JP3025164B2 - Manufacturing method of padded plastic molding - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method of manufacturing a padded plastic molded product having a pad at a predetermined portion of a core.

[0002]

2. Description of the Related Art Pad-mounted plastic molded articles having a pad having a core surface adhered to a foam surface have been used in various fields such as interior parts of automobiles and furniture. For example, in an instrument panel of an automobile, a pad 83 is partially provided on the surface of a core 81, or a pad is provided on the entire surface of the core, as shown in FIG. Is used.

[0003] Conventionally, as a plastic molded product with a pad partially provided with the pad, as shown in FIG.
In some cases, a pad 83 formed of a core 6 and a skin 87 is formed, and the pad 83 is attached to a predetermined portion of the surface of the core 81 in a later step. The pad is attached by inserting an attachment pin (claw) 85 formed in the metal insert into the attachment hole 82 formed in the core and bending it, or by clipping or screwing.

[0004] However, the molded article has a problem that the number of steps is increased because the pad must be assembled to the core in a later step. In addition, since the pad is assembled to the core with a pin or the like formed on the metal insert, a gap is likely to be formed in a joint portion between the pad and the core, and there is a problem that the appearance of a molded product is impaired. In particular, the gap at the mating portion between the pad and the core, such as the gap between 88 and 89 in the instrument panel shown in the figure, which is exposed and becomes a visible portion even after the padded plastic molded product is attached to the counterpart, is a molded product. Greatly reduces the decorativeness. Further, the plastic molded product with a pad has a problem that the molded product becomes heavy due to a metal insert existing on the back surface of the pad.

On the other hand, as a plastic molded product with a pad provided with a pad on the entire surface of a core, a product manufactured as follows is conventionally used. That is, a skin having a peripheral portion called a skirt portion on the outer periphery of the product portion,
The skirt portion is arranged on one mold surface of the mold so as to be located on the outer periphery of the cavity of the mold, while a core is arranged on the other mold surface and the skin skirt portion is sandwiched between mold surfaces,
In this state, the liquid foaming material is foamed between the skin and the core, and then the skirt of the skin is cut off.

However, in the case of the above-mentioned manufacturing method, the liquid foaming raw material easily leaks to the outside from the edge of the product portion of the skin, and burrs are easily generated. But there is an annoying problem.
In order to prevent the liquid foaming material from leaking, an elastic sealing material may be attached to the edge surface of the core in contact with the skirt portion. Is bothersome. In addition, in the padded plastic molded product obtained by the manufacturing method, the edge of the skin is simply adhered to the foam by the self-adhesive property of the foam at the time of the foam molding. There was also a risk that the edge of the skin was peeled off from the foam.

[0007]

SUMMARY OF THE INVENTION Accordingly, the present invention provides a lightweight and good-looking plastic molded product with a pad , which has no gap in the joint between the pad and the core, which is the visible portion, and
An object of the present invention is to provide a method that can easily produce a liquid foaming raw material without leakage.

[0008]

According to the present invention, there is provided a pad installation.
Surface and a side wall erected on a part of the periphery toward the core surface side
And bent to the back surface of the core at the other edge of the pad installation surface.
Invisible formed on the surface or almost extended surface of the pad installation surface
And a core having a part-side end portion in a split mold.
On the split mold surface, and the other split mold surface
And inject it between the pad mounting surface of the core and the epidermis.
The foam is covered with the skin by foaming
Having the pad on the pad installation surface of the core,
At the joint where the side wall of the surface and the side surface of the skin are in close contact,
It is exposed even after the plastic molding is attached to the counterpart
It has a visible part, and another end skin is provided at the end of the core that is not visible.
The overlapping end portions of the side portions overlap each other, and
Invisible, hidden after attaching plastic parts to hand
When manufacturing plastic molded parts,
It is characterized by the following.

That is, the side surface portion on the visible portion side is provided on the skin.
The inwardly protruding concave groove which is depressed inward on the side, the side part on the side of the invisible part
Outwardly protruding grooves that are depressed outward at the polymerization end
In the split type where the epidermis is arranged,
A concave part was formed on the surface of the mold on which the protruding concave groove was placed.
An elastic material is embedded, and the skin is covered with the side surface on the visible side.
And make contact with the side wall of the
The outwardly projecting concave groove of the skin fits into the concave portion of the elastic material and
The overlapping end of the side surface of the invisible part on the skin is
Between the outer surface of the invisible side of the installation surface and the split mold surface
Place the skin and pad so that it can be divided
Foaming generated by foaming the liquid foaming material injected between the faces
The body is integrated with the epidermis and core. In addition, the package
Inwardly protruding concave on the side of the visible side of the skin on the side wall of the installation surface
Preferably, a concave groove facing the groove is formed.

