JP3732262B2 - Method for producing foam molded article and foam mold - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a method for producing a foam-molded product, and a foam-molding die suitably used in the production method.
[0002]
[Prior art]
2. Description of the Related Art Foam molded products used for automobile instrument panels and the like are often used in which a foam is integrally formed on the surface of an insert having a predetermined shape. In addition, there is also one in which the surface of the foam is covered with a skin made of soft vinyl or the like. The insert is for maintaining the shape of the foam molded product and imparting strength, and is made of a metal press-molded product, a resin molded product, or a fiber reinforced resin molded product, and is used for attaching a part or the like at a predetermined position. An opening is formed. In particular, in a large foam molded product such as an instrument panel, a resin molded product or a fiber reinforced resin molded product is mainly used for weight reduction.
[0003]
FIG. 8 shows an example of a method for manufacturing a foam molded product in which a foam is integrally formed on the surface of such an insert. As shown in the drawing, the insert 60 is held on the mold surface 52 of the upper mold 51 of the foam molding die 50, while the skin 62 is disposed on the mold surface 54 of the lower mold 53, and the insert 60 and the skin 62 are interposed between them. A foam 64 is integrally formed on the surface of the insert 60 by injecting a foaming raw material and curing the foam.
[0004]
The insert 60 is held on the mold surface 52 by a set pin 56 provided at a predetermined position on the mold surface of the upper mold 51. On the other hand, a pin hole 61 is formed in the insert 60 at a position corresponding to the set pin 56, the insert 60 is disposed on the upper mold surface 52, and the pin hole 61 is fitted into the set pin 56.
[0005]
The set pin 56 is formed to have a diameter slightly smaller than the pin hole 61 of the insert 60 and protrudes from the mold surface 52 by at least the thickness of the insert 60 as shown in FIG. Further, although the mounting positions and the number of the set pins 56 vary depending on the type of foam molded product to be molded, a plurality of the inserts 60 are often set so as to be surely arranged at the correct position on the mold surface.
[0006]
Furthermore, as shown in FIG. 10, a set pin 70 formed so as to be able to enter and exit from the mold surface 52 of the mold is also known. The set pin 70 includes a pin body 71, a spring 72, and a drive device (not shown), and is inserted into a cylindrical pin holder 74 so as to be able to advance and retreat. A spring 72 is disposed at the rear portion of the pin main body 71, and the rear end of the pin main body 71 is connected to a drive device outside the mold via a wire 75. The set pin 70 is attached to the molding die 51 together with the pin holder 74, and is normally held in a state where the tip end of the pin body 71 protrudes from the die surface 52 by a predetermined height. The set pin 70 is pulled into the mold while the drive device is operated and the wire 75 is pulled, so that the pin body 71 compresses the spring 72. When the tensile force of the wire 75 is loosened, the pin body 71 moves forward due to the elasticity of the spring 72 and protrudes from the mold surface 52 again.
[0007]
By the way, the insert 60 made of the resin molded product and the fiber reinforced resin molded product is slightly deformed by the product shrinkage after the insert molding, and the positions of the pin hole 61 of the insert 60 and the set pin 56 provided in the molding die. May shift. Therefore, when the insert 60 is mounted on the mold surface 52, the pin hole 61 is often aligned with the set pin 56, and the insert 60 around the pin hole is mounted with a hammer or the like.
[0008]
However, with this method, the insert may be cracked, damaged, or deformed. Also, even if you hit one part of the insert with a hammer, only some set pins will fit into the pin holes. To make sure that all the set pins fit into the pin holes, you need to hit all over the inserts. However, it takes much time to fit the pin hole and the set pin.
[0009]
Further, depending on the type of vehicle, an instrument panel may be used in which a foam is formed only on a part of the surface of the insert and the other part of the insert is exposed on the product surface as a non-foamed part.
In the insert used for such an instrument panel, the foam non-forming part constituting the surface of the foam molded article cannot be provided with a pin hole in order to impair the appearance, and in addition, to avoid scratching. Be careful when hitting with a hammer.
For this reason, the pin holes are inevitably provided in the foam forming part. However, when forming the foam, the foam raw material leaks from the pin holes, causing burrs in the product, or sinking in the foam in the pin hole portion. Therefore, after the insert is set on the mold surface, it is necessary to cover the pin hole with a sealing tape or the like, which increases the number of steps and increases the cost.
[0010]
[Problems to be solved by the invention]
As a result of intensive studies, the present inventors have found that when molding a foam molded article in which a foam is formed on a part of the surface of the insert, other parts already formed in the foam non-formation portion of the insert, etc. If the opening for use is used for setting the insert on the mold surface, the above-mentioned problems are solved, and it has been found that mounting and holding the insert on the mold surface is simple and reliable, and the present invention has been achieved. .
[0011]
That is, the present invention provides a novel method for producing a foam-molded product, which can easily and reliably attach and hold the insert to the mold surface, and does not crack, damage or deform the insert, and the foam-molding thereof. It is intended to provide a type.
[0012]
[Means for Solving the Problems]
In the invention relating to the method for manufacturing a foam molded article, a part of the surface is a foam forming part, and the other part is a foam non-forming part, and an opening for a part or the like is formed in the foam non-forming part. Foam molding in which the insert and the insert are integrally formed by holding the insert detachably on the mold surface of the foam molding die, forming the foam in the foam forming portion by the foam raw material injected into the foam molding die. In the method for manufacturing an article, the foaming mold has a hook member on the mold surface side where the insert is disposed, and a hook member whose front end is bent into a substantially L shape to be a hook to the periphery of the opening, A cushion body provided on the mold surface side in the hook portion, and a drive device that performs forward and backward movement of the hook member with respect to the mold surface that is connected to the shaft portion and on which the insert is disposed, and rotates around the shaft portion. Inn The shaft holding means is disposed at a position deviated from the center of the opening in the portion where the opening of the insert is disposed, and is formed in the foam non-forming portion of the insert. A shaft portion of the insert holding means is passed through the opening, the hook is rotated to a position intersecting with the periphery of the opening, and is hooked on the periphery of the opening of the insert by the portion of the cushion body, and the hook member The insert is held on the mold surface by retreating the mold surface side and pulling the hook portion together with the periphery of the opening to hold the insert on the mold surface. After foaming, the hook member is advanced and the hook member is rotated. Then, the hooking portion is removed from the peripheral edge of the opening of the insert by setting the hooking portion to a position not intersecting with the peripheral edge of the opening .
[0013]
According to the method for manufacturing a foam molded article of the present invention, the insert is held on the mold surface by hooking the insert holding means on the opening already provided in the foam non-formation portion. There is no need to provide a pin hole for the set pin. Therefore, it is not necessary to hit the insert with a hammer when setting it on the mold surface, and it is possible to prevent the insert from being cracked, damaged or deformed. Further, there is no need to block the pin hole with a seal tape after setting, and the work is efficient and effective in reducing the cost. In addition, since the non-foamed portion of the insert is hooked, the holding means does not interfere with foam formation. Furthermore, since the obtained foamed molded article does not have sink marks or burrs that are likely to occur in the pin hole portion, the appearance is extremely good.
[0014]
The invention related to the foam mold includes an upper mold and a lower mold, and has a molded product cavity formed between the upper mold and the lower mold by the closed mold of the upper mold and the lower mold. Is a mold that removably holds an insert in which a part of the surface is a foam-forming part and the other part is a non-foamed part and an opening for a part or the like is formed in the non-foamed part. The foam-forming portion is formed by foaming a foaming raw material in the molded product cavity facing the foam-forming portion of the insert, holding the insert removably on the mold surface of the upper mold. In the foam molding die for forming the foam, on the mold surface side of the upper mold on which the insert is disposed, a hook member in which the tip of the shaft portion is bent into a substantially L shape and becomes a hook portion to the opening , Provided on the mold surface side of the upper mold in the hook portion And the cushion body, the more becomes the insert holding means and a drive device for rotating around the forward and backward and the shaft portion of the hook member with respect to the mold surface of the upper mold is connected to the shaft portion, said insert disposed The shaft portion is located at a position deviated from the center of the opening portion in the portion to be cut, and the hook portion intersects with the position where the foam non-formation portion of the insert intersects with the rotation of the hook member. It is provided to move between positions where it disappears.
