JPH08174576A - Plastic molded article with pad and manufacture thereof - Google Patents

Abstract

PURPOSE: To obtain a plastic molded article with a pad having no gap in a joining part of the pad and a core, which is to be a visible part, and being light in weight and excellent in an external appearance. CONSTITUTION: A core 11 has a pad setting face 12 and a side wall 13 formed at a position corresponding to a visible part at the peripheral edge of the pad setting face 12, while a skin 22 of a pad has a lateral side part 23 in the edge and covers the pad setting face 12. A foamed body 27 of the pad is bonded to the skin 22 and the pad setting face 12, filling a space between them, and a lateral side part 23a of the skin is held between the foamed body and the side wall of the pad setting face 12.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a padded plastic molded article having a pad at a predetermined portion of a core and a method for producing the same.

[0002]

2. Description of the Related Art A plastic molded product with a pad having a pad having a skin adhered to the surface of a foam on the surface of the core is used in various fields such as interior parts of automobiles or furniture. For example, in an automobile instrument panel, as shown in FIG. 11, a pad 83 is partially provided on the surface of a core 81, or a pad is provided on the entire surface of the core, as shown in FIG. Are used.

By the way, conventionally, as a padded plastic molded product in which the pad is partially provided, as shown in FIG. 12, a metal insert 84 and a foam 8 are previously prepared.
There is one in which a pad 83 composed of 6 and a skin 87 is formed, and the pad 83 is attached to a predetermined surface portion of the core 81 in a later step. The pad is mounted by inserting a mounting pin (claw) 85 formed in a metal insert into a mounting hole 82 formed in the core and bending it, or by a clip or a screw.

However, the molded product has a problem that the number of steps is increased because the pad has to be assembled to the core in a later step. Further, since the pad is assembled to the core with a pin or the like formed on the metal insert, there is a problem in that a gap is likely to be formed at the mating portion between the pad and the core, and the appearance of the molded product is impaired. In particular, the gap at the mating portion between the pad and the core, which becomes exposed and visible even after the plastic molded product with the pad is attached to the counterpart, for example, the gap between 88 and 89 in the instrument panel shown in the drawing, is Greatly deteriorates the decorativeness of. Further, the plastic molded product with a pad has a problem that the molded product becomes heavy due to the metal insert present on the back surface of the pad.

On the other hand, as a plastic molded product with a pad in which a pad is provided on the entire surface of the core, one conventionally manufactured as follows is used. That is, a skin having a peripheral portion called a skirt on the outer periphery of the product portion,
The skirt portion is arranged on one mold surface of the molding die so as to be located on the outer periphery of the cavity of the molding die, and the core is arranged on the other mold surface to sandwich the skirt portion of the skin between the mold surfaces,
In this state, the liquid foaming raw material is foamed between the skin and the core, and then the skirt portion of the skin is cut off.

However, in the case of the above manufacturing method, the liquid foaming raw material easily leaks out from the edge of the product portion of the epidermis to cause burrs, and the skirt portion of the epidermis has to be cut off thereafter, so that it is a post process. There is an annoying problem.
In addition, in order to prevent the liquid foaming raw material from leaking out, an elastic sealing material may be attached to the edge surface of the core in contact with the skirt portion, but in that case, a troublesome elastic sealing material attaching work is required, Becomes annoying. Further, in the plastic molded product with a pad obtained by the manufacturing method, the edge of the skin is only adhered to the foam due to the self-adhesiveness of the foam during the foam molding, and shrinkage due to deterioration of the skin or the like occurs. There was also a risk that the edge of the skin would peel off from the foam.

[0007]

SUMMARY OF THE INVENTION Therefore, the present invention is intended to provide a light-weight plastic molded product with a pad, which has a good appearance and has no gap in the joint between the pad and the core, which is the visible part. Further, another object of the present invention is to provide a method capable of easily producing the light-weighted and plastic-molded plastic article with a good appearance without leaking the liquid foaming raw material.

[0008]

The invention of a plastic molded product with a pad has a pad in which a foam is covered with a skin on the surface of a core, and is attached to a mating object at the mating portion of the pad and the core. In a plastic molded product with a pad having a visible portion that is exposed even afterward and a non-visible portion that is hidden by the attachment, the core has a pad mounting surface, and a side wall formed at a position corresponding to the visible portion at the periphery of the pad mounting surface. On the other hand, the skin of the pad covers the pad mounting surface with a side portion at the edge so as to cover the pad mounting surface, and the foam of the pad fills a space between the skin and the pad mounting surface. It is characterized in that it is adhered to the skin and the pad mounting surface, and the side surface portion of the skin is sandwiched between the side wall of the pad mounting surface.

Further, in the method for producing a plastic molded product with a pad, a pad having a foam covered with a skin is provided on the surface of the core, and the pad is exposed at the mating portion between the pad and the core even after being attached to the counterpart. In a method for manufacturing a plastic molded product with a pad having a visible portion and a non-visible portion hidden by the attachment, a core having a pad mounting surface and a side wall formed at a position corresponding to the visible portion on the periphery of the pad mounting surface. Is arranged on one of the mold surfaces of the split mold, and a skin having side portions on the edges is arranged on the other mold surface so that the side portions of the skin substantially contact the side walls of the pad mounting surface. The liquid foaming raw material injected between the skin and the pad mounting surface is foamed, and the resulting foam is integrated with the skin and the core.

[0010]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention will be described in detail below with reference to the accompanying drawings. 1 is a cross-sectional view of an embodiment of a plastic molded product with a pad according to the present invention, FIG. 2 is an enlarged cross-sectional view near the side wall of the core and the pad, which is the visible part, and FIG. 3 is also a non-visible part. It is an expanded sectional view of the side.

FIG. 4 is a sectional view of a molding die showing an embodiment of the method for producing a plastic molded product with a pad according to the present invention, and FIG. 5 is an enlarged view of a part of the molding die in the middle of foaming in the embodiment. FIG. 6 is a cross-sectional view showing the other part of the mold in the same embodiment in an enlarged manner, and FIG. 7 is a cross-sectional view showing a part of the mold in which the liquid foaming raw material is filled between the skin and the core.
FIG. 8 is a sectional view showing the other part of the forming die. Further, FIG. 9 is a partial sectional view of a molding die showing another embodiment of the manufacturing method of the present invention, and FIG. 10 is a partial sectional view of a molding die showing still another embodiment.

A plastic molded product 10 with a pad according to an embodiment of the present invention shown in FIGS. 1 to 3 is used as an instrument panel of an automobile, and has a core 11
The pad 21 and the core 1 are provided with a pad 21 in a part thereof, and a visible portion 31 which is exposed even after being attached to the vehicle body and can be seen from the outside, and an invisible portion 32 which is hidden by the attachment.
It is included in the joint portion A with 1. In the following description, the instrument panel will be used as an example,
The molded product and the 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 core 11 is made of a hard plastic such as ABS resin (acrylonitrile-butadiene-styrene resin), polypropylene or the like, or a plastic having a high shape-retaining property such as fiber reinforced plastic. It is 12. The pad mounting surface 12 is provided in a portion where the pad 21 is arranged, with a size, a shape and the like according to a design of the molded product, an application and the like.

A side wall 13 is formed on a part of the peripheral edge of the pad mounting surface 12. This side wall 13 is the pad 2
It is provided at a position corresponding to the visible part 31 in the matching part A with 1. The side surface of the pad 21 is in close contact with the side wall 13 so that no gap is formed in the visible portion 31 of the mating portion A.

Further, in this embodiment, the peripheral edge of the pad mounting surface 12 corresponding to the non-visible portion 32 of the mating portion A is bent toward the side opposite to the pad 21 to form the non-visible portion side end portion 15. ing. The non-visible portion side end portion 15 of the core may be formed as a substantially extended surface of the pad mounting surface 12 depending on the shape of the foamed molded product and the like. Reference numeral 16 is an injection hole for the liquid foaming raw material.

On the other hand, the pad 21 comprises a skin 22 and a foam 27. The skin 22 is made of plastic leather or the like formed by slush molding or the like, has a side surface portion 23 formed at the time of molding, and covers the pad mounting surface 12 so as to cover it. Reference numeral 23a
Is a skin side surface portion on the visible portion 31 side, and 23b is a skin surface side portion on the non-visible portion 32 side. In addition, the foam 2
7 is made of polyurethane resin or the like foamed between the skin 22 and the pad mounting surface 12, and fills the space between the skin 22 and the pad mounting surface 12 to adhere to the skin 22 and the pad mounting surface 12 and to the visible portion 31 side. The outer skin side surface portion 23a is sandwiched between the side wall 13 of the core.

The outer skin side surface portion 23a is sandwiched by the outer skin side surface portion 23a being pressed against the side wall 13 of the core due to the volume increase of the foam body (liquid foaming raw material) and the pressure of the foaming gas during the molding of the foam body 27. This is done by hardening the foam 27 in this state. Therefore, the skin side surface portion 23a is in close contact with the side wall 13 and no gap is formed in the joint portion. Therefore, the padded plastic molded product 10 is
The external appearance is not impaired at the mating portion of the side wall 13 of the pad mounting surface that becomes the visible portion 31 and the skin side surface portion 23a.

