JPH0825374A - Foamed molded product and product thereof and mold used therein - Google Patents

Abstract

PURPOSE:To provide a lightweight inexpensive foamed molded product composed of a simple structure and having good appearance. CONSTITUTION:A foamed molded product is constituted of a substrate 11 composed of a resin hollow member and having a recessed groove 14 provided to the outer peripheral surface thereof, the foam 21 provided to one surface of the substrate and the skin 31 covering the surface of the foam and inserted in the recessed groove 14 of the substrate at its terminal 33 to be held.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a foamed molded article in which the surface of a foam provided on one side of a substrate is covered with a skin and the end of the skin is bent to the inside of the skin and fixed to the edge of the substrate, and its production. The present invention relates to a method and a molding die thereof.

[0002]

2. Description of the Related Art In an automobile console lid or the like, as shown in FIGS. 10 and 11, a foam body 53 formed integrally with a metal or resin base body (also referred to as an insert) 51 by a molding die. There is known a foam-molded article having a structure in which a bag-shaped outer skin 55 is covered with the outer skin 57, the end 56 of the outer skin 55 is bent inward, and an outer 57 for concealing the end 56 of the outer skin is attached to the base 51. A hinge for opening and closing is further attached to the outer 57 of the console lid by screwing or the like.

However, in the above foam-molded article, after foam-molding the foam 53 integrally with the substrate 51 using a molding die, the foam 53 is covered with the skin 55, and the end 56 of the skin is used. Since the foam body 53 was rolled up and the outer skin 57 was used to conceal the end 56 of the epidermis, a hinge or the like had to be attached.
In particular, the outer skin 55 must be manually attached to the foam body 53 by covering it, and the end 56 of the outer skin must be bent so as to wrap the edge of the foam body 53 and adhered and fixed to the back surface of the base body 51. There is also a problem that the finished quality is likely to vary, and the adhesive is likely to adhere to the outer surface of the skin 55 to impair the surface appearance of the product. Further, in the case of a thick foam-molded article, there is a problem that the thickness of the foam body 53 becomes large and becomes heavy and the cost increases.

[0004]

SUMMARY OF THE INVENTION The present invention has been made in view of the above points, and has a simple structure, a good appearance, a lightweight and inexpensive foam molded article, and the foam molded article. The present invention is intended to provide a manufacturing method and a molding die that can easily obtain the above.

[0005]

A first aspect of the present invention relates to a foam molded article, wherein the surface of a foam provided on one side of a substrate is covered with a skin, and the end of the skin is bent to the inside of the skin. In the foam-molded article fixed to the edge, the base body is made of a resin hollow body and has a groove on the outer peripheral surface, and the end of the skin is inserted and sandwiched in the groove.

A second aspect of the present invention is a method for producing a foamed molded product using a mold comprising a cavity mold having a concave mold surface and a lid mold, wherein the lid mold is a resin having a groove on the outer peripheral surface. It is composed of a base body made of a hollow body and a holding plate which is removably fitted in a concave groove of the base body and has an edge protruding to the outer periphery of the base body, and an open bag-like skin is set in the cavity mold. With the step of arranging the skin end around the opening on the outer periphery of the mold surface of the cavity mold, the step of injecting a foaming raw material into the skin, the lid mold, the base of which is located in the skin and the holding plate A step of covering the cavity mold so that the edge of the cavity is located on the outer periphery of the mold surface and closing the mold; a step of foaming the foaming raw material and integrating the skin and the substrate by the foamed product, The skin, substrate and foam are one A step of the molded article demolded became,
After removing the holding plate from the concave groove of the base body, a step of fixing a skin end to inserting and fixing the end of the skin into the concave groove of the base body is performed.

A third aspect of the present invention relates to a molding die, which comprises a cavity die having a concave die surface and a lid die for covering the cavity die. In a molding die for foaming a foaming raw material by molding to form a foamed molded product in which the skin, the base and the foam are integrated, the lid mold is provided with a groove on the outer peripheral surface of a resin hollow body. It is characterized in that it comprises the base body and a holding plate that is detachably fitted in the concave groove and has an edge protruding from the outer periphery of the base body.

[0008]

In the foam-molded article of the present invention, the base body is made of a resin hollow body and serves as the core material of the foam-molded article and the conventional back outer surface, and the end of the skin is inserted into the groove on the outer peripheral surface of the base body. Since it is not necessary to attach the outer to the back surface of the base to cover the end of the skin and the base as in the conventional case, the number of parts is reduced, the assembling work is simplified, and the cost is reduced. Further, the outer appearance of the skin terminal becomes good, and peeling of the skin terminal can be prevented.
Furthermore, since the base body is made of a resin hollow body, even if the foamed molded product has a large thickness, the thickness of the foam body is increased by enlarging the hollow portion of the base body to increase the thickness of the base body itself. As a result, it is possible to prevent the total weight from becoming heavy, and it is possible to suppress an increase in product price. In addition, a rib (also referred to as a bead) shape may be provided on the surface of the substrate to increase the strength.

