JP5495437B2 - Multilayer foam substrate and method for producing the same - Google Patents

Description

  The present invention relates to a multilayer foam substrate and a method for producing the same. More specifically, the present invention relates to a multilayer foamed substrate having a mounting portion with excellent rigidity and a method for manufacturing the same.

Conventionally, when attaching other parts to a product made of a foamed resin base material, the foamed resin base material itself is not a high-strength material, so other reinforcing materials are used to reinforce the rigidity around the attachment portion of the base material. It is common.
For example, in Patent Document 1, in a mounting form of a product using a foamed resin base material (door trim upper) and another component (door trim lower), the base material is integrated with another reinforcing material (resin rib and the resin rib). The rigidity of the base material is reinforced by stacking the reinforcing plates to be formed.

JP 2005-138797 A

However, when another reinforcing material is used to reinforce the rigidity of the base material, there is a problem that the mass of the entire product increases and the number of parts increases, resulting in an increase in cost.
Further, in recent years, products using a foamed resin base material are required to be further reduced in weight and to reduce the number of parts constituting the product.
Therefore, the present condition is that the foamed resin base material which can attach other components, without using other reinforcement materials, such as a reinforcement plate, is calculated | required.

  This invention is made | formed in view of the said situation, and it aims at providing the multilayer foaming base material provided with the attachment part excellent in rigidity, and its manufacturing method.

In order to solve the above problem, the invention according to claim 1 is a multilayer foam substrate comprising a first skin layer, a resin foam layer, and a second skin layer in order,
In the multilayer foam base material, an attachment part for attaching other parts is formed,
In the attachment portion, the second skin layer is formed with a portion indented into the resin foam layer toward the first skin layer side ,
The gist is that the surfaces of the second skin layer in the recessed portion are combined and integrated into a first rib.
According to a second aspect of the present invention, in the first aspect, the attachment portion is provided with an attachment hole.
The other component has a shaft portion inserted into the mounting hole,
The end of the shaft part is provided with a head wider than the diameter of the shaft part,
The gist is that the first rib is formed in a region of the attachment portion that is covered by the head.
The gist of the invention described in claim 3 is that, in claim 2, the first rib is formed so as to surround the attachment hole.
A fourth aspect of the present invention is the method according to any one of the first to third aspects, wherein the multilayer foamed substrate is formed with stepped portions that are bent at a plurality of locations when viewed from the side surface. ,
Wherein the stepped portion is provided with a second rib,
The second rib is configured to vertically cut the ridge line of the stepped portion ,
The second rib is formed by a portion in which the second skin layer is recessed into the resin foam layer toward the first skin layer side,
The gist is that the surfaces of the second skin layer in the recessed portion are combined and integrated .

In order to solve the above problem, the invention according to claim 5 is a method for producing a multilayer foamed substrate according to any one of claims 1 to 4,
A setting step of setting the base material provided with the first skin layer, the resin foam layer, and the second skin layer in this order in a first mold;
When the resin foam layer is expanded in the thickness direction in a state where the base is evacuated from the first skin layer side , the second skin layer in the attachment portion is embedded in the resin foam layer . Process,
The present invention includes a rib forming step in which the surfaces of the second skin layer embedded in the resin foam layer are heated and melted to be integrated to form a first rib.

In the multilayer foam base material of the present invention, a retraction portion in which the second skin layer is drawn into the resin foam layer is formed in the attachment portion for attaching other components, and the second skin layer of this retraction portion is integrated. The first rib. Therefore, the rigidity of the attachment portion is improved, and other components can be attached without using other reinforcing materials.
In addition, it has a shaft part into which other parts are inserted into the mounting hole, and a head wider than the diameter of the shaft part is provided at the end, and a first rib is formed in a region covered by the head of the mounting part In this case, the rigidity of the attachment portion can be sufficiently improved, and other components can be attached through the attachment holes without using other reinforcing materials.
Furthermore, when the first rib is formed so as to surround the attachment hole, the rigidity of the attachment portion can be sufficiently improved, and other parts can be attached via the attachment hole without using other reinforcing materials. Can be attached.
Further, when viewed from the side surface of the multilayer foamed base material, a stepped portion bent at a plurality of locations is formed, and the stepped portion is provided with a second rib having a form that vertically cuts the ridge line of the stepped portion. In this case, the rigidity of the attachment portion can be sufficiently improved by the first rib, and the rigidity of the stepped portion can be sufficiently improved by the second rib.
According to the method for producing a multilayer foam base material of the present invention, the second skin layer in the attachment portion is drawn into the resin foam layer and drawn into the resin foam layer in a state where the base material is evacuated from the first skin layer side. The second skin layer is heated and melted to form the first rib. Thus, since the second skin layer drawn into the resin foam layer is heated and melted in the attachment portion to form the first rib inside the base material, the rigidity of the attachment portion in the obtained multilayer foam base material is increased. It can be improved sufficiently.

The present invention will be further described in the following detailed description with reference to the drawings referred to, with reference to non-limiting examples of exemplary embodiments according to the present invention. Similar parts are shown throughout the several figures.
1 is a schematic cross-sectional view of a multilayer foamed substrate according to Example 1. FIG. It is explanatory drawing for demonstrating the attachment structure of the multilayer foaming base material based on Example 1, and other components. It is typical sectional drawing of the attachment structure of the multilayer foaming base material based on Example 1, and other components. It is a bottom view of the attachment structure of the multilayer foam base material and other components which concern on Example 1. FIG. It is typical sectional drawing of the type | mold used for manufacture of a multilayer foaming base material. It is explanatory drawing for demonstrating the manufacturing method of the multilayer foaming base material which concerns on Example 1. FIG. It is explanatory drawing for demonstrating the manufacturing method of the multilayer foaming base material which concerns on Example 1. FIG. It is a principal part enlarged view of FIG. It is explanatory drawing for demonstrating the manufacturing method of the multilayer foaming base material which concerns on Example 1. FIG. It is a principal part enlarged view of FIG. It is explanatory drawing for demonstrating the manufacturing method of the multilayer foaming base material which concerns on Example 1. FIG. It is a principal part enlarged view of FIG. It is explanatory drawing for demonstrating the manufacturing method of the multilayer foaming base material which concerns on Example 1. FIG. It is a principal part enlarged view of FIG. It is explanatory drawing for demonstrating the structure of a slide mechanism. It is explanatory drawing for demonstrating the state in which the slide member (AA 'cross section in FIG. 15) was stored in the 2nd type | mold. It is explanatory drawing for demonstrating the state which the slide member (AA 'cross section in FIG. 15) slid to the 1st type | mold direction. It is explanatory drawing for demonstrating the state in which the slide member (BB 'cross section in FIG. 15) was stored in the 2nd type | mold. It is explanatory drawing for demonstrating the state which the slide member (BB 'cross section in FIG. 15) slid to the 1st type | mold direction. It is typical sectional drawing of the attachment structure of the multilayer foaming base material and other components which concern on other embodiment. It is typical sectional drawing of the attachment structure of the multilayer foaming base material and other components which concern on other embodiment. It is a bottom view of the attachment structure of the multilayer foam base material and other components which concern on other embodiment. It is a perspective view of the attachment structure of the multilayer foam base material and other components which concern on Example 2. FIG. It is a bottom view of the attachment structure of the multilayer foam base material and other parts which concern on Example 2. FIG. It is XX sectional drawing of the attachment structure of FIG. It is a perspective view of the door trim upper obtained using the manufacturing method of a multilayer foaming base material.

  The items shown here are for illustrative purposes and exemplary embodiments of the present invention, and are the most effective and easy-to-understand explanations of the principles and conceptual features of the present invention. It is stated for the purpose of providing what seems to be. In this respect, it is not intended to illustrate the structural details of the present invention beyond what is necessary for a fundamental understanding of the present invention. It will be clear to those skilled in the art how it is actually implemented.

1. Multilayer foam base material Embodiment 1 The multilayer foam base material according to the present invention comprises a first skin layer, a resin foam layer and a second skin layer in this order, and the multilayer foam base material has an attachment portion for attaching other parts. In the attachment portion, the second skin layer is formed with a portion indented into the resin foam layer toward the first skin layer , and the surfaces of the indented portion of the second skin layer are combined and integrated. , characterized in that there is a first rib.
The use of the multi-layer foam base material is not particularly limited. For example, it is used for interior parts for vehicles such as door trims (door trim uppers shown in FIG. 26), instrument panels, roof trims, deck boards, package trays and the like. Can do.

As long as the “multilayer foamed base material” includes the first skin layer, the resin foam layer, and the second skin layer in this order, the structure, size, shape, material, and the like are not particularly limited.
Examples of the material of the “first skin layer” and the “second skin layer” include polypropylene (PP), polyethylene (PE), polyvinyl chloride (PVC), polystyrene (PS), polyvinyl acetate (PVAc), Mention may be made of thermoplastic synthetic resins such as polytetrafluoroethylene (PTFE), acrylonitrile butadiene styrene (ABS) and polyethylene terephthalate (PET).
As the material of the “resin foam layer”, for example, the same thermoplastic resin as that of the first skin layer and the second skin layer can be used. This resin foam layer is usually a foamed material obtained by adding a foaming agent to these thermoplastic resins. Furthermore, this resin foam layer can be expanded (expanded) by vacuuming from both sides.

The “attachment part” is a part for attaching other components to the multilayer foamed base material.
As long as this attachment part is provided with the 1st rib, the structure, a shape, etc. are not specifically limited. Specifically, for example, it can be provided with a mounting hole (15) (see, for example, FIG. 1). In addition, the attachment part may be formed only in one place, and may be formed in two or more places.

The “first rib” is formed by integrating the drawing-in portion of the second skin layer drawn into the resin foam layer in the attachment portion.
As long as this 1st rib is formed in the attaching part, the shape etc. are not specifically limited. Specific shapes include, for example, a ring or a circular arc (see the first rib (14) in FIG. 1), a curved shape, a U shape (see the first rib (14) in FIG. 22), and a linear shape (see FIG. 23). 1st rib (14)) etc. are mentioned. In addition, this 1st rib may be formed only in one place in the attachment part, and may be formed in two or more places.
Moreover, when the said attachment part is provided with the attachment hole, this 1st rib shall be formed so that an attachment hole may be enclosed. In this case, the rigidity of the attachment portion (particularly around the attachment hole) can be sufficiently improved.

In addition, the first embodiment. The multilayer foamed base material according to the present invention may include a second rib formed in the same manner as the first rib at a place other than the attachment portion. When the second rib is formed at a predetermined position (for example, a stepped portion) other than the attachment portion, the rigidity at the predetermined position can be improved.
The shape of the second rib is not particularly limited. Specific examples of the shape include a ring or arc shape, a curved shape, a U shape, and a linear shape (see the second rib (7) in FIG. 23). In addition, this 2nd rib may be formed only in one place in positions other than an attachment part, and may be formed in two or more places. Further, the second rib may be connected to the first rib.

The “other parts” are attached to the attachment portion of the multilayer foamed base material, and the structure, size, shape, material, and the like are not particularly limited. As a specific structure, for example, (A) it has a shaft portion (21) to be inserted into a mounting hole formed in the mounting portion, and the tip of the shaft portion is ultrasonic caulked or the like, so that the diameter of the shaft portion is larger. Also has a structure that becomes a wide head (22) (see, for example, FIGS. 2 and 3), (B) has a shaft portion (81) that is inserted into a mounting hole formed in the mounting portion, A structure having a structure fixed on the front end side of the shaft portion with a screw (83) or a countersunk screw through a washer (82) wider than the diameter of the shaft portion (for example, see FIG. 20), and (C) a clip portion By reducing the diameter of (91), one having a structure that can be inserted into an attachment hole formed in the attachment portion and can be locked to the attachment portion (for example, see FIG. 21) can be used.
Specific other parts include interior parts for vehicles such as door trim ornaments, door pockets, speaker grills, and armrests.

  Moreover, as said multilayer foaming base material, the said attachment part (15) is provided with the attachment hole (16), for example, The said other components (2) are the shafts inserted in an attachment hole (16). A head part (21) having a width wider than the diameter of the shaft part (21) is provided at the end of the shaft part (21), and the head part (22) of the attachment part (15) The form which the said 1st rib (14) is formed in the area | region to cover can be mentioned (for example, refer FIGS. 1-3). In this case, the rigidity of the attachment portion can be sufficiently improved, and other components can be attached through the attachment holes without using other reinforcing materials.

  Furthermore, as the multilayer foam base material, for example, a stepped portion bent at a plurality of locations when viewed from the side of the substrate is formed, and the stepped portion is drawn into the resin foam layer. The 2nd rib (7) formed by integrating the 2nd skin layer is provided, and the 2nd rib (7) mentions the form made into the form which cuts the ridgeline (6) of a stepped part vertically. (See, for example, FIG. 25). In this case, the rigidity of the attaching portion can be sufficiently improved, and the rigidity of the stepped portion can be sufficiently improved by the second rib.

In addition, the first embodiment. In the multilayer foam base material according to the present invention, the surface on the first skin layer side can be a design surface. In this case, since the 2nd skin layer side in which a 1st rib and a 2nd rib are formed turns into a back surface side, the appearance of the multilayer foamed base material obtained can be improved more.
In addition, when the surface on the first skin layer side is a design surface, a rib (third rib) in which the first skin layer is drawn into the resin foam layer is further formed in the region covered with the other parts in the attachment portion. May be. In this case, since the 3rd rib formed in the 1st skin layer side (design surface side) is covered with other parts, appearance does not fall.

  Moreover, the method for producing the multilayer foamed substrate is not particularly limited. For example, the multilayer foamed substrate can be obtained by the method for producing a multilayer foamed substrate of the present invention described later.

2. Manufacturing method of multilayer foam base material Embodiment 2 The manufacturing method of the multilayer foam base material according to the first embodiment is the same as that of the first embodiment. A method for producing a multilayer foamed base material, wherein a base material provided with a first skin layer, a resin foam layer and a second skin layer in this order is set in a first mold (for example, see FIG. 6); In the state where the base material is evacuated from the first skin layer side, when the resin foam layer is expanded in the thickness direction, the second skin layer in the attachment portion is embedded in the resin foam layer (for example, FIG. 7). To a rib forming step (for example, see FIG. 11 to FIG. 14) for forming the first rib by heating and melting and integrating the surfaces of the second skin layer embedded in the resin foam layer. ).

Embodiment 2 above. The mold used in the method for producing a multilayer foamed substrate according to the present invention has a structure and size as long as the resin foam layer of the substrate can be thickened by vacuuming and the first rib can be formed. The shape, material, etc. are not particularly limited.
Specifically, for example, as shown in FIG. 5, a first mold 3A that shapes the first skin layer, and a second mold 3B that pairs with the first mold 3A and shapes the second skin layer, It is possible to use a double-sided vacuum forming die in which a slide mechanism 4 provided with a slide member 41 for forming a first rib is provided on the second die 3B.

  In the “setting step”, the base material is set in the first mold. Specifically, for example, the second skin layer in the base material is set so as to be on the second mold side including a slide mechanism for forming the first rib.

As long as the “base material” includes the first skin layer, the resin foam layer, and the second skin layer in this order, the structure, size, shape, material, and the like are not particularly limited. As this base material, for example, it can be in the form of a sheet formed by laminating the above layers. In this base material, another layer may be interposed between one or both of the first skin layer and the resin foam layer and between the resin foam layer and the second skin layer.
Moreover, the multilayer foaming base material which consists of this base material can make the surface by the side of a 1st skin layer into a design surface. In this case, since the 2nd skin layer side in which a 1st rib is formed becomes a back surface side, the appearance of the obtained multilayer foaming base material can be improved more.

Examples of the material of the “first skin layer” and the “second skin layer” include polypropylene (PP), polyethylene (PE), polyvinyl chloride (PVC), polystyrene (PS), polyvinyl acetate (PVAc), Mention may be made of thermoplastic synthetic resins such as polytetrafluoroethylene (PTFE), acrylonitrile butadiene styrene (ABS) and polyethylene terephthalate (PET). The first skin layer and the second skin layer are usually in the form of a sheet made of these thermoplastic resins.
As the material of the “resin foam layer”, for example, the same thermoplastic resin as that of the first skin layer and the second skin layer can be used. This resin foam layer is usually in the form of a sheet that is foamed by adding a foaming agent to these thermoplastic resins.

In the “second skin layer drawing step”, the second skin layer in the attachment portion is drawn into the resin foam layer in a state where the base set in the mold is evacuated from the first skin layer side. In addition, in a mounting part, the location which draws in a 2nd skin layer in a resin foam layer may be only one location, and may be two or more locations.
In this step, the means for drawing the second skin layer into the resin foam layer is not particularly limited. Specifically, for example, the slide member in the slide mechanism disposed in the second mold for shaping the second skin layer is paired with the first mold for shaping the first skin layer and moved toward the base material. Let Next, vacuuming is also performed from the second skin layer side to increase the thickness of the resin foam layer, and the second skin layer can be drawn into the resin foam layer due to the presence of the slide member (see FIGS. 7 to 10). ).
At this time, evacuation from the first skin layer side may be performed before or after the slide member is moved. Further, the evacuation from the second skin layer side does not necessarily need to be started after the slide member is moved, and may be started simultaneously with the movement of the slide member. In addition, the conditions of each vacuuming in this case are not specifically limited. Moreover, the moving amount | distance of a slide member is not specifically limited, It adjusts suitably according to the thickness (especially thickness of a resin foam layer) of a base material.

  In this step, it is preferable that the slide member disposed in the second mold is pressed against the second skin layer in the attachment portion. In this case, the second skin layer can be reliably pulled.

In the “rib forming step”, the first skin is formed by heating and melting the second skin layer drawn into the resin foam layer.
At this time, the means for heating the second skin layer is not particularly limited. Specifically, for example, in a state where both surfaces of the base material are evacuated, the second skin layer is melted by heating with a slide member in a slide mechanism disposed in the second mold, and the melted portion is integrated. By doing so, the first rib can be formed. In addition, the heating conditions (heating time, heating temperature, etc.) and vacuuming conditions in this case are not particularly limited.
In addition, the configuration of the slide mechanism disposed in the second mold is not particularly limited, but may include a slide member capable of generating heat (for example, see the slide core 41 in FIG. 15) on the distal end side. This slide member is made of a material such as carbon steel, alloy steel, aluminum, nickel, etc., and may generate heat by a heating means such as a coil heater disposed therein, or an iron-chromium-aluminum alloy, nickel -It may be made of a material such as a chromium alloy and generate heat when directly energized.

Further, when producing a multilayer foamed substrate having the second rib, the second rib is formed by using a mold in which a slide mechanism for forming the second rib is disposed in at least one of a pair of molds. can do. In particular, it is preferable to use a mold in which a slide mechanism for forming the second rib is provided for the second mold for shaping the second skin layer.
Furthermore, by changing the shape of the slide member for forming the first rib to a predetermined shape, the second rib can be formed together with the first rib using the same slide mechanism.

  Hereinafter, the present invention will be specifically described with reference to the drawings.

<Example 1>
[1-1] Multilayer Foamed Substrate As shown in FIG. 1, the multilayer foamed substrate 1 according to Example 1 includes a first skin layer 11, a resin foam layer 12, and a second skin layer 13 in this order. Thus, an attachment portion 15 for attaching other components is formed.
The attachment portion 15 is formed with a drawing portion in which the second skin layer 13 is drawn into the resin foam layer 12, and the second skin layer 13 of the drawing portion is integrated into a first rib 14. Further, a mounting hole 16 is formed in the mounting portion 15.
In the multilayer foamed substrate 1, the first skin layer 11 side is the design surface side, and the second skin layer 13 side on which the first ribs 14 are formed is the back surface side.

[1-2] Attaching Other Parts to Multilayer Foamed Substrate As shown in FIGS. 3 and 4, the other part 2 is attached to the attachment portion 15 (see FIG. 1) of the multilayer foamed base material 1 according to the first embodiment. Is attached.
The other component 2 has a shaft portion 21 that is inserted into a mounting hole 16 (see FIG. 1) formed in the mounting portion 15 of the multilayer foamed base material 1, and the end of the shaft portion 21 has a diameter from the shaft portion 21. A wide head 22 is also provided.
And as shown in FIG. 4, the 1st rib 14 in the multilayer foaming base material 1 surrounds the attachment hole 16 (refer FIG. 1) in the area | region which the head part 22 of the other components 2 covers among the attachment parts 15. As shown in FIG. It is formed in an arc shape.
In addition, as shown in FIG. 2, the head portion 22 wider than the diameter of the shaft portion 21 in the other component 2 is inserted into the mounting hole 16 of the multilayer foam base 1, and then the tip of the shaft portion 21 is inserted. Is formed by applying ultrasonic caulking.

