JP2014091284A - Foamed molded product and method for producing the same - Google Patents

Abstract

PROBLEM TO BE SOLVED: To improve product quality mainly by improving sealing property of a terminal part.SOLUTION: There is provided a foamed molded product obtained by integrating a core member 2 and a skin material 4 by a foamed layer 3. An end wall 71 extending toward a terminal part of the core material 2 is provided at a terminal part of the skin material 4. A sealing recessed part 72 recessed toward the rear surface side of the core material 2 is provided at the terminal part of the core material 2 and a bifurcated seal part 73 capable of being inserted into the sealing recessed part 72 is provided at a front end of the end wall 71. An enlarging protrusion 78, which can bring both side surfaces 74 and 75 of the bifurcated seal part 73 into pressure contact with an outer peripheral wall surface 76 and an inner peripheral wall surface 77 of the sealing recessed part 72 by opening bifurcated seal part 73, is provided in the inside of the sealing recessed part 72.

Description

  The present invention relates to a foam molded article that can improve the sealing performance of a terminal portion and a method for manufacturing the same.

  Vehicles such as automobiles are provided with a vehicle interior front panel 1 called an instrument panel or dashboard as shown in FIG. 4 at the front of the vehicle interior.

  As shown in FIG. 5, such a vehicle interior front panel 1 includes a foamed molded product having a multilayer structure integrally including a core material 2, a foam layer 3, and a skin material 4. (For example, refer to Patent Document 1).

  Here, the core material 2 is made of a hard and thick resin, the foam layer 3 is made of a foam material such as urethane foam, and the skin material 4 is made of a soft and thin resin.

  As shown in FIG. 6, the interior interior panel 1 having such a multilayer structure has a foam layer 3 between a core material 2 and a skin material 4 set in a foam molding die 5 of a foam molding apparatus. It is manufactured by injecting a foaming liquid 6 as a raw material and foaming the foaming liquid 6 inside the foaming mold 5.

  At this time, the foamed male mold 7 and the foamed material 7 are formed so that the core material 2 having a hard thickness and high shape retaining property is on the upper side, and the skin material 4 having a soft thin wall and having no shape retaining property or low shape retaining property is on the lower side. Each is set in a female mold 8.

  The core material 2 and the skin material 4 described above are fitted with the position restricting portions 13 and 14 with respect to the position restricting portions 11 and 12 formed on the foam molding die 5 at the time of foam molding. Therefore, the position is regulated.

  In the above-described foamed molded product, it is necessary to seal the leakage of the foamed liquid 6 and the like so that the foamed layer 3 does not stick out from the end portions of the core material 2 and the skin material 4. However, since it is difficult to completely seal the leakage of the foaming liquid 6 or the like, conventionally, the core material 2 and the skin material 4 are formed to be slightly larger than the outer shape of the product, and in the subsequent process after foam molding. The outer part of the foam molded product is cut off and removed from the outer part of the product to adjust the outer shape of the product.

Japanese Patent No. 4161165

  However, since it is wasteful to make the foam molded product larger than the outer shape of the product, the foam molded product is formed to the same size as the product, and there are no parts to be cut or removed, or fewer parts to be cut and removed. It is hoped that.

  However, in order to be able to foam-mold the foam-molded product to the size of the product itself, the above-mentioned sealing problem is sufficiently solved so that the appearance defect or the like due to the foaming of the foamed layer 3 does not occur. There is a need.

  For example, in Patent Document 1 described above, as shown in FIG. 7, a sealing recess 15 is provided in the core material 2, and the end portion of the skin material 4 is thicker than the width of the sealing recess 15. The thick portion 16 for forced fitting that can be forcibly fitted to the concave portion 15 for sealing is provided, and the thick portion 16 for forced fitting is forcibly fitted to the concave portion 15 for sealing so that sealing is performed. It was.

