JP3411969B2 - Foam resin molded product and its mold - Google Patents

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a foamed resin molded article in which a pad is partially provided on the surface of the molded article and an improvement of a molding die therefor, and more particularly to measures for leaking raw materials from a pad molding portion during manufacturing. Is.

[0002]

2. Description of the Related Art As a foamed resin molded article, for example, JP-A-8
As disclosed in Japanese Patent Publication No. 174576, there is an instrument panel for an automobile which partially has a pad on the panel surface. The pad is formed by integrally covering the foamed layer with a skin to give a soft feeling.

In the instrument panel, the outer skin is set in the lower mold and the base material is set in the upper mold, and a liquid is formed in a space between the outer skin and the base material in a mold closed state of the upper mold and the lower mold. By injecting the foamed resin material, the pad is partially integrally formed on the surface of the base material.

When manufacturing such an instrument panel with a pad, it is necessary to take some measures so that the raw material does not leak from the pad molding portion. In the above publication, the skin is formed at the boundary between the base material and the pad. By contacting the peripheral portion of the vertical wall portion of the base material, by pressing the skin on the vertical wall portion of the base material by the foaming pressure when molding the foam layer of the pad, so that the liquid foamed resin raw material does not leak There is. Furthermore, by forming a groove groove in the peripheral edge of the epidermis, by any chance,
When the liquid foamed resin raw material penetrates between the peripheral portion of the skin and the vertical wall portion of the base material during molding, the liquid foamed resin raw material that has penetrated is housed in the groove groove so as not to leak outside. There is.

10 and 11 show the structure of a general conventional example of a pad molding portion in an instrument panel. As shown in FIGS. 10 and 11, in this conventional example,
The pad molding portion of the base material 103 of the instrument panel 101 has a concave portion 111 including a base material surface portion 105, a vertical wall portion 107, and an open portion 109 having no vertical wall portion 107.
Is molded.

On the other hand, the pad 113 has a skin layer 115 and a foam layer 117 formed by curing a liquid foam resin material between the skin layer 115 and the base material surface portion 105 of the recess 111.
The pad 113 is integrally molded with the recess 111 to manufacture the instrument panel 101.

In this instrument panel 101,
As shown in FIGS. 10 (a) and 10 (b), the peripheral portion of the outer skin 115 has a bent portion 115a that is bent toward the foam layer 117 side over the entire circumference. 115
A vertical wall portion region 119 of a corresponding to the vertical wall portion 107 of the concave portion 111 surrounds the outer periphery of the foam layer 117 and is in contact with the vertical wall portion 107 (FIG. 10A, FIG. 11A). )
And FIG. 11B). The vertical wall region 1 corresponding to the vertical wall portion 107 of the recess 111 of the bent portion 115a.
The grooved groove 115b for preventing the leakage of the raw material described in the above publication is formed in the reference numeral 19 (see FIGS. 10A and 11B). On the other hand, in the bent portion 115a, the open portion region 1 corresponding to the open portion 109 of the recess 111.
Numeral 21 surrounds the outer periphery of the foam layer 117, and the bent portion 1
The tip end of 15a is bent to the side opposite to the foam layer 117 and abuts against the base material surface portion 105 to form an extended portion 115c (see FIGS. 10 (b), 11 (a) and 11 (b)). ).

[0008]

However, the base material 103 is to be solved.
In the instrument panel 101 in which the pad 113 is partially integrally formed on the surface of the recessed groove 115, as described above,
Even if the raw material leakage countermeasure is performed by b, the liquid foamed resin raw material leaks to the outside from the boundary portion between the vertical wall portion region 119 and the open portion region 121 at the time of molding to form a burr, which causes a burr on the surface of the pad 113 (skin 115). There is a problem in that it may adhere to the peripheral edge, deburring work is required, and productivity decreases.

In this way, the liquid foamed resin material leaks from the boundary between the vertical wall region 119 and the open region 121 because the extended portion 115c of the outer skin 115 in the open region 121.
Can be sandwiched between a lower mold (not shown) and the base material 103 to prevent raw material leakage. However, since the vertical wall portion 119 has the vertical wall portion 107, the lower mold is not located there. And the lower die and vertical wall portion 1 for pressing the extended portion 115c.
07, that is, the vertical wall region 119 and the open region 1
There is a risk that the liquid foamed resin raw material will leak out from the boundary with 21.