Further, in this embodiment, the skin side surface portion 23a sandwiched between the side wall 13 of the pad mounting surface and the foam 27.
An inwardly projecting recessed groove 24 that is recessed inward is formed in the. Due to the inwardly projecting groove 24, the foam body 27 and the skin side surface portion 23a are engaged with each other, and the skin side surface portion 23a is securely fixed to the foam body 27 by the synergistic effect of the adhesion. Therefore, even if the skin 22 contracts due to deterioration or the like,
On the side of the visible portion 31 that greatly affects the appearance, the skin side surface portion 23a is not likely to be peeled from the foam 27, and a good appearance can be maintained for a long period of time.

Further, the inwardly projecting concave groove 24 of the outer skin side surface portion 23a enhances the rigidity of the outer skin side surface portion 23a at the time of manufacturing the plastic molded product 10 with the pad, and unnecessary waviness or the like on the outer skin side surface portion 23a. To prevent the side surface 23 of the epidermis
It also has an effect of preventing a defective seal between a and the side wall 13 of the core. Further, the inwardly projecting concave groove 24 accommodates the invading foam even if the foam (foaming raw material) invades between the skin side surface portion 23a and the side wall 13 of the core and reaches the surface of the skin 22. It also has the function of preventing leakage.

The skin 22 has a superimposing end 25 formed on the edge of the outer skin side 23b corresponding to the end 15 on the non-visible side of the core 11, and the superimposing end 25 is formed on the core 1.
1 overlaps with the non-visible portion side end portion 15. Since the mating portion of the non-visible side end portion 15 of the core and the superimposing end portion 25 of the skin 22 is hidden by the mating object after the plastic molded product with the pad is attached, there is a gap or a burr of the foam. Is not a problem in appearance. Reference numeral 26 is
The outward protruding recessed groove formed in the superimposing end portion 25 of the surface skin increases the rigidity of the superimposing end portion 25.

The thus formed padded plastic molded product 10 is attached to a mating object, which is a vehicle body in this embodiment. At this time, in the visible portion 31 of the mating portion of the pad 21 and the core 11, the skin side surface portion 23a is sandwiched between the foam body 27 and the side wall 13 and closely adhered to each other without any gap, so that the appearance is good. Further, this plastic molded product with a pad 10 is lightweight because there is no metal insert for attaching the pad 21.

Next, an embodiment of the manufacturing method of the present invention will be described with reference to the drawings. The molding die 40 shown in FIG. 4 is composed of split dies 41 and 43, and has a cavity 44 for molding therein.
Have. A nozzle hole 42 for inserting the injection nozzle N of the foam molding apparatus is formed in one of the split molds 41. The core 11 is arranged on the mold surface of the one split mold 41 by using a clip or the like provided on the mold surface.
At this time, the pad mounting surface 12 of the core 11 is made to face the other split mold 43 side. Also, the pad mounting surface 1
On the mold surface of the other split mold 43 that faces 2 is the skin 2
2 has its side surface portion 23 directed to the pad mounting surface 12 and has the skin side surface portion 23a having the inwardly projecting groove 24 as the core 11
Is arranged so as to be on the side wall 13 side.

An elastic material 45 is embedded in the mold surface of the split mold 43 in which the superimposing end portion 25 of the skin is arranged, and a recessed portion on the surface of the elastic material 45 is better understood from FIG. The outwardly projecting concave groove 26 of the superposing end portion 25 is fitted and held at 46.

Then, the split dies 41 and 43 are closed. With this closed mold, the outer skin 22 covers the pad mounting surface 12 so as to cover it, and the outer skin side surface portion 23a having the inwardly projecting groove 24 is substantially in contact with the side wall 13 of the core 11.
When the mold is closed and when the epidermis 22 is arranged, the epidermis side surface portion 2
3a has high rigidity due to the inwardly projecting concave groove 24,
There is no possibility of forming an irregular gap due to corrugation or the like between the side wall 13. Further, by the closed mold, the superimposing end portion 25 of the skin 22 overlaps the non-visible portion side end portion 15 of the core 11, and is sandwiched and sealed between the mold surfaces of the split molds 41 and 43.

