JP5953604B2 - Foam molded product and method for producing the same - Google Patents

Description

  The present invention relates to a foam molded article that can improve the sealing performance of a terminal portion and a method for manufacturing the same.

  Vehicles such as automobiles are provided with a vehicle interior front panel 1 called an instrument panel or dashboard as shown in FIG. 6 at the front of the vehicle interior.

  As shown in FIG. 7, such a vehicle interior front panel 1 includes a multi-layer foam molded product integrally including a core material 2, a foam layer 3, and a skin material 4. (For example, refer to Patent Document 1).

  Here, the core material 2 is made of a hard and thick resin, the foam layer 3 is made of a foam material such as urethane foam, and the skin material 4 is made of a soft and thin resin.

  As shown in FIG. 8, the interior interior panel 1 having such a multilayer structure has a foam layer 3 between a core material 2 and a skin material 4 set in a foam molding die 5 of a foam molding apparatus. It is manufactured by injecting a foaming liquid 6 as a raw material and foaming the foaming liquid 6 inside the foaming mold 5.

  At this time, the foamed male mold 7 and the foamed material 7 are formed so that the core material 2 having a hard thickness and high shape retaining property is on the upper side, and the skin material 4 having a soft thin wall and having no shape retaining property or low shape retaining property is on the lower side. Generally, it is set in each of the female molds 8.

  The core material 2 and the skin material 4 described above are fitted with the position restricting portions 13 and 14 with respect to the position restricting portions 11 and 12 formed on the foam molding die 5 at the time of foam molding. Therefore, the position is regulated.

  In the above-described foamed molded product, it is necessary to seal the leakage of the foamed liquid 6 and the like so that the foamed layer 3 does not stick out from the end portions of the core material 2 and the skin material 4. However, since it is difficult to completely seal the leakage of the foaming liquid 6 or the like, conventionally, the core material 2 and the skin material 4 are formed to be slightly larger than the outer shape of the product, and in the subsequent process after foam molding. The outer part of the foam molded product is cut off and removed from the outer part of the product to adjust the outer shape of the product.

Japanese Patent No. 3163756

  However, since it is wasteful to make the foam molded product larger than the outer shape of the product, the foam molded product is formed to the same size as the product, and there are no parts to be cut or removed, or fewer parts to be cut and removed. It is hoped that.

  However, in order to be able to foam-mold the foam-molded product to the size of the product itself, the above-mentioned sealing problem is sufficiently solved so that the appearance defect or the like due to the foaming of the foamed layer 3 does not occur. There is a need.

  Therefore, as shown in FIG. 9, an end wall 15 extending toward the skin material 4 is provided at the terminal portion of the core material 2, and the foam layer is formed at the terminal portion of the skin material 4 while extending toward the core material 2. By providing the end face seal wall portion 16 that is pressed against the inner surface of the end wall 15 by the foaming pressure when molding 3, the end portion is sealed using the foaming pressure.

  Furthermore, a fixed liquid stop wall portion 17 capable of preventing a foaming liquid or the like as a raw material of the foam layer 3 from reaching the end portion of the core material 2 is provided in the vicinity of the end portion of the core material 2. By providing away from the foamed liquid, the fixed liquid stop wall portion 17 prevents the foamed liquid from directly reaching the end portion of the core material 2. Further, the flow of the foamed fluid is adjusted by temporarily stopping the foamed fluid formed by foaming of the foamed liquid by the fixed liquid stop wall 17 and then overcoming it as shown by the broken line. I have to.

  However, if the fixed liquid blocking wall portion 17 is fixed and the distance between the fixed liquid blocking wall portion 17 and the inner surface of the skin material 4 is narrowed, the foam that overcomes the flexible liquid blocking wall portion. On the other hand, the flow of the foam fluid will cause non-uniformity, and the void portion due to the foam fluid not filling the portion where the flow of the foam fluid in the end portion of the foam molded product has deteriorated There was a risk of causing.

