JP2014091288A - 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 21 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 22 recessed toward the rear surface side of the core material 2 is provided at a terminal part of the core material 2. A sealing insertion part 24 which has a gap 23 and can be inserted into the sealing recessed part 22 is provided at a front end part of the end wall 21. Further, an inner surface sealing part 26 which is press-contacted by a foaming pressure in molding the foamed layer 3 is formed between an inner surface wall 25 of the sealing recessed part 22 and a front end part of the sealing insertion part 24.

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. 7 at the front of the vehicle interior.

  As shown in FIG. 8, such a vehicle interior compartment interior panel 1 includes a foam molded article 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. 9, 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. 3155227

  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.

  Therefore, for example, an outer wall seal structure as shown in FIG. 10 has been examined informally.

  In the outer wall seal structure, first, an end wall 15 extending toward the end portion of the core material 2 is provided at the end portion of the skin material 4. In addition, a sealing recess 16 that is recessed toward the back side of the core material 2 is provided at the end portion of the core material 2, and a gap 17 is provided at the tip of the end wall 15 with respect to the inside of the sealing recess 16. Thus, an insertable seal insertion portion 18 is provided.

  A bent top surface that can be brought into contact with the top surface 16b of the sealing recess 16 without contacting the sharp inner wall surface 16a of the sealing recess 16 with the tip side portion of the sealing insertion portion 18 The contact piece 18b is formed.

  Further, the connecting portion (base portion) of the sealing insertion portion 18 to the end wall 15 can be pressed against the outer wall surface 16c (outer wall side sealing surface) inclined upward from the sealing concave portion 16 by foaming pressure. The bent outer wall side seal piece 18c is formed, and sealing is performed between the outer wall surface 16c (outer wall side seal surface) and the outer wall side seal piece 18c.

  However, in the case of such an outer wall seal structure, when the top surface contact piece 18b of the seal insertion portion 18 is turned downward as indicated by an arrow in the figure, the top surface contact piece 18b is separated from the top surface 16b. Further, there is a concern that the outer wall side sealing piece 18c is separated from the outer wall surface 16c, and the sealing function is not performed.

  In addition, when the top surface contact piece 18b is shorter than the design allowable value due to a manufacturing error, the foam pressure is likely to go around to the back side of the top surface contact piece 18b, so that the top surface contact with the foam pressure is reduced. There is a possibility that the contact piece 18b is turned.

  Therefore, in the outer wall seal structure as described above, since the top surface abutting piece 18b is weakly turned, the sealing performance is unstable, and the top surface abutting piece 18b varies due to a manufacturing error of the skin material 4. There is a problem that the allowable range is narrow.

  Moreover, since the outer wall side sealing piece 18c is provided at the position of the connecting portion with respect to the end wall 15 of the skin material 4, it is easily affected by the shape and rigidity of the end wall 15 of the skin material 4, and the skin material Depending on the shape, rigidity, and the like of the end wall 15 of 4, the following capability of the sealing recess 16 with respect to the outer wall surface 16c may be deteriorated.

