JP5508996B2 - Foam molding - Google Patents

Description

  The present invention relates to a foamed molded article formed by heating foamable resin particles filled in a foam molding die.

  The foam molded body is obtained by pre-foaming resin particles, filling the obtained foamable resin particles into a foam molding die, heating with steam to foam again, cooling with cooling water, etc. In general, it is manufactured by a so-called in-mold molding method such as releasing from a mold (see, for example, Patent Document 1).

JP-A-11-343360 (see paragraph 0003)

  By the way, in recent years, in a vehicle or the like, a foamed molded article having a light weight and good moldability manufactured as described above is often used as an interior material.

  And, on the indoor floor of the vehicle, a tibia pad (interior material) made of a foamed molded body is interposed between the floor panel and the floor carpet for the purpose of improving cushioning against the occupant's feet and improving the ride comfort. There is. Many of these tibia pads have a flat plate shape having a flat surface. Therefore, depending on the movement of the occupant's feet placed on the floor carpet, a sliding force is applied to the lower tibia pad from the upper floor carpet (others), making it easy for the floor carpet to move on the flat surface of the tibia pad. The floor carpet may be displaced with respect to the tibia pad. For this reason, it is necessary to fix the floor carpet to the tibia pad using a double-sided tape or the like, which takes time and there is room for improvement.

  In view of the above-described situation, the present invention intends to solve the problem by providing a foamed molded article that can effectively prevent displacement even when a force in a sliding direction is applied. To do.

The foamed molded product of the present invention is a foamed molded product formed by heating foamable resin particles filled in a foam molding die to solve the above-mentioned problems, and a plurality of the molded molded products aligned in one direction. And a plurality of second ridges arranged in the other direction and arranged so as to cross the first ridges on the surface, the first ridges and the second ridges. Is characterized in that it is a short ridge having a tapered cross section at the tip side and a height of 1 mm or less so that at least the tip side has flexibility .

  According to the above-described configuration, for example, when another object is placed on the upper side of the foam molded body and the other object receives a moving force that moves in a sliding direction due to an external force, the forces are aligned in one direction. The first ridge and the plurality of second ridges crossing this and aligned in the other direction are supported so that the first and second ridges do not fall down and have the same moving force. It is possible to maintain a state that is stably received in a posture. Therefore, when the first protrusion and the second protrusion of the foam molded article are appropriately brought into contact with another object and exert an anchor effect, the other object can be made difficult to slide against the foam molded article. However, it becomes difficult to position-shift with respect to a foaming molding. Even if the other object is not only a soft material such as a sheet (or mat) but also a metal material such as a sheet metal, the first protrusion of the foam-molded product is not provided if the surface is not completely smooth. And the 2nd protrusion can contact the surface of a sheet metal appropriately, and can exhibit an anchor effect.

  As described above, according to the present invention, when a force in the sliding direction is applied, a plurality of first protrusions aligned in one direction and a plurality of second protrusions aligned in the other direction intersecting with the force. By supporting with the ridge, the first ridge and the second ridge do not fall down, and the moving force can be stably received in the same posture. Alternatively, it is possible to effectively prevent the foam molded body from being displaced with respect to other objects.

It is a perspective view of the state just before closing the lid | cover of the tool box (foaming molding of 1st embodiment) with which the vehicle was mounted | worn. It is an enlarged view of the upper surface of the flange part of the tool box, (a) is a perspective view, (b) is a plan view, and (c) is a longitudinal sectional view. FIG. 2 is a foam molding die for molding a foam molded body, wherein (a) is a longitudinal sectional view and (b) is a bottom view. It is a longitudinal cross-sectional view of the vehicle lower part which interposed the tibia pad (foaming molding of 2nd embodiment). (A), (b), (c) is a longitudinal cross-sectional view of the foaming molding of other embodiment. (A), (b), (c) is a longitudinal cross-sectional view of the mold for foam molding for shape | molding the foaming molding of FIG. 5, respectively. It is a bottom view of the metal mold | die for foam molding of other embodiment which changed the position of the through-hole.

  Hereinafter, an embodiment of a foamed molded product according to the present invention will be described with reference to the drawings.

