JP2015205446A - Foamed molding - Google Patents

Abstract

PROBLEM TO BE SOLVED: To prevent peeling of end parts of a skin material and a core material.SOLUTION: In a foamed molding, a skin material 11 and a core material 13 are integrated with a foamed layer 12 formed between them, and a seal part 21 for preventing leakage of a foaming liquid serving as a raw material for the foamed layer 12 is provided between the end part of the skin material 11 and the opposing part of the core material 13 opposing the end part. The seal part 21 includes a flange part 22 for sealing provided in the end part of the skin material 11 and a concave part 23 for sealing provided in the opposing part of the core material 13. A convexoconcave surface part 27 for allowing the foaming liquid to penetrate for adhesion is provided between the inclined surface 26 for sealing of the flange part 22 for sealing and the outer-side inclined surface 24 of the concave part 23 for sealing.

Description

  The present invention relates to a foam molded article.

  For example, 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. 9 at the front of the vehicle interior.

  As shown in FIG. 10, such a vehicle compartment front interior panel 1 includes a multi-layer foam molded product that integrally includes a skin material 2, a foam layer 3, and a core material 4. (For example, refer to Patent Document 1).

  As shown in FIG. 11, the interior front panel 1 having such a multilayer structure is placed between the skin material 2 and the core material 4 which are set and fixed in the foam molding die 5 of the foam molding apparatus. It is manufactured by injecting a foaming liquid 6 as a raw material of the foaming layer 3 and foaming the foaming liquid 6 inside the foaming mold 5.

  The skin material 2 and the core material 4 described above are position-regulated by fitting the position-regulating portion 8 to the position-regulating portion 7 formed in the foam-molding die 5 during foam molding. Has been done.

  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 skin material 2 and the core material 4. However, since it is difficult to completely seal the leakage of the foaming liquid 6 and the like, conventionally, the skin material 2 and the core 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.

  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-described defect is not caused by the appearance of the foamed layer 3 caused by leakage of the foaming liquid 6. It is necessary to sufficiently solve the sealing problem.

  Therefore, for example, in Patent Document 1, a seal portion for preventing leakage of foaming liquid is provided between the end portion of the skin material and the facing portion of the core member facing the end portion. . That is, the seal portion is provided at the end portion of the skin material, and is for a seal flange portion that is bent toward the core material side, and for the seal that is bent toward the skin material side provided at the opposite portion of the core material. And a flange portion for sealing the skin material is brought into contact with the inner surface side of the flange portion for sealing the core material. Then, the end portions are sealed by pressure-bonding the sealing flange portions using foaming pressure.

JP 2007-160579 A

  However, since the thing of the said patent document 1 was not especially adhere | attached between the flange parts for both seals which comprise a seal part, by the shrinkage | contraction by heat shrink of a skin material or a secular change, etc., both flange parts for seals There is a possibility that the end portion of the foam molded product is deformed due to separation or separation. Then, the alignment between the foam-molded product and the adjacent part is shifted, resulting in problems such as deterioration in appearance.

  Therefore, the main object of the present invention is to solve the above-described problems and prevent peeling of the end portions of the skin material and the core material.

In order to solve the above problems, the present invention provides:
The skin material and the core material are integrated by a foam layer formed between them,
Between the terminal part of the skin material and the facing part of the core material facing the terminal part, a seal part for preventing leakage of the foaming liquid as a raw material of the foam layer is provided,
The sealing portion is provided at the end portion of the skin material and is bent toward the core material side, and is provided at the opposing portion of the core material so as to accommodate the sealing flange portion. A recess for sealing,
The sealing recess has a V-shaped cross section having an outer inclined surface and an inner inclined surface, and the sealing flange portion is on the outer surface side of the tip portion along the outer inclined surface. A foam molded article having an inclined surface for sealing that extends to reach a boundary between the outer inclined surface and the inner inclined surface,
A foam-molded article, wherein an uneven surface portion for allowing a foaming liquid to enter for bonding is provided between the sealing inclined surface and the outer inclined surface.

  According to the present invention, the following effects can be obtained by the above-described configuration. That is, an uneven surface portion was provided between the sealing inclined surface of the sealing flange portion and the outer inclined surface of the sealing concave portion. Thereby, the sealing inclined surface and the outer inclined surface can be bonded by the foaming liquid that has entered between the inclined inclined surface and the outer inclined surface through the uneven surface portion while maintaining the sealing performance of the sealing portion. It becomes possible. Therefore, even when the skin material is about to be deformed due to heat shrinkage or aging deterioration, the terminal portion of the skin material and the core material is prevented from being peeled or separated. In addition, it is possible to eliminate such a problem that the end portion of the foam molded product is deformed and the alignment with the adjacent parts is shifted.

It is an expanded longitudinal cross-sectional view of the terminal part of the foaming molded product concerning the Example of this invention. It is an expanded longitudinal cross-sectional view of the seal | sticker part of the skin material and core material set to the foam molding apparatus. It is the elements on larger scale of the seal part of Drawing 2 (before foaming). It is the elements on larger scale of the seal part similar to FIG. 3 (during foaming). It is the elements on larger scale of the seal part similar to FIG. 3 (after foaming). It is the elements on larger scale of the seal part similar to FIG. 3 which provided the 2nd uneven surface part. It is a partial expanded sectional view of the seal part similar to FIG. 3 when not providing an uneven surface part. It is an expanded vertical sectional view of the terminal part of the foam-molded product similar to FIG. 1 which shows a malfunction state when an uneven surface portion is not provided. It is a whole perspective view of the vehicle interior front part interior panel used for description of a prior art example. FIG. 10 is a partial enlarged cross-sectional view of (foam molded product having a multilayer structure) of the interior front panel in FIG. 9. It is explanatory drawing of the foam molding apparatus for foam-molding a foam-molded article.

Hereinafter, the present embodiment will be described in detail with reference to the drawings.
1 to 8 are for explaining this embodiment.

  <Configuration> The configuration of this embodiment will be described below.

  For example, a vehicle such as an automobile is provided with a vehicle interior front panel called an instrument panel or the like at the front of the vehicle interior (see FIG. 9). In addition to the instrument panel, there are various types of door panels, sub-panels attached to these, and the like in the vehicle interior front panel.

  As shown in FIG. 1, such a passenger compartment front interior panel is configured as a foam molded article 14 having a multilayer structure having a skin material 11, a foam layer 12, and a core material 13.

  Here, the core 13 is made of a hard thick resin. The foam layer 12 is made of a foam material such as urethane foam. The skin material 11 is made of a soft thin resin. An adjacent component 15 may be installed next to the foam molded product 14.

  As shown in FIG. 2, the foam layer 12 is foamed into a liquid resin material between the skin material 11 and the core material 13 set in the foam mold of the foam molding device 16 (the molding space 17). It forms by inject | pouring the foaming liquid which mixed the agent and making it foam as shown in order in FIGS. FIG. 4 shows a foamable fluid 18 formed by foaming a foaming liquid.

  At this time, as shown in FIG. 2, the foam molding apparatus 16 has a soft thin and non-shape-retaining skin material 11 having a low shape-retaining property on the lower side, and is hard and thick and has a high shape-retaining property. The core material 13 is set so as to be on the upper side. In addition, it is preferable to project the anchor part 19 for obtaining the anchor effect with respect to the foam layer 12 in the vicinity of the terminal part of the core material 13.

  In contrast to the basic configuration described above, this embodiment includes the following configuration.

(Configuration 1) As described above, the foam molded article 14 of this embodiment is formed by integrating the skin material 11 and the core material 13 by the foamed layer 12 formed therebetween. And between the terminal part of the said skin material 11, and the opposing part of the said core material 13 which opposes this terminal part, the seal part 21 for preventing the leakage of the foaming liquid used as the raw material of the foam layer 12 is provided. To be provided.
The sealing portion 21 is provided at the end portion of the skin material 11 and is bent toward the core material 13 side. The sealing flange portion 22 is provided at the opposing portion of the core material 13 and the sealing flange is provided. It has a sealing recess 23 that can accommodate the portion 22.
The sealing recess 23 has a V-shaped cross section having an outer inclined surface 24 and an inner inclined surface 25. Further, the sealing flange portion 22 extends on the outer surface side of the tip portion along the outer inclined surface 24 until reaching the boundary between the outer inclined surface 24 and the inner inclined surface 25. It is supposed to have.
Further, an uneven surface portion 27 for allowing the foaming liquid (foaming layer 12) to enter is provided between the sealing inclined surface 26 and the outer inclined surface 24.

  Here, the terminal portion of the skin material 11 is a portion that becomes a peripheral portion of the foam molded product 14, an opening formed inside the foam molded product 14, an edge of a notch, or the like. The sealing flange portion 22 provided at the terminal portion of the skin material 11 is formed thicker than other portions of the skin material 11. Further, the facing portion of the core material 13 is a portion corresponding to the terminal portion of the skin material 11, and when the core material 13 is larger than the skin material 11, it is provided at an intermediate portion of the core material 13. There is also.

  The uneven surface portion 27 may be provided on either the sealing inclined surface 26 or the outer inclined surface 24. Further, the uneven surface portion 27 is formed at least at an inner portion between the uneven surface portion 27 and the sealing inclined surface 26. Although the uneven surface portion 27 varies depending on foaming conditions and the like, the uneven surface portion generally has an uneven shape with a depth of about 0.3 mm to 0.1 mm. An adhesive layer 28 is formed on the uneven surface portion 27 by the foaming liquid (foam layer 12) that has entered during foam formation.

  (Configuration 2) The uneven surface portion 27 is a texture pattern 31 provided on one of the sealing inclined surface 26 or the outer inclined surface 24 described above.

  Here, the embossed pattern 31 is an uneven pattern generally provided on the surface of a vehicle interior part.

  (Structure 3) The non-formation area | region which does not have the above-mentioned uneven | corrugated surface part 27 so that the foaming liquid for sealing entered into the outer part between the above-mentioned inclined surface 26 for sealing and the outer inclined surface 24 may not leak outside. 29 is formed.

  Here, the ratio of the size of the uneven surface portion 27 and the non-formation region 29 is, for example, about 7 to 3 to 9 to 1.

  (Structure 4) As shown in FIG. 6, the non-formation region 29 is provided with a second uneven surface portion 35 for degassing that is finer than the uneven surface portion 27 described above and into which the foaming liquid cannot enter.

  Here, the second concavo-convex surface portion 35 (small concavo-convex surface portion) varies depending on foaming conditions and the like, and is generally a texture pattern having a concavo-convex shape with a depth of about 0.1 mm or less.

<Effect> According to this embodiment, the following effects can be obtained.
(1) The skin material 11 and the core material 13 are set in the foaming mold of the foam molding apparatus 16 and the foaming liquid is injected between the skin material 11 and the core material 13 so that the foaming liquid is foamed and foamed. The layer 12 is formed, and the foam molded product 14 in which the skin material 11 and the core material 13 are integrated by the foam layer 12 is molded.

  At this time, the tip end portion of the sealing flange portion 22 provided at the end portion of the skin material 11 is accommodated in the sealing recess portion 23 provided at the opposing portion of the core member 13, and the sealing flange portion 22 is sealed. By bringing the inclined surface 26 into contact with the outer inclined surface 24 of the sealing recess 23 and performing sealing, the sealing inclined surface 26 and the outer inclined surface 24 are pressure-bonded by foaming pressure (self-sealing). The foam layer 12 is prevented from sticking out from the terminal portion (or the terminal-corresponding portion) due to the foaming pressure. Therefore, it is possible to finish the terminal portion neatly, and it is possible to eliminate the necessity of trimming the terminal portion by post-processing or the like, and it is possible to eliminate waste of the skin material 11 and the core material 13 due to the cutting. Become.

  An uneven surface portion 27 is provided between the sealing inclined surface 26 of the sealing flange portion 22 and the outer inclined surface 24 of the sealing concave portion 23. Thus, the sealing inclined surface 26 and the outer inclined surface 24 are retained by the foaming liquid that has entered between the sealing inclined surface 26 and the outer inclined surface 24 via the uneven surface portion 27 while maintaining the sealing performance of the seal portion 21. Can be adhered (adhesive layer 28).

  Therefore, even when the skin material 11 is about to be deformed due to heat shrinkage or aging deterioration, for example, as shown in FIG. 7, the surface material 11 and the core material are not provided as shown in FIG. 13 is prevented from peeling off or leaving, so that the terminal portion of the foamed molded product 14 is deformed by the above-described peeling or the like, and as shown in FIG. Such problems can be eliminated (peeling portion 41, deforming portion 42).

  (2) The concavo-convex surface portion 27 is constituted by the embossed pattern 31. As a result, the foaming liquid can enter between the sealing inclined surface 26 and the outer inclined surface 24 through the fine groove of the texture pattern 31, so that the uneven surface portion 27 that is optimal for bonding can be easily obtained. Can be formed.

  (3) The non-formation region 29 without the uneven surface portion 27 described above is provided in the outer portion between the sealing inclined surface 26 and the outer inclined surface 24. Thereby, it is possible to prevent the foaming liquid for sealing that has entered the uneven surface portion 27 from leaking out.

  (4) The second uneven surface portion 35 finer than the above-described uneven surface portion 27 is provided in the non-formed region 29. As a result, the second uneven surface portion 35 prevents the foaming liquid from entering, prevents leakage of the foaming liquid to the outside, and occurs when the foamed layer 12 is formed by the second uneven surface portion 35. The gas can be degassed.

  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. Therefore, the present invention is not limited to the configuration of the embodiment, and it is a matter of course that the present invention includes any design change within a range not departing from the gist of 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 modified examples are disclosed as those of the present invention, it is a matter of course that possible combinations of configurations extending over these are included even if not specifically described. It is. 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 11 Skin material 12 Foam layer 13 Core material 14 Foam molded product 21 Seal part 22 Seal flange part 23 Seal recessed part 24 Outer inclined surface 25 Inner inclined surface 26 Sealed inclined surface 29 Non-formation area 31 Wrinkle pattern 35 Second unevenness Face

Claims (4)

The skin material and the core material are integrated by a foam layer formed between them,
Between the terminal part of the skin material and the facing part of the core material facing the terminal part, a seal part for preventing leakage of the foaming liquid as a raw material of the foam layer is provided,
The sealing portion is provided at the end portion of the skin material and is bent toward the core material side, and is provided at the opposing portion of the core material so as to accommodate the sealing flange portion. A recess for sealing,
The sealing recess has a V-shaped cross section having an outer inclined surface and an inner inclined surface, and the sealing flange portion is on the outer surface side of the tip portion along the outer inclined surface. A foam molded article having an inclined surface for sealing that extends to reach a boundary between the outer inclined surface and the inner inclined surface,
A foam-molded article, wherein an uneven surface portion for allowing a foaming liquid to enter for bonding is provided between the sealing inclined surface and the outer inclined surface. The foam molded product according to claim 1,
The foam-molded product, wherein the uneven surface portion is a texture pattern provided on one of the sealing inclined surface or the outer inclined surface. The foamed molded product according to claim 1 or 2,
Foam characterized in that a non-formed region without an uneven surface portion is formed in an outer portion between the inclined surface for sealing and the outer inclined surface so that the foaming liquid for sealing that has entered does not leak outside. Molding. The foam molded product according to claim 3,
A foam-molded article, wherein the non-formed region is provided with a second uneven surface portion for degassing that is finer than the uneven surface portion and into which the foaming liquid cannot enter.