JP2014091285A - 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: A tapered protrusion 53, which extends toward a skin material 4 and has an outside slant surface 51 and an inside slant surface 52 at least at the front end of the skin material 4, is provided at a terminal part of a core material 2. A bifurcated protrusion 56, which extends toward the core material 2, has an outside arm part 54 and an inside arm part 55 at least at the front end of the core material 2 and can nip the tapered protrusion 53, is provided at a terminal part of the skin material 4. The outer arm part 54 of the bifurcated protrusion 56 has a core material abutting terminal part 57 abutting on the inner surface of the terminal part of the core material 2 and an outside slant surface abutting part 58 abutting on the outside slant surface 51, and the inside arm part 55 has a core material separating terminal part 61 separated from the inner surface of the terminal part of the core material 2 and an inside slant surface abutting part 62 abutting on the inside slant surface 52.

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 a foam molded product in which a core material and a skin material are integrated by a foam layer, and extends toward the skin material at a terminal portion of the core material. In addition, a tapered tapered protrusion having an outer inclined surface portion and an inner inclined surface portion is provided at least at the distal end portion thereof, and extends toward the core material at the terminal portion of the skin material, and at least at the distal end portion thereof, the outer arm. A core member that has a fork portion and an inner arm portion, and is provided with a bifurcated protrusion portion that can sandwich the tapered protrusion portion, and an outer arm portion of the bifurcated protrusion portion is in contact with an inner surface of a terminal portion of the core member A core member separation end portion that has an abutting end portion and an outer slope contact portion that contacts the outer slope surface portion, and the inner arm portion is spaced from the inner surface of the end portion of the core material, and the inner slope And an inner slope contact portion that contacts the surface portion.
The invention described in claim 2 is characterized in that, in the above, the inner arm portion is configured to be thinner than the outer arm portion.
According to a third aspect of the present invention, in the above, a gas duct capable of accommodating a gas generated when the foamed layer is formed is provided in a sandwiched portion between the tapered protrusion and the bifurcated protrusion. Features.
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 in which a foam layer is integrated with a foam layer, a tapered projection provided at the end portion of the core material and a bifurcated projection provided at the end portion of the skin material are sandwiched. The core material abutting end portion of the outer arm portion of the bifurcated projection is brought into contact with the inner surface of the end portion of the core material, and the outer slope contact portion is brought into contact with the outer inclined surface portion of the tapered projection. In addition, by separating the core material separation end of the inner arm portion of the bifurcated projection from the inner surface of the end portion of the core material, by bringing the inner slope contact portion into contact with the inner slope surface portion of the tapered projection, Sealing between the end portion of the core material and the end portion of the skin material is performed by the foaming pressure when forming the foam layer. And characterized in that.

According to the first aspect of the present invention, the following operational effects can be obtained by the above configuration.
That is, by adopting a seal structure in which a bifurcated protrusion provided on the end portion of the skin material is sandwiched between the tapered protrusion provided on the end portion of the core material, the end portion of the core material and the end portion of the skin material Can be sealed in a state of being arranged substantially in parallel, and the thickness of the end portion of the foamed molded product can be prevented from being increased due to the sealing. That is, the terminal shape of the product can be made clear.
Further, the tapered protrusion and the bifurcated protrusion can be easily and reliably sandwiched. As a result, it is possible to eliminate problems such as poor fitting of the seal portion and deformation of the skin material during fitting.
Furthermore, the core material abutting end portion of the outer arm portion of the skin material is abutted against the inner surface of the end portion of the core material, so that the position regulation of the core material and the skin material in the thickness direction can be reliably performed. it can.
Then, the outer slope contact portion of the outer arm portion is brought into contact with the outer inclined surface portion of the tapered projection portion, and the inner slope contact portion of the inner arm portion is brought into contact with the inner inclined surface portion of the tapered projection portion. It is possible to restrict the position of the material and the skin material in the surface direction.
In addition, the core arm separation end of the inner arm part is separated from the inner surface of the end part of the core material, so that the inner arm part is sure to bend and turn against the inner surface of the end part of the core material. Can be prevented. Moreover, a soft tactile sensation can be imparted to the inner portion of the end portion of the foam molded product with respect to the tapered protrusion.
Since the inner slope contact portion of the inner arm portion is pressed against the inner slope surface portion of the tapered protrusion by the foaming pressure at the time of forming the foam layer, both are sealed. Sealing can advantageously take place at a position inside the tapered projection, which is located inside.
As a result, the foam layer is prevented from sticking out of the foam layer due to leakage of foaming liquid, etc. around the terminal part of the product, the quality around the terminal part is improved, and the foam molded product is formed in the same size as the product. It becomes possible.
According to the second aspect of the present invention, the following effects can be obtained by the above configuration.
That is, since the inner arm portion is configured to be thinner than the outer arm portion, it is possible to improve the followability and adhesion of the inner arm portion with respect to the inner inclined surface portion of the tapered protrusion, thereby improving the sealing performance. Moreover, the tactile sensation of the inner portion of the end portion of the foam molded product than the tapered protrusion can be made softer.
On the contrary, when the outer arm portion is thicker than the inner arm portion, it is possible to give a sense of rigidity to the terminal portion of the foam molded product. Further, the position regulation in the thickness direction between the core material and the skin material can be made stronger.
According to the third aspect of the present invention, the following operational effects can be obtained by the above configuration.
In other words, gas (or air confined in the foaming mold) generated during molding of the foam layer is accommodated in the gas duct by the gas duct provided inside the sandwiched portion between the tapered projection and the bifurcated projection. Will be 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, by sandwiching the tapered protrusion provided at the end portion of the core material and the bifurcated protrusion provided at the end portion of the skin material, the core abutting end of the outer arm portion of the bifurcated protrusion is While contacting the inner surface of the terminal portion of the core material, the outer inclined surface contact portion is contacted to the outer inclined surface portion of the tapered protrusion, and the core material separation end of the inner arm portion of the bifurcated protrusion is the core material The end portion of the core material and the skin material are separated from the inner surface of the end portion of the core member by the foaming pressure when the foam layer is formed by contacting the inner inclined surface contact portion with the inner inclined surface portion of the tapered protrusion. The effect similar to that of the first aspect of the present invention can be obtained by sealing between the terminal portions of the first and second terminals.

