JP4253765B2 - Attached part of foam molded product with skin and manufacturing method of foam molded product with skin - Google Patents

Description

TECHNICAL FIELD The present invention relates to an attachment part for a foam-molded article with a skin and a method for producing a foam-molded article with a skin, and more specifically, an attachment part that is mounted on a skin material molded by spray molding and constitutes a foam-molded article with a skin. And a method of manufacturing a foam-formed product with a skin, in which a synthetic resin material is spray-coated to form a skin material on which mounting parts are mounted .

  Various vehicle interior members such as instrument panels, floor consoles, door panels, pillar garnishes, and the like are installed in passenger compartments of automobiles such as passenger cars. These vehicle interior members are (1) a single-layer structure type made of a synthetic resin base material molded into a required shape, and (2) a two-layer structure type made of a base material and a skin material attached to the outside of the base material. (3) A base material, a skin material, and a three-layer structure type composed of a foam interposed between the base material and the skin material are provided for each vehicle type and grade. Among these, the vehicle interior member of the three-layer structure type (3) is generally composed of a base material, a skin material, and a foam, and thus can generally be referred to as a “foam molded product with a skin”. However, the foam-formed product with a skin is not limited to the vehicle interior member described above, and includes furniture, office supplies, and the like.

  FIG. 14 is a schematic perspective view of an instrument panel which is a foamed article with a skin. The instrument panel 10 includes a synthetic resin skin material 30 preformed in a required shape on the outside of a synthetic resin base material 12 molded in a required shape, and the base material 12 and the skin material 30. It has a three-layer structure in which a foam 14 made of elastic urethane foam or the like is interposed. The first to third air outlets 16, 18, 20, and the like are mounted at required positions on the outer surface in the three-layer region, that is, required positions of the skin material 30. FIG. 15 is a cross-sectional view taken along the line X-X of FIG. 14 and illustrates the first air outlet 16. The first air outlet 16 corresponds to the base material opening 12 </ b> A of the base material 12. The bezel 22 is housed and held in a mounting opening 32 formed in the material 30, and is integrally formed on the inner side of the bezel 22, which is inserted into the mounting opening 32 and is integrally molded with a decorative frame 22 </ b> A on the front surface. The plurality of fins 24 and the like. However, in the illustrated first air outlet 16, the bezel 22 is attached to the mounting opening 32 of the skin material 30, and the fins 24 can be displaced in the front end of the duct D facing the inside of the bezel 22. It is a variable fin type. The second air outlet 18 and the third air outlet 20 are fixed fin types in which fins 24 are integrally formed inside the bezel 22, although detailed illustration is omitted.

  When the skin material 30 described above is classified from the molding mode, the one formed from the resin sheet material based on the vacuum forming technique and the one formed from the resin powder based on the powder slush molding technique have become mainstream. However, in the vacuum forming technique and the powder slush molding technique described above, there is a problem that the forming process of the skin material 30 and the mounting process of the air outlets 16, 18, and 20 to the skin material 30 must be performed in separate processes. Is inherent. That is, in the vacuum forming technique, since there is a limit to the shape deformation of the resin sheet material, it is possible to form the resin sheet material so as to follow the attachment parts having the outer shape having a large shape change such as the air outlets 16, 18, and 20. Impossible. Further, with the powder slush molding technique, the skin molding surface is heated to around 200 ° C., so the air outlets 16, 18, and 20 made of synthetic resin cannot be set on the skin molding surface.

Therefore, in recent years, materials made of polyurethane or the like molded from polyurethane based on spray molding technology have been put into practice. This spray molding technique is to apply a synthetic resin raw material such as polyurethane to the required thickness on the skin molding surface of the skin molding die molded into the required shape, and then demolding after curing this synthetic resin raw material, This is a molding method for obtaining a skin material having a required thickness to which the surface shape and surface pattern of the skin molding surface are transferred. In such a spray molding technique, since the heating temperature of the skin molding surface is about 60 ° C., it is possible to set the air outlets 16, 18, 20 made of synthetic resin, and the air outlets 16, 18, 20 Since the synthetic resin raw material can be appropriately spray-coated even if the outer surface shape is complicated, there is an advantage that the molding process of the skin material 30 and the mounting process of the air outlets 16, 18, and 20 can be performed simultaneously. . That is, as illustrated in FIG. 16, the bezel 22 as a separately molded mounting part is fixedly set by the fixing jig 56 on the set portion 54 of the skin molding surface 52 of the skin molding die 50, and then illustrated in FIG. as to, to the outer surface of the skin layer forming surface 52 and the bezel 22, when gradually spraying the spray gun SG to the required thickness of the synthetic resin material U while reciprocally multiple times, the bezel 22 by the curing of the synthetic resin raw material U Can be formed. A technique related to this is disclosed in Patent Document 1, for example.
JP 2003-112326 A

By the way, the skin material 30 described above often gives a texture pattern, a geometric pattern, or the like to the outer surface in order to improve the texture of the instrument panel 10, and accordingly, the skin molding surface 52 of the skin molding die 50. The pattern is a reverse pattern for transferring and reproducing these patterns and has a subtle uneven shape, and a large number of concave grooves (texture grooves) 58, etc., enlarged as illustrated in FIG. 18 are formed. . For this reason, when mounting parts such as the bezel 22 are set on the skin molding surface 52, a large number of gaps 60 due to the concave grooves 58 are formed in the contact area S between the skin molding surface 52 and the bezel 22. become. Therefore, when the synthetic resin raw material U is spray-applied from the skin molding surface 52 to the outer surface of the bezel 22 without a gap, the synthetic resin raw material U applied to the contour portion between the outer contour edge of the bezel 22 and the skin molding surface 52. Since the viscosity is still low immediately after adhesion, it moves along the concave groove 58 described above by capillary action, enters the gap 60, and is cured as it is. For this reason, as shown in FIG. 19, a thin burr 26 is formed on the outer edge of the front face of the decorative frame 22A in the bezel 22, and the burr 26 is cut off after the molding is completed. However, there are inherent problems such as an increase in molding cost due to the addition of a post-operation process, and a problem in which the quality of the foamed molded product with the skin (instrument panel 10) is deteriorated when the cutting operation of the burr 26 is inappropriate. Was.

Therefore, in the present invention, the mounting parts constituting the foamed molded article with the skin and the synthetic resin raw material spray-coated on the skin molding surface are prevented from entering the gap in the contact area between the skin molding surface and the mounting part. Thus, an object of the present invention is to provide a method for producing a foam-molded article with a skin , which can reduce the molding cost and improve the quality by molding the skin material .

In order to solve the above problems and achieve the intended purpose, the present invention is set in the skin mold prior to molding the skin material by spray-coating the synthetic resin raw material on the skin molding surface of the skin mold, In the mounting part that is mounted on the molded skin material and constitutes the foamed molded product with the skin,
The outer peripheral edge of the mounting part is extended so as to protrude outward, and is opposed to the skin molding surface in a non-contact manner at the outer edge portion of the contact area that contacts the skin molding surface. The distance from the skin molding surface gradually decreases as the contact area is approached, and an outer protruding edge that defines a raw material circulation space is provided between the surface and the skin molding surface.
Further, in order to solve the above-mentioned problems and achieve the intended object, another invention is to provide an attachment part by means of an outer protruding edge extending on an outer edge portion of a contact area with the skin molding surface of the attachment part. , And set in the skin mold in a state of defining a raw material distribution space in which the distance between the outer protruding edge and the skin molding surface gradually decreases toward the contact area,
The synthetic resin material is sprayed from above the outer projecting edge toward the skin molding surface, and the synthetic resin material is applied to the skin molding surface excluding the outer edge portion of the contact area covered with the outer projecting edge. Apply
Said synthetic resin material is spray applied to the skin layer forming surface, the passed through the raw material flow space leading to the outer edge portion of the contact region, characterized by forming a skin material obtained by mounting the mounting part.

According to the mounting part of the foam-molded product with a skin according to the present invention, the outer projecting edge extending to the entire circumference of the outer contour edge of the mounting part results in the skin molding surface and the outer projecting edge of the skin molding die. In the meantime, it is possible to define a raw material distribution space having a shape in which the interval gradually decreases as it approaches the contact area where the mounting part and the skin molding surface contact. Therefore, when molding the skin material constituting the foam-molded article with the skin, it is possible to prevent the synthetic resin raw material from being directly spray applied to the outer edge portion of the contact area, and to be spray applied to the skin molding surface. It is also possible to prevent the synthetic resin raw material from being depressurized in the raw material distribution space and arriving at the outer edge of the contact area. In addition, the synthetic resin raw material that has passed through the raw material distribution space is formed between the raw material distribution space and the contact region by the raw material introduction space defined so as to extend along the outer edge line of the contact region. Thus, it is possible to make it more difficult for the synthetic resin raw material to enter the gap in the contact area.
According to the manufacturing method of skinned foam molded article according to another aspect of the present invention, the raw material flow space defining between the outer flange and the skin layer forming surface of the mounting part, constituting the said surface unpeeled molded foam upon molding the skin material to the synthetic resin material is prevented from the fitting and the skin forming surface is directly sprayed to the outer edge portion of the contact region abutting, was spray applied to the skin layer forming surface synthetic resin raw material can be halted proof that once coming into the outer edge of the contact area. Since the synthetic resin raw material that has flowed into the raw material distribution space after spray coating requires an appropriate time to pass through the raw material distribution space, curing starts before the outer edge of the contact area arrives and the viscosity gradually increases. as growing, that obtained by suitably prevented from being hardened contact area to the formed gap enters the said synthetic resin material. Accordingly, in the skin material after the molding is completed, burrs are not formed on the outer edge of the front surface of the mounting part, and a post-working step for removing the burrs is not required, so that the molding cost can be reduced. There are beneficial effects such as no deterioration of the quality of the skin material itself and the foamed product with skin. In addition, if the synthetic resin raw material that has passed through the raw material distribution space is guided to the raw material introduction space defined between the raw material distribution space and the contact area, the intrusion of the synthetic resin raw material into the gap in the contact area is further enhanced. that give it difficult.

Next, the attachment part of the foam-molded product with skin and the method for producing the foam-molded product with skin according to the present invention will be described below with reference to the accompanying drawings by giving preferred examples. Note that, in Examples described later, as a skinned foam molded article, illustrate the instrument panel is a vehicle interior member. Therefore, in the description of the prior art referring to FIGS. 14 to 19, the same members / parts as those already described will be described with the same reference numerals.

2 is a schematic perspective view illustrating an example of a skin material in the instrument panel 10 of the preferred embodiment, and FIG. 3 is a cross-sectional view taken along line III-III in FIG. As will be described later and illustrated in FIGS. 1 and 5 to 7, the skin material 30 is formed based on a spray molding technique using a skin molding die 50, and each of the first to third air outlets. bezel (fitting) 22 constituting the 16, 18, 20 is molded in a state where the instrumentation wearing the required position, thereby obtaining handled while wearing the bezel 22. In the skin material 30 of such an embodiment, after setting the separately formed bezel 22 at a predetermined position of the skin molding surface 52 of the skin molding die 50, the synthetic resin raw material U is placed on the outer surface of the skin molding surface 52 and the bezel 22. spray applied to the required thickness, so as to mount the bezel 22 by curing the synthetic resin raw material U. However, the skin material 30 of the embodiment can be mounted with a bezel 22 in which the fins 24 are separated as in the first air outlet 16, and as in the second air outlet 18 and the third air outlet 20. It is also possible to mount the bezel 22 in which the fins 24 are integrally formed. Therefore, in this embodiment, only the first air outlet 16 is described and illustrated, and the description of the second air outlet 18 and the third air outlet 20 is omitted.

  The skin material 30 is formed from a synthetic resin raw material U colored in advance in the product color of the instrument panel 10. The synthetic resin raw material U is, for example, a soft type and a non-foamed type, and further molds a highly functional polyurethane excellent in weather resistance, light resistance, heat resistance, moisture resistance, wear resistance, and the like. The skin material 30 made of such highly functional polyurethane is formed to have a thickness T = 1.0 to 1.5 mm as a whole, and the hardness of the single body when cured is 70 to 75 (Shore A hardness). It has become.

  Each component such as the bezel 22 and the fin 24 constituting the first air outlet 16 is a molded part made of synthetic resin made of ABS or the like, and the basic configuration is the same as that illustrated in FIG. Yes. Among these, the bezel 22 to be attached to the skin material 30 has a rectangular frame shape as illustrated in FIG. 4, a frame-shaped decorative frame 22 </ b> A is formed on the front side thereof, and an outer peripheral side surface thereof. A plurality of engaging projections 28 are integrally projected. The outer contour edge of the decorative frame 22 </ b> A is aligned with the opening contour edge of the attachment opening 32 formed integrally with the skin material 30, and each engagement protrusion 28 is one of the attachment openings 32. By engaging with the engaging recess 34 that forms the part, the bezel 22 can be mounted without being easily detached from the molded skin material 30 (FIG. 3).

And in the bezel 22 of an Example, the outward protrusion edge 40 extended outwardly over the perimeter as shown in FIG. 4 was extended by the external outline edge of 22 A of decorative frames. As will be described later and illustrated in FIGS. 1A and 5B, the outer protruding edge 40 is formed when the bezel 22 is set on the skin forming surface 52 of the skin forming die 50. It comes close to the molding surface 52 without contact. Therefore, the synthetic resin raw material U of the spray-coated synthetic resin raw material U extends along the outer edge line of the contact area S between the skin molding surface 52 and the bezel 22 between the skin molding surface 52 and the outer protruding edge 40. A raw material distribution space 42 that provides resistance to flow is defined. The raw material distribution space 42 is defined such that the gap dimension gradually decreases from the raw material inflow side (the outer edge side of the decorative frame 22A) toward the contact region S, and the synthetic resin raw material U is in the contact region S. It functions to prevent the synthetic resin material U spray-coated on the skin molding surface 52 from moving to the outer edge of the contact area S at a stretch while preventing direct spray application to the outer edge portion.