Further, in the manufacturing method of the present invention, since the foam is foam-molded integrally with the skin and the substrate, it is not necessary to manually cover and adhere the skin in a later step, and the work of attaching the outer side of the back surface is also possible. It becomes unnecessary. Therefore, compared with the conventional, not only the manufacturing work is simplified, the appearance of the foamed molded product obtained is not varied, and moreover, the adhesive for adhering the skin to the foam surface adheres to the surface of the foamed molded product. Since there is no fear, the appearance of the foamed molded product will be good. Further, since the base of the foam-molded product also serves as a part of the lid mold of the molding die, the cost of the molding die becomes low and the foam-molded article can be manufactured at low cost.

Further, in the molding die of the present invention, since the base body of the foamed molded article also serves as a part (main part) of the lid mold of the molding die as described above, the entire lid mold is manufactured at the time of manufacturing the molding die. There is no need, the mold is easy to manufacture, and the mold is cheap. In addition, since the base body of the foam-molded product that constitutes a part of the lid mold is made of a hollow resin body, the lid mold is lightweight and the molding die can be easily handled.

[0011]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention will be described in detail below with reference to the accompanying drawings. 1 is a sectional view of a foam-molded article according to an embodiment of the present invention, FIG. 2 is an enlarged sectional view of a part thereof, and FIG. 3 is a perspective view showing an embodiment of a method for manufacturing a foam-molded article according to the present invention. Figure 4
Is a cross-sectional view showing assembly of the lid mold in the embodiment,
5 is a plan view of a lid mold in the embodiment, FIG. 6 is a cross-sectional view showing a foaming raw material injecting in the embodiment, FIG. 7 is a cross-sectional view showing a closed mold and foaming, and FIG. 8 is a case of removing a holding plate. FIG. 9 is a cross-sectional view showing when the epidermal terminal is fixed.

A foam molded article 10 according to one embodiment of the present invention shown in FIGS. 1 and 2 is used for a console lid of an automobile, and comprises a base 11, a foam 21, and a skin 31. The base body 11 constitutes the core material and the back surface of this foamed molded product, and is made of a hollow resin body formed by blow molding, injection molding or the like from a resin such as polypropylene-primed resin or ABS resin. In this embodiment, the cross sectional shape is substantially trapezoidal. This substrate 11 has a foamed body 21 on one surface 12.
And the front surface 13 on the back side constitutes the back surface of this foam-molded article (the back surface of the console lid in this embodiment). A groove 14 is formed on the outer peripheral surface of the side portion of the base 11 near the back surface 13. This groove 14 is
The terminal 33 of the skin 31 is inserted and pinched. Therefore, it is preferable that the opening width of the concave groove 14 is made slightly smaller than the thickness of the outer skin 31 so that the end 33 of the outer skin 31 is reliably sandwiched in the concave groove 14. Further, the hollow portion 15 of the base body 11 has an effect of reducing the amount of the foamed body 21 used to reduce the weight of the foam-molded product, and thus is appropriately determined according to the dimensions of the foam-molded product.

In the base 11 of this embodiment,
As shown in FIG. 3, a hinge 16 is integrally formed so as to be openable and closable to attach the foamed molded product 10 to a console box in an automobile. The hinge 16 has a thin base portion, and is bent at the thin portion. Of course, depending on the type of foam-molded product, the hinge may be attached in a later step or may be unnecessary.

The foam 21 is for imparting a soft surface feel and cushioning property to the foam molded article 10, and is made of synthetic resin foam such as soft urethane foam. The foam 21 covers one side surface 12 of the base 11 and is provided up to the front of the concave groove 14.

The skin 31 constitutes the surface of the foamed molded article 10, and is made of a resin such as a soft vinyl chloride resin, a woven cloth lined with a synthetic resin film, or a fine mesh. A material such as cloth, which is formed by vacuum molding, slush molding, blow molding, press molding, sewing or the like depending on the material, is used. The skin 31 is in the shape of a bag having an opening as shown in FIG. 3, and is covered on the surface of the foam 21. Then, the skin terminal 33 around the opening 32 is bent inward of the skin 31 so as to wrap around the edge of the foam 31, as shown in FIG. There is. Therefore, the skin terminal 33 is hidden in the groove 14, and the appearance of the foam-molded article becomes good, and
The peeling of the skin terminal 33 is prevented. In addition, this skin 31
As will be described later, the foaming raw material injected between the base 11 and the skin 31 adheres to the surface of the foam 21 due to the self-adhesiveness when forming the foam 21.

