JP5708297B2 - Integrated foam molded article with skin and method for producing the same - Google Patents

Description

  BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an integral foam molded article with a skin which is suitably used for automobile door trims, instrument panels, armrests, headrests, seats and other interior parts, and a method for manufacturing the same.

2. Description of the Related Art Conventionally, a resin foam-molded product with a skin is often used for automobile interior parts, and in particular, an integral foam-molded product with a skin formed by integrally molding a foam substrate and a skin layer as the main body of the foam-molded product. .
This monolithic foam molded product with a skin is made of a foam material softer than the foamed substrate on the back side of the skin as the surface material, with respect to the foamed substrate as the main body of the foam molded product, which is formed by foam molding a foamed resin stock solution. Foaming the slab foam layer and the skin layer on the back side of the slab foam layer, which is interposed between the foam substrate and the film that integrally laminates the foamed resin stock solution into the slab foam layer In the foam molding of the substrate, it is integrally formed in a joined state.

Here, the slab foam layer made of a foam material softer than the foamed substrate serves to improve the tactile sensation when the foam molded product is touched due to its softness.
Usually, a slab foam layer obtained by slab molding a foam material (generally a urethane foam material) sliced to a predetermined thickness is used.

  In this slab molding, a stock solution of foamed resin is poured onto a continuously moving conveyor, and this is continuously foamed and molded into a flat plate having a predetermined width and thickness in a pressure-released state. Mainly has a meaning as an intermediate product, and after that, various shapes are cut out from the slab molded product according to the purpose.

  Conventionally, when this slab molded product is used for the above-mentioned skin layer, the slab molded product is cut (sliced) to a predetermined thickness, and this is joined by laminating the skin of leather, cloth or other materials into a laminated state and integrating them. Is used.

By the way, a slab foam layer in the form of sliced slab foam is simply laminated and integrated with the inner surface of the foam mold, and the stock solution of the foam resin is injected into the space for molding the foam substrate. When this is foamed, the undiluted solution penetrates into the slab foam layer and is impregnated in the slab foam layer (the slab foam layer has many bubbles broken by slicing or the like and is easily impregnated with the undiluted solution. ).
Accordingly, if the stock solution is foamed and solidified as it is, the slab foam layer becomes hard, and the inherent softness and good tactile sensation of the slab foam layer are diminished. For this reason, there is a coping method in which the foam thickness is increased in consideration of the impregnation, but the design properties are adversely affected.

Therefore, in order to prevent this, conventionally, a film (usually a resin film) that prevents penetration of the foamed resin stock solution into the slab foam layer is pasted to the back surface (the surface opposite to the skin) of the slab foam layer by laminating. A three-layer structure is used as the skin layer.
By doing so, it is possible to prevent the slab foam layer from being impregnated with the foamed resin stock solution and hardening the slab foam layer.

By the way, in the case of an integral foam molded product with a skin mainly used for automobile interior parts, the design is an important factor. Conventionally, the design of this type of integral foam molded product with a skin has been It was expressed by colors, stitches, etc., and the surface was flat and monotonous.
Also, the tactile sensation when touching the surface was uniform over the entire surface and poor in change, and the feeling obtained from the tactile sensation was not sufficient.

As a prior art related to the present invention, the following Patent Document 1 discloses an invention for a foam-molded product with a skin (integrated foam-molded product with a skin). It is disclosed that the film is partially removed at a portion located at, and the slab foam layer is impregnated with the stock solution of the foamed resin through the removal portion to partially solidify the slab foam layer.
However, the thing disclosed in this Patent Document 1 is not intended to make the surface uneven, and it is intended to remove the film partially in a planar shape, and remove or process the slab foam layer. It is not intended to be different from the present invention.

On the other hand, the following Patent Document 2 discloses an invention about a vehicle interior product and a manufacturing method thereof, in which the headrest skin layer (skin) and the slab urethane layer (slab foam layer) are sewed together and embroidered, It is disclosed that a slab urethane layer that has been compressed with foaming pressure at the time of foam molding of a foam molded body (foam base) is expanded by releasing pressure by mold opening to make the embroidery part concave.
The thing disclosed in this Patent Document 2 is that the surface of the headrest becomes uneven by providing the embroidery part, but the method of making the uneven shape is different from the present invention.

On the other hand, the following Patent Document 3 discloses an invention about an interior material and a terminal treatment method for the interior material, and in this case, when foaming a foam base, a cut member in which a heat ray is disposed as a method for treating the end of the skin layer. Is disclosed in that a slit-like notch is formed in the film of the skin layer, and the slab foam layer is impregnated with the stock solution of the foamed resin through the notch to partially solidify the slab foam layer.
However, what is disclosed in this Patent Document 3 is a film that is cut out only, does not process the slab foam layer, and is not capable of forming irregularities in the appearance of appearance as a design. Different.