  However, when the forced fitting thick portion 16 is forcibly fitted to the sealing recess 15, the forced fitting thick portion 16 is difficult to fit into the sealing recess 15. There have been problems such as the occurrence of wrinkles on the skin material 4 due to the occurrence or excessive force applied to the skin material 4.

In order to solve the above-mentioned problem, the invention described in claim 1 is directed to a foam molded product in which a core material and a skin material are integrated by a foamed layer, to a terminal portion of the skin material, to a terminal portion of the core material. An end wall extending toward the end of the core material, and a recess for sealing that is recessed toward the back side of the core material, and a forked portion that can be inserted into the seal recess at the tip of the end wall By opening the bifurcated seal portion inside the seal recess, both sides of the bifurcated seal portion can be pressed against the outer peripheral wall surface and the inner peripheral wall surface of the seal recess portion, respectively. It is characterized in that a widening projection is provided.
According to a second aspect of the present invention, in the above, the opening degree of the bifurcated seal portion is increased by the penetration of the expanding projection portion inside the bifurcated seal portion or the outer surface of the expanding projection portion. It has the guide part for opening degree increase to make it happen.
The invention described in claim 3 is characterized in that, in the above, a gas duct capable of containing a gas generated when the foamed layer is formed is provided between the bifurcated seal portion and the expanding projection. And
In the invention described in claim 4, in the above, the core material and the skin material are injected by injecting a foaming liquid as a raw material of the foam layer between the core material and the skin material set in the foaming mold. In a method for manufacturing a foam molded product, wherein an end wall extending toward the end portion of the core material is provided at the end portion of the skin material, and the tip of the end wall is provided. The bifurcated seal part provided in the part is fitted into the seal concave part provided in the end part of the core material, and at the same time, the expansion protrusion provided in the seal concave part is provided in the bifurcated shape. By entering the seal portion and opening the bifurcated seal portion, both side surfaces of the bifurcated seal portion are brought into pressure contact with the outer peripheral wall surface and the inner peripheral wall surface of the sealing recess, respectively, and the end of the skin material Make a seal between the part and the end of the core It is characterized in.

According to the first aspect of the present invention, the following operational effects can be obtained by the above configuration.
That is, a bifurcated seal portion that can be inserted into the seal recess is provided at the distal end of the end wall, and both sides of the bifurcated seal portion are opened by opening the bifurcated seal portion inside the seal recess. Are provided with expansion protrusions that can be pressed against the outer peripheral wall surface and the inner peripheral wall surface of the recess for sealing, respectively. Fitting can be facilitated and occurrence of poor fitting can be prevented.
In addition, since the force acting at the time of fitting is released in the direction of expanding the bifurcated seal portion, for example, an excessive force is applied to the skin material, causing problems such as wrinkles on the skin material. Can be reduced.
Furthermore, since a double inner / outer seal structure is obtained at the position of the outer peripheral wall surface and the position of the inner peripheral wall surface of the sealing recess, high sealing performance can be obtained.
According to the second aspect of the present invention, the following effects can be obtained by the above configuration.
In other words, the opening degree increasing guide portion provided inside the bifurcated seal portion or on the outer surface of the expansion projection portion increases the opening amount of the bifurcated seal portion by entering the expansion projection portion. Thereby, the sealing force between the both side surfaces of the bifurcated seal portion and the outer peripheral wall surface and the inner peripheral wall surface of the sealing recess can be further increased.
According to the third aspect of the present invention, the following operational effects can be obtained by the above configuration.
In other words, the gas duct provided between the bifurcated seal portion and the expanding projection portion can accommodate the gas generated when the foamed layer is molded (or the air confined in the foam molding die) and the like in the gas duct. become able to. As a result, it is possible to prevent problems such as the generation of voids due to the gas (or air) remaining in the foaming mold.
According to the invention described in claim 4, the following effects can be obtained by the above-described configuration.
That is, the expanding protrusion provided inside the sealing recess is inserted into the bifurcated seal portion and the bifurcated seal portion is opened, so that both side surfaces of the bifurcated seal portion are The outer peripheral wall surface and the inner peripheral wall surface of each of the outer peripheral wall surface and the inner peripheral wall surface are forcibly pressed to perform sealing between the end portion of the skin material and the end portion of the core material, thereby achieving the same effect as in the first aspect. Can be obtained.