It is a partial expansion longitudinal cross-sectional view 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 of the mold closed 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 the elements on larger scale of the terminal part which shows the outer wall seal structure of a foaming molding.

  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 FIG. 1 and FIG. 2, a tapered tapered protrusion that extends toward the skin material 4 at the end portion of the core material 2 and has an outer inclined surface portion 51 and an inner inclined surface portion 52 at least at the tip thereof. A portion 53 is provided.
In addition, the end portion of the skin material 4 extends toward the core material 2, and has an outer arm portion 54 and an inner arm portion 55 at least at the tip thereof, so that the tapered protrusion 53 can be sandwiched. A bifurcated protrusion 56 is provided.
Then, the outer arm portion 54 of the bifurcated protrusion 56 has a core material abutting end portion 57 that contacts the inner surface of the end portion of the core material 2, and an outer slope contact portion 58 that contacts the outer inclined surface portion 51. It is supposed to have.
The inner arm portion 55 includes a core material separation end portion 61 that is separated from the inner surface of the end portion of the core material 2 and an inner slope contact portion 62 that contacts the inner slope surface portion 52. .

(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-described “outer inclined surface portion 51” is an inclined surface that proceeds inward as it proceeds toward the skin material 4 side.

  The above-mentioned “inner inclined surface portion 52” is an inclined surface that goes outward as it proceeds to the skin material 4 side.

  The “tapered protrusion 53” is formed integrally with the core material 2. The tapered protrusion 53 is provided continuously with respect to the peripheral edge of the core material 2. A small protrusion 63 is formed at the tip of the tapered protrusion 53 as necessary.

  The above-mentioned “outer arm portion 54” is positioned outward with the tapered protrusion 53 as a reference.

  The above-mentioned “inner arm portion 55” is positioned inward with the tapered protrusion 53 as a reference.

  The above-mentioned “bifurcated protrusion 56” is formed integrally with the skin material 4. The bifurcated protrusion 56 is provided continuously with respect to the peripheral edge of the skin material 4. A small recess 64 into which the above-described small protrusion 63 is fitted is formed at a branch portion between the outer arm 54 and the inner arm 55 in the bifurcated protrusion 56.

  The above-described “core member abutting end portion 57” is formed at the distal end portion of the outer arm portion 54.

  The “outer slope contact portion 58” described above is formed on the inner side surface of the outer arm portion 54. The outer slope contact portion 58 has an inclined surface having substantially the same angle as the outer inclined surface portion 51. The outer inclined surface contact portion 58 and the outer inclined surface portion 51 form an outer seal portion (seal portion S2). The outer seal portion is a sub seal.

  The above-described “core material separation end portion 61” is formed at the distal end portion of the inner arm portion 55. The core material separation end portion 61 is shorter than the core material abutting end portion 57.

