JP2011163362A - Shock absorbing material with film, and method for manufacturing the same - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a shock absorbing material and a method for manufacturing the same variable in shock absorbing performance according to portions, allowing to form complicated surface shape and high in manufacturing accuracy. <P>SOLUTION: The shock absorbing material 30 with a film is structured to include an exposed portion 32A and a covered portion 32B with a resin film 34 integrally arranged on the surface of a shock absorbing material 32 in a partially inserted form. When an impact is applied to the shock absorbing material 30 with the film, different shock absorbing performance are exhibited in the exposed portion 32A and the covered portion 32B. The shock absorbing material with different shock absorbing performance according to the exposed portion 32A and the covered portion 32B can be obtained with one shock absorbing material 30 with the film. <P>COPYRIGHT: (C)2011,JPO&INPIT

Description

  The present invention relates to an impact absorbing material and a manufacturing method thereof, and more particularly to an impact absorbing material with a film that is incorporated in an interior of an automobile and absorbs an impact received by an occupant during a vehicle collision and a manufacturing method thereof.

  2. Description of the Related Art Conventionally, it has been proposed to integrally mold members having different shock absorbing performance in shock absorbing materials used for interiors of automobiles and the like.

  As an example of the manufacturing method of the shock absorbing material as described above, by providing a weir (boundary setting member) in the lower mold of the molding die, and supplying a plurality of different materials to each section partitioned by the weir, A method of integrally molding and manufacturing members having different impact performances is disclosed (for example, see Patent Document 1).

  In addition, a manufacturing method in which a support layer such as a cloth-like body or a mesh-like body is integrally foam-molded with an impact absorbing material such as a rigid polyurethane foam has been proposed (for example, see Patent Document 2).

JP 2002-193056 A JP 2007-22146 A

  However, in the method described in Patent Document 1, if the height of the weir (depth inside the shock absorber) is large, there is a risk that the strength of the weir serving as a boundary portion at the time of demolding or use after molding may be insufficient. If the height of the weir is insufficient, depending on the input conditions of foaming raw materials (rigid urethane foam, etc.), the boundary between the two will not be constant even if multiple different raw materials are added. There is a possibility that (elasticity, hardness, and distribution thereof) are difficult to stabilize for each product. In addition, since it is necessary to distinguish between a plurality of foaming raw materials, the process becomes complicated and the cost may increase.

  In addition, since the shock absorber described in Patent Document 2 is integrally foam-molded with a supporter layer such as a cloth-like body or a mesh body on the surface of the shock absorber, the shock absorber has different physical properties such as shock absorption performance depending on the part. It is difficult to provide a support layer on only a part of the surface of the shock absorber. If the surface shape of the shock absorber is complicated, the surface shape can be handled in terms of machining and accuracy. There are drawbacks that become difficult.

  In view of the above facts, an object of the present invention is to provide an impact absorbing material that has variable shock absorption performance depending on the site, can form a complicated surface shape, and has high manufacturing accuracy, and a manufacturing method thereof.

  According to the first aspect of the present invention, there is provided a shock absorber main body made of rigid polyurethane foam molded by a mold, and pre-molded into a shape along a part of the inner surface shape of the mold before molding. A resin film integrally molded with the rigid polyurethane foam at the time of mold molding, the resin film covering a part of the surface of the shock absorber main body, and a part of the resin film inserted inside is a weir And at least a part of the shock absorbing material.

  In the above invention, the impact absorbing material made of rigid polyurethane foam is shock-absorbed depending on the site by partially covering only a part of the surface with a resin film that is molded in advance and conforms to the inner shape of the mold. Shock absorbers with different performance can be obtained.

  The invention described in claim 2 is characterized in that the resin film constitutes a container comprising a surface that contacts the mold and a weir that divides the shock absorber main body.

  In the above invention, by making the resin film into a container type, it is possible to avoid a situation in which the foaming raw material flows between the mold and the resin film and the resin film floats from the mold, and the impact absorbing material after molding Powder falling from the surface can also be suppressed.

