JP5409849B2 - Skin integrated foam - Google Patents

Description

  The present invention relates to a foam integrated with a skin having a groove-like pattern.

  Conventionally, as a skin-integrated foam product having a skin and a foam formed on the back surface of the skin, the skin is placed on the mold surface of the mold, and the foam is injected by injecting the foaming raw material into the mold. And foam are often used.

  In recent years, for example, in the case of a foam integrated product for automobile interior parts such as an instrument panel, a product having a groove-like pattern on the surface has been demanded in order to improve decorativeness.

  In addition, a two-color skin-integrated foam product has been proposed as a skin-integrated foam product in which grooves are provided on the surface of the skin, in which a color boundary is provided inside the groove and the colors are different on both sides of the groove. In this two-color skin-integrated foamed product, a skin material in which inclined convex portions are provided on both sides of a narrow groove portion and an inclined concave portion is formed on the back side of the inclined convex portion is disposed in a foaming mold, and the back surface of the skin is provided. A foam material is formed by injecting a foaming raw material. At that time, the inclined protrusion is flattened by the foaming pressure of the foam to close the opening of the groove, or narrower than the bottom side of the groove. Color boundaries are difficult to see from the outside.

  However, in the two-color skin integral foam product provided with the groove, the groove is provided to make it difficult to visually recognize the color boundary, and the groove closes the opening or the bottom of the groove. Since it is narrower than the side so that the color boundary inside the groove is difficult to visually recognize from the outside, the groove pattern is inferior in decorativeness.

JP 2004-89439 A

  This invention is made | formed in view of the said point, Comprising: It aims at provision of the skin-integrated foaming goods which have the groove-shaped pattern which is excellent in decorating property.

  The invention according to claim 1 is a foam integrated product having a single skin and a foam formed on the back surface of the skin, wherein the skin is made of a flexible plastic and formed on the surface of the skin. The groove is pressed by the foaming pressure at the time of foam formation of the foam and the groove width is narrower on the bottom side than the opening side on the surface of the skin, At both ends, there is a wrinkle pattern generated by deformation of the skin at both ends of the groove-shaped pattern when the groove width is narrower on the bottom side than the opening side due to the foaming pressure at the time of foam formation of the foam It is characterized by that.

  Invention of Claim 2 has base material in the back side of the said foam in Claim 1, and the said foam consists of what was foam-molded between the said skin and the said base material, The groove | channel of the said skin On the back side of the bottom, the foam is filled in a gap for foaming raw material flow between the bottom of the groove and the base material.

  According to the present invention, since the surface has a groove-like pattern in which the groove width is narrower on the bottom side than the opening side due to the foaming pressure at the time of foam formation of the foam, the surface of the skin is pulled to the back side of the skin with a thread. The groove shape is the same shape as the one with the groove pattern, that is, the groove width is widened on the front side and the groove width is narrowed on the bottom side. It is possible to give an impression of being a high-quality one formed with and to improve the decorativeness of the groove pattern.

  Further, according to the present invention, since the ridges generated when the groove width is narrowed are provided at both ends of the groove-like pattern, the groove-like pattern is further improved in decorativeness due to the ridge pattern at both ends. Moreover, since the foam integrated with the skin can be formed with a ridge pattern on both ends of the groove-like pattern when the foam is foamed, it is easy to manufacture.

It is a perspective view which shows one Embodiment of the skin integrated foam of this invention. It is AA sectional drawing and BB sectional drawing of FIG. It is sectional drawing of one Embodiment of the shaping | molding die used for manufacture of the skin integrated foam article of this invention. It is a partial expanded sectional view of FIG. It is CC sectional drawing of FIG. It is sectional drawing which shows the state which has arrange | positioned the skin on the type | mold surface at the time of manufacture of the skin integrated foam product using the shaping | molding die of the embodiment. It is a partial expanded sectional view of FIG. It is DD sectional drawing of FIG. It is sectional drawing which shows the time of foaming raw material injection | pouring at the time of manufacture of the same skin integrated foam. It is sectional drawing which shows the middle of foaming in the case of manufacture of the same skin integrated foam. It is a partial expanded sectional view of FIG. It is EE sectional drawing of FIG. It is sectional drawing which shows the state which extracted the slide plate from the groove | channel in the case of manufacture of the same skin integrated foam. It is a partial expanded sectional view of FIG. It is FF sectional drawing of FIG.