Next, an embodiment of the method for manufacturing the foam-molded article and the molding die used in the manufacturing method will be described with reference to FIGS. 3 to 9. This method for producing a foam-molded product uses a mold including a cavity mold having a concave mold surface and a lid mold, and includes a skin arranging step, a foaming raw material injecting step, a closing mold step, an integral foaming step, and a demolding step. It includes a step and a step of fixing the skin terminal. The following will be described in order.

The molding die 40 used comprises a cavity die 41 and a lid die 47, as shown in FIGS. The cavity mold 41 has a concave mold surface 42 according to a desired foam-molded product inside. In this embodiment, the outer peripheral surface 43 of the mold surface serving as a parting surface is provided with positioning pins 44 for positioning the skin 31 and the lid mold 47 at predetermined intervals, and a clamp 45 for clamping the mold is provided on the side portion. ing.

The lid mold 47 is made of a hollow resin body and has a groove 14 formed in the outer peripheral surface thereof, and the base 11 is removably fitted into the groove 14 of the base so that the edge is the outer periphery of the base 11. The holding plate 48 protrudes from the surface. The base 11 constitutes the mold surface of the lid mold 47 and becomes a part of the foam-molded article after foam-molding. On the other hand, the holding plate 48
Is for holding the base 11 in the cavity mold 41 and for covering the cavity mold 41 integrally with the base 11. The holding plate 48 of this embodiment is composed of two halves 48a, 48a, and a concave portion corresponding to the outer peripheral surface of the base body 11 is formed on the opposite side of each half body 48a, and is fitted into the concave groove 14. Thus, the edge of the holding plate 48 surrounds the outer periphery of the base 11. Also, the holding plate 4
8 is formed with a hole 49 into which the cavity-type positioning and holding pin 44 is fitted. The holding plate 48
Is made of a rigid resin, a metal plate, or the like.

Using the mold 40, the foam molded article 10 is manufactured as follows. First, the skin arranging step is performed. In this skin arranging step, as shown in FIGS. 3 and 6, the above-mentioned bag-shaped skin 31 having an opening is arranged on the mold surface of the cavity mold 41, and the skin end 33 is set to the cavity mold 4.
It is arranged on the outer periphery 43 of the first mold surface. At this time, the holes 34 previously formed in the skin terminal 33 are fitted into the cavity-type positioning and holding pins 44 to position and fix the skin 31.

Next, a foaming material injection step is performed. In this step, as shown in FIG. 6, the foaming raw material P is injected into the skin 31 arranged in the cavity mold 41 by using an injection nozzle N. As the foaming raw material P, a polyurethane foaming raw material is suitable.

Next, a closed mold step is performed. In this step, a lid mold 47 composed of the base 11 and the holding plate 48 is formed.
The cavity mold 41 is covered with the base 11 inside the skin 31 and the edge of the holding plate 48 on the outer periphery 43 of the cavity mold 41. At that time, the hole 49 of the holding plate 48
Is fitted to the positioning and holding pin 44 of the cavity mold to position the lid mold 47, and then the clamp 45 is tightened to close the mold as shown in FIG. In addition, the holding plate 48,
In order to prevent the foaming raw material P from adhering, it is preferable to apply a release agent in advance.

In that state, the integral foaming step is performed. In this step, the foaming raw material P injected into the outer skin 31 foams, fills the space between the outer skin 31 and the base 11, and the self-adhesiveness of the foaming raw material at the time of foaming makes the outer skin 31 and the base 11 integral with each other. The foam 21 is formed. At this time, since the holding plate 48 is fitted and closed in the concave groove 14 on the outer peripheral surface of the base body 11, the foaming raw material does not enter.

Next, a demolding process is performed. In this step, the clamp 45 is removed, the lid mold 47 is removed from the cavity mold 41, and the molded product in which the outer skin 31, the base 11 and the foam 21 are integrated is released from the cavity mold 41.

After that, a step of fixing the skin terminal is performed. In this step, as shown in FIG.
4, the holding plate 48 is pulled out, and the groove 14 is opened as shown in FIG. Then, the skin terminal 33 is bent inside the skin 31 so as to wind the edge of the foam 21,
The desired foam-molded article 10 shown in FIG. 1 can be obtained by inserting it into the concave groove 14 with a spatula or the like and holding and fixing it.

In the above embodiment, an example of a so-called open injection manufacturing method and its forming die in which the closed mold step is performed after the foaming material injection step is shown, but the present invention is not limited to this. A foaming raw material injection port may be formed in the base 11 and a foaming raw material may be injected from the foaming raw material injection port after the mold closing step, that is, a so-called closed injection molding die may be used. A foam molded article may be produced by

[0026]

As shown and described above, according to the foam-molded article of the present invention, since the skin end is inserted into the concave groove of the outer peripheral surface of the substrate and concealed, the appearance at the skin end is good. At the same time, peeling of the skin terminal is prevented. Moreover,
Since the base body also serves as the back outer side of the related art, the number of parts can be small, the manufacture thereof is easy and the cost is low.
Further, since the base body is hollow, the amount of foam can be reduced even with a thick foam-molded product, which also makes it cheap and lightweight.

Further, according to the method for producing a foam-molded product of the present invention, in addition to the effect that the foam-molded product having the above advantages can be obtained, the process can be shortened because the foam is molded integrally with the substrate and the skin, Moreover, there is an effect that it is possible to reduce the variation in the appearance of the foamed molded product that occurs when the outer skin is manually covered, and the defective appearance of the foamed molded product due to the adhesion of the adhesive.
In addition, since the molding die used partially serves as the base of the foamed molded product, it is not necessary to separately mold the mold surface of the lid molded product, and it is possible to shorten the preparation preparation period of the foamed molded product. This also makes it possible to reduce the price of the foam-molded product.

On the other hand, in the molding die of the present invention, since a part (main part) of the lid mold is made of the base body of the foam-molded article as described above, the manufacturing period of the molding die can be shortened and the cost is reduced. . Furthermore, since the base body forming a part of the lid mold is made of a resin hollow body, the lid mold is lightened, and the weight of the entire molding die is lightened, so that there is an effect that the handling becomes easy.

In addition, the foamed molded article of the present invention, the manufacturing method thereof and the molding die thereof are not limited to the console lid of an automobile, and the foamed body is wound by a skin terminal such as a glove box or other small parts. It can be applied to various foam-molded products and has extremely high utility value.

[Brief description of drawings]

FIG. 1 is a cross-sectional view of a foam molded article according to an embodiment of the present invention.

FIG. 2 is an enlarged sectional view showing a part of the foam-molded article.

FIG. 3 is a perspective view illustrating a method for manufacturing a foam-molded article according to an embodiment of the present invention.

FIG. 4 is a cross-sectional view showing an assembly of the lid mold in the embodiment.

FIG. 5 is a plan view of a lid type in the embodiment.

FIG. 6 is a cross-sectional view showing the time when a foaming raw material is injected in the example.

FIG. 7 is a cross-sectional view showing a closed mold and foaming in the embodiment.

FIG. 8 is a cross-sectional view when removing a holding plate in the embodiment.

FIG. 9 is a cross-sectional view showing a case where the epidermal terminal is fixed in the embodiment.

FIG. 10 is a cross-sectional view showing assembly of a conventional foamed molded product.

FIG. 11 is a cross-sectional view of a conventional foamed molded product.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 11 Base 14 Recessed groove 21 Foam 31 Skin 31 End of skin 41 Cavity type 47 Lid type 48 Holding plate P Foaming raw material

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Claims (3)

[Claims] 1. A foamed molded article in which the surface of a foam provided on one side of a base is covered with a skin, and the end of the skin is bent toward the inside of the skin and fixed to the edge of the base, wherein the base is a resin hollow body. And a concave groove formed on the outer peripheral surface, and the end of the skin is inserted and sandwiched in the concave groove. 2. A cavity mold having a concave mold surface,
In a method of manufacturing a foamed molded product using a mold including a lid mold, the lid mold is detachably fitted into a base body made of a resin hollow body having a groove on an outer peripheral surface thereof and the groove of the base body. A holding plate having an edge projecting to the outer periphery of the base body, setting an open bag-like skin in the cavity mold, and arranging a skin end around the opening on the mold surface outer periphery of the cavity mold, Injecting a foaming raw material into the skin, and closing the lid mold by covering the cavity mold so that the base body is located inside the skin and the edge of the holding plate is located on the outer periphery of the mold surface of the cavity mold. A step of molding, a step of foaming the foaming raw material to integrate the skin and the base with a foam to be formed, and a step of releasing a molded article in which the skin, the base and the foam are integrated, If the holding plate is a concave groove on the substrate And a step of fixing the outer end of the outer skin by inserting and inserting the end of the outer skin into the groove of the base body. 3. A cavity mold having a concave mold surface,
To form a foamed molded product in which the skin, the base and the foam are integrated by foaming a foaming raw material between the skin and the base arranged in the mold and comprising a lid mold for covering the cavity mold. In the molding die, the lid die includes a base body having a groove formed on an outer peripheral surface of a resin hollow body, and a holding plate removably fitted in the groove and having an edge protruding from the outer periphery of the base body. A molding die characterized by comprising: