JPH0376609A - Manufacture of foam-molded product formed unitarily with skin - Google Patents

Abstract

PURPOSE:To easily manufacture a foam-molded product formed unitarily with skins, even the rear surface of which is covered with the skin without spoiling the fine appearance of the rear surface thereof, by injecting a liquid foaming material onto the skin while vacuum- sucking the skin to the surfaces of top and bottom forces, and by performing the foam molding of the liquid foaming material unitarily with the skins between the skins on the surfaces of the top and bottom forces clamped before or after injecting the liquid foaming material. CONSTITUTION:In a state where a mold 26 is opened, a skin 38 is vacuum-sucked onto the surfaces of a top force 28 and a bottom force 30 to be vaccum-molded and is formed into the shape of the force surfaces. Then, an insert 40 is, if necessary, disposed in the mold, and the top force 28 and the bottom force 30 are clamped together while the skin 38 is being sucked to the surfaces of both forces. Thereafter, a liquid foaming material 42 such as a urethane foam material is injected into a space defined between the skins on the surfaces of the bottom force 30 and the top force 28. The foaming material 42 injected into the space between the skins is foamed to fill up the space between the skins 38, 38 and adheres to the inner surfaces of the skins due to adhesion properties which the foaming material exhibits when it is foamed, so that the foaming material is made into a foam-molded product formed unitarily with the skins. Thereafter, the foam-molded product is removed from the mold, and the unnecessary portions of the skins are cut off. By this method, the foam-molded product 44 formed unitarily with the skins can be used as a finished article as it is without covering the rear surface of the foam-molded product with some other materials.

Description

DETAILED DESCRIPTION OF THE INVENTION (Industrial Application Field) The present invention relates to a method for manufacturing a skin-integrated foam molded product in which the front and back sides of a foam molded product are covered with a skin.

(Prior Art) As a method for manufacturing a foam molded article having a skin, there is a skin-integrated foam molding method. The skin-integrated foam molding method is a method in which a skin is placed on the lower mold surface of a mold, a liquid foaming raw material is injected onto the skin, and the skin is foam-molded integrally with the skin.

At this time, in order to place the skin along a predetermined cavity surface, a vacuum suction hole 14 is provided on the surface of the lower mold 12 of the mold 10 as shown in FIG. 4, so that the lower mold can be vacuum-suctioned from the back side. ,
The skin of a plastic sheet or the like 16 is vacuum-suctioned onto the mold surface of the lower mold 12 to conform to the shape of the mold surface, and the liquid foaming raw material 18 is injected onto the vacuum-sucked skin to perform foam molding integrally with the skin. It has started to be done recently.

(Problems to be Solved by the Invention) In the foamed molded product thus obtained, as shown in FIG. 5, the back surface of the foam 20 is not covered with a skin, so the back surface must also be covered with a skin. In this case, the edge 22 of the epidermis 20
This requires work such as folding back and adhering it to the back surface of the foam 24.

However, if the back surface of the foam 20 is flat, adhesion of the skin is easy, but if the back surface has an uneven shape, wrinkles are likely to occur in the skin when adhering the skin, and the back surface of the resulting foam molded product tends to become less aesthetically pleasing. This is an extremely important issue in products such as automobile backrests, where the beauty of the back side (back side) of a molded product determines the value of the product.

Therefore, in the case of skin-integrated foam molded products that require the appearance of the back side, a separate part (called a back garnish) made of a resin molded product is attached to the back side of the molded product to hide the back side of the foam. Alternatively, another skin may be attached to the back side of the molded product by sewing, but this method has the drawback of increasing the amount of work required.

In view of the above points, Hatsu Milli 1 aims to provide a method for easily manufacturing a skin-integrated foamed molded product whose back surface is covered with a skin without impairing the beauty of the back surface.

(Means for Solving the Problem) In order to achieve the above-mentioned object, the present invention provides a method in which a mold consisting of an upper mold and a lower mold having vacuum suction holes on the mold surface is opened.
The skin is sucked into the upper mold surface and the lower mold surface to shape it into the shape of the mold surface, and the liquid foaming material is injected onto the skin while vacuum suctioning the skin to the mold surface, and the material is closed before or after the injection. By foam-molding the liquid foam raw material integrally with the skin between the mold surfaces of the upper and lower molds, it was decided to produce a skin-integrated foam molded product.

(Operation) The skin is vacuum-suctioned to the open mold surfaces of the upper and lower molds and shaped into the shape of the mold surfaces. Then, the liquid foaming raw material is injected onto the skin of the mold surface while the skin is being sucked into the mold surface. Then, before or after the injection, the liquid foaming material foams between the skins of the mold surfaces of the upper and lower molds that are closed, filling the space between the skins, and the adhesive properties of the foaming material developed at this time form a foam between the skins. The foam bodies are integrated to form a foam molded product.