[0015]
According to the foam molding die of the present invention, the hook portion at the tip of the hook member of the insert holding means intersects the opening periphery of the foam non-forming portion of the insert and is hooked on the opening portion, and then the hook member is retracted. By pulling the insert to the mold surface side, the insert can be securely held on the mold surface. Further, after foam molding, after the hook member is advanced and the hook portion is separated from the insert, the hook member is moved until the hook portion does not intersect with the periphery of the opening of the foam non-formation portion of the insert. If it is rotated, the foamed molded product can be removed. Therefore, it is not necessary to provide a hole for a set pin in the insert, the insert can be securely held with a simple structure, and the removal of the foam molded product is simplified, and the holding means prevents the foam formation. It will never be.
[0016]
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, the present invention will be described in detail with reference to the accompanying drawings.
FIG. 1 is a perspective view showing an example of a foam molded product molded by the manufacturing method of the present invention, FIG. 2 is a cross-sectional view showing an example of a foam molding die of the present invention, and FIG. 3 is an enlarged view of one insert holding means. FIG. 4 is a perspective view showing a state in which the insert is held on the mold surface by the insert holding means, FIG. 5 is a view showing the 5a arrow view and the 5b-5b sectional view of FIG. 3 side by side, FIG. Fig. 6 is a view in which a view of 6a and a cross section of 6b-6b are shown side by side in Fig. 4, and Fig. 7 is an enlarged perspective view of the other insert holding means.
[0017]
FIG. 1 shows an example of a foam molded product (in this example, an instrument panel) obtained by the manufacturing method of the present invention. As shown in the figure, the foamed article 10 is formed with a foam 12 (shown by a chain line in the drawing) partially covered with a skin on the surface of the insert 11. The insert 11 used in the manufacturing method of the present invention is made of a metal plate made into a predetermined shape by press molding, a resin molded product, a fiber reinforced resin molded product, or the like, and a foam forming portion on which a foam 12 is formed. 13 and a non-foamed portion 14 where the foam 12 is not formed. In the foam non-formation portion 14 of the insert 11, an opening 15 for a part or the like is formed through the front and back of the insert 11. The opening 15 is used for mounting parts and the like, and is also used for mounting and holding the insert 11 on the mold surface of the foam mold by the insert holding means described later during foam molding. A plurality of foam non-formation portions 14 are formed. The foam forming part 13 of the insert 11 is also provided with a necessary opening 15a such as a glove box opening.
[0018]
Next, an example of a method for manufacturing the foam molded article 10 will be described. FIG. 2 shows an example of the foaming mold of the present invention used in the manufacturing method. In the figure, reference numeral 20 is a foam mold, 21 is a lower mold, 22 is an upper mold, 23 is a slide mold, and 24 is a molded product cavity formed in the mold by closing the foam mold 20. . The foaming mold 20 is provided with insert holding means 30 and 40 on the mold surface 25 side (in this example, the mold surface 25 side of the upper mold 22) on which the insert 11 is held.
[0019]
The insert holding means 30 and 40 are for holding the insert 11 on the mold surface in a simple, reliable and detachable manner without damaging the insert 11, and the one insert holding means 30 is a foam body. The other insert holding means 40 holds the insert 11 from the outside of the opening 15 formed at the edge thereof.
[0020]
First, the insert holding means 30 for holding the insert 11 from the inside of the opening 15 will be described. The insert holding means 30 includes a hook member 31 and a drive device 32.
As shown in FIG. 3, the hook member 31 has a hook portion 33 at the tip of the shaft portion 34. The hook portion 33 is for holding the insert 11 on the mold surface by hooking the peripheral edge 16 of the opening 15 formed in the foam non-formation portion 14 of the insert 11 from the inside of the opening 15. The hook portion 33 has a shape bent in a substantially L shape from the tip of the shaft portion 34. The hook member 31 is connected to the drive device 32 via a shaft portion 34.
[0021]
The drive device 32 is made up of a known rotary cylinder that is operated by air or hydraulic pressure. The drive device 32 moves the hook member 31 forward and backward, and rotates about the shaft portion 34.
[0022]
The insert holding means 30 configured as described above is configured so that the hook member is disposed on a portion of the mold surface 25 of the upper mold 22 on which the insert 11 is held, where the opening 15 of the foam non-formation portion 14 of the insert 11 is disposed. 31 is provided so as to move forward and backward through the opening 15. Specifically, when the hook member 31 is rotated around the shaft portion 34, the hook portion 33 is located on the mold surface side and does not intersect with the position intersecting the peripheral edge 16 of the opening 15 of the insert 11. It is provided in a place that moves between. The hook member 31 rotates as shown in FIG. 4, and the hook portion 33 is hooked on the insert 11 when the hook portion 33 intersects the peripheral edge 16 of the opening portion 15 of the insert 11. In this state, the insert 11 can be held in close contact with the mold surface 25 by retracting the hook member 31 in the direction of the mold surface 25.
[0023]
In addition, as shown in FIG. 3, the insert holding means 30 of the present embodiment has a cushion body 35 made of an elastic body such as rubber or sponge, etc., on a hook portion 33 that is in contact with the insert 11 when the insert 11 is hooked. Is provided so that the insert 11 is not damaged when the insert 11 is hooked. Further, as can be understood from FIG. 5, the insert holding means 30 of the present embodiment is located in the vicinity of the center of the opening 15 of the insert 11 and is slightly deviated from the center of the opening 15. It is provided where the peripheral edge 16 is located.
[0024]
On the other hand, the other insert holding means 40 holds the opening 15 formed in the non-foamed portion at the edge of the insert 11 from the outside, and as shown in FIG. It consists of the same structure. Detailed description of the structure is omitted because it is redundant. In the figure, reference numeral 41 denotes a hook member, 42 denotes a driving device, 43 denotes a hook portion, 44 denotes a shaft portion, and 45 denotes a cushion body.
[0025]
The insert holding means 40 is located near the opening 15 at the edge of the insert 11 on the mold surface 25 side (in this embodiment, the upper mold surface 25 side) where the insert 11 of the foam mold 20 is disposed. Furthermore, the hook member 31 can be moved forward and backward through the outside of the opening 15, and the peripheral edge 17 of the opening 15 on the edge side of the insert 11 is located within the rotation radius of the hook 43. According to the insert holding means 40, the hook portion 43 can be hooked on the peripheral edge 17 by rotating the hook member 41 by the operation of the driving device 42. Then, by retracting the hook member 41 in the direction of the mold surface 25 and pulling the insert 11, the insert 11 can be brought into close contact with the mold surface 25 and reliably held.
[0026]
In the present embodiment, as described above, the insert 11 is held by both holding the foam non-formation portion 14 from the inside of the opening 15 and holding the other portion 15 from the outside. Depending on the shape or the like, any opening may be held from the inside or outside of the opening.
[0027]
In the production of a foam molded product using the foam mold 20, the insert 11 is disposed on the upper mold surface 25 as shown in FIGS. 3, 5, and 7, and the drive device 32 for the insert holding means 30, 40 is provided. , 42 are operated to advance the hook members 31, 41. At that time, the hooking members 31 and 41 are previously rotated by the driving devices 32 and 42 so that the hooking portions 33 and 43 are in positions where they do not intersect with the peripheral edges of the openings 15 and 15. Then, when the hook portions 33 and 43 are protruded forward from the surface of the insert 11, as shown in FIGS. 4, 6 and 7, the drive device 32 is switched and the shaft portions of the hook members 31 and 41 are switched. The hooks 33 and 43 are stopped at positions where the hooks 33 and 43 intersect with the openings 15 and 15 peripheral edges 16 and 17 of the insert 11.
Thereby, the insert 11 can be attached to the insert holding means 30 and 40 without hitting it with a hammer or the like.