  According to a third aspect of the present invention, the resin film forms a container comprising a surface that contacts the mold and a weir that separates the shock absorber main body, and the container has a bottom surface and at least one surface other than the weir. It is characterized by being open.

  In the above invention, since at least one of the side surfaces of the resin film container is open, the shock absorbing physical properties can be changed between the surface covered with the resin film and the surface not covered with the resin film. It is possible to provide a desired distribution or directionality in the performance of the shock absorber.

  Invention of Claim 4 forms the belt | band | zone which the said resin film forms from the bottom face which contacts the said metal mold | die, the weir which divides the said shock-absorbing material main body, and the side surface facing the said weir, It is characterized by the above-mentioned. To do.

  In the above-described invention, the resin film that covers a part of the surface of the shock absorbing material is not a container but an open band on both sides, so that a shock with different shock absorbing performance depending on the site can be obtained with a simpler method / structure. It can be an absorbent material.

  The invention according to claim 5 is characterized in that the resin film is formed by vacuum molding.

  In the above invention, the resin film can be easily adjusted to a desired shape by forming it in conformity with the inner shape of the mold by vacuum forming rather than post-processing.

  The invention according to claim 6 is characterized in that the resin film is polycarbonate or polyethylene terephthalate.

  In the above invention, since the resin film is made of polycarbonate or polyethylene terephthalate having good adhesiveness with hard urethane, there is no risk that the resin film may be removed at the time of demolding or cracked at the boundary of the resin film. It can be an absorbent material.

  The invention according to claim 7 is provided on a wall inside the vehicle, and the surface of the rear side of the vehicle body is covered with the resin film.

  In the above invention, the shock absorber is coated with a resin film on the surface on the rear side of the vehicle body, so that the shock absorption performance of the shock absorber is large and the absorbed energy is large on the rear side of the vehicle body where a heavy occupant contacts. Thus, the absorbed energy can be set small on the front side where a light occupant contacts.

  The invention according to claim 8 is provided on a side wall inside the vehicle, and the surface on the upper side of the vehicle body is covered with the resin film.

  In the above invention, the shock absorber is coated with a resin film on the upper surface of the vehicle body, so that the shock absorption performance of the shock absorber is large and the absorbed energy is large on the vehicle body upper side where heavy passengers contact, The absorbed energy can be set small on the lower side where the light occupant comes into contact.

  According to a ninth aspect of the present invention, a rigid polyurethane foam is formed by pre-molding a resin film in a shape along a part of the inner surface shape of the mold before mold molding, and after placing the resin film in the mold. Is injected into the mold, and when the mold is molded, the polyurethane foam and the resin film are integrally molded to form a shock absorber, and the resin film covers a part of the surface of the shock absorber main body. The shock absorber is divided into a plurality of sections by a part of the resin film inserted inside.

  In the above invention, the impact absorbing material made of rigid polyurethane foam is partly covered with a resin film that has been molded in advance and conforms to the inner surface shape of the mold, thereby absorbing the impact depending on the part. It can be set as the manufacturing method of the impact-absorbing material from which performance differs.

  According to a tenth aspect of the present invention, a mold release film is provided between the lower mold of the mold and the rigid polyurethane foam and the resin film at the time of molding, and between the mold release film and the lower mold. The impact absorbing material after molding is demolded by injecting a pressurized fluid into the mold.

  In the above invention, a release film is used, and further, a pressurized fluid such as pressurized air is blown between the release film and the mold, thereby making it easy to remove the mold after molding the shock absorber. Further, it has an effect on prevention of peeling between the resin film and the rigid polyurethane foam at the time of demolding.

  The invention according to claim 11 is characterized in that the release film is polypropylene.

  In said invention, the mold release after a shock-absorbing-material shaping | molding can be made easy by using a polypropylene with sufficient releasability with hard urethane for a release film.

