JP5387068B2 - Resin molded product provided with foam layer, and molding method of resin molded product - Google Patents

Description

  The present invention relates to a resin molded product having a foam layer and a method for molding the resin molded product.

  Interior parts used in automobiles and homes frequently use resin molded products having a three-layer structure of a skin layer, a foam layer, and a core material layer in order to enhance appearance quality and touch. For example, there is an instrument panel as an interior part of an automobile to which a resin molded product having a three-layer structure is applied. In order to attach an airbag device to an instrument panel, the core material layer of the instrument panel may be composed of a base material of the instrument panel having an opening and an airbag door attached to the opening of the base material. Widely practiced (see Patent Document 1). The airbag door includes a main body portion that is inserted into the opening portion from the surface side of the base material, and a lid portion that covers the opening portion at the top portion of the main body portion. After assembling the airbag door to the substrate, urethane foam molding is performed to form a foam layer.

  In the technique described in Patent Literature 1, the periphery of the opening of the base material is sandwiched between the inclined claw portion and the lid portion of the air bag door, and the air bag door is locked to the base material. A thin seal piece is provided on the outer peripheral edge of the lid portion of the airbag door. By pressing the seal piece against the substrate so as to surround the opening, the foam is prevented from leaking during foam molding.

JP2004-243594

  However, in the technique described in Patent Document 1, if there is a variation in the dimension between the inclined claw part and the lid part or the plate thickness dimension around the opening part of the base material, the air is not applied to the base material. There is a risk of the bag door floating. When such lifting occurs, a raised portion is formed on a part of the surface of the foam after foam molding, which causes deterioration in appearance quality and touch.

  Therefore, an object of the present invention is to prevent the formation of a raised part on the surface of the foam after foam molding, and to improve the texture and feel, and a resin molded article having a foam layer, and It is providing the molding method of such a resin molded product.

  A resin molded product including the foam layer of the present invention includes a first resin member having an opening, and a main body inserted into the opening from the surface side of the first resin member. And a second resin member provided with a lid that covers the opening at the top. A resin molded article comprising a foam layer is also provided in the first resin member, and a tongue portion extending toward a back side of the lid portion in the second resin member inserted into the opening, A first seal part provided on the tongue part facing the back side of the lid part, and a first seal part provided on the back side of the lid part and contacting the first seal part, whereby the first and second resins A second seal portion that blocks communication between the front surface side and the back surface side of the member, and the main body portion of the second resin member are elastically displaceable, and the main body portion is inserted into the opening. The elastic claw portion that elastically displaces with the tip of the tongue and contacts the second resin member with respect to the first resin member when the tip of the tongue abuts. And a plurality of grooves in which the tips of the tongues mesh with each other. If has a foam layer formed on the surface side consist of foam of said first and second resin members. And in the resin molded product provided with the foam layer, the tip of the tongue portion engages with one groove portion of the plurality of groove portions and floats with respect to the first resin member. The surface of the second resin member approaches the surface of the first resin member so that the tip of the tongue is engaged with another groove adjacent to the one groove. The second resin member is held at the position.

  The molding method of the resin molded product of the present invention includes a first resin member having an opening, a main body inserted into the opening from the surface side of the first resin member, and a top of the main body. Before the foaming step of forming a foam on the surface side of the second resin member having a lid portion that covers the opening, the surface of the second resin member is against the surface of the first resin member. And a resin member setting step for holding the second resin member at a position approaching. In the resin member setting step, a tongue portion provided on the first resin member and extending toward the back side of the lid portion of the second resin member inserted into the opening, and the second resin The second resin is provided in the main body portion of the member so as to be elastically displaceable, and is elastically displaced as the main body portion is inserted into the opening portion, and a tip of the tongue portion comes into contact therewith. An elastic claw portion having a meshing portion in which a plurality of groove portions in which a tip portion of the tongue portion engages is arranged by locking the member to the first resin member, and the tip end portion of the tongue portion is the plurality of groove portions. The second resin member in a state of being engaged with one of the grooves and being lifted with respect to the first resin member is pushed in. As a result, the tip of the tongue is meshed with another groove adjacent to the one groove, and the surface of the second resin member approaches the surface of the first resin member. 2 resin members are held.