[0028]
Subsequently, when the driving devices 32 and 42 are further switched to retract the hook members 31 and 41 in the direction of the mold surface 25, the hooks 33 and 43 are hooked as shown in FIGS. The inserted insert 11 is attracted to the mold surface 25 side together with the hook portions 33 and 43 and is in close contact with the mold surface 25, and is securely held at a predetermined position on the mold surface.
Normally, the hook members 31 and 41 are rotated to positions where the hook portions 33 and 43 do not intersect with the openings 15 and 15 peripheral edges 16 and 17 of the insert 11 before the insert 11 is held. In a state, the front surface of the insert 11 may be protruded forward. Then, the insert 11 can be held on the mold surface more quickly.
[0029]
With the insert 11 held in close contact with the mold surface 25 in this way, the foaming raw material is injected into the lower mold 21 to close the mold. In this example, an appropriate skin 27 is disposed on the mold surface 26 of the lower mold 21. Alternatively, a raw material injection port (not shown) may be provided at an appropriate position of the upper mold 22 and the foaming raw material may be injected into the mold after the mold is closed.
A foam 28 is formed between the skin 27 and the insert 11 by the foaming reaction of the foaming raw material in the mold, and the foam 28, the insert 11 and the skin 27 are integrated.
[0030]
After the foam molding, before the foam molding die 20 is opened, the hooks 33 and 43 (43 is not shown) are once moved forward to the position of the chain line in FIG. Then, the shaft portions 34 and 44 of the hook members 31 and 41 of the insert holding means 30 and 40 are rotated again, the engagement between the hook portions 33 and 43 and the peripheral edges 16 and 17 of the opening is released, and the hook members 31 and 41 are inserted. Remove from 11.
Next, the foam molding die 20 is opened and the foam molded product is taken out. It should be noted that a known protruding device (not shown) may be provided at an appropriate position of the upper die so that the foam molded product is protruded from the insert 11 side.
The obtained foamed molded article had a good appearance with no deformation or scratches on the insert, no leakage of the foaming raw material from the pin holes, and no occurrence of burrs or sink marks.
[0031]
【The invention's effect】
As illustrated and described above, according to the foam molded product manufacturing method of the present invention, the insert holding means is hooked on the opening formed in the foam non-formation portion of the insert and pulled toward the mold surface side. Install and hold the insert on the mold surface. Therefore, according to the present invention, when the insert is held on the mold surface, it can be carried out easily and reliably without hitting with a hammer, and there is no possibility of the insert being damaged or cracked.
[0032]
In addition, in the present invention, it is not necessary to provide the setting pin hole that has been provided in the insert in order to hold the insert on the mold surface, and there is an effect that the molding of the insert is simplified.
In addition, in the insert having such a non-foamed part, the pin hole has been provided in the foamed part in order to prevent the pin hole from being exposed and deteriorating the appearance of the foamed molded product. . Therefore, for the purpose of preventing leakage of the foaming raw material from the pin hole, a seal tape or the like has been attached to the pin hole. However, in the present invention, it is not necessary, and man-hours and material costs can be reduced. . Furthermore, the foam molded product produced by the present invention has no burrs and sink marks due to pin holes, and the appearance is extremely good.
[0033]
Further, according to the foaming mold of the present invention, the insert holding means is provided so that the hooking portion moves between a position where the hook portion intersects the peripheral edge of the opening of the insert and a position where it does not intersect. In addition, the product can be easily and reliably removed after molding, and the workability is excellent. Further, by adjusting the amount of advancement of the hook portion, inserts having different thicknesses and heights (depths) at the periphery of the opening can be reliably held on the mold surface.
[Brief description of the drawings]
FIG. 1 is a perspective view showing an example of a foam molded product molded by the manufacturing method of the present invention.
FIG. 2 is a cross-sectional view showing an example of a foam mold according to the present invention.
FIG. 3 is an enlarged perspective view showing one insert holding means.
FIG. 4 is a perspective view showing a state where the insert is held on the mold surface by the insert holding means.
5 is a view in which a view taken along an arrow 5a in FIG. 3 and a cross-sectional view taken along the line 5b-5b are shown side by side. FIG.