In order to solve the above problem, the invention described in claim 1 is:
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,
At the tip of the end wall, a seal insertion part is provided that can be inserted with a gap with respect to the seal recess,
An inner wall seal portion is formed between the inner wall surface of the sealing concave portion and the tip end portion of the sealing insertion portion. The inner wall sealing portion is brought into pressure contact with the foaming pressure when the foamed layer is formed.
The invention described in claim 2 is the above,
The inner wall seal portion is
An inner wall sealing surface that is formed on at least a part of the inner wall surface of the concave portion for sealing, and is inclined downward toward the inside;
An inner wall-side seal piece that is bent and formed so as to be inclined upward or horizontally toward the distal end of the insertion portion for sealing,
The inner wall seal surface is characterized in that when the inner wall side seal piece comes into contact with the inner wall side seal piece, the inner wall side seal piece can be deformed to a downward gradient inward along the inner wall seal surface.
The invention described in claim 3 is the above,
An outer wall seal portion is formed between the outer wall surface of the recess for sealing and the connecting portion of the insertion portion for sealing with the end wall, which is pressed by foaming pressure when forming the foam layer. To do.
The invention described in claim 4 is the above,
The outer wall seal portion is
An outer wall sealing surface that is formed on at least a part of the outer wall surface of the recess for sealing and is inclined in an upward gradient toward the inside;
An outer wall-side seal piece that is bent upwardly inward so as to rise at an angle that is the same as or slightly larger than the outer wall seal surface at the connecting portion of the seal insertion portion with respect to the end wall; Have
The outer wall seal surface is characterized in that, when the outer wall side seal piece comes into contact, the outer wall side seal piece can be deformed inward along the outer wall seal surface.
The invention described in claim 5 is the above,
The said core material has the rib wall part extended toward the said skin material side in the edge part of the inner wall face of the said recessed part for a seal | sticker, It is characterized by the above-mentioned.
The invention described in claim 6 is the above,
A gas duct is provided between the inner wall seal portion and the outer wall seal portion so as to accommodate a gas generated when the foamed layer is formed.
The invention described in claim 7 is the above,
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 seal insertion portion provided at the tip end portion of the end wall is formed into a seal recess provided in the end portion of the core material. On the other hand, in a state of being accommodated with a gap,
The distal end portion of the sealing insertion portion is brought into pressure contact with the inner wall surface of the concave portion for sealing by the foaming pressure at the time of forming the foam layer, and at the position of the inner wall surface of the concave portion for sealing, the end portion of the skin material and the core material A seal between the terminal portion is performed.

According to the first aspect of the present invention, the following operational effects can be obtained by the above configuration. That is, since the seal insertion portion is accommodated with a gap with respect to the seal recess, an excessive force is not applied when the seal insert is inserted into the seal recess. It is possible to prevent the insertion failure of the seal insertion portion from occurring or the skin material from wrinkling due to excessive force during insertion.
In addition, the inner wall seal portion that is pressed by the foaming pressure at the time of molding the foam layer is formed between the inner wall surface of the concave portion for sealing and the tip portion of the insertion portion for sealing. Since it becomes possible to make a seal structure that makes good use of the deformation in the direction, it is possible to effectively prevent leakage of foaming liquid or the like caused by turning up of the insertion portion for sealing.
In addition, by adopting a seal structure that utilizes deformation in the turn-up direction of the seal insertion portion, an allowable range can be widened even if the seal insertion portion varies due to a manufacturing error of the skin material.
Furthermore, since the tip of the sealing insertion portion that seals with the inner wall surface of the concave portion for sealing is a part away from the connecting portion with the end wall of the skin material, the shape of the end wall of the skin material It is possible to make it less susceptible to the influence of rigidity and rigidity. Therefore, it is prevented that the tip of the seal insertion part becomes difficult to follow the shape of the inner wall surface of the recess for sealing due to the shape and rigidity of the end wall of the skin material. Can be secured.
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, when the inner wall side seal piece comes into contact with the inner wall seal surface, the inner wall side seal piece is deformed in a downward gradient inward along the inner wall seal surface, so that the inner wall seal surface and the inner wall side are deformed. It is possible to seal the seal piece with a tight contact.
According to the third aspect of the present invention, the following operational effects can be obtained by the above configuration. That is, by forming the outer wall seal portion between the outer wall surface of the concave portion for sealing and the connecting portion to the end wall of the insertion portion for sealing, a double seal structure with the inner wall seal portion and the outer wall seal portion is achieved. As a result, the sealing performance can be further improved. In this case, the inner wall seal portion is a main seal and the outer wall seal portion is a sub seal.
According to the invention described in claim 4, the following effects can be obtained by the above-described configuration. That is, when the outer wall seal surface comes into contact with the outer wall seal piece, the outer wall seal piece is deformed inwardly along the outer wall seal surface, so that the outer wall seal surface and the outer wall seal piece are It is possible to seal the gap between them securely.
According to the fifth aspect of the present invention, the following effects can be obtained by the above configuration. That is, when the core material has a ridge wall portion extending toward the skin material side at the edge of the inner wall surface of the concave portion for sealing, a foaming liquid (for example, liquid urethane or the like) used as a raw material for the foaming layer is foamed. Can temporarily stop part of the flow of gas or foamed fluid (for example, non-solidified foam such as viscous urethane) to reduce the flow rate, regulate the flow rate, By adjusting them, they can be guided gently in the thickness direction of the foam molded product. As a result, the gas or the foamy fluid comes into pressure contact with the inner wall surface or the outer wall surface of the concave portion for sealing in an optimal state, so that sufficient sealing performance can be ensured. It becomes possible.
According to the sixth aspect of the present invention, the following effects can be obtained by the above configuration. In other words, the gas duct provided between the inner wall seal portion and the outer wall seal portion can accommodate the gas generated when the foamed layer is molded (or air confined in the foam molding die) and the like in the gas duct. As a result, it is possible to prevent problems such as the generation of voids due to gas (or air) remaining in the foaming mold.
According to the seventh aspect of the present invention, the following effects can be obtained by the above configuration. That is, the tip end portion of the sealing insertion portion is brought into pressure contact with the inner wall surface of the sealing concave portion by the foaming pressure at the time of forming the foam layer, and at the position of the inner wall surface of the sealing concave portion, the end portion of the skin material and the core The effect similar to that of the first aspect can be obtained by sealing between the end portions of the material.