[0010]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention will be described below in detail with reference to the accompanying drawings. FIG. 1 shows a pad with a pad obtained by carrying out the present invention .
Sectional view of the feeder plastic molding, FIG. 2 is an enlarged cross-sectional view of the vicinity of the joint portion between the side wall and the pad of core of its visible side, FIG. 3 is a similarly enlarged cross-sectional view of a non-visible side.

FIG. 4 is a cross-sectional view of a molding die showing an embodiment of the method for manufacturing a padded plastic molded product according to the present invention, and FIG. 5 is an enlarged view of a part of the molding die during foaming in the embodiment. FIG. 6 is a cross-sectional view showing, in an enlarged manner, another portion of the molding die in the same embodiment, FIG. 7 is a cross-sectional view showing a part of the molding die in a state where the liquid foaming material is filled between the skin and the core,
FIG. 8 is a sectional view showing another part of the molding die. FIG. 9 is a partial sectional view of a molding die showing another embodiment of the manufacturing method of the present invention, and FIG. 10 is a partial sectional view of a molding die showing still another embodiment.

Padded plastic shown in FIGS. 1 to 3
The molded article 10 is used as an instrument panel of an automobile, has a pad 21 on a part of the core 11, and is exposed even after being attached to the vehicle body and can be seen from the outside. The invisible portion 32 hidden by the pad 21 is joined to the mating portions A 1 and A 2 of the pad 21 and the core 11.
1 has. In the following, description is made with the instrument panel as an example, but the manufacture of the present invention
The method is not limited to the method for manufacturing an instrument panel , but is applied to various molded products depending on the application.

The core 11 is made of a hard plastic such as ABS resin (acrylonitrile-butadiene-styrene resin), polypropylene or the like, or a plastic having a high shape retention such as fiber reinforced plastic. It is 12. The pad installation surface 12 is provided in a portion where the pad 21 is arranged, in a size, a shape, and the like according to the design, use, and the like of the molded product.

A side wall 13 is provided upright on the core surface side at a part of the periphery of the pad mounting surface 12. This side wall 13
It is provided at a position corresponding to the visible portion 31 in the matching portion A with the pad 21. The side wall 13 has a pad 2
The side surfaces of the first portion 1 are in close contact with each other so that no gap is formed in the visible portion 31 of the fitting portion A.

In this embodiment, the matching portion A1
The periphery of the pad installation surface 12 corresponding to the invisible portion 32 of
It bends toward the core back side opposite to the pad 21 to form the invisible portion side end 15. Depending on the shape of the foam molded product and the like, the pad installation surface 1
It may be constituted by two substantially extended surfaces. Reference numeral 16 denotes an injection hole for a liquid foaming raw material.

On the other hand, the pad 21 includes a skin 22 and a foam 27. The outer skin 22 is made of plastic leather or the like molded by slash molding or the like, has a side surface 23 formed at the time of molding, and covers the pad installation surface 12 so as to cover the pad. Symbol 23a
Is a skin side portion on the visible portion 31 side, and 23b is a skin side portion on the non-visible portion 32 side. The foam 2
Numeral 7 is made of polyurethane resin or the like foamed and formed between the skin 22 and the pad installation surface 12, fills the space between the skin 22 and the pad installation surface 12 and adheres to the skin 22 and the pad installation surface 12, and The skin side surface portion 23a is sandwiched between the side wall 13 of the core.

The skin side portion 23a is held by pressing the skin side portion 23a against the side wall 13 of the core due to the volume increase of the foam (liquid foaming raw material) and the pressure of the foaming gas during the molding of the foam 27. This is performed by curing the foam 27 in the state. For this reason, the skin side surface portion 23a is in close contact with the side wall 13, and no gap is formed in the joint portion. Therefore, this padded plastic molding 10 is
The appearance is not impaired at the joining portion between the side wall 13 of the pad installation surface serving as the visible portion 31 and the skin side portion 23a.

Further, in this embodiment, the skin side portion 23a sandwiched between the side wall 13 of the pad installation surface and the foam 27 is used.
Is formed with an inwardly protruding concave groove 24 which is depressed inward. The foam 27 and the skin side 23a are engaged with each other by the inwardly protruding concave groove 24, and the skin side 23a is securely fixed to the foam 27 by a synergistic effect with the bonding. Therefore, even if the skin 22 contracts due to deterioration or the like,
On the side of the visible portion 31 which greatly affects the appearance, there is no possibility that the skin side portion 23a is peeled off from the foam 27, and a good appearance can be maintained for a long time.

Further, the inwardly protruding concave groove 24 of the skin side surface portion 23a increases the rigidity of the skin side surface portion 23a at the time of manufacturing the padded plastic molded product 10, and causes unnecessary waving or the like on the skin side surface portion 23a. To prevent the skin side 23
This also has the effect of preventing the occurrence of sealing failure between the core a and the side wall 13 of the core. In addition, even if a foam (foaming material) intrudes between the skin side surface portion 23a and the side wall 13 of the core, the inwardly protruding concave groove 24 accommodates the invading foam and extends to the surface of the skin 22. It also has the effect of preventing leakage.

In the skin 22, an overlapping end 25 is formed at the edge of the skin side 23b corresponding to the invisible end 15 of the core 11, and the overlapping end 25 is attached to the core 1.
1 overlaps with the end portion 15 on the non-visible portion side. The mating portion between the non-visible portion side end portion 15 of the core and the overlapping end portion 25 of the skin 22 is hidden by a counterpart after the padded plastic molded product is attached, so there is a gap or a burr of foam. Does not matter in appearance. Symbol 26 is
The rigidity of the end 25 for superimposition is increased by an outwardly protruding concave groove which is formed in the end 25 for superposition of the skin and is outwardly concave.

The padded plastic molded article 10 thus formed is mounted on a counterpart, in this embodiment, a vehicle body. At this time, in the visible portion 31 of the joint portion between the pad 21 and the core 11, the skin side portion 23a is sandwiched between the foam 27 and the side wall 13 and is in close contact with no gap, so that the appearance is good. In addition, the padded plastic molded product 10 is lightweight because there is no metal insert for attaching the pad 21.

Next, an embodiment of the manufacturing method of the present invention will be described with reference to the drawings. The mold 40 shown in FIG. 4 includes split molds 41 and 43, and has a cavity 44 for molding therein.
Having. A nozzle hole 42 for inserting the injection nozzle N of the foam molding apparatus is formed in one of the split dies 41. The core 11 is arranged on the mold surface of the one split mold 41 using a clip or the like provided on the mold surface.
At this time, the pad mounting surface 12 of the core 11 is directed to the other split mold 43 side. The pad installation surface 1
The mold surface of the other split mold 43 opposite to the surface 2
2 faces the side surface portion 23 toward the pad mounting surface 12, and attaches the skin side surface portion 23 a having the inwardly protruding groove 24 to the core 11.
Is arranged so as to be on the side wall 13 side.

As shown in FIG. 6, an elastic material 45 is embedded in the mold surface of the split mold 43 in which the overlapping end 25 of the skin is disposed, and a concave portion on the surface of the elastic material 45 is formed. The outwardly protruding groove 26 of the overlapping end 25 is fitted into and held by 46.

Then, the split dies 41 and 43 are closed. By this closing, the skin 22 covers the pad mounting surface 12 so as to cover the pad mounting surface 12, and the skin side surface 23 a having the inwardly protruding concave groove 24 comes into substantially contact with the side wall 13 of the core 11.
When the mold is closed and when the skin 22 is arranged, the skin side portion 2
3a has high rigidity due to the inwardly protruding concave groove 24,
There is no possibility that an irregular gap due to waving or the like will occur between the side wall 13. Also, the concave portion of the elastic member 45 of the split mold 43 is formed.
The outwardly projecting concave groove 26 is fitted into the portion 46 and is held on the mold surface.
The overlapping end 25 of the skin 22 is overlapped with the invisible end 15 of the core 11 by the closed mold, and the two split molds 41,
43 and are sealed between the mold surfaces.

Next, from the injection nozzle N inserted into the nozzle hole 42 of the split mold 41, a liquid foaming raw material P such as a polyurethane raw material is supplied through the injection hole 16 of the core 11 to the pad mounting surface 12 of the core and the skin 22. Injected in between.

The injected liquid foaming material P fills the space between the pad installation surface 12 and the skin 22 while starting a foaming reaction to form a foam. And foam (liquid foaming raw material P)
However, when reaching the skin side portion 23a on the visible portion side as shown by a chain line in FIG. 5, the skin side portion 23a is pressed toward the side wall 13 of the core 11, and is pressed against the side wall 13 to be pressed.
And the skin side 23a. At this time, since the skin side surface portion 23a is in a state where there is no undulation or the like due to the inwardly protruding concave groove 24, the skin side portion 23a is securely adhered to the side wall 13 and sealed. By the sealing, the foam is formed on the skin side surface portion 23a and the side wall 13.
Leakage from the space to the visible portion 31 of the fitting portion is prevented, and the visible portion 31 with good appearance is obtained. In addition, as shown in FIG. 7, even if the foam 27 invades between the skin side portion 23a and the side wall 13, the foam 27
a is accommodated in the inwardly protruding groove 24 of the skin side portion 23a, and is prevented from being exposed from between the skin side portion 23a and the side wall 13. Therefore, even in this case, the visible portion 31 having a good appearance can be obtained.

On the other hand, the elastic member 4 of the split mold 43 is provided at the joint between the skin 22 and the core 11 which is the invisible portion 32.
The outwardly projecting concave groove 26 fits into the concave portion 46 of No. 5 and is held on the mold surface.
Nonvisible portion end 15 of the polymerization end 25 and the core 11 of the skin 22 being is the mold surface by being sandwiched sealing both split type 41 and 43, leakage of the foam is prevented. Moreover, FIG.
As shown in FIG. 7, even when the foam 27 invades between the overlapping end 25 of the skin 22 and the non-visible portion side end 15 of the core 11, the intruding foam 27b is formed on the overlapping end 25. The foam is prevented from leaking because it is housed in the outwardly protruding groove 26. Even if the foam may leak to some extent on the invisible portion side to form burrs or the like, since the invisible portion is hidden by the attachment of the padded plastic molded product, there is no problem in appearance. . Therefore, according to this manufacturing method, the sealing material is applied to the skin 22 or the core 1.
1, so that the manufacturing operation is facilitated.

The foam (liquid foaming material) filling the space between the skin 22 and the pad mounting surface 12 adheres to the skin by self-adhesiveness generated at the time of foaming to form a pad. Also adheres. Thereafter, if the mold is opened and the molded product is taken out, the desired plastic molded product with a pad shown in FIG. 1 is obtained.

FIG. 9 shows another example of the manufacturing method.
The same members as those in the above embodiment are denoted by the same reference numerals. In this embodiment, a through hole 54 communicating between the inside and outside is formed in a side wall 53 of the core 51 facing the inwardly protruding groove 24 of the skin side surface portion 23a. Therefore, even when the amount of the foam invading between the skin side surface portion 23a and the side wall 53 is large, the intruding foam 27a flows out of the core side wall 53 through the through hole 54 of the side wall 53, so that the skin 22 Can be reliably prevented from leaking to the surface side of the device.

FIG. 10 shows a manufacturing method of still another embodiment. In this embodiment, a concave groove 64 facing the inwardly protruding concave groove 24 of the skin side surface portion 23a is formed on the side wall 63 of the core 61.
Is formed. Therefore, the outer skin 22 and the side 23
A large space formed by the inwardly protruding concave groove 24a and the concave groove 64 opposed thereto is formed between the skin side surface portion 23a and the side wall 63 of the core. As a result, the skin side 23
Even if the amount of the foam 27a invading between the a and the side wall 63 is large, the intruding foam 27a can be accommodated in a large space formed by the inwardly protruding concave groove 24 and the concave groove 64 opposed thereto. There is no possibility that the intruding foam 27a leaks to the surface side of the skin 22.

Further, the side wall 6 is formed in the concave groove 64 of the side wall 63.
If the through hole 65 communicating the inside and the outside of the core 3 is provided, even if the amount of the intruding foam 27a becomes larger, the intruding foam 27a flows out of the side wall 63 of the core through the through hole 65. The leakage of the foam to the surface of the substrate 22 can be reliably prevented.

In each of the above embodiments, the case where the pad is provided on a part of the core is shown. However, the plastic molded article with a pad and the manufacturing method of the present invention are also applied to the case where the pad is provided on the entire surface of the core. You. In that case, a side wall is provided at the edge of the core. Also, the injection of the liquid foaming raw material may be an open injection performed by opening a split mold.

[0033]

As shown and described above, the present invention
According to the manufacturing method, a concave is formed inward on the side surface on the visible side of the epidermis.
Inwardly protruding concave groove, on the overlapping end of the side part on the invisible part side
Providing outwardly protruding concave grooves depressed outward, respectively,
For the split type to be arranged, the outwardly protruding groove on the skin is arranged.
Buried elastic material with concave part on the surface of the mold to be placed
Then, the side of the visible skin side of the skin is the pad mounting surface.
So that it is substantially in contact with the side wall, and
The convex groove fits into the concave part of the elastic material and
The overlapping end of the side portion of the invisible portion is not covered with the pad installation surface.
So that it is clamped between the outer surface of the visible side end and the split mold surface
The liquid foaming material injected between the skin and the pad installation surface
Foam the ingredients. Therefore, in the present invention, the side wall of the core is
The side surface of the skin adheres tightly to the skin, and the skin on the visible side
The side part firmly adheres to the foam, and
There is no danger, and there is no metal
No need for heat-sealing, making it easy to produce lightweight padded plastic moldings with good appearance of the mating part of the pad and core, which become the visible part, without sticking the sealing material to the core etc. so that it is. Therefore, the manufacturing operation can be streamlined and economical.

[Brief description of the drawings]

FIG. 1 is a cross-sectional view of one embodiment of a plastic molded product with a pad obtained by a manufacturing method of the present invention.

FIG. 2 is an enlarged cross-sectional view of a vicinity of a portion where a side wall of a core and a pad on the visible side are joined together.

FIG. 3 is an enlarged sectional view of the non-visible portion side.

FIG. 4 is a cross-sectional view of a molding die showing one embodiment of the method for producing a padded plastic molded product of the present invention.

FIG. 5 is an enlarged cross-sectional view showing a part of a molding tool in the middle of foaming in the example.

FIG. 6 is an enlarged sectional view showing another part of the molding die in the same embodiment.

FIG. 7 is a sectional view showing a part of a molding die in a state where the liquid foaming material is filled between a skin and a core.

FIG. 8 is a sectional view showing another part of the molding die at that time.

FIG. 9 is a partial sectional view of a molding die showing another embodiment of the manufacturing method of the present invention.

FIG. 10 is a partial sectional view of a molding die showing still another embodiment.

FIG. 11 is a perspective view showing a conventional example of a molded product for an instrument panel.

FIG. 12 is a partial sectional view of a conventional molded product.

[Explanation of symbols]

 11: Core 12: Pad installation surface 13: Side wall 21: Pad 22: Skin 23, 23a, 23b: Side surface of skin 24: Inwardly protruding concave groove 31: Visible part 32: Non-visible part 40: Mold P: Liquid Foaming raw material

──────────────────────────────────────────────────続 き Continued on the front page (58) Field surveyed (Int. Cl. ⁷ , DB name) B29C 39/00-39/44 B60K 37/00

Claims (2)

(57) [Claims] (1)Pad mounting surface (12) and its peripheral
A side wall (13) erected to the core surface side at the portion;
Bend to the back side of the core or
(1)
And a core (11) having a split mold (40).
In the mold surface of one split mold (41), and the other
The skin (22) is arranged on the mold surface of the split mold (43),
Liquid foaming material injected between the pad installation surface of the core and the skin
The foam (27) is covered with the skin by the foaming of (P).
Pad (21) on the pad mounting surface of the core.
The side wall (13) of the pad mounting surface and the side portion (23a) of the skin
Is in close contact with the mating part (A).
Has a visible part (31) that is exposed even after the
And a skin (12) at the end (15) of the core on the non-visible portion side.
The overlapping end (25) of the other side (23b) overlaps
The mating part (A1) is used to
A plus that becomes an invisible part (32) that is hidden after mounting the shape
In a method for producing a tick molded article, The skin (22) has a side surface portion (23) on the visible portion (31) side.
a) an inwardly protruding groove (24) recessed inwardly, said invisible
End for polymerization (25) of the side surface part (23b) on the side of the part (32)
Are provided with outwardly protruding concave grooves (26) which are depressed outward, respectively. In the split type (43) in which the epidermis is arranged,
A concave surface is formed on the mold surface on which the outwardly protruding concave groove (26) is arranged.
The elastic material (45) formed with (46) is embedded, The side surface portion (23a) on the visible portion side is
When it is made to substantially contact the side wall (13) of the pad installation surface
In addition, the outwardly protruding concave groove (26) of the outer skin 22 is provided with the elasticity.
The skin (22) fits into the recess (46) of the material (45).
Of the side portion (23b) on the side of the invisible portion (23b)
5) is an end (1) of the pad installation surface (12) on the invisible portion side.
5) To be clamped between the outer surface and the mold surface of the split mold (43)
Arranged in a split mold (43), Injected between the skin (22) and the pad mounting surface (12)
Liquid foaming raw material (P) The foam (2)
7) is integrated with the skin (22) and the core (11).
Of molded plastic products with pads
Construction method. 2. A side wall of a pad installation surface according to claim 1,
(63) on the side (23a) of the visible side of the skin (22)
Forming a concave groove (64) facing the inwardly protruding concave groove (24);
Of padded plastic molded products characterized by
Construction method.