6 is a view in which a view taken along arrow 6a and a cross-sectional view taken along line 6b-6b are also shown in FIG.
FIG. 7 is a perspective view showing the other insert holding means.
FIG. 8 is a cross-sectional view of a general foaming mold having an insert set pin.
FIG. 9 is an enlarged cross-sectional view of the insert set pin portion.
FIG. 10 is a cross-sectional view showing another example of the insert set pin.
[Explanation of symbols]
DESCRIPTION OF SYMBOLS 10 Foam molded article 11 Insert 12 Foam 13 Foam formation part 14 Foam non-formation part 15 Opening part 16 Opening edge periphery 17 Opening edge periphery 20 Foaming mold 21 Lower mold 22 Upper mold 25 Upper mold surface 30 Insert holding Means 31 Hooking member 32 Drive member 33 Hooking portion 34 Shaft portion

Claims (2)

A part of the surface is a foam forming part (13) and the other part is a non-foamed part (14), and an opening (15) for a part or the like is formed in the non-foamed part (13). The insert (11) is detachably held on the mold surface (25) of the foam mold (20), and foamed into the foam forming part (13) by the foaming raw material injected into the foam mold (20). In the method of manufacturing a foam molded article in which the body (28) is formed and the foam (28) and the insert (11) are integrated,
The foam mold (20) is on the mold surface (25) side on which the insert (11) is disposed.
A hook member (31) whose tip end is bent into a substantially L shape to become a hook portion (33) on the periphery of the opening portion (15), and a mold surface side of the hook portion (33) The cushion member (35) provided, the hook member (31) is moved forward and backward with respect to the mold surface (25) on which the insert (11) is arranged connected to the shaft portion (34), and the shaft portion (34). The insert holding means (30) comprising the drive device (32) that rotates around the center of the insert is located at a position deviated from the center of the opening (15) in the portion where the opening (15) of the insert is disposed. The shank (34) is positioned so that it is located;
The shaft portion (34) of the insert holding means is passed through the opening (15) formed in the foam non-formation portion (14) of the insert, and the hook portion (33) is inserted into the periphery of the opening (15). To the position that intersects the opening (15) of the insert, and is hooked at the portion of the cushion body (35), and the hooking member (31) is retracted to the mold surface (25) side to hook the hook. The insert (11) is held on the mold surface (25) by pulling (33) to the mold surface (25) side together with the periphery of the opening (15),
After foam molding, the hook member (31) is advanced, and the hook member (31) is rotated so that the hook portion (33) does not intersect the peripheral edge of the opening (15). A method for producing a foam-molded article, wherein the hook (33) is removed from the periphery of the opening (15) . A molded product having an upper die (22) and a lower die (21), and formed between the upper die (22) and the lower die (21) by closing the upper die (22) and the lower die (21). Having a cavity (24);
In the upper mold (22), a part of the surface is a foam forming part (13) and the other part is a foam non-forming part (14), and the foam non-forming part (14) is used for parts and the like. A mold surface (25) for detachably holding an insert (11) in which an opening (15) is formed ,
The insert (11) is detachably held on the mold surface (25) of the upper mold, and the foamed raw material is foamed in the molded product cavity (24) facing the foam forming part (13) of the insert. In the foam mold (20) for forming the foam (28) in the foam forming part (13) by:
The mold surface (25) of the upper mold said insert (11) is arranged,
A hook member (31) whose tip end (34) is bent into a substantially L-shape to become a hook portion (33) to the opening portion (15), and an upper mold surface of the hook portion (33) ( 25) a cushion (35) body provided on the side, and the shaft member (34) connected to the shaft portion (34) to advance and retreat the hook member (31) with respect to the mold surface (25) of the upper die and the shaft portion (34). An insert holding means (30) comprising a drive device (32) for rotating around
The shaft portion (34) is located at a position deviated from the center of the opening (15) in the portion where the insert (11) is disposed , and the hook portion (33) is rotated by the rotation of the hook member (31). A foam molding die provided so as to move between a position where it does not intersect with a position where it intersects with the periphery of the opening (15) of the foam non-formation part (14) of the insert (11).

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