is taken out from the second and third molds, and the entrained portion of the skin layer is wound around and joined to the back surface of the end portion of the base material to produce an injection foam molded product having a good edge appearance. be able to.

  (6) The first mold and the second mold are formed by the second mold and the third mold holding the base material by forming protrusions on the surface side corners of the end portion of the base material. The thickness of the skin / foam material can be foamed even if the core molded part of the cavity is later cored back, and the skin / foam material is foamed even if the core part of the entrained part is later cored back. The method for producing an injection-foamed molded article according to the item (5), wherein the thickness is not obtained.

  In the invention of the item (6), in the invention described in the item (5), the first mold and the second mold are used to form protrusions at the corners on the surface side of the end portion of the base material, whereby the second mold When the core and the third mold are later cored back, the enveloping part of the skin / foaming material is formed only by the skin layer without foaming, and the integral part of the skin / foaming material is surely foamed, The manufacturing method of the injection foaming molded product which can form a foaming layer between base materials can be embodied.

First, an embodiment of an injection foaming mold of the present invention will be described in detail with reference to FIGS. In the drawings, the same reference numerals denote the same or corresponding parts.
The injection foaming mold of the present invention is roughly composed of a base material 1 and a skin / foam material 4 which is composed of a skin layer 2 and a foam layer 3 and is integrally molded with the base material 1 by injection foam molding. For forming an injection foam molded product in which a winding portion 4a for winding and joining to the back surface 1b of the base material 1 is formed by extending the edge of the skin / foaming material 4 from the end portion of the base material 1 A first mold 11 for molding at least the front surface 1a side of the base material 1, a second mold 12 for molding at least the back surface 1b side of the base material 1 and holding the base material 1, A cavity formed by the first mold 11 and the second mold 12, and a third mold 13 for molding the skin / foam material 4 between the base material 1 held by the second mold 12. 14 is a recess 15 for forming the protrusion 5 at the corner on the surface 1a side of the end of the substrate 1; And which, with the second mold 12 the third mold 13 is to form a winding portion 4a by the skin layer 2 of the skin-foam 4.

  As shown in each figure, the base material 1 in this embodiment is a panel-like one extending in a direction perpendicular to the paper surface of the figure formed in a curved cross section, and the second mold 12 side is the back surface. In 1b, the first mold 11 side becomes the surface 1a side on which the skin / foam material 4 is integrally formed in a later step. The first mold 11 and the second mold 12 constitute a base material forming mold. The relative mold opening / closing direction of the first mold 11 and the second mold 12 is the vertical direction in FIG. A notch 11a is formed at a position corresponding to the surface 1a side corner of the end portion of the base 1 in order to form the protrusion 5 projecting on the surface 1a side corner of the base 1 The second mold 12 is configured to form the recess 15 by entering the notch 11a of the first mold 11 so as to form the protrusion 5 continuously from the end surface of the base material 1 to the surface 1a side. Has been. The parting lines 16 and 17 of the first mold 11 and the second mold 12 start from positions corresponding to the apexes of the protrusions 5 of the substrate 1. The base material 1 made of a thermoplastic resin such as polypropylene molded by the first mold 11 and the second mold 12 thus configured is released from the first mold 11 when the mold is opened. The second mold 12 is left and held. Note that the height H (see FIG. 5) of the protrusion 5 formed on the substrate 1 is the thickness (TA) in a state where the mold is closed before core back is performed in the integral part 4b of the skin / foaming material 4 as described later. ), The thickness (TB) for forming the skin layer 2, and the like.

  As shown in FIG. 2, the second mold 12 and the third mold 13 constitute a skin / foaming material molding die for integrally molding the skin / foaming material 4 on the surface 1 a of the substrate 1. The surface of the second die 12 that previously formed the parting line 17 by abutting with the first die 11 is formed as a winding portion in the cavity 18 when the third die 13 is closed. A portion 18a is formed. Further, an integral part molding portion 18b of the cavity 18 is formed between the base material 1 held by the second die 12 and the third die 13 when the die is closed. In order to form the protrusions 5 at the corners on the surface 1a side of the base material 1, the second mold 12 protrudes to the apex of the protrusions 5, and the third mold 13 is integrally molded with the base material 1 for the skin / foaming Since it is formed in a shape corresponding to the shape of the material 4, the cavity 18 formed when the second mold 12 and the third mold 13 are closed is inevitably formed by the integral part molding portion 18 b. It is comparatively thick and the entrainment part molding part 18b is comparatively thin. The thickness of the cavity 18 formed by closing the second mold 12 and the third mold 13 will be described later. In this embodiment, as shown in FIG. 3, the third mold 13 is configured to slightly open upward and core back with respect to the second mold 12.