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 an operation diagram of FIG. 1 (clamping state). FIG. 3 is an operation diagram following FIG. 2 (foaming state). FIG. 4 is an operation diagram following FIG. 3 (foaming end state). It is a whole top view of a core material. It is the elements on larger scale of the corner part 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. 7 (mold open state). It is a partial expanded longitudinal cross-sectional view of the terminal part of a foaming molded article which shows the outer wall seal structure under examination now.

  A vehicle such as an automobile is provided with a vehicle interior front panel 1 called an instrument panel or dashboard as shown in FIG. 7 at the front of the vehicle interior.

  As shown in FIG. 8, such a vehicle interior front 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. 9, the interior interior panel 1 having such a multilayer structure is provided between the core material 2 and the skin material 4 set in the foam molding die 5 of the foam molding apparatus (foam molding space). It is manufactured by injecting a foaming liquid 6 which will be described later as a raw material of the foaming layer 3 and foaming the foaming liquid 6 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.
FIGS. 1-6 shows this Example and its modification. 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 will be described.

(Configuration 1)
As shown in FIG. 1 (to FIG. 4), an end wall 21 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 22 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. FIG.
Further, a seal insertion portion 24 that can be inserted with a gap 23 is provided at the tip of the end wall 21 with respect to the seal recess 22.
The inner wall seal portion 26 is pressed between the inner wall surface 25 of the sealing recess 22 and the tip end portion of the sealing insertion portion 24 by the foaming pressure when the foamed layer 3 is molded (see FIG. 4). Form.

(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.

  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.

  And the above-mentioned "end part wall 21" becomes an end surface of a product while it becomes an end surface of a foaming molded product. The end wall 21 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 21 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 21 is substantially the same as the thickness of the foam molded product, or is slightly shorter or slightly longer than that. The thickness (wall thickness) of the end wall 21 is substantially the same as the other part of the skin material 4. The end wall 21 extends continuously in the circumferential direction along the edge of the foam molded article. However, depending on the shape of the foam molded product, the end wall 21 may be discontinuous in the circumferential direction.

  The “sealing recess 22” described above includes the inner wall surface 25, the top surface 27, and the outer wall surface 28 described above. The sealing recess 22 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 22 may be discontinuous in the circumferential direction. The sealing recess 22 has a substantially constant thickness and is configured to have a concave shape on both the inner and outer surfaces.

  The “gap 23” described above is a marginal space with respect to the surface direction of the foam molded product. The gap 23 is at least relatively larger than the thickness of the end wall 21.

  The above-described “seal insertion portion 24” has substantially the same thickness as the skin material 4 and the end wall 21. The end wall 21 and the seal insertion portion 24 are continuous so as to be substantially J-shaped in a side view, that is, in a shape in which the seal insertion portion 24 is wound inside.

  The above-mentioned “foaming pressure” is mainly generated by gas or foam fluid (for example, unsolidified foam such as viscous urethane) generated from the foaming liquid 6 which is a raw material of the foam layer 3. .