  Further, a material introduction space 44 extending along the outer edge line of the contact area S is further defined between the material circulation space 42 and the contact area S. In this raw material introduction space 44, the synthetic resin raw material U that has passed through the raw material distribution space 42 and arrived at the outer edge portion of the contact area S further enters the gap 60 formed in the contact area S. It is for making it difficult. That is, since the raw material introduction space 44 has a larger volume than the gap 60 formed in the contact region S, the synthetic resin raw material U in a state where the viscosity has increased moderately through the raw material circulation space 42 is Instead of entering the gap 60 in the contact region S, the material flows toward the raw material introduction space 44, so that the intrusion of the synthetic resin raw material U into the gap 60 can be made more difficult.

  Therefore, as will be described later, the synthetic resin raw material U that has been spray-applied from the skin molding surface 52 to the outer surface of the bezel 22 and then flowed into the raw material distribution space 42 is de-energized and decelerated, and this raw material distribution space. Since an appropriate time is required to pass through 42, curing starts before reaching (arriving) the outer edge of the contact area S. For this reason, the synthetic resin raw material U at the time of arrival at the outer edge of the contact region S has increased in viscosity to such an extent that it is difficult to enter the gap 60 formed in the contact region S due to capillary action. It does not enter the gap 60 and harden. That is, the skin material 30 of the embodiment can suitably prevent the burr 26 as illustrated in FIG. 19 from being formed on the front surface of the decorative frame 22A of the bezel 22.

(Form of skin material)
Next, a method of molding the skin material 30 constituting the instrument panel 10 of the embodiment configured as described above based on the spray molding technique will be concretely described with reference to FIG. 1 and FIGS. Explained. As shown in part in FIG. 5A, the skin molding die 50 is formed in the shape of the design portion of the skin material 30, and the skin molding surface 52 having a surface such as a texture pattern or a geometric pattern applied thereto. Is an electroforming mold formed. Further, a temperature control pipe 62 through which a heat medium such as water or oil circulates is laid on the back side of the skin molding surface 52, and the surface temperature of the skin molding surface 52 is set to a temperature at which hardening of the synthetic resin raw material U is promoted (for example, (About 65 ° C.). Thus, the bezel 22 made of the set synthetic resin in the skin forming surface 52, a possibility that melted and deformed or altered by the heat of the skin layer forming surface 52 is not. A set portion 54 for setting the bezel 22 constituting each of the first to third air outlets 16, 18, and 20 is formed at a required position of the skin forming surface 52 (in FIG. 5). Only the set part of the first air outlet 16 is illustrated). Since the set portion 54 is basically a part of the skin molding surface 52, the above-described surface pattern is formed, and a fixing jig 56 having a masking function is used for fixing means such as a bolt or a magnet. It is possible to fix using.

  First, as illustrated in FIGS. 5A and 5B, the bezel 22 of the first air outlet 16 separately molded into a required shape is fixed and set to the set portion 54 using a fixing jig 56. To do. As a result, the outer edge line of the contact region S between the skin forming surface 52 and the bezel 22 is shown around the entire outer periphery edge of the decorative frame 22A of the bezel 22 as illustrated in FIG. Is formed between the skin forming surface 52 and the outer protruding edge 40, and a raw material introduction space 44 extending along the outer edge line of the contact area S is formed. The material flow space 42 and the contact area S are defined.

  When the setting of the bezel 22 to the set portion 54 of the skin molding surface 52 is completed and the skin molding surface 52 is heated to a predetermined temperature by circulation of the heat medium to the temperature adjusting pipe 62, as illustrated in FIG. By moving the spray gun SG several times over the outer surface of the bezel 22 from the skin molding surface 52 and spraying the synthetic resin raw material U little by little over multiple times, the synthetic resin raw material is finally made to the desired thickness. U is attached. In the spray application operation of the synthetic resin raw material U by the spray gun SG, when applying the synthetic resin raw material U to the outer contour edge of the bezel 22 (around the outer protruding edge 40), FIG. It is desirable to carry out from the direction indicated by the arrows shown in FIGS. 5A to 5F, and this prevents the synthetic resin raw material U from entering the raw material circulation space 42 by the force of spraying.

  FIG. 1B is an explanatory cross-sectional view after the first spray application operation by the spray gun SG. By spraying the synthetic resin raw material U from the direction of the arrow in the figure, the skin molding surface 52 is formed from the outer surface of the bezel 22. In this state, the synthetic resin raw material U is thinly attached. In this first spray application operation stage, the synthetic resin raw material U applied to the outer surface of the bezel 22 (the outer surface of the outer protruding edge 40) and the synthetic resin raw material U applied to the skin molding surface 52 are in a separated state. Therefore, the synthetic resin raw material U hardly flows into the raw material distribution space 42 except for a part that has rebounded due to the momentum of spray application.