  The foam-molded article is molded by filling foam-molding molds with foamed resin particles pre-foamed in advance and heating. The expansion ratio can be appropriately changed according to the purpose of use. As an example of the molded foam molded body, FIG. 1 shows a tool box 1 mounted on a vehicle. The tool box 1 includes a rectangular box body 5 having three storage portions 2, 3, and 4, and an annular flange portion 6 provided at the upper end of the box body 5. It is placed and supported on the upper surface 9A of a U-shaped metal frame member 9 provided on the side. The tool box 1 includes a plate-like lid 7 for covering the upper surface of the box body 5, and a plate-like annular contact member that contacts the upper surface of the box body 5 at the outer peripheral edge of the lid 7. 7A is provided.

  Moreover, although a foaming molding can be made with arbitrary foaming resin materials, it is preferable that it is a foaming molding shape | molded with the thermoplastic resin among foaming resin materials. Examples of the thermoplastic resin include polystyrene resins, polyolefin resins (eg, polypropylene resins, polyethylene resins), polyester resins (eg, polyethylene terephthalate, polybutylene terephthalate, polyethylene naphthalate), polycarbonate resins, and polylactic acid resins. Resin etc. are mentioned. Among these, it is preferable to use a composite resin containing polystyrene and polyethylene.

  As shown in FIGS. 1 and 2A, 2B, and 2C, the upper surface 8A of the outer periphery (rectangular shape) of the horizontal upper surface of the tool box 1 is more than the upper surface 8A. A number of first protrusions 8T1 that protrude upward and extend in a straight line in the left-right direction, protrude above the upper surface 8A so as to be the same height as the first protrusion 8T1, and are orthogonal to the first protrusion 8T1. Thus, a large number of second protrusions 8T2 extending in a straight line in the front-rear direction are formed. A large number of first protrusions 8T1 are aligned at a constant interval P1 in the front-rear direction, and a large number of second protrusions 8T2 are disposed at a constant interval P2 in the left-right direction (P1 = P2 in the present embodiment). Are aligned. In addition, the cross sections of the first protrusion 8T1 and the second protrusion 8T2 have a tapered shape on the tip side, specifically, an approximately triangular shape (configured by an acute outline) having an acute outline.

  Therefore, when the lid 7 is closed, the abutting member 7A of the lid 7 is pressed against the upper surface 8A of the tool box 1 by the weight of the lid 7, but the abutting member 7A is connected to the first protrusion 8T1 and the first ridge 8T1. The two ridges 8T2 can be supported stably. In addition, since the first protrusion 8T1 and the second protrusion 8T2 have a triangular cross section, the contact area between the first protrusion 8T1 and the second protrusion 8T2 and the contact member 7A is reduced, and The first protrusion 8T1 and the second protrusion 8T2 can be appropriately brought into contact with the contact member 7A. As a result, an anchor effect is generated, the upper lid 7 is difficult to move with respect to the tool box 1, and it is possible to prevent the contact member 7A and the tool box 1 from rubbing and generating abnormal noise. It has become.

  In general, it is considered that an abnormal sound (sounding mechanism) is generated due to a stick-slip phenomenon. This stick-slip phenomenon occurs when two objects move relative to each other while being in contact with a load, and sticking and slipping occur alternately on the surfaces of these objects. This is a phenomenon in which relative movement is hindered, and this causes vibration (frictional vibration) in the object, resulting in a sounding sound. That is, it is considered that a sound is generated by repeatedly performing small movements such that an object on one side slips and adheres to an object on the other (partner) side and attaches and slides. For such a phenomenon, the first protrusion 8T1 and the second protrusion 8T2 are very effective. Since such a phenomenon can be avoided, it is possible to prevent the other object from being displaced relative to one object.

  In particular, by providing a large number of second protrusions 8T2 so as to be orthogonal to the large number of first protrusions 8T1, as described above, an annular (rectangular) frame portion surrounded by four sides is continuous in the front-rear and left-right directions. By being formed in the state, the shape retention strength of the first protrusion 8T1 and the second protrusion 8T2 can be increased, which is effective in preventing abnormal noise and preventing displacement.

  Here, the ratio of the area of the ridge forming area where the first ridge 8T1 and the second ridge 8T2 are formed to the total area of the outer peripheral edge of the upper surface 8A of the tool box 1 (the ridge forming area occupying per unit area) ) Is 80% or less, more preferably 50% or less, the effect of preventing abnormal noise is even higher, and the effect of preventing misalignment is also high.

  Further, if the first protrusion 8T1 and the second protrusion 8T2 are also provided on the lower surface 6A of the flange portion 6, the tool box 1 vibrates with respect to the metal frame member 9 while the vehicle is running, for example. Therefore, it is possible to prevent the lower surface 6A of the flange portion 6 and the upper surface 9A of the frame member 9 from rubbing and generating abnormal noise. Further, if the first protrusion 8T1 and the second protrusion 8T2 are also provided on the lower surface 5A of the box body 5 that contacts the vehicle body constituting member 10 shown by a two-dot chain line in FIG. The tool box 1 can be prevented from moving with respect to the component member 10 due to vibration or the like, and the lower surface 5A of the box body 5 and the vehicle body component member 10 can be prevented from being rubbed and generating abnormal noise. .

  In addition, since the height of the 1st protrusion 8T1 and the 2nd protrusion 8T2 is a short protrusion which is 1 mm or less, in FIG. 1, the 1st protrusion 8T1 and the 2nd protrusion 8T2 are shown with the line. However, in order to clarify the shapes of the first protrusions 8T1 and the second protrusions 8T2, they are shown in enlarged views in FIGS. 2 (a), (b), and (c).

  By the way, a tortoiseshell pattern may be generated on the surface of the tool box 1 formed by heating the filled expandable resin particles due to variations in the particle diameter of the expanded particles or the expanded density. Even when the turtle shell pattern is generated in this way, as described above, the first protrusion 8T1 and the second protrusion 8T2 formed on the upper surface of the tool box 1 can be made inconspicuous and have excellent design properties. The tool box 1 can be obtained, and the commercial value can be increased. Further, even if the tool box 1 (foamed molded body) is scratched, the first protrusion 8T1 and the second protrusion 8T2 can cancel the scratch and make the scratch inconspicuous. This is an effect produced by the strip 8T1 and the second projection 8T2. For the purpose of these effects, the first ridge 8T1 and the second ridge 8T2 are formed in other portions of the tool box 1 that are not provided with the first ridge 8T1 and the second ridge 8T2. Also good.

  FIGS. 3A and 3B show a foam molding die 11 (hereinafter simply referred to as “mold”) for molding a foam molded body. The mold 11 includes a pair of molds 12 and 13 divided into left and right, and a mold 12A constituting the left mold 12 and a mold 13A constituting the right mold 13 are opposed to each other. By forming them together on the front side, a molding space filled with the expandable resin particles S is formed. The mold 11 shown in FIG. 3A is a horizontal mold that opens and closes a pair of molds 12 and 13 in the left-right direction (horizontal direction), but a vertical mold that opens and closes in the vertical direction. It may be. In FIG. 3A, the right mold 13A is plate-shaped, but a molding space is formed by the same box-shaped mold as the left mold 12A. The protrusions 8T1 and 8T2 described later may be formed.

  The left mold 12 includes the box-shaped mold 12A having an opening on the right side, and a back plate 12B for covering the back side of the mold 12A to form a heating / cooling chamber 12a. The right mold 13 includes a plate-shaped mold 13A and a back plate 13B for covering the back side of the mold 13A to form a heating / cooling chamber 13a.

  On the upper plate portion 12b of the back plate 12B of the left mold 12, the steam supply pipe 21, the cooling water supply pipe 22 and one end (lower end) of the compressed air supply pipe 23 communicating with the heating / cooling chamber 12a are spaced apart from each other by a predetermined interval. It is fixed through. In the middle of the steam supply pipe 21, the cooling water supply pipe 22, and the compressed air supply pipe 23, open / close valves 21V, 22V, and 23V are provided. The cooling water supply pipe 22 extends from the upper plate portion 12b to the vicinity of a lower plate portion 12c described later, and an opening 22a for supplying cooling water is formed at a predetermined interval in the extending direction of the extending portion 22A. ing. Although not shown, the right mold 13 is also provided with a steam supply pipe 21, a cooling water supply pipe 22, a compressed air supply pipe 23, and open / close valves 21V, 22V, and 23V.

  Further, one end (upper end) of a vacuum supply pipe 25 connected to a drain pipe 24 and a vacuum device is fixed to the lower plate portion 12c of the back plate 12B of the left mold 12 through a predetermined interval. On the way of the drain pipe 24 and the vacuum supply pipe 25, open / close valves 24V and 25V are provided. Although not shown, the right mold 13 is also provided with a drain pipe 24, a vacuum supply pipe 25, and open / close valves 24V, 25V.

  The left mold 12A will be described in detail. A plurality of first grooves M1 extending continuously in one direction at a predetermined portion (target area) of the molding surface 12K of the mold 12A are identical to the first grooves M1. A plurality of second groove portions M2 extending continuously in the other direction so as to be orthogonal to the first groove portion M1 having a depth (height) are formed.

  The multiple first groove portions M1 are aligned at a constant interval P1 in the front-rear direction, and the multiple second groove portions M2 are aligned at a constant interval P2 in the vertical direction (P1 = P2 in this embodiment). Are aligned (see FIGS. 1A and 1B). Needless to say, the intervals between the multiple first groove portions M1 and the second groove portions M2 are determined so as to improve the cooling efficiency, and the intervals between all the groove portions may not be constant. Further, in the present embodiment, the first groove portion M1 and the second groove portion M2 are orthogonal to each other, but the groove portion may be run in different directions in order to improve the cooling efficiency and the like. Depending on the shape and the like, it may be crossed obliquely instead of orthogonally.

  Here, although the target area is defined only for the molding surface 12K of the molding die 12A in FIG. 1, for example, not only the wall surface (molding surface 12K) facing the right mold, but also the molding shown in FIG. The upper and lower wall surfaces opposed in the vertical direction of the mold 12A and / or the front and rear wall surfaces opposed in the front-rear direction may be determined as the target area. In order to improve the cooling efficiency and the like, it is preferable that the first groove portion and the second groove portion are formed over the entire wall surface so as to connect the end portions of the wall surface. Further, the end portions of the first groove portion and the second groove portion of the one wall surface described above may be continuous with the end portions of the first groove portion and the second groove portion of the other wall surface, or may not be continuous. . The foamed resin particles S are filled in the molds 12A and 13A thus configured, and the foamed resin particles S are heated to form a foamed molded product. A large number of first protrusions 8T1 and second protrusions 8T2 (see FIGS. 3A, 3B, and 3C), which will be described later, protrude from the surface.

  Further, the steam or cooling water (or cooling air) introduced into the heating / cooling chamber 12a through the steam supply pipe 21, the cooling water supply pipe 22, the compressed air supply pipe 23, and the drain pipe 24 is formed into a molding space (cavity). A first through hole 12K1 for supplying to the mold 12A is formed on the bottom surface of the first groove portion M1 of the mold 12A, and similarly, a second through hole 12K2 is formed on the bottom surface of the second groove portion M2 of the mold 12A. The first through holes 12K1 are provided in the respective first groove portions M1, so that the first through holes 12K1 are formed at a constant interval P1 in the front-rear direction, like the first groove portions M1, while the second through holes 12K2 are formed in the respective second groove portions. By being provided in M2, it is formed at a constant interval P2 in the vertical direction, like the second groove portion M2. In addition, the shape of the through holes 12K1 and 12K2 may be an ellipse, a quadrangle, or the like in addition to a circle, or a vertically long slit. In the present embodiment, only one through hole 12K1 and 12K2 is provided for each of the grooves M1 and M2. However, two or more through holes 12K1 and 12K2 may be provided. Further, in addition to being provided in each first groove portion M1, one or more first through holes 12K1 are provided in every other first groove portion M1, or one or more in every second first groove portion M1. Alternatively, one or more specific first grooves M1 selected at random may be provided. Similarly, in the second through holes 12K2, one or more second through holes 12K2 are provided in every other second groove part M2, or one or more second through holes are provided in every other second groove part M2. The hole 12K2 may be provided, or one or more second through holes 12K2 may be provided in a specific second groove M2 selected at random. Of course, you may provide in the crossing position of the 1st groove part M1 and the 2nd groove part M2. Here, the diameter of the through-hole 12K1 or 12K2 may be larger than the width of the groove part M1 or M2 and further the pitch of the groove part M1 or M2, and in this case, a part of the through-hole 12K1 or 12K2 is at least one groove part M1. Or it shall be provided in M2. The positions of the through holes 12K1 and 12K2 with respect to the groove portions M1 and M2 may be arranged with regularity at regular intervals P2 as described above, for example, or may be randomly arranged. Of course, at least through holes are regularly or randomly arranged in the mold 13A of the right mold 13.

  Here, when the depth of the first groove part M1 and the second groove part M2 is 1 mm or less, more preferably 0.3 mm or less, and / or the interval P1 between the first groove parts M1, M1 and the second groove parts M2, M2. When the distance P2 is 2 mm to 50 mm, the releasability is good, and more preferably 30 mm or less (excluding 0), the releasability is even better. The depths of the plurality of groove portions M1 and M2 and the widths of the groove portions M1 and M2 may all be the same, or may be all different or may be different only partially.

  In addition, as described above, since the depth of the first groove portion M1 and the second groove portion M2 is shallow, the mold 11 is not only increased in design freedom by being manufactured by etching, but also complicated. Although it is preferable that the molding surface of the shaped mold can be accurately formed, other production methods such as cutting may be used, and the production method of the mold is not particularly limited.

  Next, the mold 11 configured as described above (in the mold 11 shown in FIG. 3, the first groove portion M1, the second groove portion M2, the first through hole 12K1, and the second through hole 12K2 are described. The process of molding the foam molded body using a foam molded body described below will not be described. The left mold 12 will be mainly described.

  First, the foaming synthetic resin particles S are filled with a filling device (not shown) in the molding space formed by the molding dies 12A and 13A with the front surfaces of the molding dies 12A and 13A together. Next, by opening the left on-off valve 21V, steam is supplied from the left steam supply pipe 21 to the left heating / cooling chamber 12a. At this time, the drain pipe (not shown) of the right mold 13 is opened, and the steam supplied to the left heating / cooling chamber 12a heats the outer surface of the left mold 12A and the through hole of the mold 12A. 12K1 and 12K2 are supplied to the molding space, led to the outside of the molding die 13A through the through hole (not shown) of the right molding die 13A, and via the drain pipe (not shown) of the right molding die 13A. And discharged to the outside of the mold 13. The foamable synthetic resin particles S filled in the molding space are heated evenly by the first heating step. Next, the left open / close valve 21V is closed, the left drain pipe 24 is opened, the drain pipe (not shown) of the right mold 13 is closed, and the right open / close valve (not shown) is opened. The steam is supplied from the steam supply pipe (not shown) to the right heating / cooling chamber 13a. The supplied steam heats the outer surface of the right molding die 13A and is supplied to the molding space through a through hole (not shown) of the molding die 13A and is molded through the through holes 12K1 and 12K2 of the left molding die 12A. It is guided to the outside of the mold 12A and discharged to the outside of the mold 12 through the drain pipe 24 of the left mold 12. The foamable synthetic resin particles S filled in the molding space are heated evenly by the second heating step. After the heating, the right opening / closing valve (not shown) is closed and the left drain pipe 24 is closed, and then the third heating step is performed. In the third heating process, the drain pipes 24 of both molds 12, 13 (the drain pipe of the right mold 13 is not shown) are closed, and the open / close valves 21V of both molds 12, 13 are closed. (The open / close valve of the right mold 13 is not shown), and the expandable synthetic resin particles S filled in the molding space are heated again.

  When heating is completed, the open / close valves 22V (the right open / close valve is not shown) of both molds 12 and 13 are opened, and cooling water is sprayed onto the molds 12A and 13A from the opening 22a of the extension 22A. The molds 12A and 13A are then cooled. At this time, a part of the cooling water enters the inside of the molds 12A and 13A through the through holes 12K1 and 12K2, and promotes cooling. The foamed molded article starts to shrink when cooled. Thereby, a gap is formed between the foamed molded body and the molds 12A and 13A. Through this gap, the cooling water is easily transmitted through the groove, and the cooling efficiency is increased.

  When the cooling with the cooling water is finished, the open / close valve 23V (the right open / close valve is not shown) of both molds 12, 13 is opened, and the compressed air is heated from the compressed air supply pipe 23 to the heating / cooling chamber 12a. , 13a is supplied to the molds 12A, 13A through the through holes 12K1, 12K2, so that the cooling water accumulated in the mold 12A through the gap between the foam molded body and the molds 12A, 13A can be obtained. Guided to the through holes 12K1 and 12K2, discharged to the outside of the molds 12A and 13A through the through holes 12K1 and 12K2, and discharged cooling water to the outside of the left and right molds 12 and 13 through the left and right drain pipes 24, respectively. Discharge. The compressed air also serves to cool the mold 12A and the foamed molded body.

  Subsequently, the process proceeds to a vacuum cooling process, and the open / close valve 24V (the right open / close valve is not shown) of the drain pipe 24 of both molds 12, 13 is closed, and then the open / close valve 25V (the right open / close valve is not shown). And the residual moisture in the heating / cooling chambers 12a, 13a and the moisture contained in the molded foam molded body or contained therein by reducing the pressure in the heating / cooling chambers 12a, 13a with the vacuum supply pipe 25. Is evaporated and the latent heat of vaporization is used to promote cooling, and the decompression cooling process is completed. After that, the molds 12A and 13A are opened and the left and right on-off valves 23V (the right on-off valves are not shown) are opened, and the left and right compressed air supply pipes 23 (the right compressed air supply pipes are not shown). By supplying compressed air (air) for releasing from the heating and cooling chambers 12a and 13a, compressed air (in the right-hand through hole is not shown) and compressed air ( Air) is supplied, and the foamed molded product is taken out of the molds 12A and 13A to complete the operation. Of course, a mold may be provided with a release pin and used in combination with compressed air (air), or the foamed molded product may be taken out only with the release pin.

  As described above, according to the mold 11 of the present embodiment, one groove M1 is continuously formed in the target area of the molding surface of the mold 12A from one end to the other in the vertical direction, and the other The groove portion M2 is continuously formed in the target area of the mold 11 from one end to the other end in the front-rear direction, and the through holes 12K1 and 12K2 are steam or foam molding for heating the expandable resin particles. Since the cooling water (or cooling air) for cooling the foamed molded body immediately after being used is used as an inlet / outlet hole for supplying the inside of the mold, it is supplied through the first through hole 12K1 and the second through hole 12K2. The steam and the cooling water are easily spread to the target area of the molding surface through the continuously formed grooves M1 and M2, and the steam and the cooling water are uniformly supplied from any direction to improve the moldability and cooling efficiency. Be able to To have.

  In addition, the steam supplied to the inside of the mold is cooled in the cooling process to become water and collected in the mold. The accumulated water and cooling water are the first groove portion M1 and the second groove portion M2. It is possible to quickly and surely discharge out of the mold through the first through hole 12K1 and the second through hole 12K2 provided corresponding to the above. From this, it is possible to prevent water from collecting in the mold, and as a result, the filling of the expandable resin particles in the next foam molding process is not hindered by the water accumulated in the mold. Therefore, it is possible to improve the formability by reliably performing the filling operation. And since the problem of water collecting in the mold does not occur, a water cooling process using water-cooled water can be positively adopted. As a result, the cooling efficiency can be improved and the cycle can be increased by shortening the time. .

  Further, the first through hole 12K1 and the second through hole 12K2 are used to supply compressed air (air) for releasing the molded foam molded body from the mold 12A. Since the through holes 12K1 and 12K2 pass through M2, by directly supplying compressed air (air) to the grooves M1 and M2, the compressed air (air) is uniformly distributed to the target area of the molding surface through the grooves M1 and M2. Easy to communicate and can be released smoothly. Moreover, since the compressed air (air) is transmitted to the two grooves M1 and M2 in different directions, the compressed air (air) can be uniformly dispersed at the time of releasing the foamed molded product after foam molding. Can be performed more smoothly.