  As shown in FIG. 4, the above-mentioned “inner wall seal portion 26” is literally a seal portion formed on the inner wall surface 25 side of the sealing recess 22. The inner wall seal portion 26 becomes the first seal portion S1.

(Configuration 2)
The inner wall seal portion 26 is formed on at least a part of the inner wall surface 25 of the sealing recess 22, and the inner wall seal surface 31 is inclined downward inward and the sealing insertion portion 24. The inner wall side seal piece 32 that is bent so as to have an upward slope toward the horizontal or inward direction is provided at the distal end portion.
When the corner portion of the leading edge of the inner wall side sealing piece 32 abuts on the inner wall sealing surface 31 as shown in FIG. 2, the inner wall sealing piece 32 is moved inwardly along the inner wall sealing surface 31 as shown in FIG. It is assumed that it can be deformed to a downward slope toward (or deformed so as to be turned downward).

(Supplementary explanation 2)
Here, the above-mentioned “inner wall sealing surface 31” is 30 ° to 30 ° with respect to the horizontal direction so that an effective component force can be generated in both the vertical direction and the horizontal direction in the figure. The inclined surface has an inclination angle 33 (see FIG. 4) of about 45 °. In this case, the inner wall sealing surface 31 is an inclined surface provided over substantially the entire area of the inner wall surface 25 of the sealing recess 22. The sealing recess 22 is such that the entire inner and outer surfaces of the inner wall surface 25 are inclined at the same angle as the inner wall sealing surface 31.
However, the inner wall sealing surface 31 may be provided only for a partial range on the top surface 27 side.

As shown in FIG. 2, the above-mentioned “inner wall side sealing piece 32” has its tip in contact with the intermediate portion of the inner wall sealing surface 31 when the sealing insertion portion 24 is inserted into the sealing concave portion 22. As shown, when the foaming pressure is applied and the sealing insertion portion 24 is completely pressed against the outer wall surface 28 and the top surface 27 of the sealing recess 22, the tip thereof is at least part of the inner wall sealing surface 31. It has a length that touches. As shown in FIG. 3, the angle of the inner wall side seal piece 32 is set so as to ensure that the inner wall side seal piece 32 is turned into the inwardly lowered state when the tip of the inner wall side seal piece 32 is rubbed by the inner wall seal surface 31. Or as shown in FIG. 2, it forms so that it may become any angle from the horizontal to the angle orthogonal to the inner-wall sealing surface 31. As shown in FIG.
In terms of structure, it is conceivable to form the inner wall side sealing piece 32 inwardly from the beginning. However, in this case, the sealing performance becomes unstable, so this is not adopted in this case.

  The inner wall side seal piece 32 is formed to be slightly longer than the top surface 27, the tip of the inner wall side seal piece 32 is inserted into the sealing recess 22, and the corner of the tip edge is the inner wall seal surface 31. In the state where it is in contact with the intermediate portion, the tip end portion of the inner wall side seal piece 32 is held in a sandwiched state at least between the foamed female die 8 and the inner wall seal surface 31 or in each portion of the seal recess 22. Yes. In this state, the tip of the inner wall side seal piece 32 is supported by the corner of the tip edge of the inner wall side seal piece 32 pressing the inner wall seal surface 31 in a line contact state. This prevents the seal insertion portion 24 from easily falling down. Further, in the initial state in which the foaming pressure at the time of foam molding is applied, the corner portion of the leading edge of the inner wall side seal piece 32 and the inner wall seal surface 31 are in a line contact state, that is, a line seal is formed, and foaming proceeds. In the later stage of foaming in which the foam fluid is completely filled, the tip of the inner wall side seal piece 32 changes from the line contact state to the surface contact state due to the foaming pressure, and the surface is sealed.

(Configuration 3)
In the above, as shown in FIG. 4, foaming is performed when the foaming layer 3 is formed between the outer wall surface 28 of the sealing recess 22 and the connecting portion of the sealing insertion portion 24 to the end wall 21. It is possible to form the outer wall seal portion 35 that is pressed by pressure.

(Supplementary explanation 3)
Here, the above-described “outer wall seal portion 35” is literally a seal portion formed on the outer wall surface 28 side of the sealing recess 22. The outer wall seal portion 35 becomes the second seal portion S2.