In order to solve the above-mentioned problem, the invention described in claim 1 is a foam molded product in which a core material and a skin material are integrated by a foam layer, and extends toward the skin material at a terminal portion of the core material. An end wall is provided, and an end face seal wall portion is provided at the end portion of the skin material, extending toward the core material and pressed against the inner surface of the end wall by foaming pressure when forming the foam layer, In the vicinity of the end portion of the skin material, a flexible liquid blocking wall portion capable of preventing the foaming liquid as the raw material of the foam layer from reaching the end portion of the skin material is provided apart from the end face seal wall portion. It is characterized by that.
According to the second aspect of the present invention, in the above, an extension portion that is recessed toward the back surface side of the core material is formed in the vicinity of the terminal portion of the core material, and the flexible liquid stop wall portion is formed on the extension portion. It is provided at a position facing the top surface or the inner wall surface or in the vicinity thereof.
The invention described in claim 3 is characterized in that, in the above, a strength securing portion for preventing the sticking is provided on the inner surface of the end face seal wall portion of the skin material.
The invention described in claim 4 is characterized in that, in the above, a resin reservoir is provided in an intermediate portion of the end wall of the core member.
The invention described in claim 5 is characterized in that, in the above, a sealing performance improving portion is provided in a portion closer to the base side than the resin reservoir of the end wall of the core member.
In the invention described in claim 6, the core material and the skin material are formed into the foam layer by injecting a foaming liquid as a raw material of the foam layer between the core material and the skin material set in the foaming mold. In the foam molded product manufacturing method for manufacturing the foam molded product integrated by the step, provided at the end portion of the skin material with respect to the inner surface of the end wall extending toward the skin material provided at the end portion of the core material In addition, the end face seal wall portion extending toward the core material is brought into pressure contact with the foaming pressure at the time of forming the foam layer, thereby sealing the end portion of the skin material and the core material, and the end portion of the skin material. The flexible liquid blocking wall portion provided in the vicinity away from the end face seal wall portion prevents the foaming liquid as the raw material of the foam layer from reaching the terminal portion of the skin material.

According to the first aspect of the present invention, the following operational effects can be obtained by the above configuration. That is, the end face seal wall portion is pressed against the inner surface of the end wall by the foaming pressure when the foam layer is formed, so that the end portions of the core material and the skin material can be sealed.
At this time, by providing a flexible liquid stop wall portion in the vicinity of the end portion of the skin material apart from the end face seal wall portion, a foaming liquid (for example, liquid urethane or the like) serving as a raw material of the foam layer becomes It is possible to prevent direct arrival at the end portion of the material. Thereby, for example, it is possible to prevent a problem that the foaming liquid that has reached the terminal portion of the skin material leaks directly from the terminal portion.
The foamed fluid formed by foaming of the foaming liquid (for example, non-solidified foam such as viscous urethane) is temporarily stopped by the flexible liquid stop wall and then climbs over the flexible liquid stop wall. As a result, the flow of the foam fluid can be regulated and adjusted.
At this time, since the flexible liquid stop wall literally has flexibility, the flexible liquid stop wall is easily bent by the pressure of the foam fluid, and the flexible liquid stop wall is bent. The foam-like fluid can easily get over the flexible liquid blocking wall portion and reach every corner of the end portion of the skin material.
Moreover, since the end portion of the foam molding space is expanded by the bending of the flexible liquid stop wall, the foamed fluid can more easily get over the flexible liquid stop wall. . Therefore, the foamy fluid gets over the flexible liquid stop wall in a substantially uniform state without being greatly disturbed. Thereby, for example, it is possible to prevent a void from being generated due to the foamy fluid not reaching the terminal portion of the foam molded product.
According to the second aspect of the present invention, the following effects can be obtained by the above configuration. That is, since the extended portion that is recessed toward the back surface side of the core material is formed in the vicinity of the terminal portion of the core material, the terminal portion of the foam molding space is further expanded. It is possible to more easily get over the stop wall, and more effectively prevent the occurrence of turbulence when the foamy fluid gets over the flexible liquid stop wall.
In addition, since the flexible liquid stop wall portion is provided at or near the top surface or the inner wall surface of the expansion portion, the function of the expansion portion and the function of the flexible liquid stop wall portion are achieved. It can be strongly related to have a synergistic effect.
Furthermore, the rigidity of the terminal portion can be improved by forming the extended portion in the terminal portion of the core member.
According to the third aspect of the present invention, the following operational effects can be obtained by the above configuration. That is, by providing a strength securing portion for preventing the sticking on the inner surface of the end face seal wall portion of the skin material, the foamed fluid formed by foaming of the foaming liquid does not completely reach the terminal portion. Even when the gap portion is generated in the terminal portion, the presence of the strength securing portion can suppress the stickiness due to the gap portion. In addition, since the strength securing portion improves the strength of the end portion of the skin material, the end portion can be made less likely to be damaged.
According to the invention described in claim 4, the following effects can be obtained by the above-described configuration. That is, by providing a resin reservoir in the middle part of the end wall of the core material, foaming liquid or foaming liquid is foamed inside the pressure contact part (seal part) between the inner surface of the end wall and the end face seal wall part. Even when the foamed fluid that is formed is trapped, it can be collected in the resin reservoir so that it does not leak outside.
According to the fifth aspect of the present invention, the following effects can be obtained by the above configuration. That is, by providing a sealing performance improving portion at a portion closer to the base side than the resin reservoir of the end wall of the core material, the pressure contact portion (seal portion) between the inner surface of the end wall and the end surface sealing wall portion is inserted. On the side, the foaming liquid or the foamed fluid formed by foaming of the foaming liquid can be surely stopped and these leakages can be effectively prevented.
According to the sixth aspect of the present invention, the following effects can be obtained by the above configuration. That is, while sealing is performed at the end portions of the skin material and the core material, the flexible liquid stop wall portion provided in the vicinity of the end portion of the skin material apart from the end face seal wall portion serves as a raw material for the foam layer. By preventing the foaming liquid from reaching the terminal portion of the skin material, the same effect as that of the first aspect can be obtained.