  Hereinafter, embodiments of the present invention will be described in detail. The skin-integrated foam 10 shown in FIGS. 1 and 2 is used for an instrument panel of a vehicle, and has a groove-like pattern M on the surface and ridge patterns 17 on both ends thereof. The skin-integrated foamed product 10 includes a base material 11, a skin 15, and a foam 19 formed by foaming on the back surface of the skin 15, and is manufactured by a manufacturing method described later.

  The substrate 11 is made of a plastic having rigidity, such as ABS resin, and is formed into a predetermined shape by injection molding or the like. In addition, the said base material 11 may be made unnecessary depending on the use of a skin integrated foam product.

  The skin 15 is made of a flexible plastic and is formed into a predetermined shape by powder slush molding or the like. The groove-shaped pattern M is formed by a groove having a narrow width by pressing a bottomed groove 16 formed at a predetermined portion on the surface of the skin 15 by a foaming pressure when the foam 19 is formed. The groove pattern M has a concave shape that is recessed from the front surface side to the back surface side of the skin 15, and intersects the length direction L of the groove pattern M at both ends of the groove pattern M on the surface of the skin 15. The ridge pattern 17 is formed in an approximately eight shape toward the outside of the groove pattern M. Further, the groove pattern M has a groove width W1 that is narrower on the bottom side (inner side of the groove) than on the opening side (outer side of the groove). That is, the groove pattern M has a substantially V-shaped cross section. Accordingly, the groove pattern M has a groove width widened on the surface side and narrowed on the bottom side, similar to the groove pattern M formed by pulling the surface of the skin 15 to the back side of the skin 15 with a thread. Therefore, it has a high-class feeling that is formed manually.

  Further, when the groove 16 of the groove pattern M is pressed by the foaming pressure at the time of foam formation of the foam 19 and the groove width is narrowed, the skin 15 is formed at both ends of the groove pattern M. It is formed by deforming. By having the ridge pattern 17 at both ends of the groove-shaped pattern M, the groove-shaped pattern M seems to have been formed into a groove shape by pulling the surface of the skin 15 to the back side of the skin 15 with a thread. The impression is emphasized, and the decorativeness of the groove pattern is further improved.

The dimension of the groove pattern M, that is, the dimension of the groove 16 is set to an appropriate value according to the required decorative property. For example, in the present embodiment, the groove width W1 on the bottom side of the groove 16 after the foam 19 is formed is 0.5 to 0.8 mm, the depth D1 of the groove 16 is 3 to 7 mm, and the length L1 of the groove 16 is. Is set to 100 to 150 mm. The groove width W1 on the bottom side of the groove 16 after the foam is formed is the groove width of the groove 16 formed when the skin 15 is formed, that is, the width of the groove 16 before the foam 19 is foamed. Is smaller than. In this embodiment, as shown in FIGS. 4 and 5, the width W2 of the groove 16 of the skin 15 before the foam 19 is formed is 1.5 to 2 mm, the depth D2 is 3 to 7 mm, and the length L2 is 100-150 mm.

  Further, the bottom of the groove 15 of the skin 15 (the top of the groove in the state where the skin is arranged in the molding die when the skin is integrally foamed) 16a is located on the back side (skin of the skin) of the base 11 facing the portion 16a. A recess 12 that is recessed to the back side of the integral foam product is formed, and a gap for foaming raw material flow is secured between the bottom portion 16a of the groove 16 of the skin and the recess 12 of the base material 11 when manufacturing the below-described integral foam product. It is configured.

  The foam 19 is formed by foaming a foaming raw material on the back surface of the skin 15 during the manufacture of a skin-integrated foam, which will be described later, and the base material 11 and the skin due to the adhesiveness of the foam at the time of foaming. 15 is integrated. The foam 19 is particularly preferably a polyurethane foam from the viewpoints of lightness, shock absorption, cost, and the like.