(Configuration 4)
The outer wall seal portion 35 is formed on at least a part of the outer wall surface 28 of the sealing recess 22, and the outer wall seal surface 36 is inclined inwardly upward and the sealing insertion portion 24. The outer wall side sealing piece 37 is formed at the connecting portion with respect to the end wall 21 so as to be bent in an upward gradient inward so as to rise at an angle that is the same as or slightly larger than the outer wall sealing surface 36. It is supposed to be.
The outer wall sealing surface 36 can be deformed inwardly along the outer wall sealing surface 36 when the outer wall sealing piece 37 comes into contact therewith.

(Supplementary explanation 4)
Here, the above-mentioned “outer wall sealing surface 36” has an angle of 30 ° to the vertical direction in order to generate an effective component force in both the vertical direction and the horizontal direction in the figure. The inclined surface has an inclination angle 38 of about 45 °. In this case, the outer wall sealing surface 36 is a partial surface provided on a portion (tip portion) near the skin material 4 on the outer wall surface 28 of the sealing recess 22. As a result, the sealing concave portion 22 has a parallel shape in which the inner and outer surfaces of the outer wall surface portion 28 extend vertically toward the end portion of the skin material 4 as a whole, and the outer wall sealing surface 36 portion is partially formed. It has a tapered shape.
However, the outer wall sealing surface 36 may be an inclined surface provided over substantially the entire area of the outer wall surface 28.

  As shown in FIG. 2, the above-mentioned “outer wall side sealing piece 37” is slightly in contact with the outer wall sealing surface 36 in a state where the sealing insertion portion 24 is inserted into the sealing concave portion 22, or is slightly spaced. So that they are separated. In this case, the interval between the seal insertion portion 24 and the outer wall seal surface 36 is substantially the same as or smaller than the thickness of the seal insertion portion 24.

(Configuration 5)
Further, the core material 2 may have a ridge wall portion 39 extending toward the skin material 4 at the edge of the inner wall surface 25 of the sealing recess 22.

(Supplementary explanation 5)
Here, the above-described “projection wall portion 39” is a hanging wall extending downward from the inner end portion (lower end portion) of the inner wall surface 25. As shown by an arrow in FIG. 3, this ridge wall portion 39 temporarily stops part of the flow of gas or foam fluid (the upper part) formed by foaming of the foaming liquid 6, This is for controlling the flow rate, regulating the flow rate, and adjusting the flow direction. The projecting wall portion 39 has a tapered shape having a required punching slope on both surfaces (inner and outer surfaces). The protruding length of the ridge wall portion 39 is about 1/5 to 1/2 of the thickness of the foam layer 3 (the height of the foam molding space).

  Note that the front end 22a (lower end) of the outer wall surface 28 of the sealing recess 22 is positioned at substantially the same level as the back surface of the core material 2, and the front end (lower end) of the ridge wall 39 is The outer wall surface 28 is positioned closer to the skin material 4 than the front end (lower end).

(Configuration 6)
In addition, as shown in FIG. 4, a gas duct 101 that can accommodate a gas generated when the foamed layer 3 is molded may be provided between the inner wall seal portion 26 and the outer wall seal portion 35. .

(Supplementary explanation 6)
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 provided in a space formed by the sealing insertion portion 24 closing the corner portion between the outer wall surface 28 and the top surface 27 of the sealing recess 22.

(6a) Further, the gas generated when the foamed layer 3 is molded is passed through the end portion of the core material 2 through the gas duct 101, and the foamed liquid 6 or the foamed liquid 6 serving as the raw material of the foamed layer 3 is obtained. 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 between the gas duct 101.

  In this case, the gas passage 102 is formed between the top surface 27 and the inner wall surface 25 in the sealing recess 22. 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.

  (6b) As shown in FIGS. 5 and 6, a plurality of the gas passages 102 are provided at intervals, and the gas duct 101 extends so as to connect the plurality of gas passages 102. It is preferable to provide a communication space.

  In this case, the gas duct 101 is continuously extended in the circumferential direction along the inside of the sealing recess 22 provided in the terminal portion of the core member 2.

