JP3205408B2 - Lid and molding method thereof - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a lid and a molding method thereof, and more particularly to a lid of a type in which a lid inner panel is attached to a back surface of a foam outer lid panel and a molding method thereof.

[0002]

2. Description of the Related Art Conventionally, for example, a lid of a console box of an automobile is constructed by assembling a lid inner panel on a back surface of a lid outer panel as disclosed in, for example, Japanese Utility Model Laid-Open No. 1-70645. .

When the lid outer panel of the lid is formed by integrally forming a foam layer between a skin material and a core material as described above, the end of the skin material extends to the back side of the panel. There are some types.
When trying to mold such a lid outer panel, if the skin material is set in the lower mold as it is, the terminal will have an undercut shape, so the core material set in the upper mold at the time of mold clamping will interfere with the terminal of the skin material And the mold cannot be clamped in a proper state.

Therefore, as disclosed in, for example, Japanese Utility Model Application Laid-Open No. 1-72311, a mold portion corresponding to the end (undercut-shaped portion) of the skin material is constituted by a split mold, and the split mold is formed at the time of molding. The skin material is set on the lower mold in a state away from the mold position to the outside of the mold, and then the terminal of the skin material is pushed outward to avoid undercut, and in this state, the skin material of the lower mold is After placing the core material on the upper mold, the upper mold is clamped. Thereafter, the leading end of the pull-up knob provided on the upper mold is provided on the back surface of the core material. To expand the tip locking portion outward, and by this expanding action, hold the core material with the pull-up knob to form a space between the skin material and the core material. The foam layer was integrally formed between the skin material and the core material by injecting the foam resin material The Tsu was to obtain a de outer panel technology The applicant has developed.

[0005]

However, the lid outer panel obtained as described above has a cylindrical locking portion projecting from the back surface of the core material, so that when the lid inner panel is assembled to the back surface of the lid outer panel. In addition, a large space is formed between the lid outer panel and the lid inner panel corresponding to the projection size of the cylindrical locking portion, and the thickness of the entire lid is increased by that much. This leads to a reduced box volume.

The present invention has been made in view of the above circumstances, and an object of the present invention is to raise a core material upward during molding as described above and to form a foamed resin in a space between the core material and the skin material. By injecting the raw material, a lid having a lid outer panel in which a foam layer is integrally formed between the skin material and the core material is obtained, and in this case, before assembling the lid inner panel to the lid outer panel, By cutting or folding the locking portion protruding from the back surface of the core material of the lid outer panel, the space between the assembled lid outer panel and the lid inner panel is reduced to reduce the thickness of the entire lid. Make it smaller
As a result, it is necessary to secure a large box volume.

[0007]

SUMMARY OF THE INVENTION In order to achieve the above object, the present invention is directed to a lid in which a lid inner panel is attached to the back of a lid outer panel, and a molding method therefor. Taken.

[0008] That is, a first solution of the present invention is to provide a lid outer panel with a locking portion of a pulling means for forming a space between a skin material formed into a predetermined shape and the skin material at the time of molding. There is formed integrally between the core member engaging with the base is thinned or formed narrow <br/> cuttable locking pieces protruding from the rear surface, and the skin material and the core material Consists of a foam layer. Further, the locking piece is cut from a core material before the lid outer panel and the lid inner panel are assembled.

[0009] A second solution of the present invention is to provide a lid outer panel which includes a cover member formed into a predetermined shape and an engaging portion of a pull-up means for forming a space between the cover member and the cover member at the time of forming. The foldable locking piece is formed of a core material protruding from the back surface, and a foam layer integrally formed between the skin material and the core material. Further, the locking piece is folded on the back surface of the core material before the lid outer panel and the lid inner panel are assembled.

[0010] A third solution of the present invention is to first set a skin material formed into a predetermined shape on a lower mold, and then thin the base portion.
A core member having meat or a narrow cut- out lockable piece protruding from the back surface is placed on the skin material of the lower die. Then, after the upper mold is clamped, the engaging portion of the pulling means provided on the upper mold is engaged with the engaging piece of the core material, and the core material is set up by pulling up the core material. I do.
Thereafter, a foamed resin material is injected into a space formed between the skin material and the core material to form a lid outer panel. Thereafter, after the locking pieces are cut off from the core material, the lid inner panel is assembled to the rear surface of the lid outer panel.