Patent Document 4 listed below discloses an invention for a method for producing a skin-integrated foam product having a groove-like pattern, and manufacturing a skin-integrated foam product having a groove-like pattern by providing a groove in the skin in advance. The point is disclosed.
However, this is different from the present invention in that a groove is previously formed in the skin.

JP 2010-105214 A Japanese Patent No. 4075419 JP-A-2-203891 JP 2007-216529 A

  The present invention is based on the circumstances as described above, can form a three-dimensional concavo-convex shape on the surface exposed to the outside in the attached state, can enhance the design, and by partially changing the tactile sensation, The object of the present invention is to provide an integral foamed article with a skin that can provide a good feeling when touched by a person, and a method for producing the same.

  Thus, claim 1 relates to an integral foam molded article with a skin, and the foamed substrate as a main body of the foam molded article formed by foam molding a foamed resin stock solution is provided on the back side of the skin as a surface material. A slab foam layer made of a foam material softer than the foam substrate, and further interposed between the slab foam layer and the back surface of the slab foam layer to prevent permeation of the foamed resin stock solution into the slab foam layer An integral foam molded product with a skin formed by integrally molding a skin layer in which a film to be laminated is integrally formed in a foamed state of the foamed substrate, wherein the film penetrates the skin layer. In addition, an impregnation port portion by notching or hole processing reaching the inside of the slab foam layer is provided, and the solidified portion by the stock solution impregnated in the slab foam layer through the impregnation port portion is a part of the slab foam layer. The skin is adhered and fixed to the solidified portion, and the slab foam layer bulges to the front side together with the skin at a portion excluding the fixed portion of the skin by the solidified portion, and is attached to the outside in an attached state. An uneven shape is formed on the exposed surface.

  According to a second aspect of the present invention, a foamed base material as a main body of a foam molded product is obtained by foaming a stock solution of a foamed resin, and is made of a foam material softer than the foamed base on the back side of the outer skin as a surface material. A slab foam layer and a skin layer that is further laminated on the back side of the slab foam layer and a film that is interposed between the slab foam layer and prevents the foamed resin stock solution from penetrating into the slab foam layer Is an integrally foamed article with skin formed by integrally molding in a joined state during foam molding of the foamed substrate, wherein the skin layer has the film and slab foam layer partially removed, The skin is adhered and fixed to a part of the foamed substrate generated by the solid solution flowing into the recess formed by the removal and solidifying, and at a part other than the removed part of the film and the slab foam layer The slurry Bulges front foam layer with the skin, and wherein the forming an uneven shape on the surface exposed to the outside the mounting state.

  Claim 3 relates to a method for producing an integral foamed article with a skin according to claim 1, and (a) a cut that penetrates the skin layer and reaches the inside of the slab foam layer. Or a step of providing an impregnation port by hole processing, (b) a step of setting the skin layer along a mold inner surface of the foaming mold in a mold open state, and (c) the mold closed state or the mold open state. The foamed resin stock solution is injected into the molding space of the foamed substrate, and in the mold closed state, the periphery of the slab foam layer impregnated with the stock solution through the impregnation port is partially solidified by solidification. A step of forming the foamed substrate integrally with the skin while foaming and solidifying the foamed resin stock solution in the space and compressing the slab foam layer with foaming pressure And (d) the foaming mold thereafter Mold is opened, characterized in that the obtained by the pressure releasing the slab foam layer in the compressed state a step of swelling with the skin except the coated portion, a skin-covered integrally foam molded article through.

  Claim 4 relates to a method for producing an integral foamed article with a skin according to claim 2, wherein (e) a step of partially removing the film and slab foam layer of the skin layer; A step of setting the skin layer along the inner surface of the foam mold in the mold open state; and (g) injecting the stock solution of the foam resin into the molding space of the foam base in the mold closed state or the mold open state. The part of the foamed substrate solidified in the recess by foaming and solidifying the stock solution in the space and the recess in the slab foam layer generated by the partial removal in the mold closed state Bonding and fixing the skin to the surface, and forming the foamed substrate integrally with the skin in a state where the portion of the slab foam layer excluding the recess is compressed with foaming pressure in the space; and (h Thereafter, the foam mold is opened and the pressure is increased. Through a step of swelling with the skin by a pressure releasing the slab foam layer state, the characterized in that to obtain a skin-covered integrally foam molded article.

  According to a fifth aspect of the present invention, in the fourth aspect, the heating mold is pressed against the film and the slab foam layer, and the film and the slab foam layer are partially melted by heating to be removed.

  A sixth aspect of the present invention is characterized in that, in the fifth aspect, the heating mold is a transfer mold capable of transferring an uneven shape to be formed on the surface.