It is a partial expanded longitudinal cross-sectional view (clamping state) of the terminal part of the foaming molded product concerning the Example of this invention. FIG. 2 is an operation diagram of FIG. 1. It is a top view of a core material. It is a partial expanded longitudinal cross-sectional view of the modification of FIG. It is a partial expanded longitudinal cross-sectional view of the modification of FIG. It is a perspective view of a vehicle interior front panel. It is a longitudinal cross-sectional view of FIG. It is a figure which shows the foaming shaping | molding die which shape | molds the compartment front interior panel of FIG. 6 (mold open state). It is a partial expanded longitudinal cross-sectional view of the terminal part of a foaming molded article which shows the outer wall seal structure under examination now.

  Vehicles such as automobiles are provided with a vehicle interior front panel 1 called an instrument panel or dashboard as shown in FIG. 6 at the front of the vehicle interior.

  As shown in FIG. 7, such a vehicle interior front panel 1 is constituted by a foam molded article having a multilayer structure integrally including a core material 2, a foam layer 3, and a skin material 4.

  As shown in FIG. 8, the interior front panel 1 having such a multilayer structure is provided between the core material 2 and the skin material 4 (foam molding space) set in the foam molding die 5 of the foam molding apparatus. The foaming liquid 6 as a raw material for the foaming layer 3 is injected as described later, and the foaming liquid 6 is foamed inside the foaming mold 5.

  The foam molding die 5 has a foam male mold 7 and a foam female mold 8. In this case, the core material 2 is the foam male mold 7, and the skin material 4 is the foam female mold 8. To be set.

  At this time, the foamed male mold 7 and the foamed material 7 are formed so that the core material 2 having a hard thickness and high shape retaining property is on the upper side, and the skin material 4 having a soft thin wall and having no shape retaining property or low shape retaining property is on the lower side. Each is set in a female mold 8.

The core material 2 and the skin material 4 described above are fitted with the position restricting portions 13 and 14 with respect to the position restricting portions 11 and 12 formed on the foam molding die 5 at the time of foam molding. Therefore, the position is regulated.
The above description is almost the same as that of the conventional example described above.

  The present invention relates to a foam molded product that can be applied to a foam molded product such as the interior interior panel 1 described above and a manufacturing method thereof. However, the application target of the foam molded product is not limited to the interior front panel 1 of the passenger compartment.

Hereinafter, examples embodying the present embodiment will be described in detail with reference to the drawings.
1 to 5 show this embodiment and its modifications. For convenience of drawing, a part of the foam molding die 5 may be omitted.

<Configuration> The configuration will be described below.
In this embodiment, assuming the above configuration, the following configuration is provided.

