JPH03118118A - Manufacture of foam molded product - Google Patents

Abstract

PURPOSE:To omit the boarding process of a skin by providing given notches on a composite sheet composed of a skin layer and a foamed layer, preliminarily forming a skin material in the manufacture of a foam molded product having a different surface section on a part of the product surface, disposing said skin material in the divisions of a mold and foam molding. CONSTITUTION:Projecting walls 13 for dividing a molded surface into base divisions 12 and a central division 6 are provided on a bottom force 11 of a mold 5. A skin material 1 is composed of vinyl chloride resin and the like, and for example, provided with fillings 4, and with a composite sheet composed of laminated foamed layers 3 of polyethylene resin or the like at the rear face. A notch 30 almost conforming with the shape of a division 6 of a mold 5 is provided on the skin material 1 and a notch 31 is also provided on its outer peripheral section with the interval width equivalent to the height of projecting walls 13, and the skin material is divided into a central section 7, a side section 8 and a folding section 32 by said notches 30 and 31. Also, notches 33 heading for the central direction are provided in four sites on the side section 8 and the folding section 32. Said central section 7 is inserted into the central division 6 of the bottom force 11 and set in the state that the notch 30 is closed to a base 35 of the projecting wall 13, while the folding section 32 is folded in the horizontal direction from the notch 31. A base skin material 14 formed preliminar ily is disposed on the base division 12 of the bottom force 11, and a tape 33 is stuck to the ends of the skin materials 14 and 1 to prevent the raw material from leaking. After that, a urethane foam liquid raw material 15 is injected and a top force 10 is closed, cured, and then released.

Description

Detailed Description of the Invention (Industrial Application Field) The present invention relates to a foamed molded product having different surface parts on a part of the product surface, more specifically, a foam molded product having different surface parts on a part of the product surface, and more specifically, a foam molded product having a fabric on a part of the skin of a synthetic resin sheet. Foam molded products with different colored parts, specific products include foam molded products such as automobile interior parts such as automobile door trims, furniture, building materials, etc. that have the above-mentioned characteristics. The present invention relates to a manufacturing method.

(Prior art) In recent years, foamed molded products such as automobile interior parts, furniture, building materials, etc., as mentioned above, have been treated with cloth or different colored synthetic resins on a part of the surface due to the diversification and increasing luxury of consumer-oriented products. High demand.

This type of foam molded product uses a foam mold that has a protruding wall that partitions the molding surface into multiple sections, a skin body is attached to each of the zones, and a liquid raw material of urethane foam is applied to the back side of the skin body. It is molded by injecting and curing the urethane foam raw material to bond the skins of each section together.

Therefore, during molding, each skin body must be attached in complete contact with the molding surface and projecting wall of the mold. Therefore,
The skin body attached to each compartment is generally preformed by vacuum forming or slush forming as shown in FIG. 7.

(Problem to be Solved by the Invention) However, the preforming of the skin itself requires a large number of steps, and therefore, the manufacturing method for this type of foam molded product requires many steps and improvements. was desired.

Therefore, instead of the above-mentioned skin, an extremely soft sheet-like material that has not been preformed and molded is placed in the mold as it is, and pressed against the molding surface and projecting wall of the mold by the foaming pressure of polyurethane foam. Attempts have been made to omit the preforming process for the body, but satisfactory results were not achieved due to problems such as wrinkles appearing on the surface of the skin body during foam molding and leakage of polyurethane foam from the joints.

In view of the above circumstances, it is an object of the present invention to disclose a method for manufacturing a foamed molded product that does not cause deterioration in quality while omitting the step of preforming the skin body.

(Means for Solving the Problems) Therefore, the feature of the present invention for achieving the above object lies in a method for manufacturing a foam molded article, which is characterized by comprising the following steps.

(a) A step of molding a skin body having notches in the foam layer of a composite sheet in which a foam layer is laminated on the back side of the skin layer. (b) A mold having a projecting wall that partitions the molding surface into multiple sections. A step of arranging a skin body in at least one section with the notch close to the base of the projecting wall.

(c) A step of pouring a liquid raw material for polyurethane foam into a mold and removing the mold after the raw material has hardened.

The notch provided in the first step of the present invention is provided to match the shape to which the skin will be attached when the final foamed molded product is made. Therefore, the notch is usually provided in an annular shape. The notch can be formed by using a cutting tool such as a knife or a cutting tool, or by melting it away with heat or chemicals, or by crushing the foam layer with a press. When creating a notch using a cutter, it is preferable to make a pattern in advance and then run the cutter along the pattern.

In addition, when using the method of melting away with heat or chemicals, there is a method in which a jig made of metal or the like is made in advance, immersed in a specified chemical to melt the metal rod, and then pressed against the foam layer of the composite sheet. is preferred.

The cross-sectional shape of the notch is most preferably triangular, but it is of course possible to have a semicircular shape or a slit shape.

Next, in a second step, the skin body is placed on the molding surface, and since the skin body is provided with a notch, the end portion of the skin body stands upright along the projecting wall and comes into close contact with the projecting wall.

In addition, since the part on the center side of the notch, that is, the part placed on the molding surface of the mold, has a foam layer, it has a certain degree of rigidity and can be attached tightly without wrinkles. be done.

Then, after placing other skins in other compartments as necessary, the skins are reinforced by injecting liquid raw materials for polyurethane foam according to known means.

(Example) Further, specific examples of the present invention will be described below.