  FIG. 1C is an explanatory sectional view after the second spray application operation by the spray gun SG, and the synthetic resin sprayed the first time by spraying the synthetic resin raw material U from the direction of the arrow in the figure. The synthetic resin raw material U is applied from the outer surface of the bezel 22 to the skin molding surface 52 so as to cover the raw material U. In the second spray application operation stage, the synthetic resin raw material U applied to the outer surface of the bezel 22 (the outer surface of the outer protruding edge 40) and the synthetic resin raw material U applied to the skin forming surface 52 are formed into a raw material distribution space. 42 is connected on the inlet side. The synthetic resin raw material U having a low viscosity immediately after spray coating gradually flows into the raw material circulation space 42.

  FIG. 1 (d) is an explanatory cross-sectional view after the third spray application operation by the spray gun SG. By spraying the synthetic resin raw material U from the direction of the arrow in the figure, the first and second spray applications are performed. The synthetic resin raw material U is applied from the outer surface of the bezel 22 to the skin molding surface 52 so as to cover the synthetic resin raw material U. In the third spray coating operation stage, more synthetic resin raw material U is applied to the inlet side of the raw material distribution space 42, and therefore the synthetic resin raw material U is applied to the periphery of the inlet side and has a low viscosity. Sequentially flows into the raw material distribution space 42.

  FIG.1 (e) is explanatory sectional drawing after the 4th spray application operation | work by the spray gun SG, It spray-applied over 3 times by spraying the synthetic resin raw material U from the arrow direction of a figure. The synthetic resin material U is applied from the outer surface of the bezel 22 to the skin molding surface 52 so as to cover the synthetic resin material U. In this work stage, the synthetic resin raw material U applied around the inlet side of the raw material distribution space 42 sequentially flows into the raw material distribution space 42, and the synthetic resin raw material U that first flows into the raw material distribution space 42 is introduced as a raw material. It comes to space 44.

  FIG. 1 (f) is an explanatory cross-sectional view after the final spray application operation by the spray gun SG. By spraying the synthetic resin raw material U from the direction of the arrow in the figure, the skin molding surface 52 from the outer surface of the bezel 22. The synthetic resin raw material U is applied to a required thickness over the period. In this work stage, a part of the synthetic resin raw material U that has passed through the raw material distribution space 42 comes to the outer edge of the contact area S, but most of it moves to the raw material introduction space 44. become.

  Here, the synthetic resin raw material U that has flowed into the raw material flow space 42 after the spray coating on the outer surface of the skin molding surface 52 or the bezel 22 and gradually decreases in the gap dimension is subjected to resistance to the flow and is reduced. Since it is decelerated and an appropriate time is required to pass through the raw material circulation space 42, curing gradually starts in the process of moving through the raw material circulation space 42. That is, the synthetic resin raw material U at the time of passing through the raw material circulation space 42 and reaching the outer edge of the contact region S has a viscosity to such an extent that it is difficult to enter the gap 60 formed in the contact region S. As illustrated in FIG. 1 (f), the material moves into the raw material introduction space 44 without entering the gap 60 and eventually hardens.

Thus, when molding the skin material 30 in the instrument panel 10 of the embodiment, the skin molding surface 52 and the bezel 22 are placed between the skin molding surface 52 and the outer protruding edge 40 after the bezel 22 is set. The raw material flow space 42 that extends along the outer edge line of the contact area S of the resin and provides resistance to the flow of the spray-coated synthetic resin raw material U is defined. It is possible to prevent the synthetic resin raw material U spray-coated on the skin molding surface 52 from reaching the outer edge of the contact area S at a stretch. Since the synthetic resin raw material U that has flowed into the raw material distribution space 42 after spray coating is deenergized and requires an appropriate time to pass through the raw material distribution space 42, before it reaches the outer edge of the contact region S. Curing is started and the viscosity gradually increases, and the synthetic resin raw material U can be suitably prevented from entering the gap 60 formed in the contact region S and being cured. Further, a raw material introduction space 44 extending along the outer edge line of the contact area S is defined between the raw material distribution space 42 and the contact area S, and the synthetic resin raw material that has passed through the raw material distribution space 42. Since U is guided to the raw material introduction space 44, it is more difficult for the synthetic resin raw material U to enter the gap 60 in the contact region S. Accordingly, the burr 26 as illustrated in FIG. 19 is not formed on the outer edge of the front surface of the decorative frame 22A of the bezel 22 in the skin material 30 after the molding is completed, and after the burr 26 is cut off after the molding is completed. The work process is not required and the molding cost can be reduced, and the quality of the skin material 30 itself and the instrument panel 10 is not lowered.

  FIG. 8 shows that the skin material 30 of the embodiment in which the bezel 22 is mounted integrally is set in the first molding die 72 and the second molding die 74 of the foam molding die 70 together with the synthetic resin base material 12 separately molded. Then, the foam material is foamed between the skin material 30 and the base material 12 to form the foam body 14, so that the three-layered instrument comprising the base material 12, the foam body 14 and the skin material 30 of the embodiment is formed. It is explanatory sectional drawing which showed the state which shape | molded the ment panel 10. FIG. In addition, the code | symbol 76 in FIG. 9 is an insert member which prevents the deformation | transformation of the bezel 22 by foaming pressure, and the code | symbol 78 is a seal member which prevents the foam 14 from leaking out. As described above, the skin material 30 of the embodiment can be set in advance on the first molding die 72 of the foam molding die 70 after being molded in a state in which the bezel 22 is integrally attached. It can be suitably implemented as a skin material constituting the instrument panel 10 having the three-layer structure exemplified above. That is, the skin material of the present application equipped with mounting parts can be suitably implemented as a skin material in a foam-molded product with a skin having a three-layer structure typified by various vehicle interior members and furniture.

(Example of change)
FIG. 10 is a cross-sectional view of the main part of the skin material according to the modified example, in which an appropriate level difference G is formed between the outer surface of the skin material 30 and the front surface of the bezel 22. As illustrated in FIG. 12, the outer protruding edge 40 extending along the outer contour edge of the decorative frame 22 </ b> A of the bezel 22 protrudes from the set portion 54 of the skin mold 50 by the step G described above. On the premise that it is, it is formed in a shape that appropriately protrudes forward from the front surface of the decorative frame 22A. However, as illustrated in FIG. 11A, the tip of the outer protruding edge 40 is close to the skin forming surface 52 in a non-contact manner when the bezel 22 is set with respect to the set portion 54 of the skin forming surface 52. The shape is set. Thus, in the state where the bezel 22 is set on the skin molding surface 52, the skin molding surface 52 and the outer projection edge 40 are disposed between the skin molding surface 52 and the outer protruding edge 40 as illustrated in FIG. A material flow space 42 extending narrowly along the outer edge line of the contact region S with the bezel 22 is defined, and the contact region is formed between the material flow space 42 and the contact region S. A material introduction space 44 extending along the outer edge line of S is defined.

  In order to mold the skin material 30 of such a modified example, the setting of the bezel 22 to the set portion 54 of the skin molding surface 52 is completed, and the skin molding surface 52 is heated to a predetermined temperature by circulation of the heat medium to the temperature control pipe 62. As shown in FIG. 13, the spray gun SG is moved a plurality of times from the skin molding surface 52 to the outer surface of the bezel 22, and the synthetic resin raw material U is sprayed little by little over a plurality of times. By doing so, the synthetic resin raw material U may be attached to the final desired thickness. In the spray application operation of the synthetic resin raw material U by the spray gun SG, when the synthetic resin raw material U is applied to the outer contour edge of the bezel 22 (around the outer protruding edge 40), FIG. It is desirable to carry out from the direction indicated by the arrows shown in FIGS. 5A to 5F, and this prevents the synthetic resin raw material U from entering the raw material circulation space 42 by the force of spraying.

  11 (b) is an explanatory cross-sectional view after the first spray application operation by the spray gun SG, FIG. 11 (c) is an explanatory cross-sectional view after the second spray application operation, and FIG. 11 (d) is the third spray operation. FIG. 11E is an explanatory cross-sectional view after the fourth spray application operation, and FIG. 11F is an explanatory cross-sectional view after the final spray application operation. In the first spray application operation stage, the synthetic resin raw material U applied to the outer surface of the bezel 22 (the outer surface of the outer protruding edge 40) and the synthetic resin raw material U applied to the skin molding surface 52 are in a separated state. Therefore, the synthetic resin raw material U hardly enters the raw material distribution space 42 except for a part that has rebounded due to the momentum of spray coating. Further, in the second spray application operation stage, the synthetic resin raw material U applied to the outer surface of the bezel 22 (the outer surface of the outer protruding edge 40) and the synthetic resin raw material U applied to the skin molding surface 52 are distributed as raw materials. The synthetic resin raw material U, which is connected at the inlet side of the space 42 and has a low viscosity immediately after spray application, gradually flows into the raw material distribution space 42.

  In the third and fourth spray application work stages, the synthetic resin raw material U applied around the inlet side of the raw material distribution space 42 flows into the narrow raw material distribution space 42, and the first synthetic resin raw material U flows into the raw material distribution space 42. It passes through the raw material distribution space 42 and moves to the raw material introduction space 44, and the raw material introduction space 44 is gradually filled. Then, in the final spray application operation stage, the synthetic resin raw material U that has passed through the raw material distribution space 42 fills the entire raw material introduction space 44.

  Here, the synthetic resin raw material U, which has been spray-coated on the outer surface of the skin molding surface 52 or the bezel 22 and then flowed into the raw material distribution space 42 which is narrowly defined, receives resistance to flow and decreases. Since a certain amount of time is required to pass through the raw material circulation space 42, curing is gradually started in the process of passing through the raw material circulation space 42. In addition, since the synthetic resin raw material U flowing into the raw material introduction space 44 from the raw material distribution space 42 takes an appropriate time to fill the raw material introduction space 44, further curing proceeds in this process. . That is, it is difficult for the synthetic resin raw material U at the time of filling the raw material introduction space 44 from the raw material distribution space 42 to the outer edge of the contact area S to enter the gap 60 formed in the contact area S. Viscosity has increased to the extent, and as illustrated in FIG. 11 (f), it will eventually harden without entering the gap 60.

  Accordingly, even in the modified skin material 30 having a step between the outer surface of the skin material 30 and the front surface of the bezel 22, burrs 26 as illustrated in FIG. 19 are formed at the front outer edge portion of the decorative frame 22A of the bezel 22. As in the case of the skin material 30 of the above-described embodiment, a post-working step for cutting off the burr 26 after the completion of molding is not required, so that the molding cost can be reduced, and the skin material 30 itself or the instrument can be reduced. The quality of the ment panel 10 is not deteriorated.

  Note that the bezel 22 of each of the first to third air outlets 16, 18, and 20 has at least a portion (decorative frame 22A) in contact with the skin molding surface 52 within a predetermined temperature (65 to 85 ° C, preferably You may make it set to the set part 54 of the skin shaping | molding surface 52, raising the temperature to about 80 degreeC. In this way, if the synthetic resin material U is sprayed from the skin molding surface 52 to the outer surface of the bezel 22 with the temperature of the bezel 22 preliminarily raised, the temperature rising portion of the bezel 22 (decorative frame) Curing of the synthetic resin raw material U applied and in contact with 22A and the outer protrusion 40) is promoted. Accordingly, the curing of the synthetic resin raw material U flowing into the raw material distribution space 42 is further promoted, and the intrusion of the synthetic resin raw material U into the gap 60 formed in the contact region S can be made more difficult. However, the same effect can be obtained by raising the temperature of the entire bezel 22 to the above-described temperature.

  In the above-described embodiment, the bezel 22 constituting the first air outlet 16 is illustrated as an attachment part. However, the attachment part targeted by the present application is not limited to this, and the second air outlet 18 and the third air outlet 18 are not limited thereto. Of course, the bezel 22 constituting the outlet 20 can be applied to all mounting parts to be mounted at a required position of the skin material 30, for example, a decorative panel or the like disposed at a required position on the outer surface of the skin material 30. Is done.

In the embodiments described above has exemplified the instrument panel 10 as a skinned foam molded article exhibiting a three-layer structure, the table unpeeled foamed molded article of the present application is not limited thereto, floor console, door panel, Various vehicle interior members such as pillar garnishes, and skin materials to be mounted on furniture and office equipment are also targeted.

The foam-molded article with a skin according to the present invention sets a mounting part separately molded at a predetermined position on the skin molding surface of the skin molding die, and sprays the synthetic resin raw material on the outer surface of the skin molding surface and the mounting part to the required thickness. In addition, the cover material is made of a synthetic resin material after curing, and is used as a component, and can be applied to various vehicle interior members such as instrument panels, furniture, and office supplies. is there.

