JPH07276385A - Plastic molded article partially having skin-integrated foam - Google Patents

Abstract

PURPOSE:To easily produce a light-weight, aesthetic plastic molded article partially having a skin-integrated foam. CONSTITUTION:A body core 11 having an opening in a mounting part of a skin-integrated foam is disposed on the molding surface of a lower mold 31 so that an end part 15 of the opening is projected into a cavity from the peripheral edge of the cavity of the lower mold 31. A skin 25 in a thermally softened state disposed on the body core 11 is sucked to an inner cavity surface 33. The end part 15 of the opening of the body core is wrapped by the outer surface of the end part and thereabouts of the skin. Thereafter, a foaming material P is casted inside the skin 25 to fill the inside of the skin 25. In this manner, a foam is molded integrally with the skin.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a plastic molded article having a foamed body with a skin partially on the product surface side of a main body core and a method for producing the same.

[0002]

2. Description of the Related Art In an automobile instrument panel, for example, as shown in FIG. 9, a foamed body 83 with a skin is formed on the product surface side of a main body core 81 according to the design of the automobile.
What is partially provided is used. FIG. 10 is an enlarged sectional view taken along the line AA.

By the way, in the above instrument panel, a foam body 83 with a skin is formed in advance by a base material 84 for attachment, a foam body 86 and a skin 87, and the foam body 83 with a skin is formed in a main body in a later step. It is attached to a predetermined part of the core 81. The mounting is performed by inserting a mounting pin (claw) 85 formed on the foamed base material 84 with skin into the mounting hole 82 formed on the main body core 81 and bending it, or by a clip or a screw. There is.

However, in the instrument panel, since the foamed body with skin 83 also has the base material 84 such as an iron plate, there is a problem that the instrument panel becomes heavy and the cost becomes high. Further, since the foam with skin 83 is attached to the main body core 81 in a later step, there is a problem in that a gap is likely to be formed in the mating portion 88 between the foam with skin 83 and the main body core 81, which impairs aesthetics. In particular, in this type of instrument panel, since the mating portion 88 between the foamed body with skin 83 and the main body core 81 is also exposed as a product surface, the problem of the gap is an important problem that cannot be ignored.
Further, there is a problem that an additional post process for attaching the foam with skin is required.

[0005]

SUMMARY OF THE INVENTION In view of the above-mentioned problems, the present invention is directed to a plastic molded article which is light in weight and has an excellent aesthetic appearance and which partially has a foam with a skin, and a manufacturing method capable of easily manufacturing the molded article. Is to provide.

[0006]

A first aspect of the present invention is a plastic molded article having a skin-covered foam in which a surface and a side surface of the foam are covered with a skin, in a product surface portion of a main body core. An opening is provided in the skin-attached foam attachment portion of the main body core, while a concave groove is provided on the side surface of the skin-included foam body, and a skin is provided by fitting the concave groove and the end of the opening portion of the main body core. It is characterized in that the foam is fixed to the main body core.

A second aspect of the present invention is a method for producing a plastic molded article, which partially has a foam with skin in which the surface and the side of the foam are covered with a skin on the product surface portion of the main body core. The main body core provided with an opening at the attachment site of the attached foam is attached to the lower mold surface so that the end of the opening projects into the cavity from the periphery of the concave cavity formed in the lower mold surface. A step of disposing, a step of disposing a thermoplastic resin skin covering the opening on the upper surface of the main body core, and holding the peripheral edge of the skin around the opening.
A step of sucking the skin that has been heated and softened during or after the holding and adsorbing it to the inner surface of the cavity, and winding the end of the opening of the main body core on the outer surface near the end of the skin, and inside the skin of the cavity. And a step of injecting a foaming raw material into the mold, and before or after injecting the foaming raw material, an upper mold having a concave portion in a mold surface portion facing the cavity of the lower mold is provided between the concave peripheral edge and the cavity peripheral edge of the lower mold. A step of covering the lower end of the outer skin and the opening end of the main body core so as to sandwich it, and closing the mold, and by foaming the foaming raw material between the outer skin and the inner surface of the mold surface recess of the upper mold, the body is integrated with the outer skin. And a step of forming a foam.

[0008]

In the plastic molded article having the foam with skin of the present invention partially, the foam with skin has the foam and the skin and does not have a heavy base material such as a conventional iron plate. , Lightweight. Moreover, in the foam with skin, the concave groove formed on the side surface is fixed to the main body core by fitting into the end portion of the opening formed in the main body core, so that the foam with skin can be removed. Or there is no fear of rising.

On the other hand, in the manufacturing method, the foaming raw material fills the inside of the skin that is wound around the end of the opening formed in the main body core and adsorbed to the inner surface of the cavity of the lower mold, and foams between the skin and the inner surface of the upper mold recess. Then, a foamed body (foamed body with skin) is formed integrally with the skin. Therefore, the shape of the skin is held by the foam, and the obtained molded product is formed by the winding of the opening end of the main body core on the outer surface near the end of the skin, that is, by the winding. The open end of the main body core is fitted in the concave groove of the outer skin, and the foam with skin is fixed to the main body core.

Moreover, since the foaming raw material is foamed in the skin in a state where the end portion of the opening of the main body core is wound and fills the skin to become a foam, the foaming pressure at that time causes the opening of the main body core. The skin is crimped to the end of the part, eliminating the gap between the body core and the skin. Therefore, there is no gap at the boundary between the skin-covered foam and the main body core, resulting in a good appearance.

[0011]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention will be described in detail below with reference to the accompanying drawings. FIG. 1 is a partial perspective view of a plastic molded article partially having a foam with skin according to an embodiment of the present invention,
2 is a cross-sectional view of the lower mold showing the step of arranging the main body core during its manufacturing, FIG. 3 is a cross-sectional view of the lower mold showing the initial stage of the skin retaining step, and FIG. 7 is a sectional view of the lower mold showing a winding step with the skin, FIG. 6 is a sectional view of the lower mold showing a foaming raw material injecting step, and FIG.
FIG. 8 is a cross-sectional view of upper and lower molds showing a closing mold process and a skin integral foaming process, and FIG. 8 is a perspective view showing an example of a skin holding device.

A plastic molded product (hereinafter also referred to as a molded product) 10 partially having the skin-covered foam shown in FIG.
Is used for an instrument panel of an automobile, and a foam 21 with a skin is provided on a part of a main body core 11. In the following description, an instrument panel will be described as an example, but the molded product and manufacturing method of the present invention are not limited to the instrument panel, and can be applied to various molded products depending on the application.

The main body core 11 is made of a hard plastic such as ABS resin or a plastic having a high shape retention property such as a fiber reinforced plastic. As shown in FIG. 2, a predetermined portion of the product surface has a hole shape. The opening 13 is formed. The opening 13 is provided in the attachment site of the foam with skin 21 in a size, shape, etc. according to the design, application, etc. of the molded product. Also, the end 1 of the opening 13
Reference numeral 5 is a portion into which the concave groove 29 on the side surface of the foamed body with skin 21 described later is fitted.

The foam with skin 21 comprises a foam 23 and a skin 25 that covers the surface and side surfaces of the foam 23, and a concave groove 29 on the side surface is fitted in the opening 13 of the main body core. The foam 23 is made of polyurethane foam or the like, and has a size that closes the opening 13 of the main body core. As will be described later, this foam 23 is foam-molded between the skin 25 and the inner surface of the concave portion of the upper mold surface, and is adhered to the inner surface of the skin 25 by the self-adhesive force during foam molding.
The side surface of the foam 23 is recessed corresponding to the groove 29.

The skin 25 is made of a thermoplastic resin such as vinyl chloride resin, and is adhered to the foam 23 while covering the surface and the side surface of the foam 23. In addition, the concave groove 2 is formed on the entire circumference of the side surface 27 of the skin that covers the side surface of the foam 23.
9 is bent, and the end portion 15 of the opening of the main body core is fitted into the concave groove 29.

The concave groove 29 is formed on the skin 2 as described later.
The outer surface near the end of 5 is a part formed by winding the end 15 of the opening of the main body core. In addition, in this embodiment, the skin 25 in a state in which the end portion 15 of the opening is wound up.
Since the foaming raw material is foamed and filled in the inside to form the foamed body 23, the skin 25 in the vicinity of the concave groove 29 adheres to the end portion 15 of the opening of the main body core by the foaming pressure of the foaming raw material, The gap at the boundary between the foamed body with skin 21 and the main body core 11 is eliminated. Further, the foamed body with skin 21 is securely fixed to the main body core 11 by the close contact of the concave groove 29. The molded article 10 having such a structure is lightweight because the foamed body 21 portion with the skin is composed of the foamed body 23 and the skin 25 and there is no heavy base material.

Next, an embodiment of a method of manufacturing the molded product 10 will be described. The manufacturing method includes a main body core arranging step, a skin holding step, a winding step, a foaming raw material injecting step,
A closed mold step and an integral skin foaming step are provided. First, FIG.
The main body core placement step is performed as shown in FIG. In the main body core arranging step, the main body core 11 having the opening 13 at the attachment site of the foam with skin is attached to the mold surface 35 of the lower mold 31.
Place it in place. A concave cavity 32 is formed on the mold surface 35 of the lower mold 31 at a position corresponding to the opening portion 13 of the main body core, and the end portion 15 of the opening portion of the main body core extends from the peripheral edge of the cavity 32 to the cavity 32. The main body core 11 is arranged so as to project inward.