A fourth solution of the present invention is to first set a skin material formed into a predetermined shape in a lower mold, and then to attach the core material having a foldable locking piece projecting from the back to the lower mold. On the skin material. Then, after the upper mold is clamped, the engaging portion of the pulling means provided on the upper mold is engaged with the engaging piece of the core material, and the core material is set up by pulling up the core material. I do. Thereafter, a foamed resin material is injected into a space formed between the skin material and the core material to form a lid outer panel. Then, after folding the locking piece on the back surface of the core material, the lid inner panel is assembled to the back surface of the lid outer panel.

[0012]

With the above arrangement, in the first to fourth solving means of the present invention, at the time of molding, the locking portion of the pulling means is engaged with the locking piece projecting from the back surface of the core material, and the core material is pulled up. A foamed resin material is injected into a space formed between the core material and the skin material to obtain a lid outer panel in which a foamed layer is integrally formed between the skin material and the core material.

In the first and third solutions,
After the locking pieces are cut from the core material of the lid outer panel, the lid inner panel is assembled to the lid outer panel.

Therefore, the lid outer panel has no locking pieces at the time of assembly, so that the space between the lid outer panel and the lid inner panel is narrowed by the absence of the locking pieces, and the overall thickness of the lid is reduced. And the volume of the box is increased accordingly.

In the second and fourth solving means, the lid inner panel is assembled to the lid outer panel after the locking piece is folded on the back surface of the core material of the lid outer panel.

[0016] For this reason, the projecting dimension of the locking piece projecting from the lid outer panel at the time of assembly is reduced, and the space between the lid outer panel and the lid inner panel is reduced by the reduced projecting dimension of the locking piece. Only the width of the box is reduced, thereby reducing the thickness of the entire lid and, consequently, the volume of the box.

[0017]

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

(First Embodiment) FIG. 10 shows a console box 1 of an automobile. The console box 1 has a box body 3 and a first box of the present invention mounted on the box body 3 by a hinge 5 so as to be opened and closed. And a lid 7 according to the embodiment.

As shown in FIG. 6, the lid 7 is formed by assembling a lid inner panel 11 on the back surface of a lid outer panel 9, and the lid outer panel 9 is composed of a skin material 13 and a core material 15 formed into a predetermined shape. The end of the skin material 13 extends to the back side of the panel and has an undercut shape.

In the center of the core material 15, a foaming resin material R such as polyurethane is filled with the skin material 13 and the core material 15 at the time of molding.
Are formed in a grid pattern (see FIG. 3), and the core material 15 is formed.
Two rectangular locking pieces 21 and 21 are protruded from the rear side of the inlets 19, 19,... Outside (see FIGS. 1 to 4 and FIG. 8). A hole 21a is formed. Further, a thin portion 21 is provided at the base of each locking piece 21.
8 is formed, and each locking piece 21 is configured to bend in the X direction of the arrow in FIG. 8 using the thin portion 21b as a fulcrum, and to be cut out from the thin portion 21b before assembly with the lid inner panel 11. . Therefore, on the back surface of the core material 15 of the lid outer panel 9 immediately after molding, there are the respective locking pieces 21 as shown in FIG. 4, and the respective locking pieces 21 are cut out thereafter, as shown in FIG. 5. However, only the thin portion 21b remains on the back surface of the core material 15. In addition, each of the locking pieces 21
At the time of molding, a locking portion 37a of a pull-up knob 37, which will be described later, is engaged with the locking hole 21a, so that the core material 15 is pulled up to form a space C between the core material 15 and the skin material 13 (FIG. 3). reference).

Further, each locking piece 2 on the back surface of the core material 15
Two positioning recesses 23, 23 each having a tapered surface 23a are formed on one outer side, and a plurality of bosses 25 having tapping holes 25a protrude outside each of the positioning recesses 23.

On the other hand, a plurality of insertion holes 11a, 11a,... Are formed near the outer periphery of the lid inner panel 11 so as to correspond to the bosses 25, respectively.
A screw 27 is inserted into each of the insertion holes 11 a in a state where the screw inner hole 11 a corresponds to the rear surface of the lid outer panel 9 and screwed into the tapping hole 25 a of each boss 25, thereby assembling the lid inner panel 11 on the rear surface of the lid outer panel 9. It has been made like that. In addition, one end (right end in the figure) of the lid inner panel 11 is provided with the constituent member 5 of the hinge 5.
a is provided.

Next, a method of forming the lid 7 configured as described above will be described.

First, as shown in FIG. 1, the split molds 33, 33 attached to the lower mold 29 by the hinges 31 are moved outward with the hinges 31 as fulcrums, and in this state, the lower mold 29 is formed. The skin material 13 formed in a predetermined shape in advance is set on the surface 29a with the back surface facing upward. An extended portion 13a for cutting after forming the lid outer panel 9 is provided at a terminal portion of the skin material 13, and a surface of the extended portion 13a is formed with a locking groove 33a of each split mold 33. A locking projection 13b for positioning to be engaged is formed.

Next, with the extended portion 13a of the skin material 13 expanded to the outside of the mold to avoid the undercut shape, the core material 15 is placed on the skin material 13 of the lower mold 29 with the back surface facing upward. Place on.

Thereafter, as shown in FIG.
3 is placed on the outer peripheral portion of the lower mold 29 with the hinge 31 as a fulcrum, the extending portion 13a of the skin material 13 is attached to each split mold 33, and the locking projections 13b are engaged with the locking grooves 33 of the split mold 33.
a, and the skin material 13 is positioned on the lower mold 29 so as not to be displaced.

Thereafter, after the upper mold 35 is clamped, a pulling knob 3 as a pulling means provided on the upper mold 35 is provided.
As shown by the imaginary line in FIG. 2, the push-down knobs 7 and 37 are pressed down against the spring force of the coil spring 39, and then, as shown in FIG. By engaging the locking portions 37a with the holes 21a and releasing the pushing force of the pulling knobs 37, the core material 15
Pull up. At this time, the positioning projections 35a, 35a provided on the molding surface of the upper die 35 are inserted into the positioning recesses 23, 23 on the back surface of the core material 15, and during this insertion process, the respective positioning projections 35a become tapered surfaces 23a of the respective positioning recesses 23. The core material 15 is guided and slid while bending the locking hole 21a of the core material 15 at the thin portion 21b. In this state, a space C is formed between the skin material 13 and the core material 15.

Next, as shown in FIG. 3, the foamed resin material R is supplied from the injection head 40 to the skin material 13 and the core material 15 through the opening 35b of the upper die 35 and the injection holes 19, 19,. After that, the opening 35b of the upper mold 35 is closed with the lid 41, and the foam layer 17 is integrally formed between the skin material 13 and the core material 15 as shown in FIG. The obtained lid outer panel 9 is obtained.

Thereafter, the lid outer panel 9 is removed, the extended portion 13a is cut from the skin material 13, and as shown in FIG.
6 is cut out from the thin portion 21b, and as shown in FIG. 6, a screw is inserted into each of the insertion holes 11a of the lid inner panel 11 with the separately formed lid inner panel 11 corresponding to the rear surface of the lid outer panel 9. 27 is inserted and screwed into the tapping hole 25a of each boss 25 of the lid outer panel 9, thereby assembling the lid inner panel 11 on the rear surface of the lid outer panel 9.
The lid 7 including the lid outer panel 9 and the lid inner panel 11 is configured.

As described above, in this embodiment, after each locking piece 21 is cut from the core material 15 of the lid outer panel 9, the lid inner panel 11 is assembled on the rear surface of the lid outer panel 9. the outer panel 9 without engaging pieces 21, to reduce the thickness of the entire lid 7 between sky can be narrowed by an amount no the locking pieces 21 between the lid outer panel 9 and the lid inner panel 11 As a result, the volume of the console box 1 can be increased.

(Second Embodiment) FIG. 7 shows a second embodiment of the present invention. In this embodiment, the locking pieces 21 are foldable, and the lid outer panel 9 and the lid inner panel 11 are connected to each other. Except that the locking piece 21 is folded on the back surface of the core member 15 before assembling, it is configured in the same manner as in the first embodiment. Description is omitted.

Therefore, in the second embodiment, the projecting dimension of the locking piece 21 projecting from the lid outer panel 9 at the time of assembly can be shortened, and the gap between the lid outer panel 9 and the lid inner panel 11 can be reduced. The gap can be narrowed by the shorter the projecting dimension of the locking piece 21, so that the thickness of the entire lid 7 can be reduced, and the volume of the console box 1 can be increased.

In each of the above embodiments, the thin portion 21b is formed at the base of the locking piece 21 so as to bend in one direction in the direction of X in FIG. 8; however, the present invention is not limited to this. For example, as shown in FIG. Alternatively, a narrow portion 21c may be formed at the base of the locking piece 21 to bend in two directions, the X direction and the Y direction. In this case, the degree of freedom in positioning the core material 15 on the upper mold 35 is increased, and the positioning can be performed with high accuracy.

Further, in the above embodiment, the case where the lid 7 is for the console box 1 has been described. However, for example, the lid 7 may be for a glove box, or may be for a box other than an automobile. Good.