  According to the resin molded product including the foam layer of the present invention, the second resin member in a state where the tip of the tongue is engaged with one of the plurality of grooves and is raised with respect to the first resin member. By pushing in, the tip of the tongue is engaged with another groove adjacent to the one groove, and the second resin member is in a position where the surface of the second resin member approaches the surface of the first resin member. Therefore, it is possible to prevent the second resin member from being lifted with respect to the first resin member, and to prevent a raised part from occurring on a part of the surface of the foam after foam molding, It is possible to improve the appearance quality and feel.

  According to the molding method of the resin molded product of the present invention, the resin member setting step is performed before the foaming step of molding the foam on the surface side of the first resin member and the second resin member. The tip of the tongue is engaged with one of the plurality of grooves and the second resin member in a state of being lifted with respect to the first resin member is pushed in, so that the tip of the tongue is adjacent to the one groove. Since the second resin member is held at a position where the surface of the second resin member is close to the surface of the first resin member by meshing with the groove portion, the second resin with respect to the first resin member The lifting of the member can be prevented. Accordingly, it is possible to prevent a raised portion from being formed on a part of the surface of the foam after the foaming step, and to improve the appearance quality and the touch feeling.

It is a perspective view which shows the instrument panel which concerns on embodiment of a resin molded product provided with a foam layer. It is a perspective view which shows the principal part of the base material as a 1st resin member which comprises the core material layer in an instrument panel, and the airbag door as a 2nd resin member. FIG. 3A is a cross-sectional view showing an airbag door, and FIG. 3B is a perspective view showing an elastic claw portion provided in a main body portion of the airbag door. FIG. 4 is a cross-sectional view taken along line 4-4 of FIG. It is the elements on larger scale which show the part to which the code | symbol 5 enclosed by the broken line was attached | subjected in FIG. It is the elements on larger scale which show the part to which the code | symbol 6 enclosed by the broken line was attached | subjected in FIG. FIGS. 7A and 7B are schematic diagrams for explaining the operation of the embodiment, and FIG. 7C is a schematic diagram for explaining the comparison in which no meshing portion is provided.

  Hereinafter, embodiments of the present invention will be described with reference to the accompanying drawings. In the description of the drawings, the same elements are denoted by the same reference numerals, and redundant description is omitted. The dimensional ratios in the drawings are exaggerated for convenience of explanation, and are different from the actual ratios.

  1 to 4, an instrument panel 10 to which a resin molded product including a foam layer 300 is applied is a resin molded product having a three-layer structure of a skin layer 400, a foam layer 300, and a core material layer 500. In general, the base body 100 having the opening 110 (corresponding to the first resin member 100) and the main body 210 inserted into the opening 110 from the surface side of the base 100 are provided. The airbag door 200 (corresponding to the second resin member 200) having a lid portion 220 that covers the opening 110 at the top of the air bag, and the foam formed of the foam 310 formed on the surface side of the base material 100 and the airbag door 200 It has body layer 300 and skin 410 arranged on the surface side of foam layer 300. The instrument panel 10 also has a tongue 120 extending toward the back side of the lid 220 in the airbag door 200 provided in the base 100 and inserted into the opening 110, and a tongue facing the back side of the lid 220. The first seal portion 130 provided on the portion 120 and the first seal portion 130 provided on the back side of the lid portion 220 are brought into contact with the front surface 101, 201 side and back surface 102 of the base material 100 and the airbag door 200. , 202 and a second seal portion 230 that blocks communication with the 202 side. The instrument panel 10 is further provided on the main body 210 of the airbag door 200 so as to be elastically displaceable. The instrument panel 10 is elastically displaced as the main body 210 is inserted into the opening 110, and the tip of the tongue 120. 121 (hereinafter also referred to as “tongue tip 121”) abuts against the base 100, an elastic claw 240 that locks the airbag door 200 with respect to the substrate 100, and the elastic claw 240 provided on the elastic claw 240. And a meshing portion 250 in which a plurality of groove portions 251 that mesh with each other are arranged. In the instrument panel 10, the tongue tip 121 is engaged with one groove 251 a of the plurality of grooves 251 and pushed into the tongue 100 by pushing the airbag door 200 in a state of being lifted with respect to the base material 100. The front surface 121 of the airbag door 200 (hereinafter also referred to as “airbag door surface 201”) is engaged with the other groove 251b adjacent to the one groove 251a, and the surface 101 of the base material 100 (hereinafter referred to as “airbag door surface 201”). The airbag door 200 is held at a position close to the “substrate surface 101” (see also FIGS. 7A and 7B).