The present invention has been made in view of the above points, and an object thereof is to prevent the liquid foamed resin raw material from leaking out from the boundary between the vertical wall region and the open region of the skin. To eliminate the deburring work and improve the productivity of foamed resin molded products.

[0011]

In order to achieve the above object, the present invention provides a structure of a boundary portion between a vertical wall region and an open region of a skin of a foamed resin molded product, and a molding corresponding to the boundary portion. The feature is that the mold structure is elaborated.

Specifically, the present invention is directed to a foamed resin molded article in which a pad is partially integrally molded on the surface of a base material and a molding die for the foamed resin molded article. The present invention relates to a foamed resin molded product and the latter molding die of the invention according to claim 6, and the following means for solving the problems have been taken.

That is, in the invention described in claim 1, the pad-molded portion of the base material is provided with a concave portion composed of a base material surface portion, a vertical wall portion, and an open portion not having the vertical wall portion. The pad comprises a skin and a foam layer formed by curing a liquid foaming resin raw material between the skin and the base material surface portion of the recess, and the peripheral portion of the skin covers the entire circumference. Has a bent portion that is bent toward the foam layer, and a vertical wall portion region of the bent portion that corresponds to the vertical wall portion of the concave portion surrounds the foam layer outer periphery and contacts the vertical wall portion. While contacting, the open portion region of the bent portion corresponding to the open portion of the recess,
A boundary between the vertical wall portion region and the open portion region is formed, which surrounds the outer periphery of the foamed layer, and the bent portion tip is bent toward the side opposite to the foamed layer to contact the base material surface portion to form an extended portion. A seal portion that is continuous over both areas is provided on the tip side of the bent portion so as to be recessed toward the foam layer side, and the back surface of the seal portion is in contact with the base material surface portion. Is characterized by.

With the above structure, in the invention according to the first aspect, the leakage of the raw material from the boundary between the vertical wall region and the open region of the skin forming the pad is continuous across both regions. The liquid foamed resin raw material does not leak during molding. Therefore, extra deburring work is unnecessary and the productivity of the foamed resin molded product is increased.

According to a second aspect of the invention, in the first aspect of the invention, the seal portion is formed in a substantially U-shaped cross section having a groove opened toward the outside of the pad. To do.

With the above structure, in the invention according to the second aspect, even if the length of the bent portion of the skin is longer than the depth of the concave portion which is the pad molding portion due to a manufacturing error, this extra length is increased. It is absorbed by the gap between the grooves of the seal portion and does not become a slack portion. Therefore, even if the pad is released from the mold pressure after molding, the pad does not swell and is molded into a regular shape.

According to a third aspect of the present invention, in the second aspect of the invention, the groove of the seal portion is covered by a mounting member that is attached to the side of the open region. To do.

With the above structure, in the invention according to the third aspect, the groove of the seal portion opened in the opening portion region is hidden by the mounting member and is not visible, and the appearance is improved.

According to a fourth aspect of the present invention, in the invention according to the first aspect, the tip of the bent portion of the epidermis ends midway without reaching the base material surface portion except for the seal portion in the vertical wall region. It is characterized by

With the above structure, in the invention according to the fourth aspect, even if the length of the bent portion in the vertical wall region of the skin becomes long due to a manufacturing error, there is a margin between the bent surface and the surface portion of the base material. Therefore, the tip of the bent portion of the skin hits the surface portion of the base material and does not slacken, and even if the pad is released from the mold pressure after molding, the pad does not swell and is molded into a regular shape.

The invention according to claim 5 is characterized in that, in the invention according to claim 1, the skin is a powder slush molded product.

With the above construction, in the invention according to the fifth aspect, even if the skin has an undercut portion, it can be easily released from the molding die, and the degree of freedom in design is increased.