It is a partial expanded longitudinal cross-sectional view which shows the seal structure of the terminal part of the foaming molded product concerning the Example of this invention (mold open state). FIG. 2 is a partially enlarged longitudinal sectional view showing a mold clamping state of FIG. 1. It is a top view of the core material of FIG. It is a perspective view of a vehicle interior front panel. It is a longitudinal cross-sectional view of FIG. It is a figure which shows the foaming shaping | molding die which shape | molds the compartment front interior panel of FIG. 4 (mold open state). It is a partial expanded longitudinal cross-sectional view which shows the seal structure of the terminal part of a foaming molded product.

  Vehicles such as automobiles are provided with a vehicle interior front panel 1 called an instrument panel or dashboard as shown in FIG. 4 at the front of the vehicle interior.

  As shown in FIG. 5, such a passenger compartment front interior panel 1 is constituted by a foam molded article having a multilayer structure integrally including a core material 2, a foam layer 3, and a skin material 4.

  As shown in FIG. 6, the interior front panel 1 having such a multilayer structure is provided between the core material 2 and the skin material 4 (foam molding space) set in the foam molding die 5 of the foam molding apparatus. The foaming liquid 6 as a raw material for the foaming layer 3 is injected as described later, and the foaming liquid 6 is foamed inside the foaming mold 5.

  The foam molding die 5 has a foam male mold 7 and a foam female mold 8. In this case, the core material 2 is the foam male mold 7, and the skin material 4 is the foam female mold 8. To be set.

  At this time, the foamed male mold 7 and the foamed material 7 are formed so that the core material 2 having a hard thickness and high shape retaining property is on the upper side, and the skin material 4 having a soft thin wall and having no shape retaining property or low shape retaining property is on the lower side. Each is set in a female mold 8.

The core material 2 and the skin material 4 described above are fitted with the position restricting portions 13 and 14 with respect to the position restricting portions 11 and 12 formed on the foam molding die 5 at the time of foam molding. Therefore, the position is regulated.
The above description is almost the same as that of the conventional example described above.

  The present invention relates to a foam molded product that can be applied to a foam molded product such as the interior interior panel 1 described above and a manufacturing method thereof. However, the application target of the foam molded product is not limited to the interior front panel 1 of the passenger compartment.

Hereinafter, examples embodying the present embodiment will be described in detail with reference to the drawings.
1 to 3 show this embodiment and its modifications. For convenience of drawing, a part of the foam molding die 5 may be omitted.

<Configuration> The configuration will be described below.
In this embodiment, assuming the above configuration, the following configuration is provided.

  First, the structure of the foam molded product in which the core material 2 and the skin material 4 are integrated by the foam layer 3 (not shown) will be described.

(Configuration 1)
As shown in FIGS. 1 and 2, an end wall 71 extending toward the terminal portion of the core material 2 is provided at the terminal portion of the skin material 4.
And the recessed part 72 for a seal | sticker dented to the back surface side of the core material 2 is provided in the terminal part of the core material 2. As shown in FIG.
Further, a bifurcated seal portion 73 that can be inserted into the sealing recess 72 is provided at the distal end portion of the end wall 71.
Then, by opening the bifurcated seal portion 73 inside the sealing recess 72, both side surfaces 74, 75 of the bifurcated seal portion 73 are formed on the outer peripheral wall surface 76 and the inner peripheral wall surface 77 of the sealing recess portion 72. On the other hand, an expanding projection 78 that can be pressed against each other is provided.