  The “inner slope abutting portion 62” is formed on the outer surface of the inner arm portion 55. The inner slope contact portion 62 has an inclined surface having substantially the same angle as the inner inclined surface portion 52. The inner inclined surface contact portion 62 and the inner inclined surface portion 52 form an inner seal portion (seal portion S1). This inner seal portion is a main seal portion. The inner seal portion and the outer seal portion constitute inner and outer double seal portions (seal portions S1, S2).

(Configuration 2)
In the above, the inner arm portion 55 may be configured to be thinner than the outer arm portion 54.

(Supplementary explanation 2)
Here, the above-mentioned “inner arm portion 55” has the same thickness as that of the other portions of the skin material 4, or is slightly thinner or slightly thicker (thin arm portion).
On the other hand, the above-mentioned “outer arm portion 54” is sufficiently thicker than the other portions of the skin material 4 (thick arm portion).

(Configuration 3)
In the above, the gas duct 101 that can accommodate the gas generated when the foamed layer 3 is molded may be provided inside the sandwiched portion between the tapered protrusion 53 and the bifurcated protrusion 56.

(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 formed between the small protrusion 63 and the small recess 64 that are sandwiched between the inner seal part (seal part S1) and the outer seal part (seal part S2). In this case, the small concave portion 64 is formed deeper than the protruding amount of the small protruding portion 63.

  (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 inclined surface portion 52 and the inner portion of the small protrusion 63. 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 small concave portion 64 provided in the terminal portion of the skin material 4.

  (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. The above-described foamed molded product is manufactured.
At this time, the tapered protrusion 53 provided in the terminal portion of the core material 2 and the bifurcated protrusion 56 provided in the terminal portion of the skin material 4 are sandwiched,
The core material abutting end portion 57 of the outer arm portion 54 of the bifurcated projection 56 is brought into contact with the inner surface of the end portion of the core material 2, and the outer slope contact portion 58 is brought into contact with the outer inclined surface portion 51 of the tapered projection 53. Abut,
Further, the core material separation end 61 of the inner arm portion 55 of the bifurcated projection 56 is separated from the inner surface of the end portion of the core material 2, and the inner slope contact portion 62 is formed on the inner inclined surface portion 52 of the tapered projection 53. By abutting, the sealing between the terminal portion of the core material 2 and the terminal portion of the skin material 4 is performed by the foaming pressure when the foaming layer 3 is formed.

(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)
By adopting a seal structure in which a bifurcated protrusion 56 provided at the terminal portion of the skin material 4 is sandwiched between the tapered protrusion 53 provided at the terminal portion of the core material 2, the terminal portion of the core material 2 and the skin material 4 are provided. It is possible to perform sealing in a state where the terminal portion is arranged substantially in parallel, and the thickness of the terminal portion of the foam molded product can be prevented from being increased due to the sealing. That is, the terminal shape of the product can be made clear.

  Further, the tapered protrusion 53 and the bifurcated protrusion 56 can be easily and reliably sandwiched. As a result, it is possible to eliminate problems such as poor fitting of the seal portion and deformation of the skin material 4 during fitting.

  Further, the core material abutting end portion 57 of the outer arm portion 54 of the skin material 4 is abutted against the inner surface of the end portion of the core material 2 so that the position regulation in the thickness direction of the core material 2 and the skin material 4 is restricted. It can be done reliably.

  Then, the outer slope contact portion 58 of the outer arm portion 54 is brought into contact with the outer inclined surface portion 51 of the tapered protrusion 53, and the inner slope contact portion 62 of the inner arm portion 55 is brought into contact with the inner inclined surface portion 52 of the tapered protrusion 53. By making it contact | abut, position control of the surface direction of the core material 2 and the skin material 4 can be performed.

  Further, the core material separation end 61 of the inner arm portion 55 is separated from the inner surface of the end portion of the core member 2, so that the inner arm portion 55 is bent against the inner surface of the end portion of the core member 2. Can be surely prevented. Further, a soft tactile sensation can be imparted to the inner portion of the end portion of the foam molded product with respect to the tapered protrusion 53.

  Since the inner slope contact portion 62 of the inner arm portion 55 is pressed against the inner inclined surface portion 52 of the tapered protrusion 53 by the foaming pressure when the foam layer 3 is molded, both are sealed. Sealing can be advantageously performed at a position inside the tapered protrusion 53 that is located slightly inside the terminal portion.

  As described above, the outside of the foam layer 3 due to leakage of the foaming liquid 6 around the terminal portion of the product is eliminated, the quality around the terminal portion is improved, and the foam molded product is made the same size as the product. It can be formed.

