JPH02305610A - Foam molded product having skin material and its manufacture - Google Patents

Abstract

PURPOSE:To improve production efficiency and obtain a product superior in quality, by a method wherein a skin body is joined to the surface of a base material free from mold release agent through an adhesive agent for integration. CONSTITUTION:A sheet S formed with vacuum molding is stuck close to a bottom force 52 of a foam mold 50, on which a bracket 60 is put. Then mold clamping is performed by lowering a top force 54 and a foamable resin layer 64 is formed by casting a foamable resin material into a demarcated cavity 62 through a casting port 56. Then when the sheet S is peeled off after taking out of the foamable resin layer 64, into which the bracket 60 is laid, by performing mold release, a base material 14 is obtained. A composite sheet 12 of a skin material is formed by a method wherein after lamination of the foamable resin layer to a vinyl chloride sheet 24 having a pattern, the same is cut off after forms of a main body 34 and members 36, 38 and joined them to one another with sewing threads 31a, 31b, a short side is windened and they are sewn together with sewing threads 32b, 32b by making use of a lining material 30. When the adhesive agent is applied to the composite sheet 12 and the same is stuck to the base material 14, a molded body of an instrument panel 10 is completed.

Description

Detailed Description of the Invention [Industrial Field of Application] The present invention relates to a foam molded article having a skin material and a method for manufacturing the same, and more specifically, to manufacturing a foam molded article having a skin material, such as an instrument panel. To achieve this, when integrating a skin material with a predetermined pattern onto a base material made of foam via an adhesive, a release sheet is placed in advance on the mold for the base material, and the molding A foam molded product having a skin material that eliminates the process of applying or removing a mold release agent to the mold, thereby improving production efficiency and making it possible to obtain a product with excellent quality, and a method for manufacturing the same. Regarding.

[Background of the invention] Recently, there has been a remarkable trend towards luxury cars.

For example, in an instrument panel, the cooling/heating air duct, the case for installing the air conditioner, etc. are installed using in-mold molding, and a skin sheet with a wrinkled pattern is attached to this to create a sense of visual unity. can be said to be a good example of this. In particular, for instrument panels, it is desirable to have seams on the skin material at bent or curved portions to create a texture that looks as if the skin material had been sewn together and stitched.

When manufacturing an instrument panel with such a structure, skin sheets with a predetermined pattern (leather grain pattern) on the surface are sewn together, and the sewn skin sheets are held between molds consisting of a male mold and a female mold. It is conceivable to perform foam molding to form the base material. In this case, there is a risk of foaming resin leaking from the sutured areas during the foaming process.
To avoid this, the sutured area must be sealed with seal tape or the like. On the other hand, the sewn skin sheet has a complicated shape in order to imitate the outer shape of the instrument panel, and the seamed areas are uneven, which causes problems such as wrinkles and bulges during the foaming process. be.

In order to avoid this kind of inconvenience, it is naturally possible to integrate the skin sheet and the base material by bonding them together. However, depending on the material of the base material, such as a hard foamable resin such as urethane, it is naturally necessary to apply a mold release agent to the mold in advance in order to smoothly release the mold from the mold. Moreover, the mold release agent remains attached to the base material to be molded, and when bonding the skin sheet to such a base material, the mold release agent may be removed using a solvent or a solvent to improve the adhesion between the base material and the skin sheet. This has to be removed by sandblasting or the like, which is a major hindrance to improving production efficiency.

[Object of the Invention] The present invention has been made in order to overcome the above-mentioned disadvantages, and in order to produce a foamed molded product having a skin material, a foam molded product is formed using a skin material provided with a predetermined pattern in advance and a mold. When integrating the molded base material with an adhesive, a release sheet is placed in the mold in advance, and a foaming agent is injected into the sheet to foam and solidify, thereby releasing the mold. Foamed molded products with a skin material that makes it possible to improve the production efficiency of this type of molded products and obtain products with excellent quality by omitting the steps of applying a mold release agent and removing the mold release agent. The purpose is to provide a manufacturing method thereof.

[Means for Achieving the Object] In order to achieve the above-mentioned object, the present invention provides a composite sheet in which a skin material and an elastic foam sheet are laminated together and cut into a predetermined shape. It consists of a skin body sutured in such a way that the surface of the skin body is located, and a base material made of a hard foam having a surface to which no mold release agent is attached. It is characterized in that it is joined and integrated through.

Further, the present invention is characterized in that the first base material, the second base material, etc. are molded from a hard foamed resin material, the respective base materials are connected to each other via an insert fitting, and the connected base materials are further connected to each other via a metal insert. It is characterized by being covered with a skin material.

Furthermore, the present invention provides a mold release sheet between the first mold and the second mold, then brings the mold release sheet into close contact with either one of the molds, and furthermore, the first mold type and second
A foamed resin material is injected into the cavity defined between the mold and the foamed material, and after the foamed material solidifies, the mold is opened and the mold release sheet is peeled off from the foamed molded product. It is characterized by fixing the skin material to the foamed molded product.

[Embodiments] Next, preferred embodiments of the foamed molded article having a skin material and the method for manufacturing the same according to the present invention will be described in detail with reference to the accompanying drawings.

In FIG. 1, reference numeral 10 indicates a foamed molded product having a skin material according to the present invention, for example, an automobile instrument panel, and the instrument panel 10 is made of vinyl chloride or the like with an uneven pattern such as a leather grain. The composite sheet 12 is made of a skin material and an elastic foamable resin such as polyurethane, and a base material 14 is made of a hard foamable resin such as urethane. As can be easily understood from the figure, the instrument panel 10 is equipped with a glove box forming part 18 for storing items, etc., an operation panel for an in-vehicle stereo and an air conditioner, a shift lever, a handbrake lever, etc. Console 1
120 and an opening 22 through which a steering wheel shaft is inserted and a speedometer or the like is disposed.

Here, the composite sheet 12 and the base material 14 that constitute the instrument panel 10 have a bonding structure as shown in FIG. 2. That is, the composite sheet 12 is cut into a plurality of pattern shapes in advance and sewn together to form a seam portion 16 that exposes the seam.
It has a shape that covers the surface of 4.

The suture portion 16 is shown in detail in FIG. As can be easily understood from the figure, the stitched portion 16 is made of a vinyl chloride sheet 24 and a foamed resin layer 2 made of elastic polyurethane or the like.
Two composite seams constructed by laminating 6) 28a, 2
8b are brought into contact with each other by bending their ends, a backing material 30 is disposed at the contact portion, and the parts are sewn together with suture threads 32a and 32b.

On the other hand, the base material 14 includes a main body 34 and a console article material 3.
6 and a visor portion 38 for a speedometer, etc. The glove box forming part 18
A bracket (not shown) for fitting a glove box, an in-vehicle stereo, an air conditioner operation panel, a speedometer, etc., is installed in the console portion 20 and the opening 22.

The instrument panel 10 to which the method of manufacturing a foamed molded product having a skin material according to the present invention is applied is basically constructed as described above, and the manufacturing process and effects thereof will be explained next.

The manufacturing process of the instrument panel 10 includes a manufacturing process of the composite sheet 12, which is a skin material, and a manufacturing process of the base material 14.

First, the manufacturing process of the composite sheet 12, which is a skin material, will be explained. A foamable resin layer 26 made of elastic polyurethane or the like is bonded to a vinyl chloride sheet 24 having a pattern such as leather wrinkles using a predetermined adhesive. Then, as shown in FIG. 4, the composite sheet 12 is cut according to the shapes of the main body 34, the console member 3G, and the visor part 38, and the suture thread 31a is cut as shown in FIGS. 3 and 5. ,3
After joining with 1b, the short side is expanded and a different suture thread 32 is attached.
A and 32b are sewn together using the backing material 30 to form the outer skin of the instrument panel IO.

Next, the manufacturing process of the base material 14 will be explained.

The main body 34, the console member 36, and the visor portion 38 constituting the base material 14 are manufactured in the same process. Therefore, here, the main body 34 has the most complicated shape.
I will explain about it. This process includes the step of molding a sheet S made of vinyl chloride using a vacuum mold to release the base material 14 from the mold described later, and the molded sheet S
The process consists of positioning and fixing the foam together with a bracket in a foaming mold, then tightening the mold, and then foaming.

This process will be explained below.

The vacuum forming mold 40 is shown in FIG. 6a. The vacuum forming mold 40
has a lower mold 42 and an upper mold 44. The lower mold 42 has a shape that follows the outer shape of the main body 34 constituting the instrument panel IO, and has a narrow recess 43 in a part thereof. The lower mold 42 has a plurality of suction ports for sucking the sheet S to be molded into the lower mold 42 and bringing it into close contact with the sheet S. The suction port is connected to a vacuum suction means (not shown). moreover,
The upper mold 44 is provided with a rod 46 for insertion into the recess 43 of the lower mold 42 . In this case, the vacuum forming mold 4
0 can also be provided with heating means.

Therefore, a sheet S stretched over a frame 47 is provided between the lower mold 42 and the upper mold 44. At this time, the sheet S may be entirely heated in advance by a heating means (not shown), or if the lower die 42 is provided with a heating means as described above, the sheet S may be lowered and heated. The lower die 42 may also be in contact with the lower mold 42 .

This softens the sheet S, making it easier to follow the predetermined shape of the lower die 42. At this time, the vacuum suction means connected to the lower mold 42 is driven to bring the sheet S into close contact with the lower mold 42 through the suction port 42a.

Then, the upper mold 44 is lowered and the rod 46 is inserted into the recess 43. As a result, the sheet S is pulled by the rod 46, and the sheet S is further brought into close contact with the lower mold 42.

Next, if the lower mold 42 has a heating means, its energy is reduced, and after a predetermined time has elapsed and the molding is completed, the vacuum suction means is stopped, the upper mold 44 is retired, and then the sheet is heated. ) Release S from the lower mold 42 (see FIG. 6C).

Furthermore, the molded sheet) S is set in the foaming mold 50. This foaming mold 50 has a lower mold 52 and an upper mold 54. The lower mold 52 is formed in a shape that directly follows the sheet S formed by the vacuum forming mold 40, and the lower mold 52 has a plurality of suction ports 52a for suctioning and bringing the sheet S into close contact with the sheet S. The suction port 52a is connected to a vacuum suction means (not shown). On the other hand, the upper mold 54 has an injection port 56 through which a foamable resin material is injected by a foamable resin material injection means (not shown). Furthermore, a sealing member is provided on the molding surfaces of the foamable resin material of the lower mold 52 and the upper mold 54 in order to prevent leakage of the foamable resin material from the joint surface between the bracket as the insert fitting and the foamable resin material. 58a to 58e are provided.

Note that when setting the seat S in the foam mold 50, a bracket 60 for fitting a glove box, a car stereo, an air conditioner operation panel, a speedometer, etc., is placed on the seat S (Fig. 6C). reference). Next, as shown in FIG. 7, after the upper mold 54 is lowered relative to the lower mold 52 and the two molds are clamped, the sheet S is drawn under the suction action of the vacuum suction means connected to the lower mold 52. is brought into close contact with the lower mold 52. In this case, the mold surface of the upper mold 54 may be coated with a mold release agent. This is because in molded products corresponding to this surface, the skin material etc. are not bonded thereafter, and the foamable resin material is effectively released from the upper mold. Next, a foamable resin material is injected from a foamable resin material injection means into a cavity 62 defined between the lower mold 52 and the upper mold 54 through the injection port 56, thereby forming a foamable resin layer 64. . After curing for a predetermined period of time, the mold is released as shown in FIG. 7C. That is, in this case, the vacuum suction means connected to the lower mold 52 is stopped and the upper mold 54 is removed to open the mold, and the foamable resin layer 64 in which the bracket 60 is embedded is taken out. Next, the sheet S is peeled off from the foamable resin layer 64 to obtain the base material 14 as a product.