FIG. 1 is a front view of a skin body molded by a process according to a specific embodiment of the present invention, FIG. 2 is a sectional view taken along the line A-A in FIG. 1, and FIG. 4 is a front view of the lower mold of the foam mold used in the example, FIG. 4 is a cross-sectional view of the foam mold in one step of the method for producing a foam molded product of this example, and FIG. FIG. 6 is a partially enlarged cross-sectional view of a projecting wall portion of FIG.

In FIGS. 1 and 2, (1) shows the skin body preformed in the first step of this embodiment.

The skin body (1) is made of vinyl chloride resin, etc., and a foam layer (3) made of polyethylene resin, polypropylene resin, etc. is laminated on the back side of the relatively soft skin layer (2).
In addition, the material is a composite sheet in which flocks (4) are provided on the surface of the skin layer (2).

The skin body (1) is provided with a notch (30) in an elliptical shape that roughly matches the shape of the section (6) of the mold (5), which will be described later.
Furthermore, a notch (31) is provided on the outer periphery of the notch (30) with a width corresponding to the height of a projecting wall (13) to be described later.
30) and (31) into a central portion (7), side portions (8), and folded portions (32).

In addition to the elliptical notches (30) and (31), four notches (33) are provided in the side portion (8) and the folded portion (32) toward the center.

In this example, the skin body (1) is made by first cutting out a part corresponding to the outer shape of the skin body from a composite sheet, and pasting a paper pattern corresponding to the shape of the side part (8) prepared in advance to the composite skin body. In this state, a cutting tool was run along the pattern to form notches (30) and (31) with triangular cross sections.

Next, the above skin body (1) is placed in the lower mold (11) of the mold (5).
). In this example, the mold (5) is the upper mold (
10) and a lower mold (11), the lower mold (11) is provided with an elliptical projecting wall (13) that partitions the molding surface into a base section (12) and a central section (6). Although each section is planar in this figure, it may be curved depending on the design. The epidermal body (1) is the lower type (11)
The central part (7) is inserted into the elliptical central section (6) fixed to the projecting wall (13), and the notch (30) is set in close proximity to the base (35) of the projecting wall (13). . At this time,
The flocked hair (4) is pressed down and falls down, and the side part (8) is a protruding wall (
13) Stand upright. The central part (7) is the central section (6
), it receives a force in the central direction from the projecting wall (13), but since the foam layer (3) is laminated on the back of the central part (7), it has a certain degree of rigidity and wrinkles partially. Never. The folded portion (32) is folded back in the horizontal direction from the notch (31). At this time, the side part (8), the folded part (
32), wrinkles occur due to the difference in circumferential length between the central part and the outer peripheral part, but these wrinkles are absorbed by weaving the cutout (33) part.

The base section (12) of the lower mold (11) is provided with a base skin body (14) preformed by known vacuum forming or slush molding means, and the base skin body (14) and the skin body (1 ) to prevent leakage of raw materials (33
) (Figure 5).

After that, a hard urethane foam liquid absorbing material (
After injecting 15), close the upper mold (10).

At this time, it is also effective to further improve the rigidity by inserting a glass mat, glass cloth, injection molded synthetic resin, or metal reinforcement into the back surface of the base skin (14). By reacting and curing the hard urethane foam raw material into a body chamber, it is possible to obtain a synthetic resin molded article having flocking only in the center as shown in FIG. 6.

In the above embodiment, the skin body was provided with a folded portion (32). The folded portion is preferable because it closes the top of the projecting wall of the mold and prevents leakage of the raw material from the portion.

However, this is not necessarily essential in the present invention. In addition, a notch was provided between the folded part and the edge part (8) to facilitate folding, but instead of the notch, the foam layer of the entire folded part could be removed by cutting, melting, etc., or pressed. The same effect can be obtained even if it is crushed by

Similarly, the notch (33) can also be omitted or replaced by means such as cutting or melting.

(Effects) The method for manufacturing a foamed molded product of the present invention includes preforming a skin body by providing a predetermined notch in a composite sheet consisting of a skin layer and a foam layer, and disposing the skin body in a section of a mold. By foam molding, it is possible to omit a large-scale molding process such as vacuum molding or slush molding of the skin.

Furthermore, since the central part of the skin body has a certain degree of rigidity, wrinkles do not occur during foam molding or when it is attached to a mold, which has the effect of maintaining high quality.

[Brief explanation of drawings]

FIG. 1 is a front view of a skin body molded by a process according to a specific embodiment of the present invention, FIG. 2 is a sectional view taken along the line A-A in FIG. 1, and FIG. FIG. 4 is a front view of the lower mold of the foam molding mold used in the example, FIG. FIG. 6 is a cross-sectional view of a foam molded product manufactured by the method for manufacturing a foam molded product according to a specific embodiment of the present invention, and FIG. 7 is a sectional view of a conventional foam molded product. FIG. (1)... Epidermal body (2)... Epidermal layer (3)... Foam layer (4)... Flocking (7)... Central part (8)... Side part (10) ... Upper mold (11) ... Lower mold (12) ... Base molding surface (13) ... Projection wall (14) ... Base skin body (30) (31) (33) ...・Notch (32)...
・Folded part (35)...Base of projecting wall

Claims (1)

[Claims] 1. A method for producing a foamed molded product, which comprises the following steps. (a) A step of molding a skin body in which notches are provided in the foam layer of a composite sheet in which a foam layer is laminated on the back side of the skin layer. (b) A step of arranging a skin body in at least one section of a mold having a protruding wall that partitions the molding surface into a plurality of sections, with the cutout being close to the base of the protruding wall. (c) A step of pouring a liquid raw material for polyurethane foam into a mold and removing the mold after the raw material has hardened.