Next, the manufacturing method of the injection-foamed molded product of the present invention will be described in detail along with the operation of the first to third molds configured as described above.
The method for molding an injection foam molded product of the present invention is roughly as follows. A styrene-based or olefin-based thermoplastic elastomer which is a material for the skin / foaming material 4 in the skin / foaming material forming molds 12 and 13 on which the substrate 1 is disposed Is injected and filled at a predetermined pressure to solidify the portion of the material of the skin / foaming material 4 in contact with the third mold 13 to form a skin layer, and the material of the skin / foaming material 4 in the integrated portion 4b. The portion between the base material 1 and the skin layer 2 is held in a melted state, and the third mold 13 is core-backed between the base material 1 and the skin layer 2 of the skin / foam material 4. The melted portion is foamed to integrally form the base material 1 and the skin / foaming material 4 composed of the skin layer 2 and the foaming layer 3, and the edge of the skin / foaming material 4 is formed on the edge of the base material 1. Forming an injection-foamed molded product in which the entrainment part 4a is formed by extending from the end The entrainment portion 4a is entrained and joined to the back surface 1b of the base material 1, and the cavity 14 is formed by closing the first die 11 and the second die 12, and the end surface 1a side. The base material 1 having the projections 5 at the corners is molded, and the base material 1 is held by the second mold 12, and the cavity 18 is formed on the surface 1 a side of the base material 1 by the second mold 12 and the third mold 13. Is formed, the material of the skin / foam material 4 is injection-filled, and the skin layer 2 is formed by contacting the third mold 13, and the entrainment portion 4a is formed by the skin layer 2, and then the second layer The mold 12 and the third mold 13 are core-backed to mold an injection foam molded product in which the foam layer 3 is formed between the base material 1 and the skin layer 2 in the integrated part 4b, and the injection foam molded product is molded. 12, 13 is taken out from the inside of the base material 1 and the entrainment part 4 a made of the skin layer 2 is formed. It is intended to bond entrainment to the surface 1b.

  When molding an injection foam molded product formed by winding and joining the winding portion 4a, first, as shown in FIG. 1, the first mold 11 and the second mold 12 are closed and the above-mentioned A cavity 14 is formed, and the melted material of the substrate 1 is injection-filled into the cavity 14. The base material 1 has a predetermined rigidity so as to maintain a predetermined shape, and has shape retention. A protrusion 5 is continuously formed over the entire width of the substrate 1 so as to extend in a direction perpendicular to the paper surface in FIG. When the molding of the base material 1 is completed, the base material 1 is released from the first mold 11 and the second mold 12 is opened. The second mold 12 is opened relative to the first mold 11 in a state where the molded base material 1 is left and held.

  Next, as shown in FIG. 2, the second mold 12 on which the molded base material 1 is left is abutted with the third mold 13, and the integral part molded part 18 b and the winding part molded part 18 a are joined. The provided cavity 18 is formed. In order to form the protrusions 5 on the corners of the surface 1a continuously from the end surface of the base material 1, the abutting surfaces constituting the parting lines 17 of the second mold 12 protrude, so that FIG. As shown, the thickness TA of the integral part molding portion 18b formed with the third mold 13 is relatively thick, and the thickness TB of the entraining part molding portion 18a is relatively thin. ing.

  Here, based on FIG. 6, the thickness (horizontal axis) at which the material of the skin / foaming material 4 is foamed / non-foamed, the thickness of the entraining portion 4a is moldable / unmoldable, and the back surface 1b of the substrate 1 An example of a thickness (vertical axis) that cannot be entangled and cannot be entangled will be described.

  If the thickness of the entrainment part 4a exceeds 1.0 mm, it will not be able to be encased in the back surface 1b of the substrate 1 in a later step, so the thickness of the entrainment part 4a that can be formed is 1.0 mm or less. (upper limit). The thinner the winding portion 4a, the better it can be wound around the back surface 1b of the base material 1. However, when the thickness of the winding portion 4a is set to be less than 0.5 mm, a material is used for the winding portion 4a. Since the film cannot be sufficiently filled and cannot be molded, the thickness that can be practically molded is 0.5 mm or more (lower limit). That is, the thickness range for forming the entrainment portion 4a is 0.5 to 1.0 mm.