Effects and effects of the invention

  As described above, according to the first aspect of the present invention, the foam as a main body of the foam molded article formed by foam molding of the foamed resin stock solution, the skin as the surface material and the slab foam layer on the back side thereof, and In an integral foam molded product with a skin formed by integrally molding a skin layer laminated integrally with the film on the back side into a bonded state, impregnation by cutting or perforating through the film to the inside of the slab foam layer The mouth portion is applied to the skin layer, and the slab foam layer is impregnated with the foamed resin stock solution through the impregnation mouth portion, so that a solidified portion by the stock solution is partially formed in the slab foam layer, and the skin is partially formed in the solidified portion. On the other hand, the slab foam layer is swelled to the front side together with the outer skin at the other part to form a concavo-convex shape on the surface.

According to the first aspect, it is possible to form a concavo-convex shape on the surface of the integral foam molded article with a skin by simply providing an impregnation port portion by cutting or perforating the film and the slab foam layer in the skin layer. When the tactile integrated foam molded product is touched, the tactile sensation is different between the concave shape portion and the convex shape portion, so that the tactile sensation can be changed.
Further, by changing the position, shape, etc. of the impregnation port portion, it is possible to easily change the uneven shape and tactile sensation of the surface to various shapes and tactile sensations.

  In addition, by changing the depth of the impregnation port part reaching the inside of the slab foam layer, the depth of the concave part and the height of the convex part can be increased, that is, the difference between them can be increased or decreased. In addition to being able to change the appearance of the uneven shape, the tactile sensation can also be changed.

  Next, according to the second aspect of the present invention, there is provided a foamed base material produced by partially removing the film of the skin layer and the slab foam layer, and injecting the solid solution of the foamed resin into the recess formed by the removal and solidifying. A part of the epidermis is adhered and fixed to a part, and the slab foam layer is swelled together with the epidermis in the part other than the removed part to form an uneven shape on the surface.

  Also according to the second aspect, the surface of the integral foam molded product with a skin can be provided with a concavo-convex shape, the design of the surface of the integral foam molded product with a skin can be enhanced, and the tactile sensation of the surface can be achieved by the concavo-convex shape. Can be changed, and the feeling when touching the integral foamed product with skin can be enhanced.

In addition, by changing the position, size, shape, etc. of the removed part of the film and slab foam layer, the uneven shape of the surface of the integral foamed product with skin can be changed variously, and the tactile sensation can also be changed variously. be able to.
According to the second aspect of the present invention, in particular, the planar size and depth of the concave portion can be easily increased and increased.

Claim 3 relates to a method for producing an integral foamed article with a skin according to claim 1, and in this production method, a cut or perforation that penetrates the film into the skin layer and reaches the inside of the slab foam layer in advance. An impregnation port is provided.
Then, the skin layer provided with the impregnation port portion is set along the inner surface of the foam molding die in the mold open state, and then the stock solution of the foam resin is put into the space for molding the foam base in the mold closed state or the mold open state. In the mold-closed state, the periphery of the slab foam layer impregnated with the stock solution is partially solidified through the impregnation port portion, and the periphery of the slab foam layer is partially solidified, and a part of the skin is adhered and fixed to the solidified portion, while the space The foamed substrate is molded integrally with the skin in a state in which the foamed resin stock solution is foamed and solidified, and the slab foam layer is compressed by the foaming pressure.
After that, the foaming mold is opened, and the slab foam layer that was in the compressed state is swelled together with the skin except for the solidified part by releasing the pressure by opening the mold. To get goods.
According to this manufacturing method, an integral foam molded article with a skin having a concavo-convex shape on the surface can be easily manufactured by simply providing an impregnation port portion in the skin layer in advance by a manufacturing method similar to the conventional method.

A fourth aspect relates to a method of manufacturing the integral foam-molded article with a skin according to the second aspect. In this manufacturing method, the film of the skin layer and the slab foam layer are partially removed in advance.
And the skin layer which performed the removal process is set along the type | mold inner surface of a foaming mold in a mold open state.
Thereafter, the foamed resin stock solution is injected into the molding space of the foamed substrate in the mold-closed state or the mold-opened state, and in the mold-closed state, the stock solution in the space and the slab foam layer generated by the above partial removal The stock solution that has flowed into the recess is foamed and solidified, and a part of the skin is adhered and fixed to a part of the foamed substrate solidified in the recess. The foamed substrate is molded integrally with the skin while the portion excluding the portion is compressed.
Thereafter, the foam mold is opened, and the compressed slab foam layer is swelled together with the skin by releasing the pressure to produce an integral foam molded product with a skin having an uneven shape on the surface.