  (6c) 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 7)
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, an end wall 21 extending toward the end portion of the core material 2 is provided at the end portion of the skin material 4, and the sealing insertion portion 24 provided at the distal end portion of the end wall 21 is provided on the end portion of the core material 2. In a state of having a gap 23 with respect to the sealing recess 22 provided in the terminal portion,
The distal end portion of the seal insertion portion 24 is brought into pressure contact with the inner wall surface 25 of the seal recess 22 by the foaming pressure when the foam layer 3 is formed, and the skin material 4 is positioned at the position of the inner wall surface 25 of the seal recess 22. Sealing is performed between the terminal portion and the terminal portion of the core member 2.

(Supplementary explanation 7)
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. 9, 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 die 5 of the foam molding apparatus opened (mold open 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 this case, the parts that are not necessary for the product are parts that are inside the opening formed in the product.

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

(Operation effect 1)
Since the sealing insertion portion 24 is accommodated in the sealing recess 22 with a gap 23, an excessive force is not applied when the sealing insertion portion 24 is inserted into the sealing recess 22. Therefore, it is possible to prevent the insertion failure of the seal insertion portion 24 from occurring or the skin material 4 from being wrinkled due to an excessive force at the time of insertion.

  Further, the inner wall seal portion 26 that is pressed by the foaming pressure at the time of molding the foamed layer 3 is formed between the inner wall surface 25 of the sealing concave portion 22 and the distal end portion of the sealing insertion portion 24, thereby providing a seal. Since it is possible to make a seal structure that effectively utilizes the deformation of the insertion portion 24 in the turning direction, it is possible to effectively prevent leakage of the foamed liquid 6 and the like caused by turning of the insertion portion 24 for sealing. become.

  Further, by adopting a seal structure that utilizes deformation in the turning direction of the seal insertion portion 24, the allowable range is widened even if the seal insertion portion 24 is uneven due to a manufacturing error of the skin material 4. Can do.

  Further, since the distal end portion of the sealing insertion portion 24 that seals with the inner wall surface 25 of the sealing concave portion 22 is a portion away from the connecting portion with the end wall 21 of the skin material 4, the skin material 4 It is possible to make it difficult to be influenced by the shape and rigidity of the end wall 21. Therefore, it is prevented that the tip portion of the sealing insertion portion 24 becomes difficult to follow the shape of the inner wall surface 25 of the sealing concave portion 22 due to the influence of the shape and rigidity of the end wall 21 of the skin material 4, It becomes possible to always ensure a certain sealing performance.

  As described above, the outside of the foam layer 3 due to leakage of the foaming liquid 6 around the end wall 21 of the product is eliminated, the quality around the end wall 21 is improved, and the foam molded product is the same as the product. It can be formed in a size.

(Operation effect 2)
When the inner wall side seal piece 32 comes into contact with the inner wall seal surface 31, the inner wall side seal piece 32 is deformed to a downward gradient inward along the inner wall seal surface 31, thereby causing the inner wall seal surface 31 to be deformed. And the inner wall side sealing piece 32 can be securely adhered and sealed.

(Operation effect 3)
Since the outer wall seal portion 35 is formed between the outer wall surface 28 of the seal recess 22 and the connecting portion of the seal insertion portion 24 to the end wall 21, the inner wall seal portion 26 and the outer wall seal portion 35 are connected to each other. Since a heavy seal structure is obtained, the sealing performance can be further improved. In this case, the inner wall seal portion 26 is a main seal and the outer wall seal portion 35 is a sub seal.

(Operation effect 4)
When the outer wall side seal piece 37 comes into contact with the outer wall seal surface 36, the outer wall side seal piece 37 is deformed inward along the outer wall seal surface 36, whereby the outer wall seal surface 36 and the outer wall side It is possible to seal the seal piece 37 with close contact with certainty.

(Operation effect 5)
Since the core material 2 has a ridge wall portion 39 extending toward the skin material 4 at the edge of the inner wall surface 25 of the sealing recess 22, the foam liquid 6 (for example, liquid state) serving as the raw material of the foam layer 3 is provided. (E.g. urethane) foaming gas or foam fluid (for example, non-solid foam such as viscous urethane) temporarily stops part of the flow to control the flow rate or regulate the flow rate. Or by adjusting the flow direction, these can be gently guided toward the thickness direction of the foam molded product. As a result, the gas or the foam-like fluid comes into pressure contact with the inner wall surface 25 or the outer wall surface 28 of the concave portion 22 for sealing in an optimal state. It can be secured.