  Moreover, the molding procedure of the instrument panel 10 which is a resin molded product includes a base material 100 having an opening portion 110 and a main body portion 210 which is inserted into the opening portion 110 from the surface side of the base material 100. Prior to the foaming step of forming the foam 310 on the surface side of the airbag door 200 including the lid portion 220 covering the opening 110 at the top of the main body 210, the airbag door surface 201 is against the substrate surface 101. And a resin member setting step for holding the airbag door 200 at a close position. In the resin member setting step, the tongue portion 120 provided on the base material 100 and extending toward the back side of the lid portion 220 of the airbag door 200 inserted into the opening 110, and the main body portion 210 of the airbag door 200 are provided. The airbag door 200 is elastically displaceable and elastically displaces as the main body 210 is inserted into the opening 110, and the airbag door 200 is engaged with the base material 100 by the tongue tip 121 contacting. In the elastic claw portion 240 having the engagement portion 250 in which a plurality of groove portions 251 with which the tongue portion tip end 121 is engaged are stopped, the tongue end portion 121 engages with one groove portion 251a of the plurality of groove portions 251 and is based on the base portion. The airbag door 200 in a state of being lifted with respect to the material 100 is pushed in. As a result, the front end 121 of the tongue is engaged with the other groove 251b adjacent to the one groove 251a, and the airbag door surface 201 is held at a position close to the base material surface 101. . Details will be described below.

  In order to attach an airbag device to the instrument panel 10, a core member 510 of the instrument panel 10 is composed of a base material 100 and an airbag door 200 (see FIGS. 1 and 2). An airbag case 600 containing an inflator, a bag, and the like is attached to the main body portion 210 of the airbag door 200 (see FIG. 3A). Reference numeral 211 in FIG. 3A indicates a locking hole for locking the airbag case 600. The reason why the base material 100 and the airbag door 200 are separated is that a material suitable for the operation of the airbag is used for the airbag door 200. Further, the reason why the airbag door 200 is fitted into the base material 100 is to eliminate the fastening operation and the like and to manufacture the instrument panel 10 at a low cost compared to the case where the airbag door 200 is fastened with a bolt or the like.

  A known material can be appropriately selected for each of the skin 410, the core material 510 (the base material 100 and the airbag door 200), and the foam 310. For example, as the material of the skin 410, vinyl chloride resin (PVC), olefinic thermoplastic elastomer (TPO), polyurethane thermoplastic elastomer (TPU), or the like can be used. The skin 410 is formed into a shape determined by vacuum forming or the like. As a material of the substrate 100, polypropylene resin (PP), acrylonitrile / butadiene / styrene resin (ABS), or the like can be used. As a material of the airbag door 200, TPO etc. which are softer than PP which is the material of the base material 100, for example, and which hardly scatter when the airbag is activated can be used. For example, urethane foam can be used as the foam 310.

  The tongue portion 120 is formed by bending a part of the base material 100 and has a flange shape extending toward the back side of the lid portion 220. The end portion of the tongue portion 120 on the opening 110 side is divided into a bifurcated shape. One end portion 122 divided into a bifurcated shape faces the elastic claw portion 240, and the other bulging portion 123 bulges toward the back surface of the lid portion 220.

  The outer peripheral edge 221 of the lid 220 is formed on an inclined surface facing the tongue 120. A gap S is provided between the outer peripheral edge 221 of the lid 220 and the tongue 120. The foam 310 flows into the gap S during foam molding.

  Referring to FIG. 5, the first and second seal portions 130 and 230 that form a pair are configured by a combination of arcuate surfaces 130 a and 230 a having a concave cross section and arc surfaces 130 b and 230 b having a convex cross section. The curvature radii of the concave arcuate surfaces 130a and 230a are formed larger than the curvature radii of the arcuate surfaces 130b and 230b having a convex cross section. Furthermore, in the illustrated example, a plurality of pairs of first and second seal portions 130 and 230 are provided. For convenience of explanation, the pair of first and second seal portions 130 and 230 shown on the right side in FIG. 5 are referred to as a primary seal portion 710, and the pair of first and second seal portions 130 and 130 shown on the left side are shown. 230 is referred to as a secondary seal portion 720.

  Regarding the primary seal portion 710, the first seal portion 130 is disposed at the base of the bulging portion 123, and has a circular arc surface 130a having a concave cross section. The second seal portion 230 is disposed on the back surface of the lid portion 220 so as to face the first seal portion 130, and has a circular arc surface 230b having a convex cross section.

  Regarding the secondary seal portion 720, the first seal portion 130 is disposed on the top of the bulging portion 123 and has a circular arc surface 130b having a convex cross section. The second seal portion 230 is disposed on the back surface of the lid portion 220 so as to face the first seal portion 130, and has an arc surface 230a having a concave cross section.

  The primary seal portion 710 and the secondary seal portion 720 are both on the front surface 101, 201 side and the back surface of the base material 100 and the airbag door 200 when the first seal portion 130 and the second seal portion 230 come into contact with each other. The communication with the 102 and 202 side is cut off. Since the primary seal portion 710 is disposed at a position continuous with the gap S, it greatly contributes to the sealing performance of the foam 310. The secondary seal portion 720 prevents the foam 310 from leaking at a portion near the tongue tip 121 where the elastic force of the elastic claw portion 240 is urged. The secondary seal portion 720 functions as a preliminary seal when the foam 310 leaks from the primary seal portion 710.

  Here, the arc surfaces 130a and 230a having a concave cross section (the first seal portion 130 of the primary seal portion 710 and the second seal portion 230 of the secondary seal portion 720) have a radius of curvature of the arc surface 130b having a convex cross section. 230b (the second seal portion 230 of the primary seal portion 710 and the first seal portion 130 of the secondary seal portion 720) are formed to have a larger radius of curvature, so the seal portions 130 and 230 are viewed in cross section. Point contact. The radius of curvature of the arcuate surfaces 130a and 230a having a concave cross section and the radius of curvature of the arcuate surfaces 130b and 230b having a convex cross section are not particularly limited, and the seal portions 130 and 230 are viewed in cross section. Appropriate dimensions can be adopted within the range of point contact.

  In the illustrated example, since the outer peripheral edge 221 side of the two second seal parts 230 in the cover part 220 has a convex cross-sectional shape, the rigidity of the outer peripheral edge 221 part of the cover part 220 is increased to prevent deformation. There is an advantage that you can.