(Supplementary explanation 1)
Here, the above-mentioned “core material 2” is made of a hard and thick resin. The core material 2 is formed so as to have a substantially uniform thickness as a whole except for exceptional portions. The terminal portion of the core material 2 is a peripheral edge portion of the core material 2.
The above-mentioned “skin material 4” is composed of a soft thin resin. The skin material 4 is formed so as to have a substantially uniform wall thickness as a whole except for exceptional portions. The terminal portion of the skin material 4 is the peripheral edge of the skin material 4.
The skin material 4 is generally manufactured by powder slush molding or vacuum molding.
The above-described powder slush molding is basically performed by melting and adhering resin powder to a heated mold, and the above-described vacuum molding is, in short, vacuum-heating a heat-softened thermoplastic resin sheet. Then, the thermoplastic resin sheet is shaped by being brought into close contact with the vacuum forming die. Powder slush molding and vacuum molding are suitable for producing a skin material 4 having a uniform thickness.
In addition, the skin material 4 is being manufactured by injection molding. The injection molding is suitable for manufacturing the skin material 4 having portions with different thicknesses, the skin material 4 having a complicated shape, and the like. However, although the injection molding itself is general, the skin material 4 is soft and thin (and has a large area), so it is difficult to manufacture by injection molding, and much more than ordinary injection molding. Advanced technology is required.
In this case, the skin material 4 is preferably manufactured by injection molding.

  The above-mentioned “foam layer 3” is made of a foam material such as urethane foam. The foam layer 3 is interposed between the core material 2 and the skin material 4, and integrates the core material 2 and the skin material 4. The foam layer 3 is formed so as to have a substantially uniform wall thickness as a whole except for exceptional portions.

  The “foaming liquid 6” described above is, for example, a liquid resin material mixed with a foaming agent. For the foaming liquid 6, for example, liquid urethane is used. For example, when the expansion ratio of the foam layer 3 is 5 times, the injection amount of the foam liquid 6 is set to 1/5 of the volume of the foam molding space. When the foaming liquid 6 foams, gas is generated, and the foaming liquid 6 is foamed by this gas to form a foam fluid (for example, an unsolidified foam such as viscous urethane). The foamed fluid is then cured by crosslinking to form the foam layer 3.

  The above-mentioned “end wall 71” is formed integrally with the skin material 4, and becomes at least a part of the end face of the foam molded product and at least a part of the end face of the product. The end wall 71 is preferably formed in a bent shape so as to be perpendicular to the surfaces of the core material 2 and the skin material 4. However, the end wall 71 may be inclined with respect to the surfaces of the core material 2 and the skin material 4.

  In this case, the length of the end wall 71 is substantially the same as the thickness of the foam molded product, or is slightly shorter or slightly longer than that. The end wall 71 extends continuously in the circumferential direction along the edge of the foam molded product. However, depending on the shape of the foam molded product, the end wall 71 may be discontinuous in the circumferential direction.

  The “sealing recess 72” described above is formed integrally with the core member 2 and has the outer peripheral wall surface 76, the inner peripheral wall surface 77, and the top surface 79 described above. The outer peripheral wall surface 76 and the inner peripheral wall surface 77 are substantially straight with respect to the surfaces of the core material 2 and the skin material 4. The top surface 79 is substantially parallel to the surfaces of the core material 2 and the skin material 4. The above-described expanding projection 78 is provided at an intermediate portion of the top surface 79 so as to extend downward in the drawing. As shown in FIG. 3, the sealing recess 72 is a circumferential groove or the like that continuously extends in the circumferential direction along the edge of the foam molded product. However, depending on the shape of the foam molded product, the sealing recess 72 may be discontinuous in the circumferential direction. The sealing recess 72 is configured to have a substantially constant thickness and to have a concave shape on both the inner and outer surfaces.

  The above-described “bifurcated seal portion 73” is formed integrally with the distal end portion of the end wall 71. The bifurcated seal portion 73 has substantially the same length as the depth of the sealing recess 72.

  Further, both side surfaces 74 and 75 of the bifurcated seal portion 73 are substantially straight with respect to the surfaces of the core material 2 and the skin material 4.