(Operation effect 6)
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.
The gas duct 101 provided between the inner wall seal portion 26 and the outer wall seal portion 35 accommodates the gas generated when the foamed layer 3 is molded (or air confined in the foam molding die 5) and the like in the gas duct 101. be able to. As a result, it is possible to prevent problems such as the occurrence of voids due to gas (or air) remaining 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.

(6a) 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.

  (6b) 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.

  (6c) 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 7)
The distal end portion of the seal insertion portion 24 is brought into pressure contact with the inner wall surface 25 of the seal recess 22 by the foaming pressure when the foam layer 3 is formed, and the skin material 4 is positioned at the position of the inner wall surface 25 of the seal recess 22. By performing sealing between the terminal portion and the terminal portion of the core member 2, the same effect as the 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 Car interior part interior panel 2 Core material 3 Foam layer 4 Skin material 5 Foaming mold 6 Foam liquid 21 End wall 22 Sealing recessed part 23 Clearance 24 Sealing insertion part 25 Inner wall surface 26 Inner wall seal part 27 Top surface 28 Outside Wall surface 31 Inner wall seal surface 32 Inner wall side seal piece 33 Inclination angle 35 Outer wall seal portion 36 Outer wall seal surface 37 Outer wall side seal piece 38 Inclination angle 39 Projection wall portion 101 Gas duct 102 Gas passage 103 External communication hole S1 First seal portion S2 Second seal part

Claims (7)

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,
At the tip of the end wall, a seal insertion part is provided that can be inserted with a gap with respect to the seal recess,
A foam molded article, wherein an inner wall seal portion that is pressed by a foaming pressure when molding a foam layer is formed between an inner wall surface of the sealing concave portion and a tip portion of the sealing insertion portion. The inner wall seal portion is
An inner wall sealing surface that is formed on at least a part of the inner wall surface of the concave portion for sealing, and is inclined downward toward the inside;
An inner wall-side seal piece that is bent and formed so as to be inclined upward or horizontally toward the distal end of the insertion portion for sealing,
The inner wall sealing surface is characterized in that when the inner wall side sealing piece comes into contact with the inner wall side sealing piece, the inner wall side sealing piece can be deformed to a downward gradient inward along the inner wall sealing surface. Item 2. The foam molded article according to Item 1.   An outer wall seal portion is formed between the outer wall surface of the recess for sealing and the connecting portion of the insertion portion for sealing with the end wall, which is pressed by foaming pressure when forming the foam layer. The foam-molded article according to claim 1 or 2. The outer wall seal portion is
An outer wall sealing surface that is formed on at least a part of the outer wall surface of the recess for sealing and is inclined in an upward gradient toward the inside;
An outer wall-side seal piece that is bent upwardly inward so as to rise at an angle that is the same as or slightly larger than the outer wall seal surface at the connecting portion of the seal insertion portion with respect to the end wall; Have
4. The outer wall sealing surface according to claim 3, wherein when the outer wall side sealing piece comes into contact, the outer wall side sealing piece can be deformed inward along the outer wall sealing surface. The foamed molded article as described.   The said core material has a rib wall part extended toward the said skin material side in the edge part of the inner wall surface of the said recessed part for sealing, The any one of Claim 1 thru | or 4 characterized by the above-mentioned. Foam molded products.   6. The gas duct according to claim 3, wherein a gas duct capable of containing a gas generated when a foam layer is formed is provided between the inner wall seal portion and the outer wall seal portion. The foamed molded article as described. 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 seal insertion portion provided at the tip end portion of the end wall is formed into a seal recess provided in the end portion of the core material. On the other hand, in a state of being accommodated with a gap,
The distal end portion of the sealing insertion portion is brought into pressure contact with the inner wall surface of the concave portion for sealing by the foaming pressure at the time of forming the foam layer, and at the position of the inner wall surface of the concave portion for sealing, the end portion of the skin material and the core material A method for producing a foam-molded article, characterized by causing a seal between the terminal portions.