JP3155225B2 - Foam 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 foam molded article, and more particularly to a measure for sealing at a joint between a core material and a skin.

[0002]

2. Description of the Related Art Conventionally, foam molded articles in which a foam layer is integrally formed between a core material and a skin are often used for interior parts such as instrument panels of automobiles.

[0003] Such a foamed molded article is formed by foaming and hardening a foaming material between a skin and a core material . The foaming material is formed by the rising wall around the skin forming region of the core material and the periphery of the skin periphery. Leakage from the joint with the upright portion impairs the appearance, so it is necessary to take sealing measures. In the past, the following sealing measures have been taken.

[0004] A soft foam sealing material of communicating bubbles is interposed between the upright wall of the core material and the peripheral upright portion of the skin, and the gas generated as the foaming material foams progresses outside the mold via the soft foam sealing material. Although it is discharged, the foaming raw material is prevented from leaking out of the mold (Japanese Patent Application Laid-Open No. 8-281670).

[0005] A foam material is applied to the upright peripheral edge of the skin and foamed at the time of molding to form a seal material, thereby providing the seal material with a gas discharging function and a material leakage preventing function in the same manner as described above. (JP-A-4-27510)
No.).

[0006] An elongated band-shaped recessed groove whose surface is recessed is formed at the peripheral edge standing portion of the epidermis, and a reinforcing function is provided by an elongated band-shaped ridge protruding toward the backside of the epidermis due to the depression of the recessed groove. In addition to this, the rigidity of the upright peripheral portion is increased to prevent deformation such as waving, and the foaming material to be leaked is accommodated in a concave groove so as not to leak out of the mold (Japanese Patent Laid-Open No. 8-132920).

[0007] All of these sealing measures utilize the foaming pressure of the foaming material foamed between the core material and the skin. In other words, it is assumed that the peripheral upright portion of the skin is brought into close contact with the upright wall of the core material by the foaming pressure of the foaming raw material, and the sealing property of the joined portion is ensured.

[0008]

However, in the initial stage of foaming of the foamed raw material, the foaming pressure is naturally low, so that the peripheral upright portion of the skin does not strongly press against the upright wall of the core material. Even if such measures are taken, it is difficult to say that the sealing property is always sufficient, and there is a possibility that the foamed material leaks and the appearance is deteriorated.

SUMMARY OF THE INVENTION The present invention has been made in view of the above circumstances, and an object of the present invention is to provide a sealing method in which the peripheral edge rising portion of the skin is strongly pressed against the rising wall of the core material in the initial stage of foaming when the foaming pressure is weak. An object of the present invention is to improve the appearance and improve the appearance by preventing leakage of the foaming raw material.

[0010]

In order to achieve the above-mentioned object, the present invention is characterized in that the shape of the peripheral upright portion of the skin is devised.

Specifically, the present invention is directed to a foam molded article in which a foam layer is integrally molded between a core material and a skin, and has taken the following solutions.

That is, a first solution of the present invention is to provide an upright wall on the outer periphery of a skin forming area of the core material . further,
The core is bent around the periphery of the skin,
A peripheral upright portion to be joined to the upright wall of the material is provided. In addition, the entire outer periphery or a part of the peripheral upright portion protrudes toward the back surface of the skin, and
It is characterized in that a strip-shaped recessed groove whose surface side is recessed is provided, and a thin hinge is provided on the entire periphery or a part thereof at a tip end side of the recessed groove of the peripheral upright portion.

With the above arrangement, in the first solution of the present invention, the entire periphery or a part of the peripheral upright portion on the surface side of the skin is band-shaped.
Since the belt-like ridges protrude on the back side of the skin by being recessed, the ridges provide a reinforcing function to the upright peripheral portion and increase its rigidity, so that the upright peripheral portion prevents deformation such as waving It fits the core material and improves the sealing performance. Furthermore, even when the foaming pressure acting on the peripheral erected portion in the initial stage of foaming is weak, the tip side portion of the thin hinge is easily bent with the thin hinge as a fulcrum due to the weak foaming pressure, and is strongly pressed against the rising wall of the core material. . Therefore, the degree of adhesion between the upright wall of the core material and the front end portion of the peripheral upright portion of the skin is increased, so that the sealing property is secured, and the foaming material does not leak out, and the appearance is improved.

A second solution of the present invention is characterized in that, in the first solution, the thickness of a portion on the distal end side of the thin hinge of the peripheral upright portion is smaller than the thickness of other portions.

With the above arrangement, according to the second solution of the present invention, the portion of the peripheral upright portion closer to the tip than the thin hinge is thinner than the other portions and is easily affected by the foaming pressure. It bends smoothly and reliably, and is further strongly pressed against the upright wall of the core material to further secure the sealing property, and the leakage of the foaming raw material is reliably prevented and the appearance is further improved.

[0016]

Embodiments of the present invention will be described below with reference to the drawings.

FIGS. 2 and 3 show a foam molded product according to an embodiment of the present invention. In this example, the foam molded product is an instrument panel 1 which is an interior component of an automobile.
The instrument panel 1 is composed of an upper panel portion 1a constituting an upper half portion and a lower panel portion 1b constituting a lower half portion. The upper panel portion 1a is a foam layer between the core material 3 and the skin 5. 7 has a three-layer structure integrally formed, and the lower panel portion 1b has a single-layer structure of only the core material 3. This instrument panel 1
The material for the core material 3 is not particularly limited, but generally, the core material 3 is a hard resin such as acrylonitrile / butadiene / styrene (ABS) resin, and the skin 5 is polyvinyl chloride (P
A soft resin such as VC) and a hard foamed resin such as a hard polyurethane foam are generally used for the foamed layer 7. The core material 3 may be formed by compression molding or injection molding, and the skin 5 may be formed by slash molding or vacuum molding.

[0018] to expand詳示FIG. 1 (a), the core
An upright wall 9 is provided on the material 3 so as to correspond to the entire periphery of the upper panel portion 1a which is the outer periphery of the rectangular skin formation region. On the other hand, on the peripheral edge of the skin 5, the peripheral upright portion 1 bent to the back side of the skin 5 and joined to the upright wall 9 of the core member 3.
2 is provided in the area surrounded by the peripheral upright portion 11 (FIG. 2).
And almost the entire area of the upper panel portion 1a in FIG.

As one of the features of the present invention, an elongated band-like recessed groove 17 in which the surface side of the skin 5 is recessed is formed all around the middle of the peripheral upright portion 11 of the skin 5.
As a result, an elongated strip-shaped ridge 19 protrudes from the back surface of the skin 5. Another feature of the present invention is that a thin hinge 21 having a V-cut shape is formed on the entire periphery of a portion 11a on the distal end side of the recessed groove 17 of the peripheral upright portion 11. These concave grooves 17 (projection 1
9) and the thin hinge 21 are formed simultaneously with the formation of the skin 5.

Between the upright wall 9 of the core material 3 and the skin body 13 side with respect to the recessed groove 17 of the peripheral upright portion 11 of the skin 5,
For example, a soft foam sealing material 23 of open cells such as a urethane slab seal material is interposed, and a gas generated at the time of foam molding is discharged out of the mold through the open cells of the soft foam sealing material 23. The foaming raw material 35 (shown in FIGS. 4 and 5) is further blocked by the soft foam sealing material 23 and does not leak out of the mold.

Next, a method of manufacturing the instrument panel 1 configured as described above will be described with reference to FIGS.

Prior to the production, a core material 3 and a skin 5 which are formed in a predetermined shape in advance are prepared. The skin formation region outer circumference of the core member 3 is projected the upright wall 9, the peripheral edge of the skin 5, peripheral erected which is bent on the back side of the epidermis 5 is joined to the upright wall 9 of the core member 3 The part 11 is provided in a protruding manner.
On the entire periphery of the peripheral upright portion 11, the elongated strip-shaped recessed groove 17 in which the surface side of the skin 5 is recessed is formed simultaneously with the molding of the skin 5, and the elongated strip-shaped ridge is formed on the back side of the skin 5 by the recessed groove 17. 19 are protruded. Further, the thin hinge 2 having the V-cut shape is provided on the entire periphery of the distal end portion 11a from the concave groove 17 of the peripheral edge standing portion 11.
1 is molded. In addition, the flexible foam sealing material 23 of the communicating bubble is formed on the entire periphery of the peripheral edge standing portion 11.
7 is attached to the skin body 13 side.

When the preparation is completed as described above, first,
As shown in FIG.
The outer skin 5 is set on the lower mold 27 in a state where the surface of the outer skin 5 is in contact with the lower mold 27 as a fixed mold, and is closely attached to the lower mold 27 so as not to move the skin 5 by a negative pressure from a vacuum suction hole (not shown). Let it. In this state, the peripheral upright portion 11 of the skin 5 faces upward. On the other hand, the core material 3 is set on the upper mold 29 as a movable mold in a posture in which the skin formation region faces downward (a posture in which the back surface side faces upward).

Next, the plurality of slide cores 31 arranged around the lower mold 27 are advanced by the extension operation of the fluid pressure cylinder 33, and the leading ends of the cores are brought into contact with the peripheral upright portions 11 of the skin 5 from the side to thereby advance the slide cores 31. After positioning so that the peripheral edge standing portion 11 does not fall outward, a foaming raw material 35 is injected into the back surface of the skin 5 from an injection head (not shown). Here, the injection of the foaming raw material 35 is performed by an open injection method, but may be performed by a closed injection method of injecting the foaming raw material 35 between the core material 3 and the skin 5 in a mold-clamped state.

Thereafter, as shown in FIG. 5, the upper mold 29 is lowered, and each slide core 31 is retracted by the contraction operation of the fluid pressure cylinder 33, and the mold is clamped as shown in FIG. In a state where the molding die 25 is clamped, the elastic material 37 made of a rubber sheet or the like adhered to the inclined surface on the core tip side of each slide core 31 is pressed against the outer surface of the upright wall 9 of the core material 3, and the core material 3 is pressed. Position so that it does not move. Thereby, the soft foam sealing material 2 is formed at the peripheral upright portion 11 of the skin 5.
3 comes into contact with the upright wall 9 of the core material 3.

In this state, the foaming raw material 35 is confined between the core material 3 and the skin 5, and starts foaming in this closed space. As the foaming of the foaming material 35 progresses, the foaming pressure increases
Acting on the peripheral upright portion 11 of the core material 3
Is pressed against the upright wall 9. At this time, the peripheral upright portion 11
Of the core member 3 is strongly pressed by the foaming pressure against the thin hinge 21 as a fulcrum. At the same time, the soft foam sealing material 23 is pressed against the upright wall 9 of the core material 3 to reduce its thickness,
1 comes into close contact with the upright wall 9. Then, the foaming raw material 35 is completely foamed and hardened, the foamed layer 7 is integrally formed between the core material 3 and the skin 5, and the peripheral upright portion 11 of the skin 5 is joined to the upright wall 9 of the core material 3. The obtained instrument panel 1 is obtained.

As described above, in the present embodiment, since the elongated belt-shaped recessed groove 17 in which the surface side of the skin 5 is recessed is formed on the entire periphery of the peripheral upright portion 11 of the skin 5, the recessed groove 17 is recessed. The elongated belt-shaped ridges 19 projecting to the back side of the skin 5 can provide a reinforcing function to the peripheral upright portion 11 to increase its rigidity.
The edge rising portion 11 is prevented by preventing
The sealing property can be ensured by fitting to the upright wall 9 of the core material 3.

Further, in this embodiment, the thin hinge 2 is provided on the entire periphery of the peripheral upright portion 11 on the tip side from the concave groove 17.
Since the molding 1 is formed, even when the foaming pressure acting on the peripheral edge standing portion 11 is weak at the initial stage of foaming, the weak foaming pressure makes it possible to easily make the tip side portion 11a of the thin hinge 21 with the thin hinge 21 as a fulcrum. Deflected, upright wall 9 of core material 3
Can be pressed strongly. Thus, the upright wall 9 of the core member 3 and the distal end portion 11a of the peripheral upright portion 11 of the skin 5
By increasing the degree of close contact with the outer wall, the joint between the peripheral upright portion 11 and the upright wall 9 can be reliably sealed to prevent leakage of the foaming raw material 35, and the appearance can be improved.

In this embodiment, since the soft foam sealing material 23 for communicating bubbles is interposed between the upright wall 9 of the core member 3 and the peripheral upright portion 11 of the skin 5, the foaming of the foaming raw material 35 is prevented. The gas generated with the progress is transferred to the soft foam sealing material 23.
Can be discharged to the outside of the mold through the communication bubble, and the high-quality instrument panel 1 can be obtained by eliminating voids caused by the gas remaining in the foam layer 7.

In this embodiment, the case where the concave groove 17 and the thin hinge 21 are formed over the entire periphery of the peripheral upright portion 11 is shown. However, the present invention is not limited to this. Depending on the shape of the foam molded product, the concave groove 17 and the thin hinge 21 are formed. 21 may be partially formed in the peripheral upright portion 11.

Next, a modified example of the instrument panel 1 will be described.

(Modification) As shown in FIG. 1 (b), in the instrument panel 1 of this modification, an elongated strip-shaped recess in which the surface of the skin 5 is recessed all around the middle of the upright edge 11 of the skin 5. The groove 17 is formed in the same manner as in the above-described embodiment. However, in the above-described embodiment, the thickness t1 of the portion 11a on the distal end side of the thin hinge 21 and the thickness t2 of the other portions are substantially the same. On the other hand, this modified example is different from the above-described embodiment in that the thickness t1 of the distal end portion 11a of the thin hinge 21 is about half as thin as the thickness t2 of the other portions. The other points are the same as those of the above-described embodiment, and therefore, the same portions are denoted by the same reference numerals and detailed description thereof will be omitted. Also in this modification, depending on the shape of the foam molded product, the concave groove 17 and the thin hinge 21 may be used.
It is needless to say that the edge rising portion 11 may be partially formed.

Therefore, in this modification, the same operation and effect as those of the above embodiment can be obtained.

In addition, in this modified example, the thickness t1 of the portion 11a on the tip side of the thin hinge 21 of the peripheral upright portion 11 of the skin 5 is made smaller than the thickness t2 of the other portions. 11a can be smoothly and reliably bent by a slight foaming pressure, and the sealing force can be further ensured by the strong pressing force obtained by this, and leakage of the foaming material 35 can be reliably prevented. Appearance can be further improved.

In the above two examples, the case where the foam molded product is the instrument panel 1 has been described. However, the present invention is not limited to this case. It can be applied to goods.

Further, the shape of the concave groove 17 formed in the peripheral edge rising portion 11 of the skin 5 is not limited to the above-described embodiment, and the cross section may be square or V-shaped.

[0037]

As described above, according to the present invention,
Since the entire circumference or a part of the skin surface side of the peripheral erected part of the skin is caused to project the strip-shaped ridge on the skin back side by <br/> recessed in a band, peripheral erected portion by the reinforcing function of the ridge Stiffness can be increased to prevent deformation such as waving, and the peripheral upright portion can be fitted to the core material to improve sealing properties. Further, since the thin hinge is provided on the entire periphery or a part of the peripheral upright portion at the distal end side from the concave groove, even when the foaming pressure acting on the peripheral upright portion is weak at the initial stage of foaming, the thinner hinge portion is provided at the distal end side. Easily, and the strong pressing force increases the degree of close contact between the upright wall of the core material and the tip side of the upright edge of the skin to ensure sealing, and prevents foaming material from leaking out to foam molding. The appearance of the product can be further improved.

[Brief description of the drawings]

FIG. 1A is a cross-sectional view showing an enlarged part A of FIG. 3;
(B) is a (a) equivalent view showing a modification.

FIG. 2 is a sectional view taken along line BB in FIG.

FIG. 3 is a perspective view of an instrument panel.

FIG. 4 is a cross-sectional view corresponding to line BB of FIG. 3 showing a mold opening state of the molding die.

FIG. 5 is a BB view of FIG. 3 showing a state immediately before clamping of the mold;
It is sectional drawing corresponding to a line.

FIG. 6 is a cross-sectional view showing a clamped state of the molding die and corresponding to line BB in FIG. 3;

[Explanation of symbols]

DESCRIPTION OF SYMBOLS 1 Instrument panel (foam molded article) 3 Core material 5 Skin 7 Foam layer 9 Standing wall 11 Peripheral edge standing part 11a Tip side 17 Depressed groove 21 Thin hinge t1 Thickness of tip end part from thin hinge t2 Thickness of other parts

Claims (2)

(57) [Claims] 1. A foam molded article in which a foam layer is integrally formed between a core material and a skin, wherein an upright wall is provided around an outer periphery of a skin forming region of the core material , and is peripheral erected portion joined to the standing wall of the core member is bent to the rear surface side of the epidermis is provided on the entire circumference or a portion of the peripheral edge upstanding section protrudes table skin back side
A foam molding characterized by being provided with a band-shaped recessed groove in which the skin surface side is recessed, and a thin hinge is provided on the entire periphery or a part of the peripheral upright portion on the tip side from the recessed groove. Goods. 2. The foam molded article according to claim 1, wherein a thickness of a portion on a tip side of the thin hinge of the peripheral upright portion is smaller than thicknesses of other portions.