  The foam molded body foam-molded by the mold 11 having the above-described configuration may be the tibia pad 14 provided at the front seat foot of the vehicle shown in FIG. 4 (or a floor spacer provided at the rear seat foot of the vehicle). May be). The tibia pad 14 is disposed between the floor panel 15 and a floor carpet 16 as an interior material disposed on the floor panel 15. The tibia pad 14 is intended to increase the cushioning property of the occupant's feet 17 and enhance the riding comfort.

  The tibia pad 14 is foam-molded into a plate shape by heating foamable resin particles, and a plurality of first protrusions 14T1 projecting upward from the upper surface 14A and extending straight in the left-right direction on the upper surface 14A. A plurality of second protrusions 14T2 projecting upward from the upper surface 14A so as to have the same height as the first protrusions 14T1 and extending in a straight line in the front-rear direction so as to be orthogonal to the first protrusions 14T1 are formed. ing. A large number of first protrusions 14T1 are aligned at a constant interval P3 (may be the same as or different from the constant interval P1 in FIG. 2B) in the front-rear direction, The second protrusions 14T2 are aligned at a constant interval in the left-right direction (not shown, but may be the same as or different from the constant interval P3 of the first protrusion 14T1). ing. Moreover, the cross section of 1st protrusion 14T1 and 2nd protrusion 14T2 is a taper shape at the front end side, specifically, substantially triangular shape.

  By providing the tibia pad 14 formed in this way, even if the floor carpet 16 receives the load of the foot 17 when the occupant gets into the vehicle, the load is stabilized by the first protrusion 14T1 and the second protrusion 14T2. By supporting well, the 1st protrusion 14T1 and the 2nd protrusion 14T2 contact the floor carpet 16 appropriately, Therefore, it can prevent effectively that abnormal noise generate | occur | produces. In addition, since the floor carpet 16 is difficult to move with respect to the tibia pad 14, it is possible to prevent the floor carpet 16 from being displaced with respect to the tibia pad 14. In FIG. 4, the first protrusion 14T1 and the second protrusion 14T2 are provided only on the surface of the tibia pad 14. However, the first protrusion 14T1 and the second protrusion 14T2 may be provided on the back surface of the tibia pad 14. Good.

  In addition, this invention is not limited to the said embodiment, A various change is possible in the range which does not deviate from the summary of this invention.

  In the above-described embodiment, the interior material provided in the vehicle is shown as the foam molded body, but other than the interior material provided in the vehicle, for example, an ornament placed in the room, a sofa, a bed, or under the floor You may comprise a cushioning material etc. with the foaming molding of this invention.

  Moreover, in the said embodiment, although the cross-sectional shape of the 1st protrusion of the foaming molding and the 2nd protrusion was made into the triangle, it was made to project from the surface of the molding foam in the curved shape as shown to Fig.5 (a). That is, it may be semicircular protrusions 18T1 and 18T2. Further, as shown in FIG. 5 (b), the two surfaces from the surface of the molded foam are projected in a curved shape from the tip of the base portion 19T21 that rises vertically and in parallel with each other, that is, in the shape of the upper half of the oval shape. The ridges 19T1 and 19T2 may be used. Moreover, as shown in FIG.5 (c), the protrusion 20T1 and 20T2 which protruded smoothly from the surface of the shaping | molding foam in the curved shape, ie, the shape of the upper half of the ellipse shape, may be sufficient. The ridge formed in this way has a tapered shape having a smoothly continuous outline (configured by a smoothly continuous outline), but may not be a tapered shape. For example, the cross-sectional shape having the same width in the vertical direction may be a rectangular shape (having corners at the four corners of the tip). In addition to the shape shown in FIG. 5, for example, in the case of having a base portion in which two surfaces rise from the surface of the foamed molded body, the tip (upper end) of one surface is set to be more than the tip (upper end) of the other surface. The structure which makes it high, connects the front-end | tips from which those heights differ, and forms an inclined surface, or the structure which has the taper shape mentioned above from each of the front-end | tip (upper end) of two surfaces from which height differs may be sufficient. The surface of the base portion may be perpendicular to the surface of the foam molded article, or may be configured as an inclined surface that rises toward the center of the ridge. Moreover, the taper shape which gave the level | step difference from the base part may be sufficient.