  Referring again to FIGS. 2 to 4, a plurality of elastic claws 240 are provided in the main body 210. Each elastic claw portion 240 has a cantilever support structure in which a slit 212 is formed on the outer periphery other than the base end portion 241. The elastic claw portion 240 is elastically displaceable toward the inner side and the outer side of the main body portion 210 with the base end portion 241 at the approximate center (see an arrow 242 in FIG. 3A). The elastic claw 240 includes a guide surface 243 that guides the tongue 120 when the main body 210 is inserted into the opening 110, a contact surface 244 with which the tongue tip 121 contacts, a guide surface 243, and a contact surface 244. And a connection surface 245 formed on a continuous circular arc surface. As the main body 210 is inserted into the opening 110, the tongue 120 presses the guide surface 243. The elastic claw portion 240 is displaced toward the inside of the main body portion 210 and accumulates the elastic force. When the main body portion 210 is further inserted, the tongue portion 120 gets over the connection surface 245 from the guide surface 243. The elastic claw portion 240 is displaced toward the outside of the main body portion 210 while releasing a part of the stored elastic force, thereby bringing the tongue portion tip 121 into contact with the contact surface 244. The elastic claw portion 240 locks the airbag door 200 with respect to the base material 100 by the tongue portion tip 121 coming into contact with the contact surface 244.

  Referring also to FIG. 6, a plurality (four in the illustrated example) of groove portions 251 in the meshing portion 250 is a direction in which the elastic claw portion 240 is elastically displaced on the contact surface 244 (arrow 242 in the drawing). It is formed side by side. Each groove 251 extends in a direction perpendicular to the direction in which the elastic claw 240 is elastically displaced (direction perpendicular to the paper surface of FIG. 6). The meshing part 250 has a stepped shape due to the plurality of grooves 251. When the tongue 121 is engaged with any one of the grooves 251, the elastic claw 240 holds the airbag door 200 on the base material 100 while retaining a part of the elastic force stored when the main body 210 is inserted. Lock against. The elastic force at this time acts to press the lid 220 against the tongue 120. Although the height dimension of each groove part 251 can set an appropriate dimension, since it should just be able to absorb the shaping | molding error of the base material 100 or the airbag door 200, it can be set as the height of about 0.5 mm, for example. In this case, a molding error of about 2 mm can be absorbed in four steps.

  Next, the effect | action of this embodiment is demonstrated, also referring FIG. In FIG. 7, for easy understanding, the elastic claw 240 is shown to be elastically displaced in the right horizontal direction.

  The main body 210 of the airbag door 200 is inserted into the opening 110 of the base material 100 from the front surface 101 side. The lid portion 220 of the airbag door 200 covers the opening portion 110, and the outer peripheral edge 221 faces the tongue portion 120 of the base material 100 with a gap S therebetween. As the main body 210 is inserted into the opening 110, the tongue 120 presses the guide surface 243. The elastic claw portion 240 is displaced toward the inside of the main body portion 210 and accumulates the elastic force. When the main body portion 210 is further inserted, the tongue portion 120 gets over the connection surface 245 from the guide surface 243. The elastic claw 240 is displaced toward the outside of the main body 210 while releasing a part of the stored elastic force. Thereby, the elastic claw part 240 makes the contact surface 244 contact the tongue part front end 121, and locks the airbag door 200 with respect to the base material 100 (resin member setting process). The base material 100 and the airbag door 200 become the core material 510 of the instrument panel 10 having a three-layer structure. Then, the skin 410 and the core material 510 (the base material 100 and the airbag door 200) are set in the mold, and the space between them is filled with the foam 310 (foaming step). Thus, the instrument panel 10 that is a resin molded product including the foam layer 300 is obtained.

  With reference to FIG. 7A, when the core member 510 is constituted by the base material 100 and the airbag door 200, the tongue tip 121 is engaged with one groove 251a of the plurality of grooves 251. It is assumed that the airbag door 200 is in a state of being lifted with respect to the base material 100.

  Referring to FIG. 7B, in the resin member setting step that is performed before the foaming step, the airbag door 200 that is lifted with respect to the base material 100 is pushed in. When the entire airbag door 200 moves downward in the figure, the tongue tip 121 moves relatively in the groove 251a toward the upper side in the figure. The elastic claw 240 is urged by a stored elastic force toward the right horizontal direction in the figure. When the tongue tip 121 moves beyond the edge of one groove 251a, the elastic claw 240 moves in the right horizontal direction in the figure, and the tongue tip 121 engages with another groove 251b adjacent to the upper side of the groove 251a. In this way, by pushing the air bag door 200 in the lifted state, the tongue 121 is engaged with the other groove portion 251b adjacent to the one groove portion 251a, and the air bag door surface 201 is moved to the air bag door surface 201. A position close to the substrate surface 101 is held.

  When the lifted size of the airbag door 200 with respect to the base material 100 is large, the tongue door 121 engages with the groove 251c positioned further upward by pushing the airbag door 200, and the airbag door 200 is brought into contact with the airbag door surface. 201 is held at a position closer to the substrate surface 101.

  The outer peripheral portion of the lid portion 220 is pushed in until the surface 101 in the outer peripheral portion of the lid portion 220 is smoothly connected to the base material surface 101 with a gap S therebetween.

  Referring to FIG. 7C, when the elastic claw portion 800 is not provided with a meshing portion, the tip 804 of the tongue portion 803 is elastically caused by a molding error of the base material 801 or the airbag door 802. There is a possibility that the tip 804 of the tongue 803 cannot be locked against the elastic force of the elastic claw 800 even if it is in contact with the claw 800. In this case, the tip 804 of the tongue 803 slides on the contact surface 805 of the elastic claw 800, and all the elastic force of the elastic claw 800 is released, and the airbag door 802 is moved against the base 801. The pressing force is lost. For this reason, the airbag door 802 is lifted with respect to the base material 801. The lift of the air bag door 802 causes a raised portion on the surface of the foam after foam molding, that is, a part of the skin, resulting in a decrease in appearance quality and touch. Further, due to the lift of the airbag door 802, it becomes difficult to sufficiently seal the foam during foam molding.

  In order to suppress the lift of the airbag door 802 relative to the base material 801, the dimensional accuracy of the molding surface in the resin mold for molding the airbag door 802 and the base material 801 must be increased, and the molding surface is finished. The tuning work to be performed increases, and the manufacture of each of the base material 801 and the airbag door 802 becomes complicated.

  On the other hand, in this embodiment, since the meshing part 250 is provided in the elastic claw part 240, even if there is a molding error of the base material 100 or the airbag door 200, the tongue tip 121 is provided. Can be meshed with any of the plurality of grooves 251. The tongue tip 121 abuts against the elastic claw 240, and the tongue tip 121 can be locked against the elastic force of the elastic claw 240, so that the airbag door 200 is securely attached to the substrate 100. Can be locked. Since the elastic claw portion 240 is restricted from returning to the original position before the displacement, and all the elastic force of the elastic claw portion 240 is not released, the force that presses the airbag door 200 against the base material 100 is always applied. Has occurred. For this reason, the situation which the airbag door 200 floats with respect to the base material 100 does not arise. Since the lifting of the airbag door 200 with respect to the base material 100 can be prevented, it is possible to prevent the surface of the foam 310 after foam molding, that is, a part of the skin 410 from being raised, and to improve the appearance quality and touch. It is possible to improve.

  Moreover, the airbag door 200 can be held at a position where the airbag door surface 201 is close to the substrate surface 101 by pushing the airbag door 200 in a state of being lifted with respect to the substrate 100. In addition, the dimension of the gap S between the lid part 220 and the substrate 100 can be kept within the designed dimension range, and the foam 310 can be sufficiently sealed during foam molding.

  As described above, the meshing portion 250 provided in the elastic claw portion 240 prevents the airbag door surface 201 from being lifted with respect to the substrate surface 101 by meshing the tongue tip 121 with any of the groove portions 251. On the other hand, the airbag door surface 201 approaches the substrate surface 101 by pushing in the airbag door 200 that is lifted with respect to the substrate 100 and engaging the tongue portion tip 121 with another adjacent groove portion 251b. The airbag door 200 is maintained at the position.

  When the first seal portion 130 and the second seal portion 230 come into contact with each other, the communication between the front surface 101, 201 side and the back surface 102, 202 side of the base material 100 and the airbag door 200 is blocked. Thus, the foam 310 at the time of foam molding is sufficiently sealed, and the foam 310 is prevented from leaking to the back side.

