JP3006983B2 - Foam products - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a foamed product, and more particularly to a foamed product in which a foam adhered to one surface of a core material is covered with a skin.

[0002]

2. Description of the Related Art For example, in the case of automobile interior parts such as airbag doors, it is often the case that a foam material is injected between a core material and a skin and foamed integrally with the core material and the skin. Have been. FIG. 6 shows an example. Code 40
Is an airbag door, 41 is a core material, 42 is a foam, and 43 is a skin. The core material 41 is made of metal, resin, or the like, and is integrally formed on the back surface of the airbag door 40. The foam 42 is provided on one surface of the core 41 in a predetermined airbag door shape. Further, the skin 43 is made of soft vinyl chloride, leather, or the like, and covers the surface of the foam 42. In the foamed product obtained by this method, the foam 42 is integrally bonded to the core material 41 and the skin 43 by the self-adhesive property at the time of foaming the foaming raw material.

In the case of the airbag door 40, a high peel strength between the core material 41 and the foam 42 and a tensile strength of the foam 42 are required in response to an impact when the airbag is deployed and the door is opened. Have been. However, in the above structure, the strength may not be sufficient depending on the impact received from the airbag.
As shown in FIG.
1 and the powder of the foam 42 may be scattered into the room.

[0004] In order to increase the peel strength between the core material and the foam and reduce the generation of powder of the foam, the core material is pre-treated with a chemical or the like in advance, or the composition of the foam is changed. However, in the former method, not only is it difficult to handle the core material after the treatment, but also there is a problem that the number of steps is increased and the working efficiency is reduced. In the latter method, it is difficult to change the composition of the foam every time when various kinds of products are manufactured at the same time.

[0005]

DISCLOSURE OF THE INVENTION The present invention has been proposed in view of such problems, and is a foamed product which can prevent the generation of foam powder when the foam is peeled from a core material. It is intended to provide.

[0006]

That is, the present invention provides:
In a foam product comprising a core material, a foam bonded to one surface of the core material, and a skin covering the foam surface, the foam penetrates into the bonding surface of the foam with the core material to the inside. The present invention relates to a foamed product characterized in that a three-dimensional net-like structural material bonded and integrated with a foam is embedded.

[0007]

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 perspective view showing an example of the foamed product of the present invention, FIG. 2 is a cross-sectional view thereof, FIG. 3 is a perspective view showing an example of a three-dimensional network material used in the product of the present invention, and FIG. FIG. 5 is a cross-sectional view showing a production example of a product, and FIG.

FIGS. 1 and 2 show an airbag door which is an example of the foam product of the present invention. Reference numeral 10 denotes an airbag door, 11 denotes a core material, 12 denotes a foam, and 13 denotes a skin.
The core material 11 is formed of a predetermined core material such as metal or hard plastic, and is provided integrally on the back surface of the airbag door 10. In this example, the core 11
A mounting portion 14 of the airbag door extends from one end of the airbag door. Reference numeral 15 denotes a mounting hole.

A foam 12 is integrally provided on one surface of the core material 11. The foam 12 is made of a known urethane foam or the like, and adheres to the core material 11 by self-adhesion at the time of foaming the raw material.

The skin 13 is made of a flexible material such as soft vinyl chloride or leather, and is formed in advance into a predetermined skin shape by vacuum forming or the like. The skin 13 covers the surface of the foam 12 and constitutes the front surface of the airbag door. Inside the airbag door 10,
A three-dimensional net-like structural material 20 is embedded in the bonding surface 16 between the core material 11 and the foam 12. In this example, it is provided in a band shape along the lower end of the core material 11.

FIG. 3 shows an example of the three-dimensional net-like structural material 20. The three-dimensional network structure material 20 of this example includes a network skeleton 21 from which the cell membrane of the soft urethane foam has been removed, and a large number of holes 22 having a hole diameter of about 0.5 to 3 mm. As shown in the figure, the three-dimensional net-like structural material 20 has an open cell structure in which holes 22 communicate with each other, and is embedded with the foam 12 penetrating into the inside and bonded and integrated.

As a result, since the foam 12 is in a state of being entangled with the net frame portion 21 of the three-dimensional net structure member 20, the tensile strength of the buried portion is improved, and when the airbag door 10 is opened, the tensile strength is increased. Foam 1 from core 11 by impact
2 can be hardly peeled off, and even if peeled off, the destruction of the foam can be prevented, and the foam powder can be hardly generated. As the three-dimensional network structure material 20, various materials such as a fiber laminate having a rough three-dimensional network structure such as a nonwoven fabric of polyamide resin and polyester fiber can be used in addition to the soft urethane foam described above. Filter MF-08 "(manufactured by Inoac Corporation) is useful.

The three-dimensional net-like structural material 20 is arranged at an appropriate position and an appropriate size according to the shape of the foamed product to be molded and the required strength.

FIGS. 4 and 5 show an example of a method for producing the foamed product of the present invention. In the figure, reference numeral 30 denotes a foam molding die, 31 denotes an upper die, and 32 denotes a lower die, which has a molded product cavity 33.
Note that the present invention is not limited to this example, and can be applied to various foam products in which destruction of the foam or generation of foam powder due to the destruction is a problem.

As shown in FIG. 4, a core material 36 is provided on the upper mold 31 and a skin 37 previously formed in a skin shape is provided on the lower mold 32. In the core material 36, the three-dimensional net-like structural material 20 is provided at a predetermined position on the molded product cavity 33 side.
Is fixed with double-sided tape. Then, a foaming raw material 35 such as a polyurethane raw material is injected into the molded product cavity 33 from an injection head 34, and then the upper mold 31 is formed.
Is closed and subjected to foam molding. Injected foaming raw material 3
5 is foamed in the cavity on the back side of the skin 37,
6 and adheres to the back surface of the skin 37 and also penetrates into the pores 22 of the three-dimensional network structure material 20, and is entangled with the network skeleton portion 21 to form a foam integrated with the three-dimensional network structure material 20. . After the foaming raw material 35 is cured, the molded product is removed from the molding die 30 to obtain a desired foamed product.

[0016]

As shown and described above, in the foamed product of the present invention, the three-dimensional net-like structural material in which the foam penetrates to the inside and is integrally bonded is embedded in the bonding surface between the core and the foam. As a result, the tensile strength of the foam is increased, so that the foam can be prevented from being torn or broken even by impact. In addition, even when the three-dimensional network structure material is peeled, since the three-dimensional net-like structural material is entangled in the foam in a root shape, it is possible to suppress the generation of foam powder from the peeled surface.

[Brief description of the drawings]

FIG. 1 is a perspective view showing an example of a foam product of the present invention.

FIG. 2 is a sectional view thereof.

FIG. 3 is a perspective view showing an example of a three-dimensional net-like structural material used for the product of the present invention.

FIG. 4 is a sectional view showing a production example of the foamed product of the present invention.

FIG. 5 is a cross-sectional view showing the foamed state.

FIG. 6 is a sectional view showing an example of a conventional foamed product.

FIG. 7 is a sectional view showing another state.

[Explanation of symbols]

 Reference Signs List 10 airbag door 11 core material 12 foam 13 skin 20 three-dimensional net-like structural material

Continuation of the front page (56) References JP-A-57-104747 (JP, A) JP-A-3-158212 (JP, A) JP-A-53-64278 (JP, A) (58) Fields investigated (Int) .Cl. ⁷ , DB name) B29C 39/10-39/12 B29C 39/22-39/24 B32B 3/06-3/08 B32B 5/18 B60R 21/20

Claims (1)

(57) [Claims] 1. A foamed product comprising a core, a foam bonded to one surface of the core, and a skin covering the surface of the foam, wherein the foam has a foam on a surface of the foam bonded to the core. A foamed product characterized in that a three-dimensional net-like structural material, which penetrates into the interior and is bonded and integrated with the foam, is embedded.