The invention according to claim 6 is the mold for the foamed resin molded product according to any one of claims 2 to 5, wherein the mold comprises an upper mold and a lower mold. The upper mold has
A base material contacting surface is formed on which the base material is set by abutting the back surface side thereof, while a skin contacting surface on which the epidermis is set by contacting the front surface side is formed on the lower mold. In addition, a slide core is provided which engages with a groove having a substantially U-shaped cross section in the seal portion of the skin so as to be retractable from the opening side, and the slide core is in the mold closed state of the upper mold and the lower mold. The liquid foamed resin raw material is injected between the surface skin and the base material surface portion of the recessed portion forming the pad molding portion of the base material in a state in which is engaged with the groove of the seal portion. .

With the above structure, in the invention according to claim 6, when molding the foamed resin molded article, the seal portion of the skin is positioned by the slide core of the mold and does not move, and is opened from the vertical wall portion region of the skin. A seal is secured at the boundary with the partial area.

[0025]

BEST MODE FOR CARRYING OUT THE INVENTION Embodiments of the present invention will be described below with reference to the drawings.

FIG. 3 shows an instrument panel 1 which is an automobile interior product as a foamed resin molded product according to an embodiment of the present invention. In this instrument panel 1, a resin pad 5 is partially integrally formed on the surface of a resin base material 3. In this example, the pad 5 is almost the entire upper panel of the instrument panel 1. It is provided over. The area where the pad 5 is provided is shown in FIG. 3 with dots, and the area without dots is the area where the base material 3 is exposed.

1 and 2 are enlarged views of the portion F of FIG. 3, which is the center console S as a mounting member.
(See FIG. 1 (b)), which is adjacent to the mounting location. The base material surface portion 7, the pad molding portion of the base material 3 at the center console mounting location,
A recess 13 is provided which is composed of a vertical wall portion 9 and an open portion 11 that does not have the vertical wall portion 9, and the pad 5 is integrally molded in the recess 13.

On the other hand, the pad 5 is a resin foam skin 15 which is a powder slush molded product formed by powder slush molding, and a liquid foamed resin raw material between the skin 15 and the base material surface portion 7 of the recess 13. And a foam layer 17 formed by curing. That is, in the instrument panel 1, the outer skin 15 is set in the lower mold of a molding die (not shown), while the base material 3 is set in the upper mold of the molding die, and the upper skin and the lower mold are closed. It is molded by injecting a liquid foaming resin material such as urethane foam into the space between 15 and the base material surface portion 7 and allowing it to foam and cure.

The peripheral portion of the outer skin 15 has a bent portion 15a which is bent at a right angle toward the foam layer 17 over the entire circumference, and the vertical wall portion 9 of the recess 13 of the bent portion 15a. The vertical wall portion region 19 corresponding to the above surrounds the outer periphery of the foam layer 17 and is in contact with the vertical wall portion 9 (FIG. 1A, FIG.
(C), FIG. 2 (a) and FIG. 2 (b)). Further, in the vertical wall portion region 19 of the bent portion 15a corresponding to the vertical wall portion 9 of the recessed portion 13, a groove groove 15b for preventing material leakage is formed (FIG. 1 (a), FIG. 1). (C) and FIG.2 (b)). When the liquid foamed resin raw material enters between the peripheral edge portion of the skin 15 and the vertical wall portion 9 of the base material 3 at the time of molding, the grooved groove 15b is formed by introducing the liquid foamed resin raw material into the groove groove 1b.
It is intended to be housed in 5b so as not to leak outside. In addition to the above-described leakage of raw material, the groove 15b also has a function of ensuring rigidity of the bent portion 15a and a function of preventing the outer skin 15 from coming off by engaging the outer skin 15 and the foam layer 17. .

The concave portion 1 of the bent portion 15a is also included.
The open portion region 21 corresponding to the open portion 11 of No. 3 surrounds the outer circumference of the foam layer 17 and the tip of the bent portion 15a is bent toward the side opposite to the foam layer 17 so as to contact the base material surface portion 7 and extend. The installation portion 15c is configured (see FIG. 1 (b), FIG. 2 (a) and FIG. 2 (b)).

