JP3011280B2 - Manufacturing method of skin-integrated foam molded product - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a molding method for integrally molding a skin and a foam layer with a foaming mold, and relates to a manufacturing method for controlling generation of wrinkles generated on the skin when the mold is closed. .

[0002]

2. Description of the Related Art Conventionally, foam molded products used as interior materials such as instrument panels of automobiles are, for example,
A foam material such as a polyurethane foam, a polystyrene foam, or a foamed polyethylene is foamed together with a skin formed of a polyvinyl chloride resin or the like, and is integrally molded. Such molding methods are, for example, real HirakiAkira 63-68
No. 414, JP-A-63-293012, JP-A-1-1
No. 5,2018, and Japanese Patent Publication No. 2-37845 are proposed. Generally, after a skin is set in a foaming mold, a foaming material is injected into the mold, foamed and hardened, and integrally molded. In order to prevent the foamed material injected into the foaming mold from leaking to the outside, it is general to form a seal surface with the end of the skin facing the mating surface of the foaming mold.

[0003]

However, in the above-mentioned foaming mold, when the sealing surface formed by the skin has an inclination angle with respect to the mold closing direction, the skin of the same part is formed by the mold closing operation. However, there was a problem that wrinkles were generated near the end of the molded product as a result. Further, in such a skin-integrated molded product, since the skin is on the outer surface side, wrinkles are generated on the product itself, so that improvement is desired.

[0004]

SUMMARY OF THE INVENTION In order to solve the above-mentioned problems, the present invention relates to a foaming mold that forms a sealing surface inclined with respect to the mold closing direction .
A ridge portion was provided in the foam material filling portion, and a shape portion having a shape corresponding to the ridge portion was provided in the foaming mold. Then, after setting the skin with the shape portion and the ridge portion aligned, a foam material was injected into the mold, and a foam layer was integrally formed on the back surface of the skin.

[0005]

[Function] By setting the ridge provided on the foam material filling portion and the shape provided on the foaming mold in the vicinity of the sealing surface of the skin so that wrinkles are generated when the mold is closed. It is limited between the ridges, and its generation position can be controlled. In other words, in the conventional case, the occurrence position of wrinkles was successful, so it was not known until the completion of molding whether or not the product was defective, but in the case of the present invention, the occurrence of wrinkles is not completely eliminated, There is no defect such as failure as a product.

[0006]

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a perspective view showing a method for producing a foam-integrated molded article of the present invention. 1 is a longitudinal sectional view of a foam mold used in the manufacturing method of the present invention, FIG. 2 is an enlarged view of a portion A in FIG. 1, FIG. 3 is a conventional example of the same portion, and FIG. Perspective view of instrument panel, FIG. 5
FIG. 5 is a sectional view taken along line BB of FIG. 4. The method for producing a skin-integrated foam molded article of the present invention is applied to, for example, the production of an instrument panel 1 for a vehicle as shown in FIG. 4, and is integrally molded with foam dies 2 and 3 as shown in FIG. That is, in the instrument panel 1, a core material 4, a skin 5, and a foam layer 6 therebetween are integrally formed. For example, the surface of the skin 5 is formed by slash-molding a polyvinyl chloride resin or the like (the lower surface in FIG. 1). Side) has been subjected to drawing or the like in advance.

Now, the molding method of the present invention using the foaming dies 2 and 3 will be described in comparison with a conventional method. The foam upper mold 2 is vertically movable with respect to the lower mold 3, and moves upward to open the mold and move downward to close the mold. Then, when the mold is closed, a foam material filling portion 7 conforming to the shape of the molded product is formed. While the mold is opened, the skin 5 and the core 4 are set in the mold. Then, a part of the end of the skin 5 set on the lower mold 3 extends to the mold mating surface around the filling portion 7, and the gap between the core 4 and the skin 5 or between the upper mold 2 and the skin 5 when the mold is closed. -Lead surface 8
Are positioned.

Since the surface direction of the seal surface 8 has an inclination angle with respect to the mold closing and mold opening directions (vertical vertical direction) of the upper mold 2, conventionally, the seal of the skin 5 is conventionally used. Wrinkles occurred near the surface 8. That is, as shown in FIG. 3, by closing the upper die 2, the skin 5 tends to shift in the X direction in the figure along the sealing surface 8, and the sealing surface is resisted by the resistance from the Y direction. Wrinkles are generated in the vicinity of the surface 8, particularly in the skin 5 around the lower side of the sealing surface 8. In addition, the wrinkles are generated at random, and as a result, the appearance quality of the product is often impaired.

Therefore, in the case of the present invention, as shown in FIG. 2, a product portion (filled with a foam material) near the seal surface 8 of the skin 5 is used.
The filling portion 7) is provided with a ridge 10 in advance , and the lower mold 3 is also provided with a shape portion 11 having the same corresponding shape. The ridges 10 of the skin 5 may be continuous along the seal surface 5 or a plurality of ridges 10 may be provided intermittently along the seal surface 5. good. In addition, this protruding direction may be on the product appearance surface side as shown in the figure,
Conversely, it may be directed toward the inside of the product. However, there is the advantage that wrinkles are less noticeable when projected outward than inward. Also, the formation of the ridge portion 10 on the skin 5
For example, press molding, vacuum molding, slash molding or the like is used.

[0010] The outer skin 5 as described above is positioned in a state where the ridge portion 10 is fitted into the shape portion 11 of the lower mold 3, and after the core material 4 is set and then the mold is closed, the end portion is overlapped. A sealing surface 8 is formed at the portion. Then, a foam material is injected from the injection port 12 shown in FIG.
And enters the filling portion 7 between the core material 4 and the core material 4. The closing of the mold may be performed after filling the filling portion 7 with the foam material. When the mold is closed, a force in the X direction acts on the skin 5 as shown in FIG. No force is transmitted to the product part, wrinkles are formed on the seal surface 8 and the ridge 1
It will be limited to 0. And this ridge 10
5 can be made inconspicuous by the ceramic collar 15 below the window glass 14, for example, by setting the root of the window glass 14 in the defroster section of the instrument panel 1 as shown in FIG. still,
It has been found that this method can not only control the position of wrinkles but also reduce the amount of wrinkles.

[0011]

As described above, the method for producing a skin-integrated foam molded article according to the present invention uses a skin set in a foaming mold.
Form a sealing surface in a direction inclined from the closing direction,
Inject foam material into the inside to form a foam molded product with integral skin
In the manufacturing method, the vicinity of the seal surface of the epidermis
In addition to providing a ridge in the foam material filling section,
Is provided with a shape portion having a shape corresponding to the ridge portion.
After setting the skin and aligning the ridge and
Inject foam material and form a foam layer integrally on the back of the skin
As a result, the position of wrinkles generated when the foaming mold is closed can be controlled to an appropriate position, and the amount of wrinkles can be reduced. The defect rate can be reduced.

[Brief description of the drawings]

FIG. 1 is a longitudinal sectional view of a foaming mold used in the production method of the present invention.

FIG. 2 is an enlarged view of a portion A in FIG.

FIG. 3 is an explanatory view of a conventional example of the same part.

FIG. 4 is a perspective view of an automobile instrument panel manufactured by the method of the present invention.

FIG. 5 is a sectional view taken along line BB of FIG. 4;

[Explanation of symbols]

(1) Instrument panel (5) Skin (6) Foam layer (7) Filling part (8) Seal surface (10) Ridge part (11) Shape part

──────────────────────────────────────────────────続 き Continued on the front page (58) Field surveyed (Int. Cl. ⁷ , DB name) B29C 39/00-39/44 B29C 33/00-33/76

Claims (1)

(57) [Claims] A sealing surface is formed in a direction inclined from a mold closing direction by a skin set in a foaming mold, and a foaming material is injected into the mold to form a foam molded product integrally with the skin. in the manufacturing method, the epidermal sheet - Le the vicinity, provided with a ridge to the foam material filling unit, provided the shape of the shape corresponding to the projecting strip portion is foamed type, the shaped portion and the butt the ridges are aligned by injecting foam material into a mold after setting the epidermis, is formed integrally with the foam layer on the back surface of the skin, the manufacturing method of the integral skin foam molded article, wherein a call.