  A slight gap is formed between the outer peripheral wall surface 76 and the inner peripheral wall surface 77 of the sealing recess 72 and both side surfaces 74 and 75 of the bifurcated seal portion 73 in order to facilitate the fitting of both. It is preferable to do so.

  A groove 81 for bifurcating the bifurcated seal portion 73 is formed at the tip of the bifurcated seal portion 73. The groove portion 81 has, for example, a narrow shape with a width becoming narrower toward the back side, such as a V groove or a U groove. In this case, the groove portion 81 has a pair of slope portions 82 and 83 on its inner surface.

  On the other hand, the above-mentioned “expansion protrusion 78” can expand (forcibly expand) the bifurcated seal 73 by entering the bifurcated seal 73. For this purpose, the expanding projection 78 has a tapered shape that is slightly wider or larger in angle than the groove 81 of the bifurcated seal portion 73.

  And between the both side surfaces 74 and 75 of the bifurcated seal portion 73 and the outer peripheral wall surface 76 and the inner peripheral wall surface 77 of the sealing recess 72, as shown in FIG. The inner and outer double seal portions (seal portions S1, S2) including the outer seal portion (seal portion S2) are formed. In this case, the inner seal portion becomes the main seal, and the outer seal portion becomes the sub seal portion.

(Configuration 2)
In the above, the opening degree increase for increasing the opening degree of the bifurcated seal part 73 by the penetration of the expanding projection part 78 inside the bifurcated seal part 73 or the outer surface of the expanding projection part 78. A guide portion 84 may be provided.

(Supplementary explanation 2)
Here, the above-described “opening degree increasing guide portion 84” is a protrusion provided inside the bifurcated seal portion 73. The opening increasing guide portion 84 may be a protrusion provided on the outer surface of the expansion protrusion 78 or the like.

(Configuration 3)
A gas duct 101 that can accommodate a gas generated when the foamed layer 3 is molded may be provided between the bifurcated seal portion 73 and the expansion projection 78.

(Supplementary explanation 3)
Here, the above-mentioned “gas duct 101” is for accommodating or releasing the gas generated by the foaming liquid 6 foaming, the air confined in the foaming mold 5 or the like.

  The gas duct 101 is located between the inner seal part (seal part S1) and the outer seal part (seal part S2), and is located at the back of the groove part 81 of the bifurcated seal part 73. In addition, a small concave portion having a depth that cannot be reached by the distal end portion of the projection portion 78 is provided, and the small concave portion is closed by the distal end portion of the expanding projection 78.

  (3a) Further, a gas generated when the foamed layer 3 is formed through the gas duct 101 through the end portion of the core material 2 to pass through the foamed liquid 6 as a raw material of the foamed layer 3, and the foamed liquid 6 A fine gas passage 102 having a size that does not pass through the foamed fluid (before the foamed layer 3 is solidified) is provided.

  Here, the gas passage 102 communicates between the core material 2 and the skin material 4 (foam molding space) and the gas duct 101.

  In this case, the gas passage 102 is formed between the inner peripheral wall surface 77, the top surface 79, and the inner surface of the expanding projection 78 in the sealing recess 72. The gas passage 102 may be a (fine) groove or a (fine) hole.

  The size (groove width and groove depth or diameter) of the gas passage 102 varies depending on various conditions such as the volume and shape of the foam molding space, the type of foaming liquid 6 used, the foaming ratio, and the molding temperature. Therefore, it cannot be generally stated, but it can be set optimally by trial and error.

  In the case of this embodiment, when the gas passage 102 has a diameter (or groove depth) of 0.3 mm, the foamed liquid 6 or a foamed fluid formed by foaming the foamed liquid 6 (for example, viscous urethane) It has been confirmed by various experiments that leakage of non-solidified foams such as, etc., can be eliminated if the leakage is smaller than that.

