JP2991320B2 - Plastic molded article partially having foam with skin and method for producing the same - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a plastic molded product partially having a foam with skin on the product side of a main body core and a method for producing the same.

[0002]

2. Description of the Related Art For example, in the case of an instrument panel of an automobile, as shown in FIG.
Is partially provided. FIG. 10 is an enlarged sectional view cut along the line AA.

In the above-mentioned instrument panel, a foam 83 with a skin is formed in advance with a base material 84 for attachment, a foam 86 and a skin 87, and the foam 83 with a skin is formed in a main body in a later step. It is attached to a predetermined portion of the core 81. The attachment is performed by inserting an attachment pin (claw) 85 formed in the base material 84 of the foam with skin into an attachment hole 82 formed in the main body core 81 and bending it, or by clipping or screwing. I have.

However, in the instrument panel, since the foam 83 with the skin also has the base material 84 such as an iron plate, there is a problem that the instrument panel becomes heavy and the cost increases. In addition, since the foam 83 with the skin is attached to the main body core 81 in a later step, a gap is easily generated in the joint portion 88 between the foam 83 with the skin and the main body core 81, and there is a problem that the aesthetic appearance is spoiled. In particular, in this type of instrument panel, the joint portion 88 between the foamed body 83 with the skin and the main body core 81 is also exposed as a product surface, so that the above-mentioned gap problem is an important problem that cannot be ignored.
Further, there is a problem that an additional post-process for attaching the foam with skin is required.

[0005]

SUMMARY OF THE INVENTION In view of the above, the present invention has been made in view of the above points, and is a light-weight and aesthetically pleasing plastic molded article partially having a foam with a skin, and a production method capable of easily producing the molded article. It is intended to provide.

[0006]

According to a first aspect of the present invention, there is provided a plastic molded product having a foam having a skin in which the surface and side surfaces of the foam are covered with a skin on a product surface portion of a main body core. An opening is provided in the body core at the attachment portion of the foamed skin, while a groove is provided on the side surface of the foamed skin, and the skin is formed by fitting the groove and the end of the opening of the body core. The foam body is fixed to the main body core.

A second invention relates to a method of manufacturing a plastic molded product having a foam with a skin in which the surface and side surfaces of the foam are covered with a skin on a product surface portion of the main body core. The body core provided with an opening at the attachment site of the foam is attached to the lower mold surface such that the end of the opening protrudes into the cavity from the periphery of the concave cavity formed in the lower mold surface. Arranging, and arranging a thermoplastic resin skin covering the opening on the upper surface of the main body core, and holding a peripheral edge of the skin around the opening;
A step of sucking and adsorbing the heated and softened skin during or after the holding to the inner surface of the cavity, and winding the end of the opening of the main body core around the outer surface near the end of the skin; The step of injecting the foaming material into, and after or before injecting the foaming material, the upper mold having a concave portion in the mold surface portion facing the cavity of the lower mold, between the peripheral edge of the concave portion and the peripheral edge of the lower mold cavity. A step of covering the lower mold so as to sandwich the skin end and the opening end of the main body core and closing the mold, and foaming the foaming material between the skin and the inner surface of the mold surface recess of the upper mold to form an integral part of the skin. Forming a foam.

[0008]

The plastic molded article having a part of the foam with a skin of the present invention has a foam part with a skin consisting of a foam and a skin, and does not have a heavy base material such as a conventional iron plate. , Lightweight. Moreover, the foam with skin is fixed to the main body core by fitting the concave groove formed on the side face to the end of the opening formed in the main body core. Or there is no fear of lifting.

On the other hand, in the manufacturing method, the inside of the skin, which is wound around the end of the opening formed in the main body core and adsorbed on the inner surface of the lower mold cavity, is filled with the foaming material and foamed between the skin and the inner surface of the upper mold recess. Then, a foam (foam with skin) integral with the skin is formed. For this reason, the shape of the skin is held by the foam, and the obtained molded product is formed by winding the opening end of the main body core around the outer surface near the end of the skin, that is, the formed product is formed by the winding. The end of the opening of the main body core fits into the concave groove of the skin, and the foam with the skin is fixed to the main body core.

In addition, the foaming material foams in the skin in a state in which the end of the opening of the body core is rolled up, and fills the skin to form a foam. The skin is crimped to the edge of the part, eliminating the gap between the body core and the skin. For this reason, there is no gap at the boundary between the foam with skin and the body core, and a good appearance is obtained.

[0011]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention will be described below in detail with reference to the accompanying drawings. FIG. 1 is a partial perspective view of a plastic molded product partially having a foam with skin according to one embodiment of the present invention,
2 is a cross-sectional view of the lower die showing the process of disposing the main body core during the manufacturing, FIG. 3 is a cross-sectional view of the lower die showing an initial stage of the skin holding process, and FIG. 4 is a lower die showing the completion of the skin holding process. 5, FIG. 5 is a cross-sectional view of a lower mold showing a step of winding by a skin, FIG. 6 is a cross-sectional view of a lower mold showing a foaming material injection step, and FIG.
Is a sectional view of the upper and lower molds showing a mold closing step and a skin integral foaming step, and FIG. 8 is a perspective view showing an example of a skin holding device.

A plastic molded product (hereinafter also referred to as molded product) 10 partially having the foam with skin shown in FIG.
Is used for an instrument panel of an automobile. A foam 21 with a skin is provided on a part of the main body core 11. In the following description, an instrument panel will be described as an example. However, the molded article and the manufacturing method of the present invention are not limited to the instrument panel, and are applied to various molded articles depending on the application.

The main body core 11 is made of a hard plastic such as ABS resin or a plastic having a high shape retention such as a fiber reinforced plastic. As shown in FIG. The opening 13 is provided. The opening 13 is provided in a mounting portion of the foam with skin 21 in a size, a shape, and the like according to a design, a use, and the like of a molded product. The end 1 of the opening 13
Reference numeral 5 denotes a portion where a concave groove 29 on the side surface of the foamed body 21 described later fits.

The foam 21 with a skin comprises a foam 23 and a skin 25 covering the surface and side surfaces of the foam 23, and a concave groove 29 on the side is fitted in the opening 13 of the main body core. The foam 23 is made of polyurethane foam or the like, and has a size to close the opening 13 of the main body core. The foam 23 is formed by foaming between the skin 25 and the inner surface of the concave portion of the upper mold surface as described later, and adheres to the inner surface of the skin 25 by self-adhesive force at the time of foaming.
In addition, the side surface of the foam 23 is depressed corresponding to the concave groove 29.

The skin 25 is made of a thermoplastic resin such as a vinyl chloride resin and is adhered to the foam 23 so as to cover the surface and side surfaces of the foam 23. A groove 2 is formed on the entire periphery of the side surface 27 of the skin covering the side surface of the foam 23.
9 is bent, and the end 15 of the opening of the main body core fits into the concave groove 29.

As described later, the groove 29 is formed in the skin 2.
The outer surface near the end of No. 5 is a portion formed by winding the end 15 of the opening of the main body core. Further, in this embodiment, the skin 25 in a state where the end 15 of the opening is wrapped around.
Since the foaming material is foamed and filled therein to form the foam 23, the skin 25 near the concave groove 29 is in close contact with the end 15 of the opening of the main body core due to the foaming pressure of the foaming material, The gap at the boundary between the foam with skin 21 and the main body core 11 is eliminated. Further, the foam 21 with the skin is securely fixed to the main body core 11 by the close contact of the concave grooves 29. The molded article 10 having such a configuration is lightweight because the foam 21 with the skin is composed of the foam 23 and the skin 25 and there is no heavy base material.

Next, an embodiment of a method of manufacturing the molded article 10 will be described. The manufacturing method includes a main body core arrangement step, a skin holding step, a winding step, a foaming material injection step,
The method includes a mold closing step and a skin integral foaming step. First, FIG.
The main body core arrangement step is performed as shown in FIG. In the main body core disposing step, the main body core 11 having the opening 13 at the attachment portion of the foam with skin is attached to the mold surface 35 of the lower mold 31.
Place in place. A concave cavity 32 is formed in the mold surface 35 of the lower mold 31 at a position corresponding to the opening 13 of the main body core, and an end 15 of the opening of the main body core is formed from the periphery of the cavity 32 to the cavity 32. The main body core 11 is arranged so as to protrude inward.