As shown in FIG.
The base material 14 of the instrument panel 10 is formed by joining the visor portion 38 of the speedometer and the visor portion 38 of the speedometer. At this time, no release agent is applied to at least one surface of the base material 14, as can be easily understood from the peeling of the sheet S.

Next, an adhesive is applied to the composite sheet 12 manufactured as described above, and the composite sheet 12 and the base material 14 are bonded together to complete the molded product of the instrument panel 10.

As described above, according to the present invention, since the foaming process is performed through the sheet S in the foaming process, unlike the conventional technology, there is no need to apply a mold release agent to one side of the foam mold. This makes it possible to easily release the foam molded product from the mold.Also, in order to bond the composite sheet 12 and the base material 14 made of the foam molded product, an adhesive is applied to the base material 14. In this case, no step of removing the mold release agent is required.

Next, FIG. 8 shows another embodiment of the present invention.

In the manufacturing process in this embodiment, a foaming process is performed via the sheet S, similar to the embodiment described above. In the manufacturing process in this embodiment, the molding of the sheet S and the foaming process are performed using a single foaming mold 70. This foaming mold 70 has a lower mold 72 and an upper mold 74. The lower mold 72 has a shape in which the sheet S corresponds to the outer shape of the instrument panel 10 and a cavity corresponding to a foamable resin layer to be described later is defined when the foam molding mold 70 performs mold clamping. ing. Is the lower mold 72 a block that can be divided into three? 2a, 7
2b and? 2c, and has a suction port 82 for sucking the sheet S to the lower mold 72 and bringing it into close contact with the lower mold 72. The suction port 82 is connected to a vacuum suction means (not shown).

The upper mold 74 has an injection port 84 through which a foamable resin material is injected by a foamable resin material injection means (not shown). At least the block 72b of the lower mold 72 has a heating means (not shown), and has a function of driving the heating means to heat the sheet S when molding the sheet S.

First, as shown in FIG. 8a, the sheet S is placed above the lower mold 72 for molding, and then is allowed to hang down.

At this time, the sheet S is heated by a heating means (not shown) of the lower mold 72.

Next, as shown in FIG. 8, the upper mold 74 is lowered and clamped with the lower mold 72. That is, a cavity 86 is defined between the lower mold 72 and the upper mold 74. Then, the vacuum suction means connected to the lower mold 72 is driven, and the suction port 8
2, the sheet S is brought into close contact with the lower mold 72. After curing for a predetermined period of time, when the molding process of C) S is completed, the mold is opened as shown in FIG. 8C. In this case, the vacuum suction means connected to the lower mold 72 is in operation, and the sheet S remains in close contact with the lower mold 72.

Next, a foam molding process is performed. Lower mold 7 of foam mold 70
Brackets 88 and 90 are attached to 2 to mount a glove box, an in-vehicle stereo, an air conditioner operation panel, a speedometer, etc.

Next, as shown in FIG. 8d, the upper mold 74 and the lower mold 72 are clamped, and the foamed resin material is injected into the cavity 86 from the foamed resin material injection means (not shown) through the injection port 84. injected into. That is, a foamable resin layer 92 is formed. After curing for a predetermined period of time, the upper mold 74 is removed from the lower mold 72, as shown in FIG. 8e. In this case, the vacuum suction means connected to the lower mold 72 is stopped, the mold is opened, and the foamable resin layer 92 is taken out. Next, by peeling the sheet S from the foamable resin layer 92, the base material 14 as a product is completed (see FIG. 8f).

As described above, according to this embodiment, since the sheet S forming process and the foam molding process can be performed using a single foam mold 70, the manufacturing process can be shortened and production efficiency can be improved. It is possible to plan.

[Effects of the Invention] As described above, according to the present invention, when integrating a skin material with a base material formed by a mold via an adhesive,
The base material was molded through a release sheet.