  Further, if the gas passage 102 is made too small in order to prevent leakage of the foaming liquid 6 and the foamed fluid, gas or air trapped in the foaming mold 5 may not be sufficiently released. confirmed.

  Therefore, it was confirmed that the size of the gas passage 102 may be practically set within a range of 0.05 mm to 0.25 mm in diameter and suitable for the molding conditions.

  (3b) Then, as shown in FIG. 3, a plurality of the gas passages 102 described above are provided at intervals, and the gas duct 101 extends to connect the plurality of gas passages 102. It is preferable to do so.

  In this case, the gas duct 101 is continuously extended in the circumferential direction along the inner part of the groove part 81 of the bifurcated seal part 73 provided in the skin material 4. In order to form the gas duct 101 having a sufficient size, the groove 81 of the bifurcated seal portion 73 is formed so as to have a depth that does not reach the tip of the expansion projection 78.

  (3c) Further, an external communication hole 103 capable of communicating with the outside is connected to the gas duct 101.

  In this case, one or a plurality of external communication holes 103 are provided for each important point such as a corner portion of the core member 2 or an intermediate portion of the side portion.

  Next, the manufacturing method of a foam molded product is demonstrated.

(Configuration 4)
By injecting a foaming liquid 6 as a raw material of the foam layer 3 between the core material 2 set in the foaming mold 5 and the skin material 4, the core material 2 and the skin material 4 are integrated by the foam layer 3. To produce a foamed molded product.
At this time, an end wall 71 extending toward the end portion of the core material 2 is provided at the end portion of the skin material 4, and the bifurcated seal portion 73 provided at the distal end portion of the end wall 71 is attached to the end portion of the core material 2. It is fitted to the sealing recess 72 provided in the terminal portion, and at the same time, the expanding projection 78 provided in the sealing recess 72 is inserted into the bifurcated seal 73, By opening the bifurcated seal portion 73, both side surfaces 74, 75 of the bifurcated seal portion 73 are brought into pressure contact with the outer peripheral wall surface 76 and the inner peripheral wall surface 77 of the sealing recess 72, respectively, and the end of the skin material 4 Sealing is performed between the portion and the end portion of the core material 2.

(Supplementary explanation 4)
The above-described sealing is performed in a mold clamping process described later.

  In addition, the above-described gas duct 101 is used for degassing in a foaming process to be described later.

  <Operation> Next, the operation of this embodiment will be described.

  As shown in FIG. 6, the interior interior panel 1 of the multilayer structure has the foamed male mold 7 and the foamed female mold 8 in the foam-molding mold 5 of the foam-molding apparatus opened (mold-opened state). The core material 2 is set on the foamed male mold 7 and the skin material 4 is set on the foamed female mold 8 (core material / skin material setting step).

  At this time, the foamed male mold 7 and the foamed material 7 are formed so that the core material 2 having a hard thickness and high shape retaining property is on the upper side, and the skin material 4 having a soft thin wall and having no shape retaining property or low shape retaining property is on the lower side. Each is set in a female mold 8.

  Next, a foaming liquid 6 as a raw material for the foam layer 3 is injected between the core material 2 and the skin material 4 set in the foaming mold 5 to form the foaming male mold 7 and the foaming female mold 8. Tighten (clamping process). The injection of the foaming liquid 6 may be performed from the injection port provided in the foaming mold 5 after the foaming mold 5 is clamped.

  Then, the foamed liquid 6 is foamed within the mold-molded foaming mold 5 to form the foamed layer 3 between the core material 2 and the skin material 4 (foaming step).

  At this time, in the foaming mold 5, first, the foaming liquid 6 spreads into the mold by its own weight, and when the foaming liquid 6 has spread to some extent, gas is generated from the foaming liquid 6 and foaming is started. The above-described gas tends to spread inside the foaming mold 5, and a foam fluid (for example, an unsolidified foam such as viscous urethane) in which the foaming liquid 6 is foamed by the gas follows the gas. Thus, the inside of the foaming mold 5 is tried to spread to the end.

  Then, by holding the above-described mold clamping state for a predetermined time, when the foamed fluid that reaches the end inside the foaming mold 5 is solidified, a foamed molded product is obtained. The mold 5 is opened to take out the foam molded product molded from the foam molding die 5 (mold opening process and foam molded product take-out process).

  After that, the product is completed by cutting away portions of the foamed molded product that are not necessary for the product in a later step. In addition, the part which is not necessary for the product in this case is a part inside the opening formed in the product.

  <Effect> According to this embodiment, the following effects can be obtained.

(Operation effect 1)
A bifurcated seal portion 73 that can be inserted into the sealing recess 72 is provided at the tip of the end wall 71, and the bifurcated seal portion 73 is opened inside the sealing recess 72, thereby providing a bifurcated seal portion. 73 is provided with an expanding protrusion 78 capable of pressing the both side surfaces 74 and 75 of the seal 73 against the outer peripheral wall surface 76 and the inner peripheral wall surface 77 of the sealing recess 72, respectively, while having a sealing structure by forced pressing. However, it is possible to facilitate the fitting of the sealing insertion portion to the sealing recess 72 and to prevent the occurrence of poor fitting.

  Further, since the force acting at the time of fitting is released in the direction of expanding the bifurcated seal portion 73, for example, an excessive force is applied to the skin material 4 so that the skin material 4 is wrinkled. Can be reduced.

  Further, since a double inner / outer seal structure is obtained at the position of the outer peripheral wall surface 76 and the position of the inner peripheral wall surface 77 of the sealing recess 72, high sealing performance can be obtained.

(Operation effect 2)
The opening increasing guide portion 84 provided on the inside of the bifurcated seal portion 73 or on the outer surface of the expansion projection portion 78 increases the opening amount of the bifurcated seal portion 73 by entering the expansion projection portion 78. By increasing the sealing force, the sealing force between both side surfaces 74 and 75 of the bifurcated seal portion 73 and the outer peripheral wall surface 76 and the inner peripheral wall surface 77 of the sealing recess 72 can be further increased.

(Operation effect 3)
The foam layer 3 can be prevented from sticking out by at least one seal portion S1, S2 provided between the end portion of the skin material 4 and the end portion of the core material 2.

  A gas duct 101 provided between the bifurcated seal portion 73 and the expanding projection portion 78 causes gas (or air confined in the foam molding die 5) generated when the foamed layer 3 is molded to the gas duct 101. Can be accommodated. As a result, it is possible to prevent problems such as the generation of voids due to the remaining gas (or air, etc.) in the foaming mold 5.

  Further, by providing the gas duct 101 inside the seal portions S1 and S2 or between the plurality of seal portions S1 and S2, it is assumed that the foam liquid 6 serving as a raw material of the foam layer 3 and the foam liquid 6 are foamed in the gas duct 101. Even when the foamed fluid formed as described above flows in, it is possible to prevent the foamed liquid 6 and the foamed fluid from leaking immediately to the outside.

  As a result, it is possible to prevent the foamed layer 3 from sticking out, improve the appearance quality of the terminal portion of the obtained foamed molded product, and use the foamed molded product as it is.

  (3a) By providing the gas passage 102 communicating with the gas duct 101 at the end portion of the core material 2, a path for allowing gas to escape to the gas duct 101 can be secured.

  Further, the gas passage 102 has a size that allows gas to pass but does not allow the foam 6 or foam fluid to pass through, so that the foam 6 or foam fluid leaks to the outside through the gas passage 102. Can not be.

  (3b) A plurality of gas passages 102 are provided at intervals, and the gas duct 101 is a communication space extending so as to connect the plurality of gas passages 102, whereby the core material 2 and the skin material 4 It is possible to collect the gas accumulated in each part between the two gas passages 102 through a plurality of gas passages 102 in one gas duct 101 which is a communication space. As a result, the gas can be efficiently released to the gas duct 101.