  6A, 6B, and 6C show molds for forming the foamed molded body shown in FIGS. 5A, 5B, and 5C. That is, FIG. 6A shows a mold for forming the foamed molded body of FIG. 5A, and semicircular groove portions M3 and M4 are formed. Moreover, the metal mold | die which shape | molds the foaming molding of FIG.5 (b) is shown in FIG.6 (b), and the groove parts M5 and M6 of the shape of the upper half of an oval shape are formed. Moreover, the metal mold | die which shape | molds the foaming molding of FIG.5 (c) is shown in FIG.6 (c), and the groove parts M7 and M8 of the elliptical upper half shape are formed.

  Moreover, in the said embodiment, although the space | interval of the 1st protrusion and the space | interval of the 2nd protrusion were both made into the fixed space | interval, you may implement by setting one or both to the indefinite space | interval which is not constant.

  Moreover, in the said embodiment, although the 1st protrusion and the 2nd protrusion of the foaming molding were comprised in the shape of a straight line, you may comprise in a continuous zigzag shape, and you may comprise in the shape of a continuous curve. . In addition to making the first and second ridges orthogonal, the first and second ridges may be provided so as to intersect at a predetermined angle other than 90 degrees.

  In the embodiment, the first through hole 12K1 is formed in the first groove portion M1, and the second through hole 12K2 is formed in the second groove portion M2. However, as shown in FIG. A portion that is not the groove portion M2, that is, an intermediate portion between the first groove portions M1 and M1 arranged in parallel (not necessarily an intermediate portion) and an intermediate portion between the second groove portions M2 and M2 arranged in parallel (in the intermediate portion) Specifically, the through-hole 12K is formed in the central portion (not necessarily the central portion) of the planar portion 12H formed by being surrounded by the first groove portion M1 and the second groove portion M2. May be. In FIG. 7, the through holes 12K are formed in all of the flat surface portions 12H surrounded by the four sides, but may be formed only in the specific flat surface portions 12H. Moreover, the metal mold | die provided with not only the 1st through-hole 12K1 and 2nd through-hole 12K2 which were shown in FIG. 3 but the through-hole 12K shown in FIG. 7 may be sufficient.

  DESCRIPTION OF SYMBOLS 1 ... Tool box, 2, 3, 4 ... Storage part, 5 ... Box main body, 5A ... Lower surface, 6 ... Flange part, 6A ... Lower surface, 7 ... Cover, 7A ... Abutting member, 8A ... Upper surface, 8T1, 8T2 ... Projection, 9 ... Frame member, 9A ... Top surface, 10 ... Car body component, 11 ... Mold, 12 ... Mold body, 12A ... Bottom surface, 12H ... Plane portion, 12K, 12K1, 12K2 ... Through hole, 12a, 13a ... heating and cooling chamber, 13 ... lid, 14 ... tibia pad, 14A ... top surface, 14T1, 14T2 ... ridge, 15 ... floor panel, 16 ... floor carpet, 17 ... foot, 18T1, 18T2 ... ridge, 19T1, 19T2 ... Ridges, 20T1, 20T2 ... ridges, M1 to M8 ... grooves, P1, P2, P3 ... fixed intervals, S ... expandable resin particles

Claims (1)

A foam molded article formed by heating foamable resin particles filled in a mold for foam molding,
A plurality of first protrusions which are aligned in one direction, aligned in the other direction, and, provided in the first ridge and intersecting manner arranged a plurality of second protrusions and the surface, the first collision The strip and the second ridge are foams characterized in that at least the tip side has flexibility, and the cross-section is a tapered ridge having a tapered shape on the tip side and a height of 1 mm or less. Molded body.

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