The foam molded product obtained by demolding is then covered with a skin around the foam. Moreover, the skin is shaped into the shape of the mold surface and is adhered and integrated with the foam formed between the skins while being attracted to the mold surface, so the back surface of the foam molded product is uneven. It does not cause wrinkles.

(Tip Embodiment) FIGS. 1 and 2 are cross-sectional views of a mold for manufacturing a skin-integrated foam molded crystal according to an embodiment of the present invention.

The mold 26 includes an upper mold 28 and a lower mold 30 connected by a hinge so as to be openable and closable. The mold surfaces of the upper mold 28 and the lower mold 30 are formed into a desired foam molded product shape. In addition, a large number of vacuum suction holes 34 are formed on the mold surface, and the vacuum suction holes 34 are connected to a vacuum pump (1) and a vacuum pump (
(not shown).

With the mold 26 opened, the skin 38 is vacuum-suctioned onto the mold surfaces of the upper mold 28 and the lower mold 30 for vacuum forming and shaped into the shape of the mold surfaces. At this time, in order to facilitate the shaping of the epidermis 38,
It is preferable to heat the epidermis depending on the material of the epidermis.

The skin 38 used may be a single plastic sheet, a fabric lined with a non-breathable plastic film, or a laminated layer of fabric, thin soft urethane foam, and a non-breathable plastic film. Further, the front side and back side of the foam molded product may be covered with a skin made of a different material. For example, a fabric laminate is vacuum-suctioned onto the mold surface of the lower mold 30 that forms the front side of the foam-molded product, and a plastic sheet is vacuum-suctioned onto the mold surface of the upper mold 28 that forms the back side of the foam-molded product. May be inhaled. Note that the skin 38 is formed between the part of the upper mold 28 that is sucked into the mold surface and the lower mold 3.
The part to be sucked to the mold surface portion of 0 is not limited to a continuous part, but may be a separate part.Next, if necessary, insert 40 is installed in the mold, and the epidermis 38 is sucked to the mold surface. The upper mold 28 and the lower mold 30 are still closed, and a liquid foaming raw material 42 such as a urethane foam raw material is injected between the skins of the lower mold and upper mold surfaces.

Note that the injection of the liquid foaming raw material may be performed with the upper mold 28 and the lower mold 30 open, and then the upper mold 28 and the lower mold 30 may be closed.

The foaming raw material 42 injected between the epidermis foams and forms the epidermis 38.
．． 38, and due to the adhesion exhibited at that time, it adheres to the inner surface of the skin, forming a foamed molded product that is integrated with the skin. The foam molded product is then removed from the mold and the excess skin is removed.

Figure 3 shows the skin-integrated foam molded product 4 obtained in this way.
4 is a sectional view of FIG. The skin-integrated foam molded product 44 has a skin 38 adhered to the peripheral surface of the foam 46, and the skin 38 is attached to the peripheral surface of the foam 46.
The surrounding area of the foam 46 is covered with 8. Therefore, the skin-integrated foam molded product 44 can be used as a product without covering the back side of the foam with a separate material.

<Effects> In this invention, vacuum suction holes are provided in the upper mold surface and the lower mold surface as described above, and after the skin is vacuum formed by the upper mold and the lower mold, the upper mold surface and the lower mold surface are vacuum-formed. The liquid foaming material is injected onto the skin of the lower mold surface while the skin is suctioned to the mold surface, and the liquid foaming material is foamed between the skin of the upper mold surface and the lower mold surface.

Therefore, the process from molding the skin to foam molding can be performed continuously using one mold, which has the advantage of facilitating manufacturing work.

Furthermore, since the obtained foam molded product is covered with a skin not only on the front side but also on the back side of the foam, there is no need to cover the back side of the foam with a separate part.

Moreover, since the liquid foaming raw material between the skins foams and fills the inside of the skin while the skin is shaped into the shape of the mold surface and vacuum-suctioned to the mold surface, wrinkles do not occur on the skin. As a result, the beauty of the back side of the molded product is not impaired.

[Brief explanation of drawings]

1 and 2 are cross-sectional views of a mold for producing a skin-integrated foam molded product according to an embodiment of the present invention, and FIG. 3 is a cross-sectional view of a skin-integrated foam molded product obtained by the implementation.
FIG. 4 is a sectional view of a mold showing a conventional manufacturing method, and FIG. 5 is a sectional view of a skin-integrated foam molded product obtained by the conventional method.

Claims (1)

[Claims] With a mold consisting of an upper mold and a lower mold having vacuum suction holes on the mold surface opened, the skin is sucked into the upper mold surface and the lower mold surface to shape it into the shape of the mold surface, and the skin is molded. The liquid foaming material is injected onto the epidermis while vacuum suction is applied to the surface, and the liquid foaming material is foam-molded integrally with the epidermis between the skins of the upper and lower mold surfaces that are closed before or after the injection. A method for manufacturing a skin-integrated foam molded product.