Next, a liquid foaming raw material P such as a polyurethane raw material is injected from the injection nozzle N inserted into the nozzle hole 42 of the split mold 41 through the injection hole 16 of the core 11 to the pad mounting surface 12 and the skin 22 of the core. Injected in between.

The injected liquid foaming raw material P fills the space between the pad mounting surface 12 and the skin 22 while initiating a foaming reaction to form a foam. And foam (liquid foaming raw material P)
However, when the skin side surface portion 23a on the visible portion side is reached as shown by the chain line in FIG. 5, the skin side surface portion 23a is pressed toward the side wall 13 side of the core 11 and pressure-bonded to the side wall 13 thereof.
And the outer skin side surface portion 23a are sealed. At this time, since the outer skin side surface portion 23a is in a state where there is no waviness due to the inwardly projecting concave groove 24, the outer skin side surface portion 23a surely adheres to the side wall 13 and seals. Due to the seal, the foam is formed so that the skin side surface portion 23a and the side wall 13
Leakage from the gap to the visible portion 31 of the mating portion is prevented, and the visible portion 31 having a good appearance is obtained. Moreover, as shown in FIG. 7, even if the foam 27 intrudes between the skin side surface portion 23a and the side wall 13, the invading foam 27
a is accommodated in the inwardly projecting concave groove 24 of the outer skin side surface portion 23a, and is prevented from being exposed from between the outer skin side surface portion 23a and the side wall 13. Therefore, even in this case, the visible portion 31 having a good appearance can be obtained.

On the other hand, at the joining portion between the skin 22 and the core 11 which is the invisible portion 32, the superimposing end portion 25 of the skin 22 is formed.
And the end portion 15 of the core 11 on the non-visible portion side is divided into both split dies 41, 43.
It is sandwiched and sealed by the mold surface to prevent the foam from leaking. Moreover, as shown in FIG. 8, even when the foam 27 intrudes between the superimposing end 25 of the skin 22 and the non-visible side end 15 of the core 11, the invading foam 27 b will cause the superimposing end 25 to overlap. The foam is prevented from leaking out because it is accommodated in the outwardly projecting concave groove 26 formed in the. In addition, even if the foam may leak to some extent on the non-visible side to form burrs or the like,
Since this invisible part is hidden by mounting the plastic molded product with a pad, there is no problem in appearance.
Therefore, according to this manufacturing method, the sealing material is applied to the skin 2
2 or the core 11 does not need to be attached, which facilitates the manufacturing work.

The foam (liquid foaming raw material) filling the space between the skin 22 and the pad mounting surface 12 adheres to the skin by the self-adhesive property generated during the foaming to form a pad, and the pad mounting surface 12 of the core 11 is formed. Also glue together. After that, if the molding die is opened and the molded product is taken out, the desired plastic molded product with a pad shown in FIG. 1 is obtained.

FIG. 9 shows another example of the manufacturing method.
The same members as those in the above-described embodiment are designated by the same reference numerals. In this embodiment, a through hole 54 that communicates the inside and the outside is formed in the side wall 53 of the core 51 that faces the inwardly projecting groove 24 of the skin side surface portion 23a. Therefore, even when a large amount of foam penetrates between the skin side surface portion 23a and the side wall 53, the invading foam 27a flows out of the core side wall 53 through the through hole 54 of the side wall 53. It can be surely prevented from leaking to the surface side of.

Further, FIG. 10 shows a manufacturing method of still another embodiment. In this embodiment, on the side wall 63 of the core 61, a concave groove 64 that faces the inwardly protruding concave groove 24 of the skin side surface portion 23a.
Is formed. Therefore, the skin 22 and the side surface 23
A large space formed by the inwardly projecting concave groove 24 of a and the concave groove 64 facing it is formed between the skin side surface part 23a and the side wall 63 of the core. As a result, the side surface 23 of the epidermis
Even if the amount of the foam 27a invading between the a and the side wall 63 is large, the invading foam 27a can be accommodated in the large space formed by the inwardly projecting concave groove 24 and the concave groove 64 opposed thereto. There is no possibility that the invading foam 27a will leak to the surface side of the skin 22.

Further, the side wall 6 is formed in the concave groove 64 of the side wall 63.
If the through-hole 65 communicating between the inside and the outside of 3 is provided, the intruding foam 27a flows out of the side wall 63 of the core through the through-hole 65 even if the amount of the invading foam 27a increases. 22 It is possible to reliably prevent the foam from leaking to the surface.

In each of the above embodiments, the pad is provided on a part of the core, but the plastic molded product with a pad and the manufacturing method of the present invention are also applied to the case where the pad is provided on the entire surface of the core. It In that case, sidewalls are provided at the edges of the core. Moreover, the injection of the liquid foaming raw material may be an open injection performed by opening a split mold.