For this reason, there is no need for the process of applying a mold release agent to the mold or removing it after molding as in conventional technology, and as a result, production efficiency is improved and products with excellent quality can be obtained. I can do it. Moreover, the effect of suppressing production costs can be obtained.

Although the present invention has been described above with reference to preferred embodiments, the present invention is not limited to these embodiments.
Of course, various improvements and changes in design are possible without departing from the gist of the present invention.

[Brief explanation of drawings]

FIG. 1 is an explanatory perspective view of an instrument panel to which the method for manufacturing a foam molded product having a skin material according to the present invention is applied; FIG. 2 is an exploded perspective view of the instrument panel shown in FIG. 1; FIG. is a partially omitted enlarged perspective view of the sutured part of the instrument panel shown in FIG. Figures 6a to 6C are explanatory diagrams of the vacuum forming process of the release sheet, and Figure 7 [! Ia to C are explanatory diagrams of the foam molding process of the base material of the instrument panel shown in FIG. 1, and FIGS. 8a to f are explanatory diagrams of the process of another embodiment of the present invention. 10... Instrument panel 12... Composite sheet 14... Base material 16... Sewing portion 32a
, 32b... Suture thread 34... Main body 38... Part of visor 40... Vacuum forming mold 52... Lower mold 54... Upper mold 60... Bracket
64... Foamable resin layer 72... Lower mold
74... Upper mold 82... Suction port 8
8.90... Bracket 92... Foaming resin layer

Claims (11)

[Claims] (1) A composite sheet made by laminating a skin material and an elastic foam sheet and cutting it into a predetermined shape, then stitching the composite sheet so that the seams are located at a predetermined location, and a mold release agent attached to the composite sheet. a base material made of a hard foam having a free surface, and a foam molded product having a skin material, characterized in that a skin material is integrally bonded to the surface of the base material without a mold release agent via an adhesive. . (2) The foam molded product according to claim 1, wherein the surface of the base material to be bonded to the skin body is formed as a surface free of a mold release agent by a mold release sheet placed in the mold. A foam molded product with (3) A first base material, a second base material, etc. are molded from a hard foam resin material, each base material is connected to each other via an insert fitting, and the connected base material is then molded into a skin material. A foam molded product having a skin material characterized by being covered by a foam material. (4) The foam molded product according to claim 3, wherein the insert metal fitting is embedded in a hard foam layer constituting any one of the base materials. (5) A mold release sheet is provided between the first mold and the second mold, and then this mold release sheet is brought into close contact with one of the molds, and then the first mold and A foamed resin material is injected into a cavity defined between the second molding mold and foamed, and after the foamed material solidifies, the mold is opened and the mold release sheet is peeled off from the foamed molded product. 1. A method for producing a foam molded article having a skin material, which comprises adhering a skin material to the obtained foam molded product. (6) The method of manufacturing a foam molded product having a skin material according to claim 5, wherein the mold release sheet is brought into close contact with one of the molds in a heated state. (7) A method for producing a foamed molded product having a skin material according to claim 6, wherein the release sheet is heated by a heated mold. (8) In the manufacturing method according to any one of claims 5 to 7, the foamed resin material is injected while the release sheet is in close contact with one of the molds under suction to obtain a foamed molded product. A method for manufacturing a foam molded product having a characteristic skin material. (9) In the manufacturing method according to any one of claims 5 to 8, an insert fitting for bonding the foamed molded product is placed on the release sheet in advance, and the insert fitting is embedded in the foamable resin. A method for producing a foam molded product having a skin material characterized by: (10) In the manufacturing method according to any one of claims 5 to 9, the release sheet is suction-molded into a predetermined shape using a first mold, and then the release sheet is set in a foam mold. 1. A method for producing a foam molded product having a skin material, the method comprising performing foam molding of a foam resin material. (11) In the manufacturing method according to any one of claims 5 to 9, the release sheet is suction-molded into a predetermined shape using a mold, and then a foamed resin material is injected into the same mold to perform foam molding. 1. A method for producing a foam molded product having a skin material, the method comprising: