JP3197323B2 - Method for producing urethane foam molded article and urethane foam molded article - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION The present invention, urethane foam molded article manufacturing method and a urethane foam molding having a core and a skin layer
More particularly , the present invention relates to a method for producing a urethane foam molded article that partially exposes a core material, and a urethane foam molded article . INDUSTRIAL APPLICATION This invention is utilized for manufacture of an armrest, a headrest, etc. in a motor vehicle.

[0002]

2. Description of the Related Art Conventionally, a core material for reinforcement and the like, a urethane foam layer embedded inside the core material, and a skin material for improving appearance, feel, etc. are integrally formed as interior parts of an automobile. Urethane foam molded articles are used. However, as shown in FIG. 5, when there is a mating part 5 in this urethane foam molded article, if the skin material 23 and the urethane foam part 6 are provided in the assembling space, the assembly cannot be performed as it is. For this reason, conventionally, (1) after setting a skin material and a core material in a molding die, injecting and heating a raw material urethane into these, and manufacturing a urethane foam molded product integrally molded over the whole, as shown in FIG. The removal skin material part 23 and the removal urethane foam part 6 which are no longer needed in the final product were removed by post-processing. On the other hand, (2) as shown in FIG. 6, the skin material 2 is sandwiched between the core material 3 and the molding die 1, and the sealing material 7 is used to seal the skin material 2 to obtain a final product. Skin material part 2 that becomes unnecessary in some cases
Attempts have been made to omit the urethane foam 3 and the urethane foam part 6 in advance.

[0003]

However, according to the above-mentioned method (1), the operation of removing the urethane foam part 6 particularly in the post-process is not only a large man-hour but also involves a loss of urethane raw material. There was a problem that was also large.
Also in the above-mentioned trial (2), it is extremely difficult to seal the core material 3 and the skin material 2 which are each three-dimensionally changed by surface contact, so that complete sealing cannot be performed and burrs are generated. Problems such as soiling of the mold.

The present invention overcomes the above disadvantages,
Even if the core material and the skin layer change three-dimensionally, a urethane foam molded product (also referred to as a final product) which can improve the sealing property, eliminate the urethane removal work in a later process, and reduce urethane raw material loss. Production method and c )
An object of the present invention is to provide a polyurethane foam molded article .

[0005]

According to the present invention, there is provided a method for producing a urethane foam molded article having a core material and a skin layer, the method comprising the steps of:
A first ridge contacting the core at a position near the center of the core and a second ridge contacting the core at a position near one end of the core on a surface facing the core . Are formed, and the first ridge portion and the second ridge portion during foam molding,
Foam molding is performed in a state where the intrusion of the raw material urethane between these two ridges is prevented, and then at least the first
Protrusion and remove the skin material portion between the second projecting portion, and wherein the Rukoto expose the core material. Also, according to the present invention,
Manufacturing method is a urethane foam molded article having a core material and a skin layer
Forming the core material and the skin layer.
On the surface facing the core material of the skin material
A ridge surrounding the void formed between the core material and the skin material
A step of arranging the provided skin material in a mold, and foam molding
Sometimes, while preventing the intrusion of raw urethane into
Of urethane foam molding and after demolding, at least
Also, a step of removing the skin material corresponding to the space,
It is characterized by consisting of. Further, the urethane of the present invention
Foam molded product is urethane foam molding with core material and skin layer
In the article, the above-mentioned core material and a position near the center of the core material
The first ridge contacting the core and the one end of the core
Position the second ridge in contact with the core at a position facing the core;
A skin material having a mating surface to form the skin layer
And then the first ridge and the second ridge.
It starts in a state where the intrusion of raw urethane between the strips is prevented.
Foam molding, and then at least the first protrusion and the second protrusion
Is obtained by removing the skin material between the
At a location between the first ridge and the second ridge.
The core material is exposed. In addition,
Ming's urethane foam molded product has the core material and the skin layer
The surface facing the core material of the skin material to be formed
A projection surrounding the void formed between the core material and the skin material.
When the foam material is placed in the mold,
While preventing the intrusion of the raw urethane into the voids,
Perform urethane foam molding, and after demolding , at least
It is obtained by removing the skin material at the location corresponding to the gap.
And the core material is exposed at a location corresponding to the gap.
It is characterized by the following.

Here, the term "protrusion" refers to a linear or ridge-shaped projection, and the tip of the projection comes into contact with the core to prevent the urethane raw material from flowing into a predetermined space. A thing. "Skin material" refers to a member used as a raw material when manufacturing the foam molded article (the skin material part for removal is not deleted in a later process), and is set together with a core material in a molding die. Say. The “skin layer” refers to a layer that covers the surface of the urethane foam layer for the purpose of improving the appearance and feel of the urethane foam molded product (having the removed skin material portion removed) as the final product. . The term "center of the core material" means closer to the center than the position of the second ridge formed and arranged at a position on one end side of the core material so as to be in contact with the core material.

[0007]

According to the method for producing a urethane foam molded article of the present invention, a first ridge and a second ridge which come into contact with a core material are formed on a skin material, and a raw material is inserted between these two ridges. Foam molding can be performed in a state where penetration of urethane is prevented. Therefore, since the skin material portion and the urethane foam portion do not exist in the space where the counterpart component is assembled and arranged, it is not necessary to remove these in a later process. In particular, in the case of surface contact, a large force is required to maintain the sealing property. However, since the present invention seals by line contact in the form of a ridge, the core material and the skin layer change three-dimensionally. However, it is simple and excellent in airtightness, and it is possible to completely shut off the intrusion of the raw material urethane between the two ridges.

[0008]

As described above, according to the present manufacturing method, it is possible to eliminate the urethane removing operation in the subsequent step, suppress the urethane raw material loss, and provide the urethane foam molded article as it is as an assembly part. Therefore, it can greatly contribute to improvement of productivity and the like.

[0009]

The present invention will be described below in detail with reference to examples. (1) Manufacture of Urethane Foam Molded Product FIG. 1 shows one embodiment of the production of a urethane foam molded product according to the present invention. It is a cross-sectional view showing a state in which a urethane foam layer 4 is formed in a space. The molding die 1 includes an upper die (not shown) and a lower die 11 for manufacturing an armrest.
First, the mold 1 is opened, and the skin material 2 is inserted and set so as to be attached to the inner wall of the lower mold 11. The skin material 2 is made of a vinyl chloride resin obtained by injection molding. Thereafter, the core material 3 is arranged at a predetermined position in a predetermined cavity. The core member 3 is made of polypropylene or metal, and is held by a pin or the like (not shown) projecting from the lower mold 12 into the cavity.

Here, when the skin material 2 and the core material 3 are arranged on the skin material 2 on the side facing the core material 3, the first ridge portion 21 and the second ridge portion 21 that can contact the core material 3 are provided. Ridge 22
Are formed on the surface facing the core material . The first ridge portion 21 is located at a position closer to the center of the core material 3 as shown in FIG.
The protruding ridges 22 are formed at a position on one end side of the core member 3 as shown in the figure, and the two protruding ridges 21 and 22 are formed integrally with the base except for the protruding ridges 21 and 22. Incidentally, among the skin material 23, the skin material portion 23 to be removed, as shown in FIGS. 1 and 2, is from just one end portion 231 of the first protrusions 21 to the final end 232 .

In the case of this embodiment in which the gap between the skin material 2 and the core material 3 is about 2 mm as shown in FIG. It is a semicircular cross section of about 0.5 mm, and the skin material 2 and the core material 3 are not in surface contact.
The line contact configuration is adopted. The reason why the height of the ridge portion is slightly larger than the gap distance is that the skin material 2 and the core material 3 are pressed against each other, so that the sealing property can be improved. In the present embodiment, the first ridge 21 and the second ridge 22
Is a semicircular cross section, but is not limited to such a shape, and may be a triangular cross section as shown in FIG. These are also for exhibiting the functionality by line contact.

Next, in a state where the skin material 2 and the core material 3 are arranged, the raw material urethane is injected, and then the upper mold 11 is closed, or after the upper mold 11 is closed, a cavity is formed by penetrating the mold. A raw material urethane is injected from a raw material injection port (not shown) reaching the inside, and foam molding is performed. Thus, a predetermined urethane foam layer 4 is formed between the skin material 2 and the core material 3, and the first ridge 21 and the second ridge 2 are formed at the time of foam molding.
By 2, foam molding is performed in such a state that the intrusion of the raw material urethane between these two ridges is prevented.

[0013] then removed thus produced molded article from the mold, immediately one end portion of the first protrusions 21 2
The urethane foam molded product shown in FIG. 2 was manufactured by removing the skin material portion 23 for removal after 31. This molded product is a skin layer 2A formed excluding the urethane foam layer 4, the core material 3 disposed therein, and the skin material portion 23 for removal.
And consisting of Since the core material 3 is exposed at the location where the removing skin material portion 23 has been removed and the recessed portion is formed, the core material 3 can be assembled as it is without interfering with the mating component.

(2) Effects of Embodiment In this embodiment, the first ridge 21 in contact with the core 3 is
Of the core material 3 at a position closer to the center of
At the one end side, the intrusion of raw urethane from both sides between these two ridges is prevented. Therefore, a desired end product can be easily obtained by removing the predetermined skin material portion 23 for removal. That is, since there is no leakage of the urethane material between the first ridge portion 21 and the second ridge portion 22, the work of removing unnecessary urethane in the subsequent process is eliminated, and no loss of urethane raw material occurs. In particular, the ridges formed on the skin material come into contact with the core material by wire contact instead of surface contact that requires high precision processing over the entire sealing surface, so the sealing effect is high and the excellent sealing state is easily achieved It can also be. Further, since the height of the ridge portion is slightly larger than the gap distance between the skin material 2 and the core material 3, the penetration of the raw urethane is completely suppressed by the mutual pressing action of the skin material 2 and the core material 3. be able to.

The present invention is not limited to the above-described specific embodiments, but can be variously modified within the scope of the present invention according to the purpose and application. For example, the shapes and sizes of the first ridge and the second ridge are not limited to those shown in FIG. 1, and any shape or the like may be used as long as the raw material urethane can be prevented from entering between the two ridges. Also,
As shown in the above embodiment, both the first ridge and the second ridge may completely cross the mold and may be separated from each other. However, the present invention is not limited to this. Three-dimensionally, the first ridge portion and the second ridge portion may be part of a ring shape and connected (that is, concave portions surrounded by banks on all sides). Furthermore, skin material,
The material of the core material, the gap distance between them, and the like can be variously selected depending on the purpose, application, and the like.

[Brief description of the drawings]

FIG. 1 is an explanatory cross-sectional view showing a production state of a urethane foam molded article according to the present embodiment.

FIG. 2 is a cross-sectional view of the urethane foam molded article according to the present embodiment.

FIG. 3 is an enlarged sectional view showing a positional relationship between a first ridge (second ridge) and a core member according to the present embodiment.

FIG. 4 is an enlarged sectional view of another embodiment showing a positional relationship between a first ridge (second ridge) and a core material.

FIG. 5 is an explanatory cross-sectional view showing a state in which a urethane foam molded product has been conventionally manufactured, and a material obtained by removing a removing skin material and a removing urethane portion has been assembled to an assembling counterpart.

FIG. 6 is an explanatory sectional view showing a state in which a skin material and a core material are conventionally sealed by surface contact.

[Explanation of symbols]

1; Mold, 11; Upper, 12; Lower, 2; Skin, 2
DESCRIPTION OF SYMBOLS 1; 1st protrusion part, 22; 2nd protrusion part, 23; skin material part for removal, 2A; skin layer, 3; core material, 4; urethane foam layer, 5; Urethane foam for removal,
7; sealing surface.

──────────────────────────────────────────────────の Continued on the front page (51) Int.Cl. ⁷ identification code FI B29L 31:58 (58) Investigated field (Int.Cl. ⁷ , DB name) B29C 39/10-39/12 B29C 39/22 -39/24 B32B 3 / 10,5 / 18 B60R 21/02-21/045

Claims (4)

(57) [Claims] 1. A core material and the manufacturing method of urethane foam molded article having an skin layer, the core member and direction of the skin material and thus to form the skin layer
On the mating surface , a first ridge contacting the core at a position near the center of the core, a second ridge contacting the core at a position on one end side of the core, There is formed by the first protrusions and the second protrusions when foam molding, intrusion of these materials urethane into the space between the protrusions is foam molded in the condition to be prevented, then at least the remove the <br/> skin material portion between the first protrusion and the second protrusion, the production method of the urethane foam molded article, characterized in Rukoto expose the core material. 2. A urethane foam having a core material and a skin layer.
In the method for producing a shaped article, the core material and the skin material for forming the skin layer
On the surface facing the core, between the core and the skin
A skin material having a ridge that surrounds the void formed in
A step of arranging the urethane material in the mold during foam molding
While performing the step of foaming and molding the raw urethane, and after demolding , at least the skin material at a location corresponding to the void is removed.
A process for producing a urethane foam molded article, comprising:
Law. 3. A urethane foam having a core material and a skin layer.
In the shaped article, the core material is contacted with the core material at a position near the center of the core material.
The first ridge and the core at one end of the core.
The second ridge in contact with the material is provided on the surface facing the core material.
And a skin material that will form the skin layer
And then feed the raw material between the first ridge and the second ridge.
Foam molding is performed in a state where the intrusion of urethane is prevented, and then, at least between the first and second protrusions.
The first ridge is obtained by removing the skin material portion.
The core material is located at a position corresponding to between the portion and the second ridge portion.
A urethane foam molded product characterized by being exposed. 4. Forming the core material and the skin layer.
The core material on the surface facing the core material of the skin material
And a ridge that surrounds a gap formed between the skin material and
And the skin material are placed in a molding die, and into the above gap during foam molding.
Of urethane raw material while preventing intrusion of urethane raw material
Perform foam molding and after demolding, at least correspond to the above voids
Obtained by removing the skin material at the location,
The core material is exposed at the corresponding location.
Urethane foam molded products.