  On the other hand, if the thickness of the cavity 18 in the closed state before the core back for molding the skin / foaming material 4 is less than 1.5 mm, it cannot be foamed when the core is later backed (non- In order to foam when foaming is performed in the subsequent step, a thickness of 1.5 mm or more is required. Therefore, in this embodiment, the thickness TA of the integral part molding part 18b that integrally molds the base material 1 and the skin / foaming material 4 is set to 1.5 mm or more, and the winding part molding part 18a has a thickness TA. The thickness TB is set in the range of 0.5 to 1.0 mm.

  In addition, since the thickness TB is set to a value in the range of 0.5 to 1.0 mm, that is, a value less than 1.5 mm where non-foaming is performed, the material of the skin / foaming material 4 is used. Even when the core is backed in a later step, foaming does not occur, and the entrainment portion 4a is formed only by the skin layer 2.

  Further, the height H of the protrusion 5 formed on the surface 1a side corner portion of the base material 1 is such that the cavity surface of the third mold 13 and the surface 1a of the base material 1 in the closed state before the core back is performed. It can be set to a value obtained by subtracting the thickness of the skin layer 2 to be formed from the distance between them (= the thickness TA of the integral part molding portion 18b). Furthermore, the thickness of the skin layer 2 to be formed can be set to the same value as the thickness TB of the entrainment portion 4a. For example, as described above, the thickness TA of the integrated portion molding portion 18b is set to 1.5 mm or more, and the thickness TB of the winding portion molding portion 18a is set to a range of 0.5 to 1.0 mm. In the case of the form, the height of the protrusion 5 is set to 1.0 to 1.5 mm.

  As described above, when the integral part molding part 18b and the entrainment part molding part 18a are respectively formed in the cavity 18 having a predetermined thickness and the melted material of the skin / foaming material 4 is injected and filled, it is shown in FIG. As described above, the portion in contact with the third mold 13 is cooled and solidified to form the skin layer 2. And in the entrainment part 4a, it is comprised only by the skin layer 2, and even if it makes a core back in a next process, it does not foam and will be shape | molded by comparatively thin thickness TB. On the other hand, the integral part 4b is formed by contacting the third mold 13 of the material of the skin / foaming material 4 by providing the protrusions 5 at the corners on the surface 1a side of the substrate 1. A predetermined thickness is secured between the skin layer 2 and the base material 1 to maintain a melted state and a predetermined pressure. Therefore, as shown by the arrows in FIG. 3, when the core back is opened by relatively slightly opening the second mold 12 and the third mold 13, the melted state is maintained in the integral part molding portion 18 b. The material in a state of being released is surely foamed, and an injection foam molded product in which the foam layer 3 is formed between the base material 1 and the skin layer 2 is molded.

  When the molding of the injection foam molded product is completed, as shown in FIG. 4 (a), the injection foam molded product is taken out from the second and third molds 12 and 13, and as shown in FIG. 4 (b). The winding portion 4a formed of only the skin layer 2 is relatively thinly wound on the back surface 1b side of the base material 1 and is bonded to the back surface 1b of the base material 1 by pressing an ultrasonic vibration horn and thermally welding it. To do.

  In the injection foam molded product thus molded, the second and third molds 12 and 13 were closed by forming the protrusions 5 at the corners on the surface 1a side of the end of the base material 1. Even if the material of the skin / foaming material 4 is injection-filled in the state, it is possible to secure a thickness capable of foaming when the core portion is later backed in the integral portion molding portion 18b, and in the entrainment portion molding portion 18a. Can guarantee the thickness of only the skin layer 2 without foaming even when the core is later backed. Therefore, as shown in FIG. 4B, the winding portion 4a can be formed relatively thin. Therefore, when the winding portion 4a is wound and joined to the back surface 1b of the substrate 1, the conventional technique ( As shown in FIG. 10 (b), the rounded portion of the winding portion 4a ′ is not increased, and the winding portion 4a is in close contact with the end surface of the substrate 1 so that no gap is generated. Thus, the edge of the injection-foamed molded product can be formed with good appearance and can be surely wound and joined. Therefore, it is not necessary to cover and cover another member such as a cover, and labor and cost can be reduced.

It is principal part sectional drawing shown in order to demonstrate one Embodiment of the base material shape | molded by the 1st type | mold and 2nd type | mold of this invention. The main part sectional view shown in order to explain the state which formed the skin layer by injecting and filling the skin / foaming material with the second mold and the third mold holding the base material clamped according to the present invention It is. The second mold and the third mold are slightly opened from the state of FIG. 2 to make the core back, and the integral part that maintains the melted state of the skin / foaming material is foamed. It is principal part sectional drawing shown in order to demonstrate the state which formed the foaming layer in the middle. It is principal part sectional drawing shown in order to demonstrate the completed product of the state in which the injection-molded injection-molded product shape | molded and the entrainment part were wound and joined to the back surface of the base material. It is the principal part expanded sectional view shown in order to demonstrate the dimension of the cavity formed with the 2nd type | mold and 3rd type | mold which hold | maintained the base material. Thickness of foam / non-foam when the core / backed material is made later and the thickness of the entrainment part can be molded / cannot be molded, and it cannot be rolled up nicely on the back of the base material. It is the chart shown in order to demonstrate an example of the relationship with. It is principal part sectional drawing shown in order to demonstrate one Embodiment of the base material shape | molded by the 1st type | mold and 2nd type | mold of the prior art. Cross-section of the main part shown for explaining the state of forming the skin layer by injection filling the skin / foaming material with the second mold and the third mold holding the base material clamped in the prior art FIG. Explaining the state in which the second mold and the third mold are slightly opened from the state of FIG. 8 to make the core back, and the foamed layer is formed by foaming the entire part that maintains the melted state of the skin and foam material. It is principal part sectional drawing shown in order to do. It is principal part sectional drawing shown in order to demonstrate the injection foam molded product shape | molded by the prior art, and the finished product of the state which the entrainment part was wound and joined to the back surface of the base material.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1: Base material, 1a: Front surface, 1b: Back surface, 2: Skin layer, 3: Foam layer, 4: Skin / foam material, 4a: Entrainment part, 4b: Integrated part, 5: Protrusion, 11: 1st type | mold 12: 2nd mold, 13: 3rd mold, 14: Cavity, 15: Recess, 18: Cavity, 18a: Entraining part molding part, 18b: Integrated part molding part

Claims (3)

It is composed of a base material, and a skin / foaming material that is integrally formed with the base material by injection foam molding comprising a skin layer and a foam layer, and an edge of the skin / foam material is an end portion of the base material Is an injection foam molded product in which the entrainment part formed by extending from is entrained and joined to the back surface of the substrate,
An injection foam molded product, wherein protrusions are formed on the corners on the surface side of the end of the substrate. It is composed of a base material, and a skin / foaming material formed integrally with the base material by injection foam molding, comprising a skin layer and a foam layer, and the entrainment part for entraining and joining the back surface of the base material An injection foam molding die for molding an injection foam molded product formed by extending the edge of the skin / foam material from the end of the base material,
A first mold for molding at least the surface side of the substrate;
A second mold for shaping at least the back side of the substrate and holding the substrate;
A third mold for molding the skin / foaming material with the base material held by the second mold,
The cavity formed by the first mold and the second mold has a recess for forming a protrusion on the surface side corner of the end of the base material,
An injection foaming mold characterized in that the second mold and the third mold form the entrainment portion by a skin layer of the skin / foaming material. The skin / foaming material is injected and filled into the mold in which the base material is placed at a predetermined pressure to form a skin layer on the part of the skin / foaming material in contact with the mold, and the skin / foaming material. The portion between the base material and the skin layer of the material is held in a molten state, and the mold is core-backed to melt between the base material and the skin layer of the skin / foam material. The part is foamed, and the base material and the skin / foam material composed of the skin layer and the foam layer are integrally formed, and the edge of the skin / foam material is extended from the end of the base material to entrain the part Is a method for producing an injection foam molded article, wherein the injection foam molded article is formed, and the entrainment part is wound around and joined to the back surface of the substrate,
A cavity is formed by the first mold and the second mold, and a base material having protrusions on the surface side corners of the end is formed,
Holding the base material in the second mold, forming a cavity on the surface side of the base material by the second mold and the third mold, and injecting and filling the material of the skin / foam material into the third mold Forming a skin layer by contacting, and forming the entrainment portion by the skin layer,
Thereafter, the second mold and the third mold are core-backed to mold an injection foam molded product in which a foam layer is formed between the base material and the skin layer,
A method for producing an injection foam molded article, comprising: taking out the injection foam molded article from a mold, and entraining and joining the entrained portion made of the skin layer to the back surface of the end of the substrate.

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