  First, the structure of the foam molded product in which the core material 2 and the skin material 4 are integrated by the foam layer 3 (not shown) will be described.

(Configuration 1)
As shown in FIG. 1 (see also FIG. 2), an end wall 21 extending toward the skin material 4 is provided at the end portion of the core material 2.
Further, an end face seal wall portion 22 that extends toward the core material 2 and is pressed against the inner surface of the end wall 21 by the foaming pressure when the foam layer 3 is formed is provided at the end portion of the skin material 4.
Furthermore, an end face seal is provided in the vicinity of the end portion of the skin material 4 to prevent the foaming liquid 6 as a raw material of the foam layer 3 from reaching the end portion of the skin material 4. Provided away from the wall 22.

(Supplementary explanation 1)
Here, the above-mentioned “core material 2” is made of a hard and thick resin. The core material 2 is formed so as to have a substantially uniform thickness as a whole except for exceptional portions. The terminal portion of the core material 2 is a peripheral edge portion of the core material 2.
The above-mentioned “skin material 4” is composed of a soft thin resin. The skin material 4 is formed so as to have a substantially uniform wall thickness as a whole except for exceptional portions. The terminal portion of the skin material 4 is the peripheral edge of the skin material 4.
The skin material 4 is generally manufactured by powder slush molding or vacuum molding.
The above-described powder slush molding is basically performed by melting and adhering resin powder to a heated mold, and the above-described vacuum molding is, in short, vacuum-heating a heat-softened thermoplastic resin sheet. Then, the thermoplastic resin sheet is shaped by being brought into close contact with the vacuum forming die. Powder slush molding and vacuum molding are suitable for producing a skin material 4 having a uniform thickness.
In addition, the skin material 4 is being manufactured by injection molding. The injection molding is suitable for manufacturing the skin material 4 having portions with different thicknesses, the skin material 4 having a complicated shape, and the like. However, although the injection molding itself is general, the skin material 4 is soft and thin (and has a large area), so it is difficult to manufacture by injection molding, and much more than ordinary injection molding. Advanced technology is required.
In this case, the skin material 4 is preferably manufactured by injection molding.

  The above-mentioned “foam layer 3” is made of a foam material such as urethane foam. The foam layer 3 is interposed between the core material 2 and the skin material 4, and integrates the core material 2 and the skin material 4. The foam layer 3 is formed so as to have a substantially uniform wall thickness as a whole except for exceptional portions.

  The “foaming liquid 6” described above is, for example, a liquid resin material mixed with a foaming agent. For the foaming liquid 6, for example, liquid urethane is used. For example, when the expansion ratio of the foam layer 3 is 5 times, the injection amount of the foam liquid 6 is set to 1/5 of the volume of the foam molding space. When the foaming liquid 6 foams, gas is generated, and the foaming liquid 6 is foamed by this gas to form a foam fluid (for example, an unsolidified foam such as viscous urethane). The foamed fluid is then cured by crosslinking to form the foam layer 3.

  The above-mentioned “end wall 21” is formed integrally with the core material 2 and serves as an end surface of the foam molded product or a part thereof, and also serves as an end surface of the product or a part thereof. The end wall 21 is preferably formed in a bent shape so as to be perpendicular to the surfaces of the core material 2 and the skin material 4. However, the end wall 21 may be inclined with respect to the surfaces of the core material 2 and the skin material 4.

  In this case, the length of the end wall 21 is substantially the same as the thickness of the foam molded product, or is slightly shorter or slightly longer than that. The length of the end wall 21 is preferably about half or more of the thickness of the foam molded product. The end wall 21 extends continuously in the circumferential direction along the edge of the foam molded article. However, depending on the shape of the foam molded product, the end wall 21 may be discontinuous in the circumferential direction.

  The above-mentioned “end face seal wall portion 22” is formed integrally with the skin material 4 and overlaps on the inner peripheral surface side of the end wall 21 described above, thereby becoming a part of the end face of the foam molded product. It is also a part of the end face of the product. The end face seal wall portion 22 is preferably formed in a bent shape so as to be perpendicular to the surfaces of the core material 2 and the skin material 4. However, the end face seal wall portion 22 may be inclined with respect to the surfaces of the core material 2 and the skin material 4.

  In this case, the length of the end surface seal wall portion 22 is set to a length that does not reach the inner surface of the core member 2 at the last minute. The end surface seal wall portion 22 extends continuously in the circumferential direction along the edge of the foam molded product. However, depending on the shape of the foam molded product, the end face seal wall portion 22 may be discontinuous in the circumferential direction.

  The end face seal wall portion 22 is formed to have substantially the same thickness as the other portions of the skin material 4.

The “flexible liquid blocking wall portion 23” described above is formed integrally with the skin material 4.
The flexible liquid stop wall portion 23 is formed so as to be substantially perpendicular to the surfaces of the core material 2 and the skin material 4.

  The length (height h) of the flexible liquid stop wall 23 is set according to the amount of the foam liquid 6 injected between the core material 2 and the skin material 4 (foam molding space). . For example, in order to increase the expansion ratio of the foamed layer 3 to 5 times, the length of the flexible liquid stop wall 23 is set when the amount of the foamed liquid 6 injected is 1/5 of the volume of the foam molding space. (Height h) is at least 1/5 or more of the height of the foam molding space. That is, the height of the foamed liquid 6 is set higher than the height at which the foamed liquid 6 can be stopped. However, since the foam molding space usually has irregularities and height differences depending on the shape of the product, it is a matter of course that these irregularities and elevation differences are further set in consideration. In addition, it is preferable that the flexible liquid blocking wall portion 23 has a length (height h) that does not reach the core material 2.

  The installation position of the flexible liquid stop wall portion 23 is set to a distance s necessary for preventing the flexible liquid stop wall portion 23 from coming into contact with the end face seal wall portion 22 when the flexible liquid stop wall portion 23 is bent outward. It is preferable to have a position away from the flexible liquid stop wall portion 23 and the like (including a strength securing portion 27 described later) inward. That is, it is preferable that the above-described distance s is equal to or greater than the height h of the flexible liquid stop wall 23 (s ≧ h).

(Configuration 2)
In the above, an extended portion 24 that is recessed toward the back surface side of the core material 2 may be formed in the vicinity of the end portion of the core material 2.
The flexible liquid stop wall portion 23 is provided at a position facing the top surface 25 or the inner wall surface 26 of the expansion portion 24 or in the vicinity thereof.

(Supplementary explanation 2)
Here, the above-mentioned “expansion portion 24” expands the volume of the terminal portion of the foam molding space. The extended portion 24 is a circumferential groove or a recessed portion that continuously extends in the circumferential direction along the edge of the foam molded product. However, the extended portion 24 may be discontinuous in the circumferential direction depending on the shape of the foam molded product. The extended portion 24 has a substantially constant thickness and is configured to have a concave shape on both the inner and outer surfaces.

  The “top surface 25” described above is a surface parallel to the surface of the core member 2 formed so as to be wider than the end surface seal wall portion 22.

  The “inner wall surface 26” described above is an inclined surface that inclines inwardly downward from the inner end portion of the top surface 25 toward the upper end portion of the flexible liquid stop wall portion 23.

(Configuration 3)
In the above, the strength securing portion 27 for preventing the sticking may be provided on the inner surface of the end face seal wall portion 22 of the skin material 4.

(Supplementary explanation 3)
Here, the above-described “strength securing portion 27” can be, for example, a reinforcing rib or a partially thick portion. The strength securing portion 27 is provided at least in a portion of the end surface seal wall portion 22 where the end surface seal wall portion 22 and the end portion wall 21 do not overlap. The strength securing portion 27 may extend its upper end portion to a position where the end face seal wall portion 22 and the end wall 21 overlap. However, if the strength securing portion 27 is too high, the followability to the end wall 21 at the top of the end seal wall portion 22, that is, the sealing performance may be hindered. It is preferable that the height is not reached. For example, the strength securing unit 27 has a height that reaches or below a resin reservoir 28 described later.

  As shown in FIG. 3, a plurality of strength securing portions 27 are provided at intervals along the peripheral edge in the vicinity of the terminal portion of the skin material 4. It is desirable to provide the strength securing portion 27 at a fine pitch so that the anti-sticking function can be effectively exhibited.

(Configuration 4)
In the above, the resin reservoir 28 may be provided in the intermediate part of the end wall 21 of the core member 2.

(Supplementary explanation 4)
Here, the above-mentioned “resin reservoir 28” is a space for accommodating the foamed liquid 6 that is a raw material of the foamed layer 3 and the foamed fluid formed by foaming the foamed liquid 6. The resin reservoir 28 is provided at the position of the intermediate portion in the thickness direction of the foam molded product. The resin reservoir 28 extends in the circumferential direction along the end wall 21. The resin reservoir 28 can also contain gas generated from the foaming liquid 6, air confined in the foaming mold 5, and the like.

  Then, the above-described resin reservoir 28 divides the pressure contact portion (seal portion) between the inner surface of the end wall 21 and the outer surface of the end surface seal wall portion 22 in the thickness direction of the foamed molded product, whereby a double seal structure is obtained. It will be formed (seal part S1, S2).

(Configuration 5)
In the above, as shown in FIGS. 4 and 5, a sealing performance improving portion 29 may be provided in a portion of the end wall 21 of the core member 2 on the base side of the resin reservoir 28.

(Supplementary explanation 5)
Here, the above-described “sealability improving portion 29” literally serves to further improve the sealability on the base side (the core material 2 side or the upper side in the drawing) of the end wall 21. With this sealing performance improving portion 29, the sealing performance on the base side of the end wall 21 is improved more than the sealing performance on the distal end side (the skin material 4 side) of the end wall 21. The sealing performance improving portion 29 can be, for example, a small protruding portion 31 as shown in FIG. 4 or a stepped portion 32 as shown in FIG.

  The above-mentioned “small protrusion 31” is such that it can follow the end face seal wall 22 so that it can be contacted without any gap, for example, a small one having a slight protrusion amount and a gentle slope portion. And so on.

  Further, the above-described “stepped portion 32” is configured to follow the end face seal wall portion 22 so that it can be contacted without a gap, for example, has a slight stepped amount inward.

  Next, the manufacturing method of a foam molded product is demonstrated.

(Configuration 6)
By injecting a foaming liquid 6 as a raw material of the foam layer 3 between the core material 2 set in the foaming mold 5 and the skin material 4, the core material 2 and the skin material 4 are integrated by the foam layer 3. To produce a foamed molded product.
At this time, with respect to the inner surface of the end wall 21 provided toward the skin material 4 provided at the end portion of the core material 2,
An end face seal wall portion 22 extending toward the core material 2 provided at the terminal portion of the skin material 4 is brought into pressure contact with the foaming pressure when the foamed layer 3 is molded, thereby allowing the terminal of the skin material 4 and the core material 2 to be contacted. While letting the part seal,
Further, the foamed liquid 6 as the raw material of the foamed layer 3 is transferred to the end portion of the skin material 4 by the flexible liquid stop wall portion 23 provided in the vicinity of the end portion of the skin material 4 and away from the end face seal wall portion 22. Try to prevent it from reaching.

(Supplementary explanation 6)
More specifically, as shown in FIG. 8, the interior front panel 1 having a multilayer structure has a state in which the foam male mold 7 and the foam female mold 8 in the foam mold 5 of the foam molding apparatus are opened ( In the mold open state, the core material 2 is set on the foamed male mold 7 and the skin material 4 is set on the foamed female mold 8 (core material / skin material setting step).

  At this time, the foamed male mold 7 and the foamed material 7 are formed so that the core material 2 having a hard thickness and high shape retaining property is on the upper side, and the skin material 4 having a soft thin wall and having no shape retaining property or low shape retaining property is on the lower side. Each is set in a female mold 8.

  Next, a foaming liquid 6 as a raw material for the foam layer 3 is injected between the core material 2 and the skin material 4 set in the foaming mold 5 to form the foaming male mold 7 and the foaming female mold 8. Tighten (clamping process). The injection of the foaming liquid 6 may be performed from the injection port provided in the foaming mold 5 after the foaming mold 5 is clamped.

  Then, the foamed liquid 6 is foamed within the mold-molded foaming mold 5 to form the foamed layer 3 between the core material 2 and the skin material 4 (foaming step).

  At this time, in the foaming mold 5, first, the foaming liquid 6 spreads into the mold by its own weight, and when the foaming liquid 6 has spread to some extent, gas is generated from the foaming liquid 6 and foaming is started. The above-described gas tends to spread inside the foaming mold 5, and a foam fluid (for example, an unsolidified foam such as viscous urethane) in which the foaming liquid 6 is foamed by the gas follows the gas. Thus, the inside of the foaming mold 5 is tried to spread to the end.

  Then, by holding the above-described mold clamping state for a predetermined time, when the foamed fluid that reaches the end inside the foaming mold 5 is solidified, a foamed molded product is obtained. The mold 5 is opened to take out the foam molded product molded from the foam molding die 5 (mold opening process and foam molded product take-out process).

  After that, the product is completed by cutting away portions of the foamed molded product that are not necessary for the product in a later step. In this case, the parts that are not necessary for the product are parts that are inside the opening formed in the product.

  <Effect> According to this embodiment, the following effects can be obtained.

(Operation effect 1)
The end seal wall portion 22 is pressed against the inner surface of the end wall 21 by the foaming pressure when the foam layer 3 is formed, so that the end portions of the core material 2 and the skin material 4 can be sealed. .

  At this time, by providing a flexible liquid stop wall portion 23 in the vicinity of the end portion of the skin material 4 apart from the end face seal wall portion 22, a foam liquid 6 (for example, liquid urethane) that is a raw material of the foam layer 3 is provided. Etc.) can be prevented from reaching the terminal portion of the skin material 4 directly. Thereby, for example, it is possible to prevent a problem that the foaming liquid 6 that has reached the terminal portion of the skin material 4 leaks directly from the terminal portion.

  The foamed fluid formed by foaming of the foaming liquid (for example, unsolidified foam such as viscous urethane) is temporarily stopped by the flexible liquid stop wall 23 and then gets over the flexible liquid stop wall 23. As a result, the flow of the foam fluid can be regulated and adjusted.

  At this time, since the flexible liquid stop wall portion 23 is literally flexible, it is easily bent by the pressure of the foam fluid, and the flexible liquid stop wall portion 23 Due to the bending, the foamy fluid can easily get over the flexible liquid stop wall portion 23 and reach every corner of the end portion of the skin material 4.

  Moreover, since the end portion of the foam molding space is expanded by the bending of the flexible liquid stop wall portion 23, the foam fluid can more easily get over the flexible liquid stop wall portion 23. become. Therefore, the foamed fluid gets over the flexible liquid stop wall 23 in a substantially uniform state without being greatly disturbed. Thereby, for example, it is possible to prevent a void from being generated due to the foamy fluid not reaching the terminal portion of the foam molded product.

(Operation effect 2)
Since the extended portion 24 that is recessed toward the back surface side of the core material 2 is formed in the vicinity of the terminal portion of the core material 2, the terminal portion of the foam molding space is further expanded, so that the foam fluid is flexible. It is possible to more easily get over the liquid stop wall portion 23, and to more effectively prevent the occurrence of turbulence when the foamy fluid gets over the flexible liquid stop wall portion 23.
Further, since the flexible liquid stop wall portion 23 is provided at a position facing the top surface 25 or the inner wall surface 26 of the extension portion 24 or in the vicinity thereof, the function of the extension portion 24 and the flexible liquid stop wall are provided. The functions of the unit 23 can be strongly associated with each other to have a synergistic effect.
Furthermore, the extension part 24 is formed in the terminal part of the core material 2, whereby the rigidity of the terminal part can be improved.

(Operation effect 3)
By providing the strength securing portion 27 for preventing the sticking on the inner surface of the end seal wall portion 22 of the skin material 4, the foamed fluid formed by the foaming liquid 6 foaming does not completely reach the terminal portion. Thus, even when a gap portion is generated in the terminal portion, the presence of the strength securing portion 27 can suppress the stickiness due to the gap portion. Moreover, since the strength ensuring part 27 improves the strength of the terminal portion of the skin material 4, the terminal portion can be made less likely to be damaged.

(Operation effect 4)
By providing the resin reservoir 28 at the intermediate portion of the end wall 21 of the core material 2, the foamed liquid 6 or the like can be formed inside the pressure contact portion (seal portion) between the inner surface of the end wall 21 and the end face seal wall portion 22. Even when a foam-like fluid formed by foaming of the foaming liquid 6 enters, it can be collected by the resin reservoir 28 and prevented from leaking outside.

(Operation effect 5)
By providing a sealing performance improving portion 29 at a portion of the end wall 21 of the core material 2 closer to the base than the resin reservoir 28, a pressure contact portion (seal) between the inner surface of the end wall 21 and the end face seal wall portion 22 is provided. On the entry side of (part), the foamed liquid 6 and the foamed fluid formed by foaming of the foamed liquid 6 can be surely stopped, and these leaks can be effectively prevented.

(Operation effect 6)
The foam layer 3 is sealed by a flexible liquid stop wall 23 provided at the end portion of the skin material 4 and the core material 2 and provided in the vicinity of the end portion of the skin material 4 and away from the end face seal wall portion 22. By preventing the foaming liquid 6 serving as the raw material from reaching the terminal portion of the skin material 4, it is possible to obtain the same function and effect as those described above (the function and effect 1).

  Although the embodiments of the present invention have been described in detail with reference to the drawings, the embodiments are only examples of the present invention, and the present invention is not limited to the configurations of the embodiments. Needless to say, design changes and the like within a range not departing from the gist of the invention are included in the present invention. Further, for example, when each embodiment includes a plurality of configurations, it is a matter of course that possible combinations of these configurations are included even if not specifically described. Further, when a plurality of embodiments and modifications are shown, it is needless to say that possible combinations of configurations extending over these are included even if not specifically described. Further, the configuration depicted in the drawings is of course included even if not particularly described. Further, when there is a term of “etc.”, it is used in the sense that the equivalent is included. In addition, when there are terms such as “almost”, “about”, “degree”, etc., they are used in the sense that they include those in the range and accuracy recognized by common sense.

DESCRIPTION OF SYMBOLS 1 Car interior part interior panel 2 Core material 3 Foam layer 4 Skin material 5 Foaming mold 6 Foaming liquid 15 End wall 16 End face seal wall part 17 Fixed liquid stop wall part 21 End wall 22 End face seal wall part 23 Flexible Reactive liquid stop wall portion 24 Expansion portion 25 Top surface 26 Inner wall surface 27 Strength securing portion 28 Resin reservoir 29 Sealability improvement portion 31 Small projection portion 32 Step portion S1 Seal portion (first)
S2 Seal part (second)

Claims (6)

In the foam molded product in which the core material and the skin material are integrated by the foam layer,
An end wall extending toward the skin material is provided at the end portion of the core material,
The end portion of the skin material is provided with an end face seal wall portion that extends toward the core material and is pressed against the inner surface of the end wall by foaming pressure when forming the foam layer.
Further, a flexible liquid blocking wall portion capable of preventing the foaming liquid as a raw material of the foam layer from reaching the terminal portion of the skin material is separated from the end face seal wall portion in the vicinity of the terminal portion of the skin material. A foam-molded product characterized by being provided. In the vicinity of the end portion of the core material, an extended portion that is recessed toward the back surface side of the core material is formed,
The foamed molded article according to claim 1, wherein the flexible liquid blocking wall portion is provided at a position facing the top surface or the inner wall surface of the extension portion or in the vicinity thereof.   The foam molded product according to claim 1 or 2, wherein a strength securing portion for preventing sticking is provided on an inner surface of an end face seal wall portion of the skin material.   The foam molded article according to any one of claims 1 to 3, wherein a resin reservoir is provided in an intermediate portion of the end wall of the core member.   The foam-molded article according to claim 4, wherein a sealing performance improving portion is provided in a portion closer to the base side than the resin reservoir of the end wall of the core material. By injecting a foaming liquid, which is the raw material for the foam layer, between the core material and the skin material set in the foam molding die, a foam molded product in which the core material and the skin material are integrated by the foam layer is manufactured. In the method of manufacturing a foamed molded product,
On the inner surface of the end wall that extends toward the skin material provided at the terminal part of the core material,
An end face seal wall portion extending toward the core material provided at the end portion of the skin material,
By pressing with the foaming pressure when molding the foam layer,
While sealing the end portion of the skin material and the core material,
The flexible liquid stop wall provided in the vicinity of the end portion of the skin material apart from the end face seal wall portion prevents the foaming liquid as the raw material of the foam layer from reaching the terminal portion of the skin material. A method for producing a foam molded article.