JPH04282209A - Manufacture of foam molded article integral with skin - Google Patents

Abstract

PURPOSE:To provide the manufacturing method for controlling wrinkle developing on a skin at mold closing in the integral molding of the skin and foamed layer with foaming molds. CONSTITUTION:In the manufacturing method, in which foam molded article integral with skin is molded by pouring a flaming material in foaming molds having mold mating faces tilting to the mold closing direction under the condition that the skin is set in the foaming molds and a sealing face is formed by facing some part of the skin to said mold mating faces, a projecting bead is provided along the sealing face near the sealing face of the skin and, at the same time, the contour part having the shape corresponding to said projecting bead is provided on the foaming mold. After the skin is set under the condition that both the bead and the contour part are registered, foaming material is poured in the molds so as to integrally mold foamed layer onto the rear surface of the skin. Thus, the wrinkle developing on the skin at mold closing is limited between the sealing face and the projecting bead, resulting in not impairing the product value.

Description

[Detailed description of the invention]

0001

[Field of Industrial Application] The present invention relates to a molding method in which a skin and a foam layer are integrally molded using a foaming mold, and relates to a manufacturing method that controls the generation of wrinkles on the skin when the mold is closed. .

0002

[Prior Art] Conventionally, foam molded products have been used as interior materials for automobile instrument panels, for example.
It is integrally molded with a skin made of polyvinyl chloride resin or the like by foaming a foam material such as polyurethane foam, polystyrene foam, or foamed polyethylene. Such a molding method is described, for example, in Japanese Patent Application Laid-Open No. 63-684.
No. 14, JP-A-63-293012, JP-A-1-15
It has been proposed as a manufacturing method such as No. 2018 and Japanese Patent Publication No. 2-37845, and generally, a skin is set in a foaming mold, then a foaming material is injected into the mold, and the foaming material is cured and integrally molded. In order to prevent the foam material injected into the foam mold from leaking to the outside, it is common to have the end of the skin face the molding surface of the foam mold to form a sealing surface.

0003

[Problems to be Solved by the Invention] However, in the above-mentioned foaming mold, if the sealing surface formed by the skin has an angle of inclination with respect to the mold closing direction, the mold closing operation may cause the skin in the same area to There was a problem in that the molded product was misaligned along the sealing surface, resulting in wrinkles occurring near the ends of the molded product. In such skin-integrated molded products, since the skin is on the exterior side, the occurrence of wrinkles would be a defect in the product itself, so improvements were desirable.

0004

[Means for Solving the Problems] In order to solve the above problems, the present invention provides a foam mold that forms a sealing surface inclined with respect to the mold closing direction, in which a protrusion is provided in the vicinity of the sealing surface of the skin. In addition, the foaming mold was provided with a shaped part corresponding to the protrusion. After aligning the shaped part and the protruding part and setting the skin, a foaming material was injected into the mold to integrally mold the foam layer on the back surface of the skin. Furthermore, a skin without any protrusions may be set in the foaming mold provided with such a shaped part.

[0005]

[Function] By aligning the protrusions provided on the skin with the shaped parts provided on the foam mold, the occurrence of wrinkles when the mold is closed is limited between the sealing surface and the protrusions, and wrinkles do not occur. You can control the position. In other words, in the past, the location of wrinkles was determined, and it was not known whether the product would be defective or not until the molding was completed, but in the case of this proposal, wrinkles are not completely eliminated, but There are no defects that would make the product defective. Furthermore, even in the case of the epidermis that does not have protrusions, some wrinkles can be absorbed by the foam-shaped part. In other words, this is because the same area becomes a place for the deformed epidermis to escape, and the force that tends to deform the epidermis is blocked.

[0006]

EXAMPLES The method for producing a skin-integrated foam molded product of the present invention will be explained based on the attached drawings. FIG. 1 is a longitudinal sectional view of a foaming mold used in the manufacturing method of the present invention, FIG. 2 is an enlarged view of part A in FIG. 1, FIG. 3 is a conventional example of the same part, and FIG. Perspective view of the instrument panel, Figure 5
is a sectional view taken along the line B-B in FIG. 4. The method of manufacturing an integrally foamed skin molded product of the present invention is applied, for example, to the manufacture of a vehicle instrument panel 1 as shown in FIG. 4, and is integrally molded using foam molds 2 and 3 as shown in FIG. That is, in this instrument panel 1, a core material 4, a skin 5, and a foam layer 6 therebetween are integrally molded. For example, the skin 5 is formed by slush molding polyvinyl chloride resin, etc. (side) has been subjected to drawing processing etc. in advance.

Next, the molding method of the present invention using the foaming molds 2 and 3 will be explained in comparison with the conventional method. The foaming upper mold 2 is vertically movable relative to the lower mold 3, and is moved upward to open the mold and moved downward to close the mold. When the mold is closed, a foamed material filling portion 7 matching the shape of the molded product is formed. While the mold is being opened, the skin 5 and core material 4 are set in the mold. A part of the end of the skin 5 set in the lower mold 3 extends to the mold matching surface around the filling part 7, and when the mold is closed, a part of the end of the skin 5 is formed between the core material 4 and the skin 5, or between the upper mold 2 and the skin 5. -le surface 8
is positioned to form a

By the way, since the surface direction of this sealing surface 8 has an inclination angle with respect to the mold closing and mold opening directions (vertical up and down directions) of the upper mold 2, conventionally, the sealing surface of the skin 5 Wrinkles were found near surface 8. That is, as shown in FIG. 3, when the upper mold 2 is closed, the skin 5 tends to shift in the X direction in the figure along the sealing surface 8, and due to the resistance force from the Y direction that resists this, the sealing surface Wrinkles occur in the skin 5 near the sealing surface 8, particularly around the lower part of the sealing surface 8. Moreover, the areas where these wrinkles occur are left to their own devices, and as a result, the appearance quality of the product is often impaired.

Therefore, in the case of the present invention, as shown in FIG. 2, a protrusion 10 is provided on the product part of the skin 5 in the vicinity of the sealing surface 8, and on the other hand, a shaped part having the same corresponding shape is also provided on the lower die 3. 11 are provided. The protrusions 10 of the skin 5 may be continuous along the sealing surface 5, or a plurality of protrusions 10 may be provided intermittently along the sealing surface 5. good. Further, this protruding direction may be directed toward the external surface of the product as shown in the figure, or may be directed toward the inside of the wire product. However, there is an advantage that wrinkles are less noticeable when the skin protrudes outward rather than inward. In addition, the protrusion 1 to the epidermis 5
0 is formed by, for example, press molding, vacuum molding, slush molding, or the like.

[0010] The skin 5 as described above is positioned so that the protruding portion 10 is fitted into the shaped portion 11 of the lower mold 3, and then when the core material 4 is set and the mold is closed, the end portions overlap. A sealing surface 8 is formed on the portion. Then, a foamed material is injected from the injection port 12 shown in FIG.
It enters the filling part 7 between the core material 4 and the core material 4. Note that the mold closing may be performed after filling the filling portion 7 with the foam material. When closing the mold, as shown in FIG.
As in the past, a force in the X direction acts on the skin 5, but the force is not transmitted to the product part below it due to the protrusion 10 and the shaped part 11, and the wrinkles are caused by the sealing surface 8 and the protrusion. 10. The position of this protrusion 10 is, for example, as shown in FIG.
By making the base of the window glass 14 of the defroster part, the ceramic collar below the window glass 14 can be
Part 15 makes it possible to make it less noticeable. It has been found that this method not only allows the position of wrinkles to be controlled, but also reduces the amount of wrinkles.

By the way, it has been found that the above-described foaming molds 2 and 3 can also be applied to the skin 5 without the ridges 10 formed thereon. It is presumed that this is because the shaped portion 11 provided on the lower mold 3 acts as a relief portion for the skin that is about to shift. That is, the elongation of the epidermis 5 that tends to shift is absorbed by the shaped portion 11, which has the effect of blocking force from acting downward, and is effective in suppressing wrinkles to some extent. Then, when the foaming material injected into the filling portion 7 as described above foams and hardens, the molded product is removed from the mold.

0012

[Effects of the Invention] As described above, the method of manufacturing a skin-integrated foam molded product of the present invention can control the position of wrinkles that occur when closing a foam mold to an appropriate position, and can also reduce the amount of wrinkles. Therefore, the appearance quality of the product is not deteriorated and the product defect rate can be reduced.

[Brief explanation of the drawing]

[Fig. 1] Longitudinal cross-sectional view of a foaming mold used in the manufacturing method of the present invention

[
Figure 2: Enlarged view of part A in Figure 1

[Figure 3] Explanatory diagram of the conventional example of the same section

FIG. 4 is a perspective view of an automobile instrument panel manufactured by the method of the present invention.

[Figure 5] Cross-sectional view taken along line B-B in Figure 4

[Explanation of symbols]

Claims (2)

[Claims] [Claim 1] A sealing surface is formed in a direction inclined from the mold closing direction by a skin set in a foaming mold, and a foaming material is injected into this mold to mold a foam molded product with an integrated skin. In the manufacturing method, a protrusion is provided in the vicinity of the sealing surface of the skin, a shaped part having a shape corresponding to the protruding part is provided on the foam mold, and this shaped part and the protruding part are aligned. After setting the skin, foam material is injected into the mold.
A method for manufacturing a skin-integrated foam molded product, which comprises integrally forming a foam layer on the back side of the skin. 2. The method for manufacturing a skin-integrated foam molded product according to claim 1, wherein a skin without molded protrusions is set in the foaming mold.