It is a partial cross-sectional view showing the state of molding the skin material constituting the instrument panel of this example over time with the bezel as the mounting part set in advance on the skin molding surface of the skin molding die, a) shows the state where the raw material distribution space and the raw material introduction space are defined when the bezel is set, (b) shows the state after the first spray application work, and (c) shows the second spray application. (D) shows the state after the third spray application operation, (e) shows the state after the fourth spray application operation, and (f) shows the state after the last spray application operation. Shows the state. It is a schematic perspective view of the skin material which mounted | wore with the bezel which concerns on an Example. It is the III-III sectional view taken on the line of FIG. It is a schematic perspective view of the bezel which comprises an air outlet, Comprising: The outward protrusion edge extended in the perimeter of the external outline edge of a decorative frame is shown. (a) is explanatory sectional drawing which showed the state which set the bezel to the skin molding surface of a skin mold, (b) is explanatory sectional drawing which showed the state which set the bezel to the skin molding surface of a skin molding die is there. It is explanatory sectional drawing which showed the state which spray-coated the synthetic resin raw material with a spray gun ranging from a skin molding surface to the outer surface of a bezel. It is explanatory sectional drawing which showed the state which remove | demolds the skin material which mounted | wore with the bezel after completion of hardening of a synthetic resin raw material. It is explanatory sectional drawing which showed the state which has shape | molded the instrument panel as a foam-molded article with a skin by foam-molding between the skin material of the Example which mounted | wore with the bezel, and the base material separately shape | molded. is there. It is a fragmentary sectional view of the instrument panel which exhibits the shape | molded 3 layer structure. It is a fragmentary sectional view of the skin material which concerns on the example of a change. It is explanatory sectional drawing which showed the state which shape | molds the skin material of the example of a change illustrated in FIG. 10 with the bezel which is an attachment component previously set to the skin molding surface of a skin molding die, (a) Shows the state where the raw material distribution space is defined when the bezel is set, (b) shows the state after the first spray coating operation, and (c) shows the state after the second spray coating operation. , (D) shows the state after the third spray application operation, (e) shows the state after the fourth spray application operation, and (f) shows the state after the final spray application operation. . It is explanatory sectional drawing which showed the state which sets a bezel to the skin shaping | molding surface of a skin shaping | molding die. It is explanatory sectional drawing which showed the state which spray-coated the synthetic resin raw material with a spray gun ranging from a skin molding surface to the outer surface of a bezel. It is a schematic perspective view of the instrument panel which mounted | covered the skin material which mounted | wore with the bezel . It is the XX sectional view taken on the line of FIG. It is explanatory sectional drawing which showed the state which sets a bezel to the skin shaping | molding surface of a skin shaping | molding die. It is explanatory sectional drawing which showed the state which spray-coated the synthetic resin raw material with a spray gun ranging from a skin molding surface to the outer surface of a bezel. It is the fragmentary sectional view of FIG. 17, Comprising: It shows that the synthetic resin raw material spray-applied enters the clearance gap formed in the contact | abutting area | region of a skin molding surface and a bezel and hardens | cures. It is explanatory sectional drawing which showed the inconvenience that a burr | flash is formed in the front surface of the bezel with which the skin material after shaping | molding was completed.

Explanation of symbols

1 2 Base material 14 Foam 22 Bezel (Mounting parts)
30 Skin material 40 Outer edge 42 Raw material distribution space 44 Raw material introduction space 50 Skin molding die 52 Skin molding surface
70 Foaming mold S Contact area U Synthetic resin raw material

Claims (7)

Prior to molding the skin material (30) by spraying the synthetic resin raw material (U) on the skin molding surface (52) of the skin molding die (50), the skin molding die (50) was set and molded. In the mounting part (22) which is mounted on the skin material (30) and constitutes the foamed molded article with the skin,
The skin forming surface is extended at the outer periphery of the outer contour edge of the mounting part (22) so as to protrude outward, and in the outer edge portion of the contact area (S) that contacts the skin forming surface (52). (52) facing non-contact and gradually approaching the contact area (S), the distance from the skin molding surface (52) gradually decreases, and the material flow space (42) between the skin molding surface (52) ) With outer ridges (40) defining
Mounting parts for foam molded products with a skin characterized by the above. Between the raw material circulation space (42) and the contact area (S), the distance between the skin molding surface (52) and the minimum gap between the raw material circulation space (42) and the skin molding surface (52). The attachment part for a foamed molded article with a skin according to claim 1, which is large and defines a raw material introduction space (44) extending along an outer edge of the contact area (S). The mounting part (22) is abutted by the outer projecting edge (40) extending to the outer edge part of the contact area (S) with the skin molding surface (52) of the mounting part (22). Set the skin molding die (50) in a state in which a raw material circulation space (42) in which the distance between the outer projecting edge (40) and the skin molding surface (52) gradually decreases toward S),
The synthetic resin material (U) is sprayed from above the outer protruding edge (40) toward the skin molding surface (52), and the contact area (S) covered with the outer protruding edge (40) ) Applying the synthetic resin raw material (U) to the skin molding surface excluding the outer edge portion (52),
Spray coated the synthetic resin material (U) in the skin layer forming surface (52), guided by passing the material flow space (42) to the outer edge of the abutment area (S), said fitting (22 A method for producing a foam-molded article with a skin , characterized in that a skin material (30) to which is attached) is molded . Between the raw material circulation space (42) and the contact area (S), the distance between the skin molding surface (52) and the minimum gap between the raw material circulation space (42) and the skin molding surface (52). large, define a feed inlet space extending (44) along the outer edge of the abutment area (S),
The method for producing a foamed article with a cover according to claim 3 , wherein the synthetic resin raw material (U) that has passed through the raw material distribution space (42) is guided to the raw material introduction space (44) . Separately molded synthetic resin base material (12) and the skin material (30) mounted with the mounting part (22) are set in a foam molding die (70), and these base material (12) and skin material (30 請 Motomeko 3 or 4 manufacturing method of skinned foam molded article according you forming the foaming material to foam and allowed to foam (14) between). The method for producing a foam-formed product with a skin according to claim 5, wherein the base material (12), the skin material (30), the attachment part (22), and the foam (14) are members constituting an instrument panel. The method of manufacturing a foam-formed product with a skin according to claim 6 , wherein the mounting part (22) is a bezel constituting an air outlet .

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