JP5316006B2 - Foamed structure and method for producing foamed structure - Google Patents

Description

  The present invention relates to a foam structure and a method for producing the foam structure.

  Conventionally, as a structure for mounting a mounted part on a foam molded panel such as an instrument panel of a vehicle, the mounted part is abutted against the foam molded panel to position the mounted part, and in this state, the mounted part is attached to the foam molded panel. What is fixed is known (for example, refer patent document 1). This foam-molded panel has a foam layer as a foam structure inside.

Japanese Utility Model Publication No. 6-65058

  However, the conventional structure has a problem in that the positioning accuracy of the mounted component is low because the foamed layer is deformed when the mounted component is abutted against the foam molded panel.

  Then, an object of this invention is to suppress a deformation | transformation of a foam structure.

The foamed structure of the present invention is a structure in which a first foamed material and a second foamed material are provided between a base material and a skin material, and the second foamed material has a part thereof. The first foam material is filled and located inside the first foam material, and the other part is located outside the first foam material, of the second foam material The rigidity of the composite composed of the portion located in the first foam material and the first foam material is greater than the stiffness of the portion of the second foam material located outside the first foam material. It is characterized by being expensive.

The method for producing a foam structure according to the present invention includes a surface material between the base material and the base material, which are arranged to face each other with a space on the surface of the base material on which the first foam material is fixed, and the first foam material. A step of filling the filler, forming a solid second foam material by foaming the filler, and a portion of the second foam material located within the first foam material; Forming a composite made of the first foam material, and the step of forming the composite comprises a rigidity of a portion of the second foam material located outside the first foam material. Further, the rigidity of the composite is increased.

  According to the present invention, the rigidity of the composite composed of the first foamed material and the portion of the second foamed material located in the first foamed material is the first foamed material of the second foamed material. By being higher than the rigidity of the part located outside, deformation of the foam structure can be suppressed.

It is a perspective view which shows the instrument panel of the motor vehicle concerning one Embodiment of this invention. It is a disassembled perspective view which shows the instrument panel of the motor vehicle concerning one Embodiment of this invention. It is a perspective view which shows the trailer concerning one Embodiment of this invention. It is a horizontal sectional view of the IV section of FIG.

  Hereinafter, an embodiment of the present invention will be described with reference to the drawings.

  As shown in FIGS. 1 and 2, a tray lower 2 and a box cover 3 are attached to the instrument panel 1 of the automobile of the present embodiment, and a lid 4 is attached to the box cover 3.

  The trailer 2 includes a left side wall 5, a right side wall 6, and a connecting portion 7 that connects the left and right side walls 5 and 6. And the abutting part 3a formed in the side part of the box cover 3 is contact | abutted by the surface 9b of the left side wall 5, Thereby, the box cover 3 is positioned.

  As shown in FIGS. 3 and 4, the left side wall 5 of the trailer 2 includes a base material 8, a skin material 9 as a facing member arranged to face the base material 8, and the base material 8 and the skin material 9. And a foam structure 10 interposed therebetween.

The foam structure 10 includes a first foam material 11 and a second foam material 12 and is formed in a layer shape. The first foam material 11 has an open cell structure in which bubbles are connected to each other, and a flow path is formed inside the first foam material 11 by the open cell structure. The foam structure 10 is made of polyurethane foam, for example. This polyurethane foam preferably has a density of 0.0180 to 0.0220 g / cm ³ , a hardness of 9.5 to 13.5 kgf, and an elongation of 130% or more.

  The second foamed material 12 has a part 12a filled in the inside (flow path) of the first foamed material 11 and is located inside the first foamed material 11, and the other part 12b is the first part. It is located outside the foam material 11. The foam structure of the second foam material 12 may be an open-cell structure or an closed-cell structure in which the bubbles are independent. The second foam material 12 is made of polyurethane foam.

  The porosity of the portion 12a located in the first foam material 11 in the second foam material 12 is higher than the porosity of the portion 12b located outside the first foam material 11 in the second foam material 12. It is low. And the composite body 13 is comprised by the part 12a located in the 1st foam material 11 among the 2nd foam materials 12, and the 1st foam material 11. FIG. The rigidity of the composite 13 is higher than the rigidity of the portion 12b of the second foam material 12 located outside the first foam material 11.

  Next, a method for manufacturing the foam structure 10 will be described. First, as a first step, the solid first foam material 11 is fixed to the back surface 8a of the substrate 8 by, for example, adhesion. At this time, since the flow path of the first foam material 11 is empty, the fluid can pass through the inside (flow path) of the first foam material 11. Here, the base material 8 may be formed by, for example, resin injection molding.

  Next, as a second step, the skin material 9 is disposed opposite to the back surface 8a, which is the surface of the base material 8 on which the first foam material 11 is fixed, with the back surface 9a and the back surface 9a of the skin material 9 facing each other. A filler is filled between the back surface 8 a of the material 8 and the first foam material 11. As a result, the first foam material 11 is impregnated with the filler. This filler has foamability and fluidity and is in an unfoamed state. In this embodiment, a filler containing polyurethane and a foaming agent is applied.

  Next, as a third step, the filler is heated to foam the filler to form a solid second foam 12, whereby the first foam of the second foam 12 is formed. A composite body 13 composed of a portion 12 a located in 11 and the first foam material 11 is formed. In the third step, the growth of bubbles in the filler in the first foam material 11 out of the filler is suppressed by the first foam material 11, thereby the first foam in the second foam material 12. The porosity of the portion 12a located within the foam material 11 is lower than the porosity of the portion 12b located outside the first foam material 11 in the second foam material 12, The rigidity of the composite 13 is higher than the rigidity of the portion 12b located outside the first foam material 11.

  As described above, the foam structure 10 of the present embodiment includes the first foam material 11 and the second foam material 12, and the first foam material 11 in the second foam material 12. The rigidity of the composite body 13 composed of the portion 12a located at the first portion and the first foam material 11 is higher than the rigidity of the portion 12b located outside the first foam material 11 in the second foam material 12. Therefore, the rigidity of the foam structure 10 is improved by the amount of the composite 13 as compared with the case where the foam structure is formed only by the second foam material without the first foam material. The deformation of the body 10 can be suppressed. In the foam structure 10 having such a structure, the composite 13 can be used as a positioning member for other members. Specifically, the box cover 3 is positioned well by the composite 13 by abutting the box cover 3 as a mounted part against the surface 9b of the left side wall 5 of the portion of the trail lower 2 corresponding to the composite 13. Can do. Therefore, the assembly dimensional accuracy of the trail lower 2 and the box cover 3 can be improved. In addition, since the deformation of the foam structure 10 can be suppressed as described above, it is possible to improve the appearance quality and the mounting accuracy of the trail lower 2, and consequently suppress the interference between the trail lower 2 and other parts. And generation | occurrence | production of the abnormal sound by those interference can be suppressed.

  In the present embodiment, the first foam material 11 and the second foam material 12 are polyurethane foam, so that the foam structure 10 can be manufactured relatively easily.

  Further, in the method for manufacturing the foam structure 10 of the present embodiment, the fluid can pass through the first foam material 11, so the first foam material 11 between the base material 8 and the skin material 9. Since the filler that has passed through the first foam material 11 spreads to the back side of the material, the second foam material 12 can be formed without a gap between the base material 8 and the skin material 9.

  The present invention is not limited to this embodiment, and various other embodiments can be adopted without departing from the gist of the present invention.

8 Base material 8a Back surface (surface) of base material
9 Skin material (opposing member)
DESCRIPTION OF SYMBOLS 10 Foam structure 11 1st foam material 12 2nd foam material 12a Part of 2nd foam material 12b Other part of 2nd foam material 13 Composite

Claims (3)

A foam structure in which a first foam material and a second foam material are provided between a base material and a skin material ,
A part of the second foam material is filled in the first foam material and located inside the first foam material, and the other part is located outside the first foam material. And
The porosity of the portion of the second foam material located in the first foam material is lower than the porosity of the portion of the second foam material located outside the first foam material. And
Of the second foamed material, the rigidity of the composite composed of the first foamed material and the portion located in the first foamed material of the second foamed material is outside of the first foamed material. A foam structure characterized by having a rigidity higher than that of a portion located in the area.   The foam structure according to claim 1, wherein the first foam material and the second foam material are polyurethane foams. A method for producing a foam structure in which a first foam material and a second foam material are provided between a base material and a skin material ,
A first step of fixing a solid first foaming material through which the fluid can pass through to the substrate;
The first foam material has foamability and fluidity between the skin material and the base material, which are opposed to each other with a space on the surface of the base material on which the first foam material is fixed. And a second step of filling the unfoamed filler,
The composite is formed by foaming the filler to form a solid second foam material, and the portion of the second foam material located in the first foam material and the first foam material. A third step of forming a body;
Including
The third step suppresses the growth of bubbles in the filler in the first foam material among the filler by the first foam material, and the first step in the second foam material. The porosity of the portion located in the foam material is lower than the porosity of the portion located outside the first foam material in the second foam material, and the first foam material in the second foam material. A method for producing a foam structure, wherein the rigidity of the composite is higher than the rigidity of a portion located outside the foam material.

Images