  (3c) Since the external communication hole 103 capable of communicating with the outside is connected to the gas duct 101, the gas accumulated in the gas duct 101 can be efficiently discharged to the outside through the external communication hole 103. .

(Operation effect 4)
By opening the bifurcated seal portion 73 by inserting the expanding projection 78 provided inside the seal recess 72 into the bifurcated seal portion 73, both side surfaces 74, 75 of the bifurcated seal portion 73 are opened. Are forcibly pressed against the outer peripheral wall surface 76 and the inner peripheral wall surface 77 of the sealing recess 72, respectively, so that sealing is performed between the end portion of the skin material 4 and the end portion of the core material 2. Thus, the same effect as the above-described (effect 1) can be obtained.

  Although the embodiments of the present invention have been described in detail with reference to the drawings, the embodiments are only examples of the present invention, and the present invention is not limited to the configurations of the embodiments. Needless to say, design changes and the like within a range not departing from the gist of the invention are included in the present invention. Further, for example, when each embodiment includes a plurality of configurations, it is a matter of course that possible combinations of these configurations are included even if not specifically described. Further, when a plurality of embodiments and modifications are shown, it is needless to say that possible combinations of configurations extending over these are included even if not specifically described. Further, the configuration depicted in the drawings is of course included even if not particularly described. Further, when there is a term of “etc.”, it is used in the sense that the equivalent is included. In addition, when there are terms such as “almost”, “about”, “degree”, etc., they are used in the sense that they include those in the range and accuracy recognized by common sense.

DESCRIPTION OF SYMBOLS 1 Interior compartment panel 2 Core material 3 Foam layer 4 Skin material 5 Foaming mold 6 Foaming liquid 7 Foaming male mold 8 Foaming female mold 15 Sealing recessed part 16 Force-fitting thick part 71 End wall 72 Sealing recessed part 73 Bifurcated seal portions 74, 75 Both side surfaces 76 Outer peripheral wall surface 77 Inner peripheral wall surface 78 Expansion projection 79 Top surface 81 Groove portion 82, 83 Slope portion 84 Opening increasing guide portion 101 Gas duct 102 Gas passage 103 External communication hole S1 Seal part S2 Seal part

Claims (4)

In the foam molded product in which the core material and the skin material are integrated by the foam layer,
In the terminal part of the skin material, an end wall extending toward the terminal part of the core material is provided,
In the terminal part of the core material, a recess for sealing that is recessed toward the back side of the core material is provided,
A bifurcated seal portion that can be inserted into the seal recess is provided at the tip of the end wall,
By opening the bifurcated seal part in the seal recess,
A foam-molded article characterized in that the both sides of the bifurcated seal portion are provided with expanding projections that can be pressed against the outer peripheral wall surface and the inner peripheral wall surface of the sealing recess.   An opening increasing guide portion for increasing the opening degree of the bifurcated seal portion by entering the expanding projection portion is provided inside the bifurcated seal portion or on the outer surface of the expanding projection portion. The foam molded article according to claim 1, wherein   The foam according to claim 1 or 2, wherein a gas duct capable of containing a gas generated when a foam layer is formed is provided between the bifurcated seal portion and the expansion projection. Molding. By injecting a foaming liquid, which is the raw material for the foam layer, between the core material and the skin material set in the foam molding die, a foam molded product in which the core material and the skin material are integrated by the foam layer is manufactured. In the method of manufacturing a foamed molded product,
An end wall extending toward the end portion of the core material is provided at the end portion of the skin material, and the bifurcated seal portion provided at the distal end portion of the end wall is replaced by a sealing recess provided in the end portion of the core material. At the same time,
The projecting part for expansion provided inside the sealing recess is inserted into the bifurcated seal part and the bifurcated seal part is opened, so that both side surfaces of the bifurcated seal part are A method for producing a foam molded article, wherein the outer peripheral wall surface and the inner peripheral wall surface are pressed against each other, and sealing is performed between the end portion of the skin material and the end portion of the core material.