A feature of the present invention is that the vertical wall region 1
9 and the open area 21 at the boundary, both areas 19, 21
A seal portion 23 that is continuous over the above is provided on the tip side of the bent portion 15a so as to be recessed toward the foam layer 17 side, and the back surface of the seal portion 23 is in contact with the base material surface portion 7 (Fig. 1 (a), FIG. 1 (b), FIG. 2 (a) and FIG. 2 (b)
reference). The seal portion 23 is formed in a substantially U-shaped cross section having a groove 23a opened toward the outside of the pad 5, and has a triangular shape in a plan view as seen from the skin 15 side (FIG. 2).
(See (a)). The groove 23a of the seal portion 23 is covered by a center console S as an attachment member attached to the side of the open portion area 21 (see FIG. 1B). In addition, the bent portion 15 of the outer skin 15
The tip of a ends in the vertical wall region 19 without reaching the base material surface portion 7 except the seal portion 23 (see FIG. 1C).

Therefore, in this embodiment, the vertical wall portion region 19 and the open portion region 2 of the outer skin 15 forming the pad 5 are formed.
At the boundary with 1, the bent portion 15 is formed so that the seal portion 23 continuous over both regions 19 and 21 is recessed toward the foam layer 17 side.
Since it is provided on the tip end side, it is possible to prevent the liquid foamed resin raw material from leaking from the boundary portion between the vertical wall portion region 19 and the open portion region 21 by the seal portion 23, and at the time of molding. Raw material leakage can be eliminated. As a result, it is not necessary to perform extra deburring work, and the instrument panel 1 can be efficiently manufactured.

Further, since the seal portion 23 is formed in a substantially U-shaped cross-section having a groove 23a opened toward the outside of the pad 5, the length of the bent portion 15a of the outer skin 15 is a pad due to a manufacturing error. Even if the depth is longer than the depth of the recessed portion 13 which is the molding portion, this extra length is used as the groove 23 of the seal portion 23.
It is possible to prevent the pad 5 from being absorbed and becoming a slack portion by the interval of a, and thereby to prevent the pad 5 from bulging even when released from the mold pressure after molding and to form the pad 5 into a regular shape. You can

Further, the tip of the bent portion 15a of the outer skin 15 is provided in the vertical wall region 19 except for the seal portion 23 and the base material surface portion 7
Since it is stopped on the way without reaching
Even if the length of the bent portion 15a in the vertical wall portion region 19 is longer due to a manufacturing error, there is a space between the bent portion 15a and the base material surface portion 7, so that the tip of the bent portion 15a of the skin 15 is the base material surface portion. It is possible to prevent the pad 5 from coming into contact with and loosening, and thus, even if the pad 5 is released from the mold pressure after molding, the pad 5 can be prevented from bulging and the pad 5 can be molded into a regular shape.

In addition, since the outer skin 15 is formed of a powder slush molded product, even if the outer skin 15 has an undercut portion, it can be easily removed from the molding die, increasing the degree of freedom in design. be able to.

Furthermore, since the groove 23a of the seal portion 23 is covered by the center console S attached to the side of the open portion area 21, the groove 23a of the seal portion 23 opening in the open portion area 21 is center console S. You can improve the appearance by covering it up with invisible.

Next, the molding die 25 for manufacturing the instrument panel 1 as described above will be described.

As shown in FIGS. 4 and 5, the molding die 2 is used.
5 includes an upper mold 27 and a lower mold 29, and the upper mold 27 includes
A base material contact surface 27a is formed on which the base material 3 is set by contacting its back surface side.

On the other hand, the lower mold 29 is formed with a skin contact surface 29a on which the skin 15 is set with its surface side in contact. Further, a slide core 31 is arranged in the lower mold 29 so as to correspond to the open portion 11 side of the concave portion 13 forming the pad molding portion of the base material 3.
Is connected to the tip of the piston rod 33a of the fluid pressure cylinder 33, and the fluid pressure cylinder 33 expands and contracts so as to project from the open portion 11 side in the groove 23a of the seal portion 23 of the outer skin 15 having a substantially U-shaped cross section. It is designed to engage freely.