A lower mold 31 is provided on the inner surface 33 of the cavity.
A suction hole 34 communicating with the external vacuum suction device 40 is formed. The suction hole 34 is formed in the upper part of the cavity 32 closest to the end part 15 of the opening so that the skin can easily be wound around the end part 15 of the opening part of the main body core 11 and adhered to the inner surface 33 of the cavity during the entrainment step described later. It is also preferable to provide them. Reference numeral 41 denotes the inside of the lower mold 31 and the vacuum suction device 4.
This is a suction pipe connecting 0.

Next, as shown in FIGS. 3 and 4, a skin holding step is performed. In this skin holding step, a skin 25 made of a thermoplastic resin such as a vinyl chloride resin having a size to cover the opening 13 of the main body core is arranged on the upper surface of the main body core 11 so that the periphery of the skin 25 is closed by the opening of the main body core. Hold around 13.

At this time, in this embodiment, a skin holder 42 as shown in FIG. 8 is used. The upper frame 44 is fixed to the lower end of a column 43 which is connected to an elevating device such as an air cylinder device (not shown) and moves up and down.
A lower frame 45 is attached to the upper frame 44 by a hinge 46.
And an air cylinder device 47 for opening and closing the lower frame 45 with respect to the upper frame 44 on the upper and lower frames 44, 45 opposite to the hinge 46.
Is attached. On the lower surface of the lower frame 45, a string-shaped sealing material 48 made of an elastic material such as rubber is provided as shown in FIG. Then, as shown in FIG. 3, the periphery of the skin 25 is sandwiched between the upper and lower frames 44 and 45,
The skin holder 42 is lowered, and the lower frame 45 is crimped around the opening 13 of the main body core via the sealing material 48 as shown in FIG. Thereby, the peripheral edge of the skin 25 is held around the opening 13 of the main body core, and the sealing material 48 is held.
The periphery of the skin 25 and the periphery of the opening 13 of the main body core are sealed by the upper and lower frames 44 and 45.

In this embodiment, as shown in FIG.
While the skin 25 is held above the main body core 11 by the skin holder 42, the skin 25 is heated and softened by a heating device H such as a heater, and the softened skin 25 is removed as described above. It is arranged on the upper surface. Of course, the skin 25 may be heated and softened after being arranged on the upper surface of the main body core 11. This heating and softening of the skin 25 enables vacuum forming to be performed in the next winding step.

Next, the winding step shown in FIG. 5 is performed. In this step, the skin 25, which has been held by covering the opening 13 of the main body core 11 in the previous step, is sucked into the cavity through the lower suction hole 34 by the vacuum suction device 40 and is adsorbed on the cavity inner surface 33. At this time, the end 15 of the opening 13 of the main body core 11 projects into the cavity, and the skin 2
5 is held on the upper surface of the main body core 11 around the opening 13, the outer skin 25 is in close contact with the inner surface 33 of the cavity while the outer surface near the end 28 is wound around the end 15 of the opening of the main body core 11. . The wound portion by the skin 25 becomes the concave groove 29 shown in FIG. Then, in this state, the shape of the skin 25 is fixed by natural cooling or forced cooling by air cooling or the like. Thereafter, the edge of the skin 25 is cut off along the inner periphery of the upper and lower frames 44 and 45 of the skin holder 42, and then the skin holder 42 is raised.

Next, a foaming material injection step shown in FIG. 6 is performed. In this step, a foaming material P such as a polyurethane material is injected into the inside of the skin 25. Reference numeral 49 denotes a foaming material injection nozzle. At the time of the foaming material injection step, the suction of the skin 25 into the cavity may be performed continuously from the winding step or may be stopped.

Thereafter, as shown in FIG. 7, a closing step of covering the upper mold 51 with the lower mold 31 is performed. The mold surface 52 of the upper mold 51 has a portion facing the cavity 32 of the lower mold 31,
A recess 53 having an opening shape larger than the opening 13 of the main body core 11 is formed.
The end 28 of the skin and the end 15 of the opening of the main body core are sandwiched between the peripheral edge of the cavity 1 and the cavity 1. Also, the upper mold 51
In this case, a reinforcing core (insert) may be set as necessary, and a foam may be formed integrally with the reinforcing core in the next skin integral foaming step. Although the closing step is performed after the foaming material injection step in this embodiment, the foaming material injection step may be performed after the closing step. In this case, a foaming material injection port is formed in the upper mold, and the foaming material is injected using the injection port.

In the integral skin foaming step, the foaming raw material P is foamed between the inner surface of the outer skin 25 and the inner surface of the concave portion 53 of the upper mold, and the foam 23 integral with the outer skin 25, that is, the foam with the outer skin is opened in the main body core 11. Formed in the part. At that time, the main body core 1
At the end 15 of the opening 1, the foamed raw material also wraps around the end 15 of the opening due to the presence of the concave portion 53 of the upper die and foams, so that it fits into the end 15 of the opening via the skin 25. A combined foam 23 is formed. In addition, an end portion 15 of the opening of the main body core 11 has a skin 2 around which the end portion 15 is wound.
Since the vicinity of the end 28 of the fifth material is press-bonded by the foaming pressure of the foaming raw material P, there is no gap at the boundary between the main body core 11 and the skin 25, that is, at the boundary between the main body core 11 and the foam with skin.

Thereafter, the upper mold 51 is separated from the lower mold 31 and the molded product is released from the mold, whereby the plastic molded product 10 partially having the foam with skin shown in FIG. 1 is obtained. The molded product obtained in this manner is lightweight as described above, and has no gap at the boundary between the foam with skin and the body core,
Good appearance.

[0027]

As described above, according to the present invention, the present invention is excellent in lightness, has a good appearance with almost no gap at the boundary between the foamed body and the body core, and has a skinned appearance. It is possible to obtain a molded article which does not cause the foam to come off or peel off the skin. In addition, since the production work is performed simultaneously with the molding of the foam with the skin and the integration with the main body core, there is no need to attach the foam with the skin to the main body core in a later process, making the operation extremely easy and inexpensive. can do.

[Brief description of the drawings]

FIG. 1 is a partial perspective view of a plastic molded product partially including a foam with skin according to an embodiment of the present invention.

FIG. 2 is a cross-sectional view of a lower die showing a main body core disposing step at the time of its manufacture.

FIG. 3 is a sectional view of a lower mold showing an initial stage of a skin holding step.

FIG. 4 is a cross-sectional view of the lower mold showing the completion of the skin holding step.

FIG. 5 is a cross-sectional view of a lower mold showing a winding step.

FIG. 6 is a sectional view of a lower mold showing a foaming material injection step.

FIG. 7 is a cross-sectional view of a molding die showing a mold closing step and a skin integral foaming step.

FIG. 8 is a perspective view showing an example of the skin holding device.

FIG. 9 is a perspective view of a conventional molded product.

FIG. 10 is an enlarged sectional view taken along the line AA.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 10 Molded product 11 Main body core 13 Opening 15 End of opening 21 Foam with skin 23 Foam 25 Skin 27 Side of foam with skin 28 End of skin 29 Groove 31 Lower mold 32 Cavity 51 Upper mold 53 Upper Mold recess P Foaming material

Claims (2)

(57) [Claims] 1. A plastic molded product partially having a foam with a skin in which the surface and side surfaces of the foam are covered with a skin on a product surface portion of the body core. An opening is provided, while a concave groove is provided on a side surface of the foam with the skin, and the foam with the skin is fixed to the main body core by fitting the concave groove with an end of the opening of the main body core. A plastic molded article partially having a foamed body with a skin. 2. A method for producing a plastic molded product having a foam with a skin in which the surface and side surfaces of the foam are covered with a skin on a product surface portion of the main body core. Disposing a body core provided with an opening on the lower mold surface such that an end of the opening protrudes into the cavity from a peripheral edge of a concave cavity formed on the lower mold surface; A step of arranging a thermoplastic resin skin covering the opening on the upper surface of the main body core and holding the periphery of the skin around the opening; and suctioning the heated and softened skin during or after the holding. A step of winding the end of the opening of the main body core around the outer surface near the end of the skin, and a step of injecting a foaming material into the skin of the cavity; Before pouring, the upper mold having a concave portion in the mold surface portion facing the cavity of the lower mold is sandwiched between the peripheral edge of the concave portion and the peripheral edge of the lower mold cavity so as to sandwich the skin end and the opening end of the main body core. Covering the lower mold and closing the mold, and forming a foam integral with the skin by foaming the foaming material between the skin and the inner surface of the mold surface concave portion of the upper mold. A method for producing a plastic molded product partially having a foam with a seal.