[1-3] Manufacturing Method of Multilayer Foamed Base Material A manufacturing method of the multilayer foamed base material 1 according to the first embodiment will be described with reference to FIGS.
(1) Mold Configuration The configuration of the double-sided vacuum mold used in the production of the multilayer foamed substrate of Example 1 is shown below.
As shown in FIG. 5, the mold 3 is paired with a first mold (design surface side mold) 3A for shaping the first skin layer of the substrate to be used, and the first mold 3A. A second mold (back-side mold) 3B for shaping the two-skin layer and a vacuuming means (not shown) that can be evacuated from both sides are provided.
The first mold 3A is configured to be evacuated from the first mold 3A side, and includes a plurality of vacuum holes (not shown).
The second mold 3 </ b> B includes mold members 32 and 34, and a slide mechanism 4 including a slide core (slide member) 41 is attached to the mold member 34.
The second mold 3B is configured to be evacuated from the second mold 3B side, and a plurality of vacuum holes 33 are formed in the mold member 32. Further, even in the hole for the slide core 41, vacuuming can be performed from the gap between the mold member 32 and the slide core 41.
As shown in FIGS. 5, 8, and 15, the slide mechanism 4 is disposed at a predetermined position of the attachment body 34 via a connection portion 44 so that no vacuum leakage occurs during evacuation. A cylinder 43 fixed to the connecting portion 44; a substantially annular slide core 41 disposed at the tip of the cylinder 43 and configured to be slidable in the direction of the arrow; and an electric wire 45 disposed in the cylinder 43. Prepare.
In addition, a coil heater 42 is disposed inside the slide core 41 so that heat can be generated.
The state in which the slide core 41 (see FIG. 15) is housed in the second mold 3B is shown in FIG. 16 (slide core 41; AA ′ cut surface in FIG. 15) and FIG. 18 (slide core 41; B in FIG. 15). -B 'cut surface), and the state in which the slide core 41 slides toward the first mold 3A side is shown in FIG. 17 (slide core 41; AA' cut surface in FIG. 15) and FIG. 19 (slide core 41; FIG. 15). BB 'cut surface).

(2) Setting process and evacuation from the first skin layer side First, the base material 10 (see FIG. 6) including the first skin layer 11, the resin foam layer 12, and the second skin layer 13 in this order is used as the first skin layer. The mold 11 is set so that the 11 side becomes the first mold 3A side, and the mold is clamped so that the end portion is crushed.
In addition, in the base material 10, the 1st skin layer 11 side is a design surface side. Further, at the time of mold clamping, both ends of the base material 10 are sandwiched by support portions (not shown) outside the mold 3.
Next, as shown in FIG. 6, the substrate 10 set in the mold 3 is evacuated from the first skin layer 11 side (that is, the first mold 3 </ b> A side) that is the design surface side.

(3) Second skin layer drawing step After that, in a state where the vacuum drawing from the first skin layer 11 side is continued, as shown in FIGS. 7 and 8, in the slide mechanism 4 disposed in the second mold 3B. The substantially annular slide core 41 is slid from the storage position and pressed against the second skin layer 13 of the attachment portion 15 in the base material 10.
Next, as shown in FIG. 9 and FIG. 10, while evacuating from the first skin layer 11 side, evacuation is performed from the second skin layer 13 side (that is, the second mold 3B side), and the resin The foam layer 12 is thickened so that the second skin layer 13 in the attachment portion 15 is drawn into the resin foam layer 12.
Thereafter, the slide core 41 is heated.

(4) Rib Formation Step Next, the second skin layer 13 drawn into the resin foam layer 12 in the above step is heated to the melting temperature of the resin constituting the second skin layer 13 by the slide core 41 and melted.
Thereafter, in a state where evacuation from both sides of the first mold 3A and the second mold 3B is continued, the slide core 41 is returned to the initial storage position as shown in FIGS. 11 and 12, and FIGS. As shown in FIG. 2, the first rib 14 is formed by integrating the melted portions of the second skin layer 13.
Thus, the attachment part 15 for attaching the other components 2 is formed in the multilayer foam base material provided with the 1st skin layer 11, the resin foam layer 12, and the 2nd skin layer 13 in order. And in this attachment part 15, after the 2nd skin layer 13 was drawn in by the resin foam layer 12, the 2nd skin layer 13 of this drawing-in part was integrated, and the thickness direction of the base material 10 was formed. A first rib 14 extending in the direction is formed. In addition, after demolding, the attachment holes 16 are formed so as to be surrounded by the first ribs 14 in the attachment portion 15 of the multilayer foam base material 1 as necessary.

[1-4] Effects of Example 1 In the multilayer foamed base material 1 according to Example 1, the second skin layer 13 of the drawn-in portion drawn into the resin foam layer 12 is integrally formed in the attachment portion 15. Since the 1st rib 14 extended in the thickness direction of the base material 10 is provided, it has sufficient rigidity in an attachment part. In particular, when the other component 2 is attached, the first rib 14 is formed so as to surround the attachment hole 16 (see FIG. 1) in the region covered by the head 22 of the other component 2 in the attachment portion 15. For this reason, the rigidity of the mounting portion (particularly around the mounting hole) can be reliably improved. Therefore, other parts can be attached to the attachment portion 15 of the multilayer foam base material 1 without using other reinforcing materials.
Moreover, this multilayer foamed base material 1 is very attractive because the first skin layer 11 side is the design surface side and the second skin layer 13 side on which the first ribs 14 are formed is the back surface side. It is excellent.

<Example 2>
[2-1] Multilayer foam base material and attachment structure of this multilayer foam base material and other parts As shown in FIGS. 23 to 25, the multilayer foam base material 1 according to the second embodiment is a first skin. The layer 11, the resin foam layer 12, and the second skin layer 13 are provided in this order, and an attachment portion (not shown) for attaching other components through the attachment holes is formed.
The attachment portion is formed with a drawing portion in which the second skin layer 13 is drawn into the resin foam layer 12, and the first skin layer 13 of the drawing portion is integrated and extends in the thickness direction of the substrate 10. Ribs 14 are provided.
Further, the multi-layer foam base material 1 is formed with a stepped portion bent at a plurality of locations when viewed from the side surface, and the second skin layer drawn into the resin foam layer 12 is formed on the stepped portion. The 2nd rib 7 extended in the thickness direction of the base material 10 in which 13 was formed integrally is provided. And this 2nd rib 7 is made into the form which cuts the ridgeline 6 of a step-shaped part longitudinally.
Further, in the same manner as in the first embodiment, another part 2 having a shaft portion 21 and a head portion 22 wider than the diameter is attached to the attachment portion of the multilayer foamed substrate 1 according to the second embodiment.
And the 1st rib 14 in the multilayer foaming base material 1 is formed in the linear form in the area | region which the head part 22 of the other components 2 covers among attachment parts.
In addition, the 1st rib 14 and the 2nd rib 7 are provided in a row. Moreover, in this multilayer foamed base material 1, the 1st skin layer 11 side is a design surface side, and the 2nd skin layer 13 side in which the 1st rib 14 was formed is a back surface side (refer FIG. 23). .

[2-2] Effects of Example 2 In the multilayer foamed base material 1 according to Example 2, the second skin layer 13 of the drawing-in portion drawn into the resin foam layer 12 is integrally formed at the attachment portion. Since one rib 14 is provided, the mounting portion has sufficient rigidity. In particular, when the other component 2 is attached, the first rib 14 is formed in the region covered by the head 22 of the other component 2 in the attachment portion, so that the rigidity of the attachment portion can be reliably improved. it can. Therefore, other parts can be attached to the attachment portion of the multilayer foam base material 1 without using other reinforcing materials.
Furthermore, since the second rib 7 having a shape that vertically cuts the ridge line 6 is provided in the stepped portion, the rigidity of the stepped portion can be sufficiently improved. Since the first skin layer 11 side is the design surface side, and the second skin layer 13 side where the first ribs 14 and the second ribs 7 are formed is the back surface side, it is very excellent in appearance. ing.

  Moreover, according to the manufacturing method of the multilayer foam base material which concerns on a present Example, as shown in FIG. 26, the attachment part 15 for attaching other components is formed, In this attachment part 15, it is a resin foam layer. Door trim upper 100 made of a multi-layer foam base material including first ribs 14 formed by integrating the drawn-in portions, and second ribs 7 formed in the same manner as first ribs 14 in the stepped portion. Such vehicle interior parts can be easily manufactured. The door trim upper 100 includes the first rib 14 formed integrally with the second skin layer drawn into the resin foam layer in the attachment portion 15, and thus has excellent rigidity. Therefore, when attaching other parts, it is not necessary to use other reinforcing parts. Furthermore, in this door trim upper 100, since the second rib 7 connected to the first rib 14 is formed in the stepped portion, the rigidity in the stepped portion is also excellent.