  ADVANTAGE OF THE INVENTION According to this invention, it can be set as the impact-absorbing material which can change the impact-absorbing performance by site | parts, can form a complicated surface shape, and has high manufacturing accuracy, and its manufacturing method.

It is front sectional drawing which shows the shaping | molding method of the shock absorber with a film which concerns on 1st Embodiment of this invention. It is front sectional drawing which shows the process of releasing the shock absorber with the shape | molded film which concerns on 1st Embodiment of this invention from a metal mold | die. It is front sectional drawing which shows the process after mold release of the shaping | molding method of the shock absorber with a film which concerns on 1st Embodiment of this invention. It is a perspective view which shows the resin film used for the impact-absorbing material which concerns on 1st Embodiment of this invention. It is front sectional drawing which shows the shaping | molding method of the shock absorber with a film which concerns on 2nd Embodiment of this invention. It is front sectional drawing which shows the process of releasing the molded impact absorber with a film concerning 2nd Embodiment of this invention from a metal mold | die. It is a perspective view which shows the resin film used for the impact-absorbing material which concerns on 3rd Embodiment of this invention. It is a conceptual diagram which shows the usage example of the impact-absorbing material which concerns on embodiment of this invention. It is a comparison figure which shows the relationship between an input and a displacement in the location coat | covered with the resin film of the shock absorber which concerns on embodiment of this invention, and the location which is not coat | covered. It is a conceptual diagram which shows the usage example of the impact-absorbing material which concerns on embodiment of this invention.

  Hereinafter, embodiments will be described and embodiments of the present invention will be described. Here, in the second and subsequent embodiments, the same components as those already described are denoted by the same reference numerals, and the description thereof is omitted. In addition, the shock absorber with a film obtained in the following embodiments is used for interior materials for automobiles and other industrial materials, and is particularly attached to the inside of a door trim of an automobile to absorb the energy at the time of collision and protect an occupant. It is suitable as a shock absorbing material.

[First Embodiment]
First, the first embodiment will be described.

  As shown in FIGS. 1 to 3, in the present embodiment, a shock absorbing material molding die (mold) 10 including a lower die 12 and an upper die 14 is used. In this mold 10, a lower mold 12 and an upper mold 14 are hinged to be freely opened and closed. The lower mold 12 is formed with a concave lower mold cavity 16 in the upper central portion, and the upper mold 14 is formed as a lid for closing the upper end open portion of the lower mold cavity 16. When the mold 12 is closed, the space in the lower mold cavity 16 is closed by the upper mold 14.

  In the present embodiment, the lower mold 12 is provided with a release film 18 made of polypropylene, which is previously formed in the same shape as the lower mold cavity 16 by a vacuum forming method. The release film 18 is fixed to the upper end surface of the lower mold 12 by a fixing pin (not shown), and a film air seal packing disposed on the upper end surface of the lower mold 12 and a film presser (both shown). (Not shown) and firmly fixed to the lower mold 12. According to the study by the present inventors, even when the mold is repeatedly removed several tens of times in such a fixed state, the film is not displaced. Moreover, the demolding work can be easily performed.

  In order to mold the release film 18, it is molded using a film member molding die that is different from the impact absorbing material molding die 10 in consideration of thermal shrinkage of the film.

  Further, the impact absorbing material 32 made of rigid polyurethane foam molded by the mold 10 is partially covered with the resin film 34 while the resin film 34 is inserted inside, and one part of the resin film 34 is formed. The inside of the shock absorber 32 is divided into a plurality of sections by the portion.

  A box-shaped air chamber S is formed at the bottom of the lower mold 12, and one end of an air pipe 22 that interposes the pressure adjustment valve 20 is connected to the air chamber S. The other end of 22 is connected to an air introduction / suction device such as a vacuum pump. The air chamber S and the lower mold cavity 16 are communicated with each other through a plurality of air communication holes (air holes) 24.

  Here, as described above, it is desirable that the release film 18 has good separability from the rigid polyurethane foam and can be used repeatedly. That is, there are polyethylene film and polypropylene film as plastic films that are separated from the molded product of rigid polyurethane foam, but the polyethylene film is easily stretched and deformed and can be used only several times. On the other hand, it is preferable from the above viewpoint to use a polypropylene film that stretches at the time of separation from the rigid polyurethane foam, has little deformation, and has good separability.

Further, unlike the polyurethane foam, the rigid polyurethane foam is buckled, that is, destroyed when a force exceeding the allowable range is applied. On the other hand, the rigid polyurethane foam is expanded by internal reaction heat at the time of mold release, and the side surface of the mold 10 is pushed with a force of about 0.5 to 1 kg / cm ² . Even if the impact absorbing material 32 formed of rigid polyurethane foam presses the side surface of the mold 10 with such force, in the present embodiment, the release film 18 is installed on the mold 10 as described above, and the mold release is performed. By applying air pressure between the film 18 and the lower mold cavity 16, the molded product can be lifted from the lower mold 12 relatively smoothly, that is, can be released.

  The thickness of this polypropylene film is preferably 0.3 to 1.0 mm, particularly 0.3 to 0.6 mm. If it is thinner than 0.3 mm, sufficient strength cannot be maintained, and the film may be damaged during molding. On the other hand, if it is thicker than 1.0 mm, the dimensional error of the product becomes large, there arises a problem that the mold must be made larger, the film is hardly deformed at the time of demolding, and depending on the shape of the molded product In complicated cases, it may be difficult to separate the film and the urethane.

  Moreover, it is desirable that the release film 18 made of a polypropylene film is previously formed by a vacuum forming method. If not molded in advance, it may be difficult to sufficiently follow and restore the release film 18 to its original state after foaming, molding and demolding with a hard polyurethane foam material.

  In addition, when formed into a predetermined shape by the press molding method instead of the vacuum molding method, the corner shape of the male mold is locally pushed and manufactured by this press molding method. Further, it is somewhat difficult to follow the lower mold cavity 16, and the float from the lower mold 12 is likely to occur. Moreover, the corner part of a release film is easy to tear, and durability is inferior. In particular, when the lower mold cavity 16 has a deep shape, the thin film slides and extends through the narrow gap, so that the release film tends to be thin. Further, it is necessary to apply an even force to the release film. However, since the film thickness is thin, it becomes difficult for the upper mold 14 to press the release film evenly, and it is difficult to press the release film. There may be a case where it is difficult to manufacture a product that fits in the cavity shape. In addition, although a well-known method can be employ | adopted for a vacuum forming method, in this embodiment, it is good to vacuum-form what heated the polypropylene film for 180-200 degreeC and about 15-20 seconds.

  Hereinafter, production of the shock absorber 30 with a film in which the impact absorber 32 made of rigid polyurethane foam and the resin film 34 are integrally formed using the mold 10 will be described.

  In the present embodiment, the resin film 34 having an outer shape along the cavity shape of the lower mold 12 is formed in advance. The material of the resin film 34 is polycarbonate in this embodiment. In order to mold the resin film 34, the resin film 34 is molded by a vacuum molding method using the mold for molding a film member used when the release film 18 is molded.

  The resin film 34 may have a so-called bathtub-shaped container shape as shown in FIG. 4, for example, an exposed portion 34A that contacts the inner surface of the lower mold 12 and a weir portion 34B that divides the shock absorber 30 into a plurality of sections. And is formed as a container shape having an open direction (upper side) for injecting a molten rigid polyurethane foam material.

  The molded resin film 34 is placed in the lower mold 12. At that time, air is sucked by an air introduction / absorption device so that the release film 18 has a shape before the start of molding along the lower mold cavity 16 (see FIGS. 1 and 3). A resin film 34 is disposed.

  At this time, the weir part 34B provided as one wall of the resin film 34 and inserted into the shock absorbing material 32 and dividing it into a plurality of sections comes into contact with the upper mold 14 as shown in FIG. It may have a shape that extends to the top and completely separates the shock absorber 32, or a shape that is provided halfway in the height direction and that partitions the shock absorber 32 partway.

  Further, the molten hard polyurethane foam material is injected so as to fill the inside and outside of the resin film 34 in the lower mold 12 and the upper mold 14 is closed (see FIG. 1).

  Then, the injected hard polyurethane foam material is expanded and expanded. When the expansion is completed, the upper mold is opened, the air introduction / suction device is activated, and the release film 18 and the lower mold cavity 16 are connected via the air pipe 22, the air chamber S, and the air communication hole 24. Air is blown into the gap N, and the impact absorbing material 32 constituting the molded product is pushed up together with the resin film 34 as shown in FIG.

  At that time, since the release film 18 is fixed to the lower mold 12 only at the end, the release film 18 and the shock absorber 30 with film are pushed up by air pressure. At this time, the release film 18 is a resin film. 34 and the shock absorber 32 that is not covered with the resin film 34. When a predetermined amount of air is introduced, the release film 18 stops floating at a predetermined position, and the shock absorber with film 30 is released (demolded) from the mold 10 as shown in FIG.

Releasing air pressure during (demolding) of 0.5 kg / cm ² or more, and particularly preferably 1-5 kg / cm ^2. In addition, although it changes with the shape and size of a molded product, if the factory air pressure is increased to around 5 kg / cm ² , most molded products can be released. Normally, air is used as the fluid injected into the gap N, but a liquid such as water may be used instead of air.

  As the hard polyurethane foam raw material, a material mainly composed of a polyhydroxy compound and a polyisocyanate compound and further blended with a catalyst, a foaming agent, a foam stabilizer, a flame retardant, and other auxiliary agents as desired can be used. As these components, known components that are usually used in the production of rigid polyurethane foam can be used, and the amount used can also be a normal dose.

  In addition, it is preferable to provide a taper on the shock absorber 30 with a film which is a molded product, because it facilitates demolding and does not cause dents or scratches when being pushed up, and resistance is reduced. For this reason, although it changes with the thickness and magnitude | size of the shock absorber 30 with a film, it is suitable to form taper angle (theta) (refer FIG. 1) in the range of 3 degrees or more, especially 3 degrees-5 degrees.

  After that, when the air introduction / suction device is operated to suck the air between the release film 18 and the lower mold cavity 16, the release film 18 is easily vacuum-formed as shown in FIG. It can return to its original shape and is re-installed on the surface of the lower mold cavity so that the release film 18 can be reused. Therefore, the curing time can be shortened efficiently and reliably, the mold use time for one molding can be shortened, the number of moldings per unit time can be increased, and the productivity can be increased. Further, since the shock absorber 30 with film, which is a molded product, can be pushed up evenly by air, an excessive force is not applied to the shock absorber 30 with film, particularly at 80 ° C. ± 10 ° C. The curing time can be effectively shortened, thereby shortening the mold use time, increasing the number of moldings per unit time by about 30%, and increasing the productivity.

  As described above, in this embodiment, the resin film 34 having an outer shape along the lower mold cavity 16 is formed in advance. In this molding, in consideration of heat shrinkage of the film, vacuum molding is performed by using a film member molding die different from the shock absorber molding die 10.

  Therefore, in this case, compared with the case where the resin film 34 is not formed in advance and the resin film is simply disposed on the upper side of the release film 18 and the rigid polyurethane foam material is injected to form the shock absorber with film, even if the shock absorption is performed. Even if the surface shape of the material 32 is complicated, the resin film 34 is easily arranged with high precision at the intended position and shape of the shock absorbing material 32 to form the covering portion 32B, and the resin that covers the covering portion 32B. It can be set as the impact-absorbing material which the film 34 does not peel easily.

  That is, for example, as shown in FIG. 8 (A), if the shock absorber with film 30 has a relatively simple shape, a method of applying the resin film 34 after molding may be considered, but it is complicated as shown in FIG. 8 (B). If the surface shape is difficult, it is difficult to correctly apply the resin film 34 to this surface from the viewpoint of man-hours, work accuracy, etc. By using the manufacturing method according to the present invention as described above, for example, As shown in FIG. 8C, the resin film 34 can be provided at a desired position even with a shock absorber having a complicated surface shape.

  And since it shape | molds by vacuum forming when shape | molding the resin film 34, even if the external shape of the resin film 34 is a complicated shape, the resin film 34 can be manufactured easily. Further, as a mold for molding the resin film 34, a film member molding mold in which the release film 18 is molded can be used. Therefore, it is not necessary to install a new mold. Of course, separate molds may be used for the release film 18 and the resin film 34.

  The material of the resin film 34 is polycarbonate. Since polycarbonate has good adhesiveness to the rigid polyurethane foam, the resin film 34 can be reliably disposed on the surface of the shock absorber 32 and can be suitably fixed. In addition, since polyethylene terephthalate also has good adhesion to rigid polyurethane foam, even if the resin film 34 is made of polyethylene terephthalate instead of polycarbonate, the resin film 34 is securely disposed and fixed on the surface of the shock absorber 32. can do. Further, a thermoplastic elastomer (TPE) may be used as the material of the resin film 34.

  Furthermore, the thickness of the resin film 34 is desirably in the range of 0.05 to 1.0 mm. That is, if the thickness is less than 0.05 mm, the strength may be insufficient and it may be broken, and if the thickness exceeds 1.0 mm, the absorbed energy of the shock absorber 32 becomes large and the shock absorbing performance may be impaired.

  Also, when the release film 18 is attached to the lower mold 12 and the shock absorber 30 with film is released from the lower mold 12, the space between the release film 18 and the lower mold cavity 16 is pressurized with air. Thus, the resin film 34 is separated from the release film 18. Thereby, even if the outer shape of the resin film 34 is complicated, it is easy to release from the mold.

  Furthermore, in this embodiment, the release film 18 is made of polypropylene. The release film 18 made of polypropylene is excellent in releasability with the resin film 34 made of polycarbonate. Therefore, it is easy to separate the release film 18 and the resin film 34 forming the covering portion 32B when releasing the mold. Polypropylene is excellent in releasability from rigid polyurethane foam. Therefore, even if there is an adhesion site between the exposed portion 32A of the shock absorber 32 made of rigid polyurethane foam and the release film 18, the shock absorber 32 can be easily detached from the release film 18. Furthermore, since polypropylene has good releasability from the mold 10, the release film 18 can be easily separated from the mold 10 when being released.

  Further, when the shock absorber 30 with film 30 is molded, a hard polyurethane foam material is injected inside the resin film 34, and the covering portion 32 </ b> B of the shock absorber 32 is molded inside the resin film 34. Therefore, the powder falling phenomenon of the hard polyurethane foam from the shock absorber 32 can be reduced in the covering portion 32B.

  In the shock absorber 30 with a film thus formed, the resin film 34 is integrally disposed on the surface of the shock absorber 32 so as to be partially inserted, and includes an exposed portion 32A and a covering portion 32B. It is structured. Therefore, when an impact is applied to the shock absorber 30 with a film, the exposed portion 32A and the covering portion 32B exhibit different shock absorbing performances as shown in FIG. It can be set as the shock-absorbing material with different shock-absorbing performance depending on the location.

  Further, since the hard polyurethane forming the shock absorbing material 30 does not easily flow between the lower mold 12 and the resin film 34 in the portion where the resin film 34 has the shape of a container along the inner surface of the lower mold 12, the resin. The float of the film 34 can be prevented and the positional accuracy of the resin film 34 can be increased. At the same time, by inserting a part of the resin film 34 into the shock absorbing material 32, the shock absorbing material 32 can be restrained as a lump by the resin film 34, and the impact of the covering portion 32B covered with the resin film 34 is achieved. The absorption performance can be further harder than the exposed portion 32A.

[Second Embodiment]
Next, a second embodiment will be described. As shown in FIGS. 5 and 6, in this embodiment, the shock absorber with film 70 is formed without attaching a release film to the mold 10 as compared with the first embodiment.

  Also in this embodiment, as in the first embodiment, a resin film 74 having an outer shape along the cavity shape of the lower mold 12 is formed in advance. Then, the molded resin film 74 is placed in the lower mold 12.

  The shock absorber 72 made of rigid polyurethane foam molded by the mold 10 is covered with a resin film 74 at a part of the surface, and the resin film 74 is also inserted inside, and a part of the resin film 74 is provided. The inside of the shock absorber 72 is divided into a plurality of sections by the portion. That is, as in the first embodiment, the resin film 74 has a shape along the inner surface of the lower mold 12 and is inserted into the inside of the shock absorbing material 72 and the covering portion 74A that comes into contact therewith, and is divided into a plurality of sections. And a weir portion 74B. The weir portion 74B extends to the upper side as it comes into contact with the upper mold 14 and has a shape that completely separates the shock absorber 72 or is provided halfway in the height direction. The point which may be any of the shapes divided up to is also the same as in the first embodiment.

  Further, a liquid hard polyurethane foam material is injected into the lower mold 12, the upper mold 14 is closed, and the injected hard polyurethane foam material is expanded and expanded. When the expansion is completed, the upper mold 14 is opened, the air introduction / suction device is operated, and the resin film 74 and the lower mold cavity 16 are connected via the air tube 22, the air chamber S, and the air communication hole 24. Then, air is blown into the gap N, and the shock absorber with film 70 as a molded product is pushed up together with the resin film 74.

  In the present embodiment, the shock absorber with film 70 can be formed by a simple method that does not use a release film. Even if the surface shape of the shock absorber 72 is complicated, it is not as easy as the first embodiment, but the resin film 74 is easily and accurately arranged at the intended position and shape of the shock absorber 72. The shock absorber with film 70 can be manufactured.

  If necessary, a release agent may be applied to the surface of the lower mold cavity 16, and the surface of the lower mold cavity 16 may be coated with a fluororesin.

[Third Embodiment]
Next, a third embodiment will be described. As shown in FIG. 7A, the resin film 35 used in the present embodiment is not in the so-called bathtub-like container shape compared to the resin film 34 of the first embodiment shown in FIG. Both sides of the weir portion 35B are vacant and have a simple belt-like shape, and the shock absorber 31 with a film formed thereby has a ratio of the covering portion 32B in the surface area as shown in FIG. 7B. There are few shapes.

  According to the present embodiment, the resin film 35 is easily processed by bending a simple single plate as shown in FIG. 7A, and the impact between the exposed portion 32A and the covering portion 32B. When it is desired to reduce the difference in the absorption performance, for example, as shown in FIG. 7B, two surfaces of the portion restrained by the resin film 35 are exposed portions 32C. it can.

  Furthermore, one of the both side surfaces or the side surface of the dam portion 35B may not be completely opened, and the resin film 34 may exist partway in the depth direction to form a container shape. As a result, depending on the required shock absorption performance, the first embodiment and the present embodiment, or an intermediate shape between both embodiments in which only one surface contacting the weir portion 36B is opened as shown in FIG. The shape can be appropriately selected according to the performance, and a shock-absorbing material with a film having a desired impact-absorbing performance can be obtained.

  In addition, as an example of use of this invention, the shock absorber incorporated in the interior of a motor vehicle is mentioned. For example, as shown in FIG. 10A, the optimal seat position of an automobile occupant differs depending on the physique, but the optimal position is obtained by sliding the seat mainly in the longitudinal direction of the vehicle body.

  At this time, the person P1 having a large physique adjusts the seat to the rear of the vehicle, and the person P2 having a small physique adjusts the seat to the front of the vehicle. That is, it is desirable that the shock absorbing material that supports the belly from the left and right direction should be soft. For this reason, as shown in FIGS. 10A and 10B, it is necessary to integrally mold a plurality of types of shock absorbing materials having different shock absorbing performances (displacement / input relationship) in the longitudinal direction of the vehicle body. By applying the configuration of the present invention, an impact absorbing material that satisfies the above requirements can be obtained.

The embodiments of the present invention have been described above with reference to the embodiments. However, these embodiments are merely examples, and various modifications can be made without departing from the scope of the invention. For example, in the first embodiment, the vacuum-molded release film 18 is disposed only on the lower mold 12, but a polypropylene film can be similarly disposed on the upper mold 14. In particular, when the upper mold 14 has a cavity and the cavity shape is complicated, it is preferable to dispose a release film that is vacuum-formed in the same shape as the cavity of the upper mold 14.
Further, as shown in FIG. 10A, the surface on which the shock absorber 30 with a film is provided may be a side wall inside the vehicle or an inner surface such as a ceiling. In addition to the direction shown in FIG. 10A, various applications such as arranging a plurality of different distributions are conceivable.

DESCRIPTION OF SYMBOLS 10 Mold 12 Lower mold 14 Upper mold 18 Release film 30 Shock absorber 32 with film Shock absorber 32A Exposed part 32B Covered part 34 Resin film 34A Covered part 34B Weir part 35 Resin film 70 Shock absorber with film 72 Shock absorber 72A Exposed portion 72B Covered portion 74 Resin film 74A Covered portion 74B Weir S Air chamber θ Taper angle

Claims (11)

Impact absorber material body made of rigid polyurethane foam molded by mold,
A resin film that is pre-molded into a shape along a part of the inner surface shape of the mold before mold molding, and is molded integrally with the hard polyurethane foam at the time of mold molding,
The resin film covers a part of the surface of the shock absorber main body,
A part of the resin film inserted inside divides at least a part of the shock absorber as a weir.   2. The impact absorbing material according to claim 1, wherein the resin film constitutes a container comprising a surface that contacts the mold and a weir that separates the impact absorbing material body.   The resin film constitutes a container comprising a surface that contacts the mold and a weir that separates the shock absorber main body, and the container is open at least on one surface other than the bottom surface and the weir. The shock absorber according to claim 1.   2. The shock absorption according to claim 1, wherein the resin film forms a band composed of a bottom surface in contact with the mold, a weir for separating the shock absorber main body, and a side surface facing the weir. Wood.   The impact-absorbing material according to any one of claims 1 to 4, wherein the resin film is formed by vacuum molding.   The impact absorbing material according to any one of claims 1 to 5, wherein the resin film is polycarbonate or polyethylene terephthalate.   The shock absorber according to any one of claims 1 to 6, wherein the shock absorber is provided on a wall inside the vehicle, and a surface on a rear side of the vehicle body is covered with the resin film.   The shock absorbing material according to any one of claims 1 to 6, wherein the shock absorbing material is provided on a side wall inside the vehicle, and a surface on an upper side of the vehicle body is covered with the resin film. Before molding the mold, pre-mold the resin film into a shape along part of the inner shape of the mold,
After placing the resin film in the mold, a rigid polyurethane foam is injected into the mold,
At the time of mold molding, the shock absorbing material is formed by integrally molding the polyurethane foam and the resin film,
The impact absorbing material, wherein the resin film covers a part of the surface of the impact absorbing material body, and the impact absorbing material is divided into a plurality of sections by a part of the resin film inserted therein. Manufacturing method.   At the time of molding, a release film is provided between the lower mold of the mold and the rigid polyurethane foam and the resin film, and a pressurized fluid is injected between the release film and the lower mold. 10. The method for producing a shock absorber according to claim 9, wherein the shock absorber after molding is demolded.   The method of manufacturing an impact absorbing material according to claim 10, wherein the release film is polypropylene.

Images