[0033]

As shown and described above, in the plastic molded product with a pad of the present invention, the side surface portion of the skin is closely attached to the side wall formed on the core at the joint between the pad and the core, which is the visible portion. Therefore, the appearance is good. Moreover, it is lightweight because it does not require a metal insert for attaching the pad. Furthermore, when a concave groove that is recessed inward is provided in the skin side surface part that is sandwiched between the side wall of the core and the foam, the skin side part on the visible side firmly adheres to the foam. In addition, there is no risk of peeling and a good appearance can be maintained for a long period of time.

According to the manufacturing method of the present invention, as described above, a lightweight plastic molded product with a pad having a good appearance of the mating portion of the pad and the core, which is the visible portion, and a sealing material such as the core are used. It can be easily manufactured without sticking to. Therefore, the manufacturing work can be rationalized and economical.

[Brief description of drawings]

FIG. 1 is a sectional view of an embodiment of a plastic molded product with a pad according to the present invention.

FIG. 2 is an enlarged cross-sectional view in the vicinity of a mating portion between a side wall of a core and a pad, which is a visible portion side.

FIG. 3 is an enlarged cross-sectional view of the non-visible portion side.

FIG. 4 is a cross-sectional view of a molding die showing an embodiment of a method for manufacturing a plastic molded product with a pad according to the present invention.

FIG. 5 is an enlarged cross-sectional view showing a part of a mold during foaming in the same example.

FIG. 6 is an enlarged cross-sectional view showing another portion of the molding die in the embodiment.

FIG. 7 is a cross-sectional view showing a part of the molding die in which the liquid foaming raw material is filled between the skin and the core.

FIG. 8 is a cross-sectional view showing another portion of the molding die at that time.

FIG. 9 is a partial cross-sectional view of a molding die showing another embodiment of the manufacturing method of the present invention.

FIG. 10 is a partial cross-sectional view of a mold showing still another embodiment.

FIG. 11 is a perspective view showing a conventional example of a molded product for an instrument panel.

FIG. 12 is a partial cross-sectional view of a conventional molded product.

[Explanation of symbols]

 11: Core 12: Pad installation surface 13: Side wall 21: Pad 22: Skin 23, 23a, 23b: Side surface of skin 24: Inner protruding groove 31: Visible part 32: Invisible part 40: Mold P: Liquid Foaming raw material

Claims (5)

[Claims] 1. A pad having a foam covered with a skin is provided on a surface of a core, and a visible portion which is exposed even after being attached to an object and a non-visible portion which is hidden by the attachment at a mating portion of the pad and the core. In the plastic molded product with a pad having a portion, the core has a pad mounting surface and a side wall formed at a position corresponding to the visible portion on the periphery of the pad mounting surface, while the skin of the pad has an edge. The pad has a side surface and covers the pad mounting surface so as to cover the pad mounting surface, and the foam of the pad fills a space between the skin and the pad mounting surface to adhere to the skin and the pad mounting surface. A plastic molded product with a pad, characterized in that a side surface portion is sandwiched between the side surface portion and a side wall of the pad mounting surface. 2. The plastic molded product with a pad according to claim 1, wherein a side surface portion of the skin sandwiched between the side wall of the pad mounting surface and the foam has an inwardly projecting concave groove recessed inward. 3. A pad having a foam covered with a skin is provided on a surface of a core, and a visible portion which is exposed even after being attached to an object and a non-visible portion which is hidden by the attachment at a mating portion of the pad and the core. In a method for producing a plastic molded product with a pad having a pad portion, a core having a pad mounting surface and a side wall formed at a position corresponding to the visible portion on the periphery of the pad mounting surface is provided in one of the split molds. A surface skin having a side surface portion at the edge is arranged on the other mold surface so that the side surface portion of the skin surface is substantially in contact with the side wall of the pad mounting surface, and the surface skin and the pad mounting surface are injected. A method for producing a plastic molded article with a pad, which comprises foaming the liquid foaming raw material described above and integrating the resulting foam with the skin and the core. 4. The method for manufacturing a plastic molded product with a pad according to claim 3, wherein an inwardly projecting concave groove that is recessed inward is provided on a side surface portion of the skin which is a side wall side of the pad mounting surface. 5. The method for manufacturing a plastic molded product with a pad according to claim 4 or 5, wherein a groove facing the inwardly projecting groove of the skin side surface is formed on the side wall of the pad mounting surface.