In the present invention, the present invention is not limited to the above embodiment, and various modifications can be made within the scope of the present invention depending on the purpose and application.
That is, in the first embodiment, the other component 2 is attached to the attachment portion 15 by applying ultrasonic caulking to the tip of the shaft portion 21 of the other component 2, but as shown in FIG. The other component 8 can be attached to the tip of the shaft portion 81 of the component 8 by fixing it with a screw 83 via a washer 82 wider than the diameter of the shaft portion 81. Furthermore, as shown in FIG. 21, after the other part 9 having the clip part 91 capable of reducing the diameter is inserted into the attachment hole by reducing the diameter of the clip part 91, the second skin layer side of the attachment part It is possible to adopt a form in which the other component 9 is attached by being locked.
Moreover, in the said Example 1, although the 1st rib 14 was formed in circular arc shape, it may be formed in U shape as shown in FIG. 22, or as shown in FIG. It may be formed in a shape.
Furthermore, in the said Example 2, although the 1st rib 14 and the 2nd rib 7 were provided continuously, these may be formed independently, respectively.

  The foregoing examples are for illustrative purposes only and are not to be construed as limiting the invention. Although the invention has been described with reference to exemplary embodiments, it is to be understood that the language used in the description and illustration of the invention is illustrative and exemplary rather than limiting. As detailed herein, changes may be made in its form within the scope of the appended claims without departing from the scope or spirit of the invention. Although specific structures, materials and examples have been referred to in the detailed description of the invention herein, it is not intended to limit the invention to the disclosure herein, but rather, the invention is claimed. It covers all functionally equivalent structures, methods and uses within the scope of

  The present invention is not limited to the embodiments described in detail above, and various modifications or changes can be made within the scope of the claims of the present invention.

  The multilayer foamed base material and the method for producing the same according to the present invention are widely used as technologies related to the field of interior parts for vehicles such as trains, buses, trucks, railway vehicles such as trains and trains, construction vehicles, agricultural vehicles, and industrial vehicles. Used.

  DESCRIPTION OF SYMBOLS 1; Multi-layer foam base material, 10; Base material, 100; Door trim upper, 11; First skin layer, 12; Resin foam layer, 13; Second skin layer, 14; First rib, 15; Mounting hole, 2; Other parts, 21; Shaft, 22; Head, 3; Mold, 3A; First mold, 3B; Second mold, 32; Mold member, 33; Slide mechanism, 41; Slide member (slide core), 42; Coil heater, 43; Cylinder, 44; Connection part, 45; Electric wire, 6; Ridge line, 7: Second rib, 8; Part, 82; washer, 83; screw, 9; other parts, 91; head.

Claims (5)

A multi-layer foam base comprising a first skin layer, a resin foam layer and a second skin layer in order;
In the multilayer foam base material, an attachment part for attaching other parts is formed,
In the attachment portion, the second skin layer is formed with a portion indented into the resin foam layer toward the first skin layer side ,
The multi-layer foamed base material, wherein the surfaces of the second skin layer in the recessed portion are joined and integrated to form a first rib. The mounting portion is provided with a mounting hole,
The other component has a shaft portion inserted into the mounting hole,
The end of the shaft part is provided with a head wider than the diameter of the shaft part,
The multilayer foamed base material according to claim 1, wherein the first rib is formed in a region of the attachment portion that is covered by the head portion.   The multilayer foamed substrate according to claim 2, wherein the first rib is formed so as to surround the attachment hole. The multilayer foam base material is formed with stepped portions bent at a plurality of locations when viewed from the side surface,
Wherein the stepped portion is provided with a second rib,
The second rib is configured to vertically cut the ridge line of the stepped portion ,
The second rib is formed by a portion in which the second skin layer is recessed into the resin foam layer toward the first skin layer side,
The multilayer foamed substrate according to any one of claims 1 to 3, wherein the surfaces of the second skin layer in the recessed portion are combined and integrated . A method for producing a multilayer foamed substrate according to any one of claims 1 to 4,
A setting step of setting the base material provided with the first skin layer, the resin foam layer, and the second skin layer in this order in a first mold;
When the resin foam layer is expanded in the thickness direction in a state where the base is evacuated from the first skin layer side , the second skin layer in the attachment portion is embedded in the resin foam layer . Process,
Heating the surfaces on each of said second skin layer in which sink into the resin foam layer integrally melted, the multilayer foam substrate, characterized in that it comprises a rib formation step of forming a first rib, a Manufacturing method.

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