As shown in FIGS. 6 and 7, a step portion 31a is formed in the slide core 31 by cutting out the tip end side of the rectangular parallelepiped block, and the step portion 31a is formed on the base material 3. Opening portion 1 of concave portion 13 forming a pad molding portion
The end surface 31c of the slide core 31 comes into contact with the end of the base material 3 on the first side, and the end surface 31c of the slide core 31 comes into contact with the skin folded portion 15a on the open portion 11 side of the recess 13 (see FIG. 4). ). In addition, the tip surface 31c of the slide core 31
Has a triangular positioning piece portion 31b extending from the cutout side, and the positioning piece portion 31b is fitted into the groove 23a having a substantially U-shaped cross section in the seal portion 23 having substantially the same shape in plan view. And the seal portion 23
It is designed to be fixed so that it does not move.

In order to manufacture the instrument panel 1 with the molding die 25 thus constructed, first, the preformed base material 3 is set on the upper die 27, and the preformed skin 15 is placed on the lower die. Set to 29. At that time, the slide core 31 is made to advance inward of the concave portion 13 of the base material 3 by the extension operation of the fluid pressure cylinder 33, and the skin 15
When setting the seal part 23,
The positioning piece 31b is fitted into the groove 23a of the seal portion 23 so as to cover the positioning piece 31b, and is engaged with the groove 23a. In addition, after the outer skin 15 is set in the lower mold 29, the slide core 31 is advanced so that the seal portion 23 of the outer skin 15 is formed.
The positioning piece 31b of the slide core 31 may be engaged with the groove 23a.

Next, the upper die 27 and the lower die 29 are closed. In this mold closed state, and as described above, the slide core 3
In a state in which 1 is engaged with the groove 23a of the seal portion 23, a liquid foamed resin raw material is injected between the outer skin 15 and the base material surface portion 7 of the concave portion 13 forming the pad molding portion of the base material 3. Then, it is foamed and cured to form the foamed layer 17. The liquid foamed resin raw material may be injected in the mold open state. As a result, the pad 5 composed of the outer skin 15 and the foam layer 17 becomes the base material 3
The instrument panel 1 that is partially integrally formed on the surface of the instrument is manufactured.

As described above, since the slide core 31 is engaged with the groove 23a of the seal portion 23 and positioned so that the seal portion 23 does not move, the vertical wall region 19 of the outer skin 15 is formed.
It is possible to secure the seal by preventing the liquid foamed resin raw material from leaking out at the boundary between the open area 21 and the open area 21.

(Modification) FIGS. 8 and 9 show modifications.
In this example, the vertical wall region 19 and the open region 21 of the skin 15 are
There is a boundary part between and in two places on the upper left side and the lower left side in FIG. 9,
Therefore, the seal portion 23 that is continuous over both regions 19 and 21 is also provided at the boundary portion. Also,
The shape of the seal portion 23 on the upper left side is triangular as in the above-described embodiment, but the configuration is the same as that of the above-described embodiment except that the shape of the seal portion 23 on the lower left side is rectangular. Therefore, the same portions are denoted by the same reference numerals, and detailed description thereof will be omitted. Therefore, also in this modification, it is possible to obtain the same effects as the above-described embodiment.

In the above embodiment, the case where the foamed resin molded product is the instrument panel 1 which is an interior product of an automobile has been described, but it can be applied to door trims and other interior products other than automobiles. Is.

[0046]

As described above, according to the inventions according to claims 1 to 5, at the boundary between the vertical wall region and the open region of the epidermis, the continuous seal portion over both regions is formed in the pad. It was provided on the tip side of the bent portion of the skin so as to be immersed in the foam layer side, and the back surface of the seal portion was brought into contact with the surface portion of the base material. It is possible to prevent the raw material from leaking from the boundary portion of the above-mentioned structure by the above-mentioned sealing portion and eliminate unnecessary deburring work, thereby improving the productivity of the foamed resin molded product.

According to the sixth aspect of the invention, when the foamed resin molded product is molded, the slide core of the molding die is engaged with the groove of the seal portion of the outer skin so that the slide core is retractable. The seal can be secured by positioning so that it does not move.

[Brief description of drawings]

1A is a sectional view taken along line A1-A1 of FIG. 2A, FIG. 1B is a sectional view taken along line B1-B1 of FIG. 2A, and FIG. 1C is a sectional view of FIG. It is sectional drawing in the C1-C1 line.