A lower mold 31 is formed on the inner surface 33 of the cavity.
A suction hole 34 communicating with an external vacuum suction device 40 is formed. The suction hole 34 is provided on the upper part of the cavity 32 closest to the end portion 15 of the opening so that the skin can easily wind up the end portion 15 of the opening portion of the main body core 11 and adhere to the inner surface 33 of the cavity during the winding step described later. It is also preferable to provide. Reference numeral 41 indicates the inside of the lower mold 31 and the vacuum suction device 4.
It is a suction pipe connecting 0.

Then, as shown in FIGS. 3 and 4, a skin holding step is performed. In this skin-holding step, a thermoplastic resin skin 25 such as a vinyl chloride resin having a size that covers the opening 13 of the main body core is arranged on the upper surface of the main body core 11 so that the peripheral edge of the skin 25 is the opening of the main body core. Hold around 13.

At this time, in this embodiment, a skin holder 42 as shown in FIG. 8 is used. The outer skin holder 42 has an upper frame 44 fixed to the lower end of a column 43 which is connected to a lifting device such as an air cylinder device (not shown) and moves up and down.
The lower frame 45 is hinged to the upper frame 44.
And an air cylinder device 47 for opening and closing the lower frame 45 with respect to the upper frame 44 on the upper and lower frames 44 and 45 at positions opposite to the hinge 46.
Is attached. Further, as shown in FIG. 3, a string-like sealing material 48 made of an elastic material such as rubber is provided on the lower surface of the lower frame 45. Then, as shown in FIG. 3, the peripheral edge of the skin 25 is sandwiched between the upper and lower frames 44 and 45,
The skin holder 42 is lowered, and the lower frame 45 is pressure-bonded to the periphery of the opening 13 of the main body core via the seal material 48 as shown in FIG. As a result, the peripheral edge of the skin 25 is held around the opening 13 of the main body core, and the sealing material 48
The upper and lower frames 44 and 45 seal the periphery of the outer skin 25 and the periphery of the opening 13 of the main body core.

In this embodiment, as shown in FIG.
While the skin 25 is held above the body core 11 by the skin holder 42, the skin 25 is heated and softened by a heating device H such as a heater, and the skin 25 in the softened state is heated as described above. It is placed on the top surface. Of course, the skin 25 may be placed on the upper surface of the main body core 11 and then heated and softened. The softening of the skin 25 by heating is to enable vacuum forming performed in the next winding step.

Next, the winding step shown in FIG. 5 is performed. In this step, the outer skin 25 that covers and holds the opening 13 of the main body core 11 in the previous step is sucked into the cavity by the vacuum suction device 40 through the lower die suction hole 34 and is adsorbed to the cavity inner surface 33. At that time, the end 15 of the opening 13 of the main body core 11 projects into the cavity, and the skin 2
Since the periphery of 5 is held by the upper surface of the main body core 11 around the opening 13, the outer surface of the skin 25 near the end 28 is in close contact with the inner surface 33 of the cavity while winding the end 15 of the opening of the main body core 11. . The wound portion by the skin 25 becomes the concave groove 29 shown in FIG. Then, in that state, the skin 25 is naturally cooled or forcedly cooled by air cooling or the like to fix the shape of the skin 25. After that, after cutting the edges of the epidermis 25 along the inner circumferences of the upper and lower frames 44, 45 of the epidermis holder 42, the epidermis holder 42 is raised.

Then, the foaming material injection step shown in FIG. 6 is performed. In this step, a foaming raw material P such as a polyurethane raw material is injected inside the skin 25. Reference numeral 49 is a foaming material injection nozzle. At the time of this foaming raw material injecting step, suction of the skin 25 into the cavity may be continued from the winding step or stopped.

Thereafter, as shown in FIG. 7, a closing mold step of covering the lower mold 31 with the upper mold 51 is performed. On the die surface 52 of the upper die 51, in a portion facing the cavity 32 of the lower die 31,
An opening-shaped recess 53 larger than the opening 13 of the main body core 11 is formed, and the periphery of the recess 53 and the lower mold 3 are formed.
The edge 28 of the skin and the edge 15 of the opening of the main body core are sandwiched between the edge of the cavity 1 and the peripheral edge of the cavity 1. Also, the upper mold 51
In this case, a reinforcing core (insert) may be set as needed, and a foam may be formed integrally with the reinforcing core in the next skin-integral foaming step. Although the mold closing step is performed after the foaming material injection step in this embodiment, the foaming material injection step may be performed after the mold closing step. In that case, a foaming material injection port is formed in the upper mold, and the foaming material is injected using the injection port.

In the skin-integrated foaming step, the foaming raw material P is foamed between the inner surface of the outer skin 25 and the inner surface of the recess 53 of the upper mold, and the foam 23 integrated with the outer skin 25, that is, the foam with the outer skin is opened in the main body core 11. Formed on the part. At that time, the main body core 1
In the end portion 15 of the opening of No. 1, since the foaming raw material also wraps around the back side of the end portion 15 of the opening due to the existence of the upper concave portion 53, the foaming raw material is fitted into the end portion 15 of the opening through the skin 25. A combined foam 23 is formed. Further, the outer skin 2 in which the end 15 is wound around the end 15 of the opening of the main body core 11.
Since the vicinity of the end 28 of 5 is pressed by the foaming pressure of the foaming raw material P, there is no gap at the boundary between the main body core 11 and the skin 25, that is, the boundary between the main body core 11 and the foam with skin.

After that, the upper mold 51 is separated from the lower mold 31 and the molded product is released from the mold to obtain the plastic molded product 10 partially having the foam with skin shown in FIG. The molded product thus obtained is lightweight as described above and has no gap at the boundary between the foam with skin and the main body core.
It has a good appearance.

[0027]

As shown and described above, according to the present invention, it is excellent in lightness, has a good appearance with almost no gap at the boundary between the foam with skin and the main body core, and has the skin. It is possible to obtain a molded product without the risk of the foam coming off or the skin peeling. Also, in the manufacturing work, since the foam with skin is molded and integrated with the main body core at the same time, there is no need to assemble the foam with skin on the main body core in a later step, which is extremely easy and inexpensive to manufacture. can do.

[Brief description of drawings]

FIG. 1 is a partial perspective view of a plastic molded product partially having a foam with skin according to an embodiment of the present invention.

FIG. 2 is a cross-sectional view of a lower die showing a main body core arranging step during its manufacturing.

FIG. 3 is a cross-sectional view of a lower mold showing an initial stage of a skin retaining step.

FIG. 4 is a cross-sectional view of the lower mold showing the completion of the same skin retaining step.

FIG. 5 is a cross-sectional view of a lower die showing a winding step.

FIG. 6 is a cross-sectional view of a lower mold showing a foaming raw material injection step.

FIG. 7 is a cross-sectional view of a molding die showing a closing mold step and a skin-integrated foaming step.

FIG. 8 is a perspective view showing an example of a skin holding device.

FIG. 9 is a perspective view of a conventional molded product.

FIG. 10 is an enlarged cross-sectional view taken along the line AA.

[Explanation of symbols]

 10 Molded Product 11 Main Body 13 Opening 15 End of Opening 21 Foam with Skin 23 Foam 25 Skin 27 Side of Foam with Skin 28 Edge of Skin 29 Groove 31 Lower Mold 32 Cavity 51 Upper Mold 53 Top Mold recess P Foaming raw material

Claims (2)

[Claims] 1. A plastic molded article having, in the product surface portion of the main body core, a foamed body with a skin in which the surface and the side surface of the foam body are covered with a skin. An opening is provided, on the other hand, a concave groove is provided on the side surface of the foam with skin, and the foam with skin is fixed to the main body core by fitting the concave groove and the end of the opening of the main body core. A plastic molded product that partially has a foam with a skin, which is a feature. 2. A method for producing a plastic molded article, wherein the product surface portion of the main body core partially has a foam with skin in which the surface and the side surface of the foam are covered with a skin, wherein the attachment site of the foam with skin is attached. Arranging the main body core provided with an opening in the lower mold surface so that the end of the opening projects into the cavity from the periphery of the concave cavity formed in the lower mold surface; A step of disposing a thermoplastic resin skin covering the opening on the upper surface of the main body core and holding the peripheral edge of the skin around the opening, and sucking the skin softened by heating during or after the holding. While adsorbing to the inner surface of the cavity, winding the end of the opening of the main body core on the outer surface near the end of the skin, injecting a foaming raw material into the skin of the cavity, and after injecting the foaming raw material Before injection, the upper mold having a recess in the mold surface portion facing the cavity of the lower mold is sandwiched between the peripheral edge of the recess and the peripheral edge of the cavity of the lower mold so that the skin end and the opening end of the main body core are sandwiched. A step of covering the lower mold and closing the mold, and a step of forming a foam integral with the skin by foaming the foaming material between the skin and the inner surface of the mold surface recess of the upper mold, A method for producing a plastic molded article which partially has a foamed product.