  Concerning the first and second seal portions 130 and 230, the curvatures of the concave circular arc surfaces 130a and 230a (the first seal portion 130 of the primary seal portion 710 and the second seal portion 230 of the secondary seal portion 720). Since the radius is formed to be larger than the curvature radius of the arcuate surfaces 130b and 230b (the second seal portion 230 of the primary seal portion 710 and the first seal portion 130 of the secondary seal portion 720) having a convex cross section, the seal The parts 130 and 230 are in point contact when viewed in cross section. Therefore, even when a relative positional deviation occurs between the base material 100 and the airbag door 200, the positional deviation is absorbed by the difference in the radius of curvature, and the seal portions 130 and 230 are viewed in cross section. The foam 310 can be reliably sealed.

  In addition, since the first and second seal portions 130 and 230 that form a pair are provided in two sets of the primary seal portion 710 and the secondary seal portion 720, the secondary seal portion 720 is foamed from the primary seal portion 710. It functions as a preliminary seal when the body 310 leaks, and further prevents the foam 310 from leaking to the back side.

  As described above, in the instrument panel 10 of the present embodiment, the engagement portion 250 is provided in the elastic claw portion 240, and the tongue portion tip 121 is engaged with one of the groove portions 251 a of the plurality of groove portions 251 to the base material 100. By pushing the air bag door 200 in a state of being lifted, the front end 121 of the tongue is engaged with the other groove 251b adjacent to the one groove 251a, and the air bag door surface 201 approaches the substrate surface 101. Since the airbag door 200 is held at the position, the lifting of the airbag door 200 with respect to the base material 100 can be prevented, and the surface of the foam 310 after foam molding, that is, a portion raised on a part of the skin 410 It is possible to prevent appearance of the image and improve appearance quality and touch.

  When molding the instrument panel 10, a resin member setting step is performed before the foaming step, and the tongue tip 121 is engaged with one groove 251 a of the plurality of grooves 251 and is lifted with respect to the base material 100. When the airbag door 200 is pushed in, the tongue 121 is engaged with the other groove 251b adjacent to the one groove 251a so that the airbag door surface 201 approaches the base material surface 101. Since the door 200 is held, the airbag door 200 can be prevented from being lifted with respect to the base material 100. As a result, it is possible to prevent a raised portion from being formed on the surface of the foam 310 after the foaming step, that is, a part of the skin 410, and to improve the appearance quality and touch.

  In addition, since the airbag door 200 can be held at a position where the airbag door surface 201 approaches the substrate surface 101, the dimension of the gap S between the lid 220 and the substrate 100 is designed. The foam 310 can be sufficiently sealed at the time of foam molding.

  The first and second seal portions 130, 230 forming a pair are configured by a combination of arcuate surfaces 130a, 230a having a concave cross section and arc surfaces 130b, 230b having a convex cross section. Since the curvature radius of 230a is larger than the curvature radii of the arcuate surfaces 130b and 230b having a convex cross section, even when a relative positional deviation occurs between the base material 100 and the airbag door 200, the curvature radius is large. The misalignment is absorbed by the difference, and the sealing portions can be point-contacted when viewed in cross section, so that the foam 310 can be reliably sealed.

  Since a plurality of pairs of the first and second seal portions 130 and 230 forming a pair are provided, the foam 310 can be more sufficiently sealed during foam molding.

  The instrument panel 10 as a resin molded product including the base material 100 and the airbag door 200 and including the foam layer 300 can be obtained.

  In the embodiment, since the outer peripheral edge 221 side of the two second seal parts 230 in the lid part 220 has a convex cross section, the rigidity of the outer peripheral edge 221 part of the lid part 220 can be increased to prevent deformation. .