(Operation effect 2)
By configuring the inner arm portion 55 to be thinner than the outer arm portion 54, it is possible to improve the followability and adhesion of the inner arm portion 55 with respect to the inner inclined surface portion 52 of the tapered protrusion 53, thereby improving the sealing performance. it can. Moreover, the tactile sensation of the inner portion of the end portion of the foam molded product with respect to the tapered protrusion 53 can be made softer.

  On the contrary, when the outer arm portion 54 is thicker than the inner arm portion 55, it is possible to give a sense of rigidity to the terminal portion of the foam molded product. Further, the position regulation in the thickness direction between the core material 2 and the skin material 4 can be made stronger.

(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.

  Gas generated when the foamed layer 3 is molded (or air confined in the foam molding die 5) by the gas duct 101 provided inside the sandwiched portion between the tapered projecting portion 53 and the bifurcated projecting portion 56 is used. It can be accommodated in the gas duct 101. 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 portion (seal portions S1, S2) or between the plurality of seal portions, the foam liquid 6 serving as the raw material of the foam layer 3 or the foam liquid 6 is temporarily provided in the gas duct 101. Even if the foamed fluid formed by foaming 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)
A taper protrusion 53 provided at the terminal portion of the core material 2 and a bifurcated protrusion portion 56 provided at the terminal portion of the skin material 4 are sandwiched, and the core material protrusion of the outer arm portion 54 of the bifurcated protrusion 56 is sandwiched. The abutting end portion 57 is brought into contact with the inner surface of the end portion of the core member 2, the outer slope contact portion 58 is brought into contact with the outer slope surface portion 51 of the tapered projection portion 53, and the inner arm of the bifurcated projection portion 56 The core material separation end 61 of the portion 55 is separated from the inner surface of the end portion of the core material 2, and the inner slope contact portion 62 is brought into contact with the inner sloped surface portion 52 of the tapered protrusion 53, whereby the foam layer 3 is By causing the end portion of the core material 2 and the end portion of the skin material 4 to be sealed by the foaming pressure at the time of molding, it is possible to obtain the same effect as the above-described (effect 1). .

  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 Car interior part interior panel 2 Core material 3 Foam layer 4 Skin material 5 Foaming mold 6 Foaming liquid 7 Foaming male mold 8 Foaming female mold 51 Outer inclined surface part 52 Inner inclined surface part 53 Tapered protrusion 54 Outer arm part 55 Inner arm Portion 56 bifurcated protrusion 57 core material abutting end portion 58 outer slope contact portion 61 core material separation end portion 62 inner slope contact portion 63 small protrusion portion 64 small recess portion 101 gas duct 102 gas passage 103 external communication hole S1 seal portion (first)
S2 Seal part (second)

Claims (4)

In the foam molded product in which the core material and the skin material are integrated by the foam layer,
At the end portion of the core material, extending toward the skin material, and at least the tip thereof is provided with a tapered tapered protrusion having an outer inclined surface portion and an inner inclined surface portion,
At the terminal portion of the skin material, it extends toward the core material, and at least the tip thereof has an outer arm portion and an inner arm portion, and is provided with a bifurcated protrusion that can sandwich the tapered protrusion.
The outer arm portion of the bifurcated protrusion has a core abutting end portion that contacts the inner surface of the end portion of the core material, and an outer slope contact portion that contacts the outer inclined surface portion,
The foam-molded product, wherein the inner arm portion includes a core material separation end portion that is separated from an inner surface of a terminal portion of the core material, and an inner slope contact portion that contacts the inner inclined surface portion.   The foam molded product according to claim 1, wherein the inner arm portion is configured to be thinner than the outer arm portion.   The gas duct capable of containing a gas generated when the foamed layer is formed is provided inside a sandwiched portion between the tapered protrusion and the bifurcated protrusion. Foam molded product. 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,
By sandwiching the tapered protrusion provided in the terminal portion of the core material and the bifurcated protrusion provided in the terminal portion of the skin material,
The core material abutting end portion of the outer arm portion of the bifurcated projection is brought into contact with the inner surface of the end portion of the core material, and the outer slope contact portion is brought into contact with the outer inclined surface portion of the tapered projection portion,
Further, the core material separation end portion of the inner arm portion of the bifurcated projection is separated from the inner surface of the end portion of the core material, and the inner slope contact portion is brought into contact with the inner slope surface portion of the tapered projection. A method for producing a foam-molded article, wherein sealing is performed between a terminal portion of a core material and a terminal portion of a skin material by a foaming pressure at the time of forming a layer.