2A is an enlarged view of an F portion of FIG. 3, and FIG. 2B is a view taken along the arrow Y1 of FIG.

FIG. 3 is a front view of an instrument panel as a foamed resin molded product according to an embodiment of the present invention.

FIG. 4 is a vertical sectional view of a molding die according to an embodiment of the present invention.

5 is a cross-sectional view taken along the line GG in FIG.

FIG. 6 is a perspective view of a slide core.

FIG. 7 is a view on arrow X in FIG.

8A is a sectional view taken along line D-D in FIG.
9B is a cross-sectional view taken along the line EE of FIG. 9.

FIG. 9 is a view corresponding to FIG. 2A of the modified example.

10A is a sectional view taken along line A2-A2 of FIG. 11A, and FIG. 10B is a sectional view taken along line B2-B2 of FIG. 11A.

11A is a view corresponding to FIG. 2A of a conventional example, and FIG.
[Fig. 6] is a view from the arrow Y2 of (a).

[Explanation of symbols]

1 Instrument panel (foamed resin molded product) 3 Base material 5 Pad 7 Base material surface portion 9 Vertical wall portion 11 Opening portion 13 Recess 15 Skin 15a Bending portion 15c Extended portion 17 Foaming layer 19 Vertical wall portion area 21 Opening portion Region 23 Seal part 23a Groove 25 Mold 27 Upper mold 27a Base material contact surface 29 Lower mold 29a Skin contact surface 31 Slide core S Center console (mounting member)

─────────────────────────────────────────────────── ─── Continuation of front page (51) Int.Cl. ⁷ Identification code FI B29L 31:30 B29L 31:30

Claims (6)

(57) [Claims] 1. A foamed resin molded article in which a pad is partially integrally formed on the surface of a base material, wherein the pad molding portion of the base material includes a base material surface portion, a vertical wall portion, and the vertical wall portion. On the other hand, the pad is provided with a recess formed of an open portion, and the pad is composed of a skin and a foam layer formed by curing a liquid foaming resin raw material between the skin and the base material surface portion of the recess. The peripheral portion of the skin has a bent portion that is bent toward the foam layer over the entire circumference, and the vertical wall portion region of the bent portion that corresponds to the vertical wall portion of the recess is While enclosing the outer periphery of the foam layer and contacting the vertical wall portion, the open portion region of the bent portion corresponding to the open portion of the recess encloses the outer periphery of the foam layer and the tip of the bent portion repels. The vertical wall portion region and the open portion region are formed by being bent to the foam layer side and contacting the base material surface portion to form an extended portion. In the boundary part of the above, a seal part continuous over both regions is provided on the bent part tip side so as to be recessed into the foam layer side, and the back surface of the seal part is in contact with the base material surface part. A foamed resin molded product characterized in that 2. The foamed resin molded product according to claim 1, wherein the seal portion is formed in a substantially U-shaped cross section having a groove opened toward the outside of the pad. . 3. The foamed resin molded product according to claim 2, wherein the groove of the seal portion is covered by a mounting member which is mounted laterally of the open region. . 4. The foamed resin molded product according to claim 1, wherein the tip of the bent portion of the outer skin ends midway without reaching the base material surface portion except for the seal portion in the vertical wall region. Foamed resin molded product. 5. The foamed resin molded article according to claim 1, wherein the skin is a powder slush molded article. 6. A mold for the foamed resin molded product according to claim 2, wherein the mold has an upper mold and a lower mold, and the upper mold has a base material. Has a base material contact surface which is set by abutting the back surface side thereof, while the lower mold has a skin contact surface which is set by the skin contacting the front surface side thereof. A slide core is provided which engages with a groove having a substantially U-shaped cross section in the seal portion of the skin so as to be retractable from the opening side, and the slide core is sealed in a mold closed state of the upper mold and the lower mold. Foamed resin material, characterized in that a liquid foamed resin raw material is injected between the surface skin and a base material surface portion of a concave portion forming a pad molding portion of the base material in a state of being engaged with a groove of the base material. Molding tool for molded products.