  The manufacturing method of the skin-integrated foam 10 having the groove pattern will be described. As shown in FIGS. 3 to 8, first, the base material 11 and the skin 15 are placed in a mold 30. When the skin-integrated foamed product does not require a base material as described above, the base material 11 is not used and is not disposed in the mold 30.

  The mold 30 includes a lower mold 31 and an upper mold 41. The mold surface 32 of the lower mold 31 and the mold surface 42 of the upper mold 41 are shaped according to the outer shape of the skin-integrated foam to be manufactured. Further, the skin 15 is arranged on the mold surface 32 of the lower mold 31 with the inner surface side (back surface side) facing the mold surface 42 of the upper mold 41, while the mold surface 42 of the upper mold 41 has The base material 11 is arranged toward the mold surface 32 of the lower mold 31. The base material 11 is detachably fixed to the mold surface 42 of the upper mold 41 by holding means such as a slide pin.

  The mold 30 is provided with a slide plate 33 that can protrude and retract from a mold surface 32 where the groove 16 of the skin 15 is disposed. The slide plate 33 of the present embodiment is provided at a position where the groove 16 of the skin 15 is disposed on the mold surface 32 of the lower mold 31, and is moved from the mold surface 32 of the lower mold 31 by an advance / retreat device 34 such as an air cylinder. The upper die 41 is configured to protrude and retract toward the die surface 42.

  The slide plate 33 is made smaller than the inner dimension of the groove 16 so that a protruding portion of the lower mold 31 from the mold surface 32 can be inserted into the groove 16 of the skin 15. In the present embodiment, the dimension of the slide plate 33 protruding from the mold surface 32 is such that the thickness F is 0.5 to 1.0 mm smaller than the width W2 of the groove 16, and the length G is the groove. The projection length H is set to be smaller by 0.3 to 1.0 mm than the depth D2 of the groove 16. In particular, the slide plate 33 is substantially trapezoidal so that the amount of protrusion of the lower mold 31 from the mold surface 32 is smaller on both ends U2 side than the center U1 in the length direction U of the slide plate 33. The both ends U2 are composed of slopes. Reference numeral 33 a is the tip of the slide plate 33. In addition, the position and number of the grooves 16 provided in the skin 15 are not limited to those shown in the figure, and are determined according to the shape of the skin-integrated foamed product, the required decorative properties, and the like. Further, the position and shape of the slide plate 33 are determined according to the position and number of the grooves 16.

  The slide plate 33 is inserted into the groove 16 of the skin 15 arranged on the mold surface of the lower mold 31 so that the groove 16 is correctly held in the mold 30. The slide plate 33 is inserted into the groove 16 when the slide plate 33 is previously projected from the mold surface 32 of the lower mold 31 and the skin 15 is placed on the mold surface 32 of the lower mold 31. The slide plate 33 protrudes from the mold surface 32 of the lower mold 31 by inserting the protruding portion of the slide plate 33 into the groove 16 of the skin 15 or after the skin 15 is disposed on the mold surface 32 of the lower mold 31. And inserting into the groove 16.

  Further, when the slide plate 33 is inserted into the groove 16 of the skin 15, a gap S is formed between the tip 33 a of the slide plate 33 and the inner surface of the groove 16 of the skin 15. The gap S is substantially trapezoidal in the shape of the slide plate 33, and the both ends U2 (in the illustrated example) are more than the gap S1 between the tip 33a and the bottom 16a of the groove 16 at the center U1 in the longitudinal direction U of the slide plate 33. The gap S2 in the slope portion) is reduced. In this embodiment, the gap S1 at the center U1 is 0.5 to 1.2 mm, and the gap S2 at both ends U2 (in the illustrated example, the slope portion) is 0.3 to 0.5 mm.

  After the skin 15 and the base material 11 are arranged on the molding die 30, the slide plate 33 is inserted into the groove 16 of the skin 15, and as shown in FIGS. A foam raw material 19a such as a polyurethane raw material is injected into the mold, and the mold is closed to cause foaming of the foam raw material 19a. The illustrated example is a so-called open injection type in which the foaming raw material 19a is injected while the molding die 30 is open and then closed, but a raw material inlet is formed in the molding die 30. A so-called closed injection type in which a foaming raw material is injected into the mold from the raw material inlet in a closed mold state may be used.