  In addition, this invention is not limited to the case where it applies to the instrument panel 10 mentioned above, The 1st resin member and the 2nd resin member inserted in the opening part of a 1st resin member are included. Needless to say, the present invention can be widely applied to a resin molded product including a foam layer. Moreover, although the form which has two or more sets of the 1st and 2nd seal | sticker parts 130 and 230 which make a pair was shown, it cannot be overemphasized that only 1 set may be sufficient.

10 Instrument panel (resin molded product with foam layer),
100 base material (first resin member),
101 surface,
102 back,
110 opening,
120 tongue,
121 tip,
122 tip,
123 bulge,
130 first seal part,
130a circular arc surface having a concave cross section,
130b A circular arc surface having a convex cross section,
200 airbag door (second resin member),
201 surface,
202 back,
210 body,
212 slits,
220 lid,
221 outer periphery,
230 second seal part,
230a Circular arc surface having a concave cross section,
230b A circular arc surface having a convex cross section,
240 elastic claws,
241 proximal end,
243 guide surface,
244 abutment surface,
245 connection surface,
250 meshing part,
251 groove,
251a one groove,
251b Other grooves,
300 foam layer,
310 foam,
400 skin layers,
410 epidermis,
500 core layer,
510 core material,
600 airbag case,
710 primary seal,
720 Secondary seal part.

Claims (5)

A first resin member having an opening;
A second resin member including a main body portion that is inserted into the opening from the surface side of the first resin member, and a lid that covers the opening at the top of the main body portion;
A tongue that is provided on the first resin member and extends toward the back side of the lid in the second resin member inserted into the opening;
A first seal portion provided on the tongue portion facing the back side of the lid portion;
A second seal portion that is provided on the back side of the lid portion and that contacts the first seal portion, thereby blocking communication between the front side and the back side of the first and second resin members;
The second resin member is elastically displaceable in the main body portion, and is elastically displaced as the main body portion is inserted into the opening, and the tip of the tongue portion abuts An elastic claw portion for locking the second resin member to the first resin member;
A meshing portion provided on the elastic claw portion, in which a plurality of grooves in which the tips of the tongues mesh with each other are arranged;
A foam layer formed on the surface side of the first and second resin members and made of a foam,
By pushing the second resin member in a state where the tip of the tongue engages with one of the plurality of grooves and floats with respect to the first resin member, the tip of the tongue is The second resin member is held at a position where the surface of the second resin member approaches the surface of the first resin member by meshing with another groove portion adjacent to the one groove portion. A resin molded product with a foam layer.   The first and second seal portions forming a pair are configured by a combination of a circular arc surface having a concave cross-section and a circular arc surface having a convex cross-section, and the radius of curvature of the concave cross-sectional arc surface is a circular arc surface having a convex cross-section. A resin molded article comprising the foam layer according to claim 1, wherein the resin molded article is larger than the curvature radius.   A resin molded product comprising the foam layer according to claim 1 or 2, wherein the first and second seal portions forming a pair have a plurality of sets.   The resin comprising the foam layer according to any one of claims 1 to 3, wherein the first resin member is a base material of an instrument panel, and the second resin member is an airbag door. Molding. A first resin member having an opening, and a main body that is inserted into the opening from the surface side of the first resin member, and a lid that covers the opening at the top of the main body. Before the foaming step of forming a foam on the surface side of the resin member,
A tongue that is provided on the first resin member and extends toward the back side of the lid in the second resin member inserted into the opening;
The second resin member is elastically displaceable in the main body portion, and is elastically displaced as the main body portion is inserted into the opening, and the tip of the tongue portion abuts In the elastic claw portion having a meshing portion in which a plurality of groove portions with which the tip of the tongue portion is meshed are engaged with the second resin member with respect to the first resin member,
By pushing the second resin member in a state where the tip of the tongue engages with one of the plurality of grooves and floats with respect to the first resin member, the tip of the tongue is A resin member set which holds the second resin member at a position where the surface of the second resin member approaches the surface of the first resin member by meshing with another groove portion adjacent to the one groove portion. A molding method of a resin molded product having a process.

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