[0035]

As described above, according to the first to fourth aspects of the present invention, at the time of molding, the engaging portion of the pull-up means is engaged with the engaging piece projecting from the back surface of the core material to form the core material. And a foamed resin material is injected into a space formed between the core material and the skin material to obtain a lid outer panel in which a foam layer is integrally formed between the skin material and the core material.

According to the first and third aspects of the present invention, since the lid outer panel has no locking piece at the time of assembly, the space between the lid outer panel and the lid inner panel is narrowed accordingly. As a result, the thickness of the entire lid can be reduced, and thus the volume of the box can be increased.

According to the second and fourth aspects of the present invention, the projecting dimension of the locking piece projecting from the lid outer panel at the time of assembling is reduced, so that the space between the lid outer panel and the lid inner panel is correspondingly reduced. Can be reduced, the thickness of the entire lid can be reduced, and the volume of the box can be increased.

[Brief description of the drawings]

FIG. 1 is a molding process diagram showing a state in which a core material is placed on a skin material of a lower mold in a first embodiment.

FIG. 2 is a molding process diagram showing a mold clamping state in the first embodiment.

FIG. 3 is a molding process diagram showing an injection state of a foamed resin raw material in the first embodiment.

FIG. 4 is a molding process diagram showing a molding state of a lid outer panel in the first embodiment.

FIG. 5 is a longitudinal sectional view of the lid outer panel of the first embodiment.

FIG. 6 is a longitudinal sectional view of the lid of the first embodiment.

FIG. 7 is a longitudinal sectional view of a lid according to a second embodiment.

FIG. 8 is a perspective view of a locking piece.

FIG. 9 is a perspective view showing a modification of the locking piece.

FIG. 10 is a perspective view of a console box.

[Explanation of symbols]

 7 lid 9 lid outer panel 11 lid inner panel 13 skin material 15 core material 17 foam layer 21 locking piece 23 positioning recess 29 lower mold 35 upper mold 35a positioning projection 37 pulling knob (pulling means) 37a locking section C space R foam Resin raw material

──────────────────────────────────────────────────続 き Continued on the front page (58) Field surveyed (Int. Cl. ⁷ , DB name) B29C 39/00-39/44 B60R 7/04

Claims (4)

(57) [Claims] 1. A lid comprising a lid inner panel and a lid inner panel attached to a back surface of the lid outer panel, wherein the lid outer panel forms a space between a skin material molded into a predetermined shape and the skin material at the time of molding. a core material <br/> cuttable locking piece engaging portion engaging with the base portion is formed to be thin or narrow the pulling means protruding from the rear surface to form, the skin material and the core material And a foamed layer integrally formed between the lid and the lid, wherein the locking piece is cut from a core material before being assembled with the lid inner panel. 2. A lid in which a lid inner panel is assembled to a back surface of a lid outer panel, wherein the lid outer panel has a space between a skin material formed into a predetermined shape and the skin material at the time of molding. A foldable locking piece engaged with the locking portion of the pulling means to be formed is constituted by a core material protruding from the back surface, and a foam layer integrally formed between the skin material and the core material. Wherein the locking piece is folded on the back surface of the core material before being assembled with the lid inner panel. 3. A method for forming a lid, comprising: attaching a lid inner panel to a back surface of a lid outer panel, wherein a base material is formed into a thin or narrow width after setting a skin material formed into a predetermined shape in a lower mold. The core material having the cuttable locking piece protruding from the back surface is placed on the skin material of the lower mold, and then the upper mold is clamped, and then the pulling means provided on the upper mold is closed. The locking portion is engaged with the locking piece of the core material, and the core material is pulled up to set the core material on the upper mold, and then foamed in the space formed between the skin material and the core material. Molding a lid outer panel by injecting a resin material, and thereafter, after cutting off the locking pieces from the core material, assembling a lid inner panel on a back surface of the lid outer panel. . 4. A method of forming a lid, comprising: attaching a lid inner panel to a back surface of a lid outer panel, wherein after setting a skin material formed into a predetermined shape in a lower mold, a foldable locking piece is provided on the back surface. The core material protruding from the upper mold is placed on the skin material of the lower mold, and then the upper mold is clamped. Then, the engaging portion of the pulling means provided on the upper mold is engaged with the core material. The core material is set on the upper mold by engaging with the piece and pulling up the core material. Thereafter, a foamed resin material is injected into a space formed between the skin material and the core material to remove the lid outer panel. A method of forming a lid, comprising: forming, then folding the locking piece on the back surface of the core material, and assembling a lid inner panel on a back surface of the lid outer panel.