  The internal pressure of the mold 30 is increased by the foaming pressure due to the progress of foaming of the foaming raw material 19a, and the groove 16 of the skin 15 is pressed by the foaming pressure, but the groove 16 is correctly held by the slide plate 33. , Can prevent problems such as falling down. Further, as shown in FIG. 7, since the gap S1 is formed between the tip 33a of the slide plate and the bottom 16a of the groove 16 of the skin 15, the groove 16 is caused by the foaming pressure of the foaming raw material 19a. The bottom portion 16a can be made narrower. Further, the gap S between the inner surface of the groove 16 of the skin 15 and the slide plate 33 is smaller (that is, the center) at both ends U2 (in the illustrated example, the slope portion) than the center U1 in the length direction U of the slide plate 33. Since the gap S1> the gap S2 at both ends, the position where the ridge pattern 17 shown in FIG. 1 returns to the general shape becomes unstable, or the ridge pattern 17 undulates irregularly. Can be prevented.

  Thereafter, as shown in FIG. 13 to FIG. 15, the slide plate 33 is retracted in the course of foaming before the foaming raw material 19 a is completely foamed, and the slide plate 33 is extracted from the groove 16 of the skin 15. Since the foaming raw material 19a continues to foam and increases the pressure in the mold 30, the groove 16 is pressed to narrow the groove 16 and a narrow groove pattern is formed on the surface of the skin 15. At the same time, the ridge pattern 17 shown in FIG. 1 is formed in a substantially eight-character shape at both ends of the groove pattern. At that time, the groove 16 has a groove width W narrower on the bottom side than on the opening side (outer side of the groove) because the bottom portion (inner depth of the groove) side is easily pressed and deformed. The timing for removing the slide plate 33 from the groove 16 of the skin 15 is preferably the time when the foaming raw material 19a fills the periphery of the groove 16 of the skin 15. If the slide plate 33 is extracted from the groove 16 of the skin 15 at this timing, it is possible to prevent the occurrence of problems such as the groove 16 falling over due to the foaming pressure of the foaming raw material 19a.

  The foaming raw material 19a is filled between the skin 15 and the base material 11 by the progress of foaming, and becomes the foam 19 shown in FIG. The foam 19 is bonded and integrated with the skin 15 and the substrate 11 by the adhesiveness at the time of foaming. Thereafter, when the mold 30 is opened to remove the molded product, the skin-integrated foam 10 shown in FIGS. 1 and 2 is obtained. The skin-integrated foamed product 10 obtained in this way has a groove-like pattern M with high decorativeness in which the groove 16 of the skin 15 is narrowed. Moreover, the groove pattern M has a groove width that is narrower on the bottom side than on the opening side, and has a high-class feeling as if it was formed by pulling the surface of the skin to the back side with a thread. . Furthermore, the skin-integrated foamed product 10 has a ridge pattern 17 formed at both ends of the groove 16, and has a higher decorativeness.

DESCRIPTION OF SYMBOLS 10 Surface integrated foam product which has groove-shaped pattern on the surface 11 Base material 15 Skin 16 Groove 17 Gutter pattern 19 Foam 30 Mold 31 Lower mold 32 Lower mold surface 33 Slide plate 41 Upper mold 42 Upper mold surface M Groove pattern

Claims (2)

In a skin-integrated foamed product having a single skin and a foam formed on the back surface of the skin,
The skin is made of flexible plastic, and the groove formed on the surface of the skin is pressed by the foaming pressure at the time of foam formation of the foam so that the groove width is narrower on the bottom side than on the opening side. Having a groove pattern on the surface of the skin,
At both ends of the groove-like pattern, it is generated by deformation of the skin at both ends of the groove-like pattern when the groove width is narrower on the bottom side than the opening side due to foaming pressure at the time of foam formation of the foam. A skin-integrated foam product characterized by having a ridge pattern. The back side of the foam has a base material, and the foam is formed by foam molding between the skin and the base material,
2. The skin-integrated foam according to claim 1, wherein the foam is filled in a foaming raw material flow gap between the bottom of the groove and the base material on the back side of the bottom of the groove of the skin. Goods.

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