  Also in the manufacturing method according to claim 4, by simply removing the skin layer film and the slab foam layer in advance, according to the same manufacturing method as in the prior art, integral foam molding with a skin having an uneven shape on the surface. Goods can be obtained.

In this fourth aspect, the film and slab foam layer can be partially removed by pressing the heating mold against the film and slab foam layer and melting the film and slab foam layer by heating. (Claim 5).
If it does in this way, a film and a slab foam layer can be partially removed easily in the target position and shape.

Furthermore, in this case, the heating mold can be a transfer mold that can transfer the intended uneven shape formed on the surface of the integral foam molded article with a skin (Claim 6).
In this way, by simply pressing the heating mold against the film of the skin layer and the slab foam layer, and then producing an integral foam molded article with the skin according to the same production method as before, various objectives can be applied to the surface. It is possible to transfer and form a concavo-convex pattern having a simple shape.

It is the figure which showed the integral foam molded product with a skin of one Embodiment of this invention. It is explanatory drawing which showed the principal part process of the manufacturing method of the foaming molded article of FIG. FIG. 3 is an explanatory diagram following FIG. 2. It is explanatory drawing following FIG. It is the figure which showed the principal part of the foaming molded product of other embodiment of this invention. It is the figure which showed the foaming molded product of other embodiment of this invention. It is explanatory drawing which showed the principal part process of the manufacturing method of the foaming molded article of FIG. It is explanatory drawing following FIG. It is explanatory drawing which showed the principal part process of the manufacturing method of the foaming molded product of further another embodiment of this invention. It is explanatory drawing which showed the principal part process of the manufacturing method of the foaming molded product of further another embodiment of this invention. It is explanatory drawing which showed the principal part process of the manufacturing method of the comparative example of a foaming molded article.

Next, embodiments of the present invention will be described in detail with reference to the drawings.
In FIG. 1, reference numeral 10 denotes an integral foam molded product with a skin (hereinafter simply referred to as a foam molded product) used as an automobile interior product. The foam molded product 10 includes a resin foam base 12 as a main body and a back side thereof. The core material 14 and the skin layer 16 covering the surface of the foamed substrate 12 are integrated into a laminated state.

Here, the foam base 12 is made of a urethane resin foam, and the core member 14 is made of a rigid polypropylene resin having rigidity. The core material 14 has a plate shape as a whole.
The core material 14 needs to be hard, and in this case, a Rockwell hardness (R scale) of about 80 to 100, or about 100 to 120 is used. It is desirable to use one having a hardness of 50 or more.
Here, the core material 14 has a thickness of 2.5 mm. The core material 14 preferably has a thickness of 1.5 mm or more.

The skin layer 16 is composed of a skin 18 as a surface material made of leather, synthetic leather, woven fabric, non-woven fabric, resin sheet, or other materials, a slab foam layer 20 on the back side, and a resin film 22 on the back side. It has a layered structure.
The skin 18, the slab foam layer 20, and the film 22 are bonded together and integrated by lamination.
Here, the thickness of the skin 18 is about 0.7 mm, the thickness of the slab foam layer 20 is about 3 mm, and the thickness of the film 22 is about 30 μm.

Here, the slab foam layer 20 is made of polyurethane foam and has elasticity. However, the slab foam layer 20 has a density lower than that of the foamed substrate 12, is softer and softer than the foamed substrate 12, and has a lower strength.
This slab foam layer 20 is formed by slicing a slab molded product formed at a factory, and has a large number of bubbles, but there are many bubbles broken by processing the slice. It can be impregnated with a stock solution of foamed resin described later.
Such a slab foam layer 20 is widely commercially available.
Specifically, the skin layer 16 itself in which the skin 18 and the film 22 are bonded to the slab foam layer 20 in a three-layer structure by laminating is configured using a commercially available product.

  In the skin layer 16, a notch that penetrates the film 22 at a predetermined location and reaches the inside of the slab foam layer 20 is formed and an impregnation port portion 24 that impregnates a stock solution of a foamed resin described later by the notch is formed. Is provided.

In the slab foam layer 20, the solidified portion 26 produced by solidification of the foamed resin stock solution for forming the foamed substrate 12 impregnated inside through the impregnation port portion 24 is a portion of the impregnation port portion 24. It is formed around the impregnation port portion 24, and a part of the skin 18 is bonded and fixed to the solidified portion 26. That is, the skin 18 is partially fixed to the foam base 12 via the solidified portion 26.
In the figure, 18A represents a fixed portion of the skin 18 that is partially fixed to the solidified portion 26.
Here, the impregnation port portion 24 does not reach the skin 18 and extends to an intermediate portion of the thickness of the slab foam layer 20, but the solidified portion 26 reaches the skin 18.

  The slab foam layer 20 has a portion other than the solidified portion 26 swelled to the front side together with the skin 18 by demolding from the foaming mold for foam-molding the foamed substrate 12, and a foam-molded product is formed by the bulging portion. A convex portion 28 is formed on the surface 10.

On the other hand, in the solidified portion 26, the slab foam layer 20 is fixed to the foam base 12 together with a part of the outer skin 18, that is, restrained from being expanded and restrained from expansion, and the concave shaped portion 30 is prevented from being expanded. Is formed on the surface.
An uneven shape is formed on the surface of the foam molded article 10 by the convex portion 28 and the concave portion 30.
Here, the concavo-convex portion is formed on the surface of the foamed molded product 10 exposed to the outside in the attached state.
Here, as shown in FIG. 1A, the convex portion 28 and the concave portion 30 are formed in a form extending in a straight shape in parallel with each other.

Next, the manufacturing method of this foam molded product 10 is demonstrated below based on FIGS.
This manufacturing method is an example of manufacturing the foamed molded article 10 by a so-called closed injection method in which a foamed resin stock solution is injected into the molding space of the foamed substrate 12 with the foaming mold closed.
FIG. 2 (I) shows the skin layer 16 before molding. As shown in the figure, the skin layer 16 before molding has a thin flat plate shape (or sheet shape) having a predetermined thickness as a whole. There is no.
In this manufacturing method, as shown in FIGS. 2 (II) and (III), an incision process that penetrates through the film 22 and reaches the inside of the slab foam layer 20 is performed to provide the impregnation port 24 in the skin layer 16 .

Here, as shown in FIG. 2 (II), it is also possible to use a cutting tool as the processing tool 32, cut the film 22 and the slab foam layer 20 so as to pierce them, and provide the impregnation port portion 24. Alternatively, it is also possible to use a heating tool as the processing tool 32 and pierce the slab foam layer 20 so as to partially melt the film 22 and the slab foam layer 20 to provide the impregnation port portion 24.
In this embodiment, the processing for providing the impregnation port portion 24 is performed after the skin layer 16 is cut according to the shape of the product (foamed molded product 10).
Thus, after the skin layer 16 is cut according to the product shape, the impregnation port portion 24 is provided as post-processing, so that the impregnation port portion 24 can be accurately formed at the target position according to the product shape. .

Next, the skin layer 16 provided with the impregnation port portion 24 in this way is set together with the core material 14 in the foaming mold 34 shown in FIG.
The foaming mold 34 has a first split mold (here, upper mold) 36 and a second split mold (here, lower mold) 38, and molding the foam base 12 between them in the mold closed state. A space 52 is formed.
In this manufacturing method, the core material 14 is set as an insert along the mold surface of the first split mold 36 in FIG. 3A in the mold open state, and the skin layer 16 is set to the second split mold 38. Set so that it follows the mold surface.
Thereafter, as shown in FIG. 3A, the first split mold 36 and the second split mold 38 are combined to close the foam molding die 34.
At this time, a space 52 for molding the foam base 12 is formed in a sealed space between the core material 14 and the skin layer 16, that is, inside the skin layer 16.
In this mold-closed state, as shown in FIG. 3 (B), a foamed resin stock solution (here, a urethane resin stock solution) for forming the foamed substrate 12 is injected from the injection machine (not shown) through the injection port 40. It is injected into the above-mentioned space 52, and this is subjected to a foaming reaction.

At this time, the stock solution of the foamed resin injected into the space 52 spreads in the space 52 as shown in FIG. 4 (IV), and a part thereof enters the slab foam layer 20 through the impregnation port portion 24 of the skin layer 16. It enters and is impregnated there, and the stock solution is solidified around the impregnation port portion 24 to form the solidified portion 26 described above. At this time, a part of the skin 18 (fixed portion 18A) is bonded and fixed to the solidified portion 26.
In addition, the undiluted solution expands in the space 52 by foaming reaction, and the foaming pressure elastically compresses the slab foam layer 20 in the skin layer 16 as shown in FIG. Solidify. That is, in the space 52, the foam base 12 is foam-molded integrally with the skin layer 16.

  Thereafter, when the foaming mold 34 is opened, the slab foam layer 20, specifically the portion excluding the solidified portion 26, is on the lower side in FIG. The shape is restored to bulge, and the bulge forms the convex portion 28 shown in FIG.

In the solidified portion 26, the slab foam layer 20 is fixed to the foam base 12 together with the fixing portion 18A of the outer skin 18, and is restrained from being bulged out, so that the portion between the convex portions 28 and 28 is prevented. The concave-shaped part 30 is formed.
In this way, an uneven portion is formed on the surface of the foam molded product 10.

Incidentally, FIG. 11 shows a case where a foamed molded product is manufactured using the skin layer 16 not provided with the above-described impregnation port portion 24. As shown in FIG. Since the foam layer 20 as a whole returns to its uniform shape and expands, the surface of the foam-molded product does not have the uneven shape as described above, and the surface becomes a uniform flat surface.
In FIG. 11, (I), (II), and (III) correspond to (IV), (V), and (VI) in FIG. 4, respectively.

According to the present embodiment as described above, an uneven shape can be formed on the surface of the foam molded article 10 simply by providing the film 22 and the slab foam layer 20 in the skin layer 16 with the impregnation port portion 24 by cutting. Moreover, when the foamed molded article 10 is touched, the tactile sensation is different between the concave shaped portion 30 and the convex shaped portion 28, so that the tactile sensation can also be changed.
Further, by changing the position, shape, and the like of the impregnation port portion 24, it is possible to easily change the uneven shape and tactile sensation of the surface to various shapes and tactile sensations.

  In addition, by changing the depth of the impregnation port portion 24 reaching the inside of the slab foam layer 20, the depth of the concave portion 30 and the height of the convex portion 28, that is, the difference between them is increased or decreased. The appearance of the uneven shape can be changed variously, and the tactile sensation can also be changed variously.

  In addition, according to the manufacturing method of the present embodiment, the foam molded article 10 having a concavo-convex shape on the surface can be easily manufactured by simply providing the impregnation port portion 24 in the skin layer 16 in advance by the same manufacturing method as the conventional method. Can do.

The above example is an example in which the impregnation opening 24 is formed by making a cut in the film 22 and the slab foam layer 20 of the skin layer 16, but the slab foam penetrates the film 22 as shown in FIG. It is also possible to provide the impregnation port portion 24 by processing and forming a hole reaching the middle portion in the thickness direction of the layer 20.
In this case, the size of the planar shape of the hole can be changed variously.
In FIG. 5, 26 represents a solidified portion produced by impregnating the slab foam layer 20 into the slab foam layer 20 from the impregnation port portion 24 and solidifying, and 18 A represents the skin 18 bonded and fixed to the solidified portion 26. A part, that is, a fixed portion of the skin 18 is shown.

FIG. 6 shows another example of the foam molded product (integral foam molded product with skin) of the present invention.
In the foamed molded article 10 of this example, the film 22 and the slab foam layer 20 are partially removed up to the position on the back side of the skin 18, specifically, until reaching the skin 18, and are formed by the removal. A stock solution of foamed resin flows into the recess 54 and solidifies, and a stepped protrusion 12A that forms part of the foamed substrate 12 is formed there.
A part of the skin 18 is bonded and fixed to the protruding portion 12A. In the figure, 18A represents a fixing portion of the skin 18 to the protruding portion 12A.

The slab foam layer 20 bulges to the front side together with the skin 18 at a portion other than the removal portion, that is, a portion other than the recess 54, thereby forming a convex portion 28.
A concave-shaped portion 30 is formed between the convex-shaped portions 28 and 28, and the convex-shaped portion 28 and the concave-shaped portion 30 allow the surface of the foam molded article 10 (surface exposed to the outside in the attached state). An uneven shape is formed on the surface.
Here, as shown in FIG. 6A, the concave portion 30 is formed in a circular shape (planar shape).

In FIG. 6B, reference numeral 26 denotes a solidified portion formed by impregnation of the stock solution formed around the recess 54.
In this embodiment, the slab foam layer 20 is removed to the position on the back side of the skin 18, where the position to the back side of the skin 18 means substantially the position on the back side of the skin 18, When the slab foam layer 20 is removed, as shown in the partially enlarged view of FIG. 7 (III), the slab foam layer may be slightly left on the skin 18 side as a thin film 20A.
However, the thickness of the thin film 20A is set to 1 mm or less.
In this case, the thin film 20A is impregnated with the foamed resin stock solution, and the thin film 20A forms a thin solidified portion 26A shown in FIG.

7 and 8 show the main steps of the method for manufacturing the foam molded article 10 shown in FIG.
Also in this example, the injection method of the foamed resin stock solution is the same closed injection method as in the first embodiment.
In the manufacturing method of this embodiment, as shown in FIG. 7 (II), the heating die 56 is applied to the film 22 on the prepared flat plate-like (sheet-like) skin layer 16 (see FIG. 7 (I)). Pressing from the side, the film 22 and the slab foam layer 20 are heated and melted by the heating die 56, and the film 22 and the slab foam layer 20 are partially removed to the position on the back side of the skin 18. At this time, as shown in FIG. 7 (III), a recess 54 is formed in the skin layer 16 by its removal.
In this example as well, partial removal of the film 22 and the slab foam layer 20 is performed as post-processing after the skin layer 16 is cut into a shape that matches the product shape.

The skin layer 16 from which the slab foam layer 20 and the film 22 have been partially removed as described above is set in the foamed mold 34 shown in FIG. 3 in the mold open state together with the core material 14, and then the mold is closed, A stock solution of foamed resin is injected into the space 52 from the injection machine.
The stock solution injected into the space 52 spreads into the space 52 and a part thereof flows into the recess 54 as shown in FIG. 8 (IV), and then they expand in the space 52 and the recess 54. The foaming reaction is accompanied by solidification.

At this time, as the stock solution is solidified in the recess 54, a protruding portion 12A forming a part of the foam base 12 is formed into a stepped shape, and the skin 18 is formed with respect to the protruding portion 12A as shown in FIG. A part of is adhered and fixed. That is, the fixing portion 18A of the skin 18 in FIG. 6B is fixed to the protruding portion 12A.
In addition, the foamed substrate 12 is formed integrally with the skin layer 16 by foaming and solidifying the stock solution in the space 52.

Thereafter, when the foaming mold 34 is opened, the slab foam layer 20 bulges downward in FIG. 8 (VI), that is, on the side opposite to the foamed substrate 12 by releasing the pressure, and the convex shaped portion 28 is formed by the bulging. .
Further, since the slab foam layer 20 does not expand in the portion excluding the slab foam layer 20, that is, the portion of the recess 54 and the protruding portion 12A, the concave portion 30 is formed between the convex portions 28 and 28. It is formed.
Then, an uneven shape is formed on the surface of the foam molded product 10 by the convex shape portion 28 and the concave shape portion 30.

  Also according to this embodiment, the surface of the foam molded product 10 can be provided with a concavo-convex shape, the design of the surface of the foam molded product 10 can be enhanced, and the surface tactile sensation can be changed by the concavo-convex shape. It is possible to enhance the feeling when the foam molded product 10 is touched.

Further, by changing the position, size, shape and the like of the removed portion of the film 22 and the slab foam layer 20, the uneven shape of the surface of the foam molded article 10 can be changed variously, and the tactile sensation is also changed variously. be able to.
In this embodiment, in particular, the planar size and depth of the concave portion 30 can be easily increased and increased.

  Also in the manufacturing method of the present embodiment, a foam molded article having an uneven surface on the surface according to the same manufacturing method as in the prior art by simply removing the film 22 and the slab foam layer 20 of the skin layer 16 in advance. 10 can be obtained.

FIG. 9 shows still another embodiment of the present invention.
In this example, the heating mold 56 is configured as a transfer mold 58, and here, the transfer mold 58 is provided with a convex mold portion 60 that forms the letter "A".
In this embodiment, when the transfer mold 58 is pressed against the skin layer 16 from the film 22 side, the film 22 and the slab foam layer 20 are formed by the convex mold portion 60 constituting the letter “A”. It is melted and partially removed in a corresponding pattern, and the letter “A” is patterned by the plurality of recesses 54A.

Using the skin layer 16 from which the film 22 and the slab foam layer 20 have been partially removed in this way, when the foamed molded article 10 is molded according to the steps shown in FIGS. 7 and 8, the surface shown in FIG. The concave portion 30 forming the letter “A” is patterned.
In the case where the mold part 60 shown in FIG. 9 is formed in a concave shape, the pattern is formed so that the convex part 28 forms the letter “A” on the contrary.
Note that the letter “A” in this example is merely an example, and various other uneven shapes can be formed on the surface of the foam molded article 10 by the same method.

  According to the manufacturing method of this embodiment, the film 22 and the slab foam layer 20 can be partly removed at a desired position and shape, and thus various uneven patterns are transferred and formed on the surface. Thus, it is possible to easily obtain the foam molded article 10 formed as described above.

  The above example is an example of closed injection in which a foamed resin stock solution is injected into the molding space 52 of the foam base 12 with the foam molding die 34 closed. In the present invention, the foam resin When injecting the undiluted solution into the foaming mold 34, it is also possible to adopt a method in which the undiluted solution is poured into the molding space of the foamed substrate 12 with the foamed mold 34 opened, that is, an open pouring method.

FIG. 10 specifically shows this. FIG. 10 (I) shows a state in which the stock solution is injected into the space 52 in the mold open state, and (II) shows a state in which the foaming mold 34 is closed after that. Show.
The stock solution injected into the space 52 expands in the space 52 under the mold closed state shown in FIG. 10 (II), and a part thereof is impregnated into the slab foam layer 20 through the impregnation port portion 24 of FIG. A part of the foam layer 20 is solidified. That is, the solidified portion 26 of FIG. 1 is formed.
Alternatively, it flows into the recess 54 in FIG. 6 and solidifies there to form a stepped projection 12A that forms part of the foamed substrate 12 in FIG.

  Although the embodiments of the present invention have been described in detail above, these are merely examples, and the present invention can be implemented in various forms and modes without departing from the spirit of the present invention.

DESCRIPTION OF SYMBOLS 10 Integrated foam molding with skin 12 Foam substrate 16 Skin layer 18 Skin 20 Slab foam layer 22 Film 24 Impregnation port part 26 Solidification part 28 Convex part 30 Concave part 32 Processing tool 52 Space 56 Heating type 58 Transfer mold

Claims (6)

A slab foam layer made of a foam material softer than the foamed substrate on the back side of the outer skin as a surface material, with respect to a foamed substrate as a main body of a foam molded product, which is formed by foaming a foamed resin stock solution, and the slab foam A foam layer of the foamed substrate is formed by forming a skin layer that is further laminated on the back side of the layer and is integrally laminated with a film that is interposed between the foamed substrate and prevents the foamed resin stock solution from penetrating into the slab foam layer. An integral foam molded product with a skin formed by integrally molding in a joined state at the time of molding,
The skin layer is provided with an impregnation port portion that is formed by cutting or perforating through the film to reach the inside of the slab foam layer, and the stock solution impregnated in the slab foam layer through the impregnation port portion The solidified part is partially formed in the slab foam layer, and the skin is bonded and fixed to the solidified part,
With the skin, the slab foam layer bulges to the front side together with the epidermis at the portion excluding the fixing part of the epidermis by the solidified part, and forms an uneven shape on the surface exposed to the outside in the attached state Integrated foam molded product. A slab foam layer made of a foam material softer than the foamed substrate on the back side of the outer skin as a surface material, with respect to a foamed substrate as a main body of a foam molded product, which is formed by foaming a foamed resin stock solution, and the slab foam A foam layer of the foamed substrate is formed by forming a skin layer that is further laminated on the back side of the layer and is integrally laminated with a film that is interposed between the foamed substrate and prevents the foamed resin stock solution from penetrating into the slab foam layer. An integral foam molded product with a skin formed by integrally molding in a joined state at the time of molding,
In the skin layer, the film and the slab foam layer are partially removed, and the skin is partially formed on the foamed substrate generated by the solid solution flowing into the recess formed by the removal and solidifying. Is glued and fixed,
The slab foam layer bulges to the front side together with the skin at a portion other than the removed portion of the film and the slab foam layer, and has an uneven shape on the surface exposed to the outside in the mounted state. Foam molded product. A method for producing an integral foamed article with a skin according to claim 1,
(a) providing the skin layer with an impregnation port by cutting or perforating through the film and reaching the inside of the slab foam layer;
(b) setting the skin layer along the mold inner surface of the foam mold in the mold open state;
(c) The foamed resin stock solution is injected into the molding space of the foamed substrate in the mold closed state or the mold open state, and the slab foam layer impregnated with the stock solution through the impregnation port portion in the mold closed state. In the state where the periphery of the impregnation port part is partially solidified and the skin is adhered and fixed to the solidified part, while the stock solution of the foamed resin is foamed and solidified in the space, and the slab foam layer is compressed with foaming pressure. Forming the foam substrate integrally with the skin;
(d) thereafter, opening the foam mold, and expanding the compressed slab foam layer together with the skin except for the solidified portion by releasing the pressure;
A method for producing an integral foam-molded article with a skin, characterized in that an integral foam-molded article with a skin is obtained. It is a manufacturing method of the integral foam-molded article with a skin of Claim 2,
(e) partially removing the film and slab foam layer of the skin layer;
(f) setting the skin layer along the mold inner surface of the foam mold in the mold open state;
(g) The slab produced by injecting a stock solution of the foamed resin into the molding space of the foamed substrate in a mold-closed state or in a mold-open state, and in the mold-closed state, the stock solution and the partial removal in the space The stock solution that has flowed into the recess of the foam layer is foamed and solidified, and the epidermis is adhered and fixed to a part of the foamed substrate solidified in the recess, and in the space, the slab foam layer is formed by foaming pressure. Molding the foamed substrate integrally with the skin in a compressed state except for the recess;
(h) after that, the step of opening the foaming mold and bulging the compressed slab foam layer together with the skin by releasing the pressure;
A method for producing an integral foam-molded article with a skin, characterized in that an integral foam-molded article with a skin is obtained.   5. The method for producing an integral foamed article with skin according to claim 4, wherein a heating mold is pressed against the film and the slab foam layer, and the film and the slab foam layer are partially melted by heating to be removed. .   6. The method for producing an integral foamed article with a skin according to claim 5, wherein the heating mold is a transfer mold capable of transferring an uneven shape to be formed on the surface.

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