JPH0885120A - Structure of seal end of foam molded article with skin integrated - Google Patents

Abstract

PURPOSE: To improve the sealing structure, reduce the manhour for a pretreatment and an aftertreatment attendant on a leakage of burr and resolve problems at the end part or the open end part of a skin-integrated foam molded article from product appearance and function viewpoints by forming the aforesaid part in a given structure. CONSTITUTION: In the end part or the open end part of a skin-integrated foam molded article formed by providing a synthetic resin foam layer 30 between a substrate 10 and a skin layer 20, the substrate 10 and the skin layer 20 are each provided with overlap parts opposed to each other with a width (w) of 5mm or more through the synthetic resin foam layer having a thickness (d) of 2mm or less.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a structure of a seal end portion of a skin-integrated foam-molded article.

[0002]

2. Description of the Related Art For example, an instrument panel of an automobile is formed by a skin-integrated foam-molded article in which a foam layer of polyurethane resin or the like is formed on a base material and the top of the foam layer is covered with a skin layer of a soft synthetic resin sheet. Composed. In this molded product, a skin material shaped into a predetermined shape is set in a lower mold of a foaming mold, and a foaming material such as polyurethane resin is introduced to the back surface of the skin material so as to be integrated with a base material set in the upper mold. It is usually foamed and molded. This type of skin integrated foam molded product is
There is an advantage that a complicated three-dimensional panel-shaped object such as an instrument panel can be integrally formed.

However, in the case of a complicated three-dimensional panel-like object such as an instrument panel, there are not a few openings and irregular portions due to the relationship with the meter devices and the mounting portion, and such a shape is required. When a product is integrally foam-molded, an effective seal cannot always be obtained.

FIG. 3 shows an example of the state of molding at the opening of the instrument panel. As shown in FIG.
Due to the relationship with the base material 50, it is impossible to seal the opening P portion,
The foamed resin material 61 forming the synthetic resin foam layer 60 flows out and is formed as a burr B in this portion. This burr B is cut and removed by a line indicated by CC in the drawing. Reference numeral 70 in the figure denotes a skin material which is formed in a predetermined shape in advance, 91 is a lower mold, and 92 is an upper mold.

However, as shown in FIG. 4, although the burr B that has flowed out to the opening P is removed by the cutting line C-C, the burr B leaks out, and the mold release process is performed in advance and the post-complication is complicated. Not only is deburring necessary,
Often, there is a problem that a defective molding portion called a rising bottom N1, a rough cell N2, and a sink N3 appears at the peripheral edge of the opening P.

[0006] These problems not only increase the number of man-hours for working such a molded product and increase the cost, but also give rise to product appearance and functional claims such as deformation and deterioration of the seal end. However, conventionally, in the product design of this kind of end portion, the design was simply done without much improvement or countermeasure in this respect.

[0007]

SUMMARY OF THE INVENTION In view of the above-mentioned problems, the present invention improves the sealing structure by making the end portion and the open end portion of the foam-in-situ integrated foam-molded product have a constant structure to improve the burrs. Reduce the number of pre- and post-treatment processes required for leakage,
It is proposed for the purpose of improving the product appearance and functional problems in the portion.

[0008]

That is, the present invention provides:
At the end portion or the open end portion of the foam-integrated surface-molded article in which the synthetic resin foam layer is formed between the base material and the skin layer, the base material and the skin layer are separated by a synthetic resin foam layer having a thickness of 2 mm or less. The present invention relates to a structure of a seal end portion of a skin-integrated foam-molded article, which has opposing overlapping portions having a width of 5 mm or more.

[0009]

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 sectional view of a molding die having an opening of an instrument panel showing an example of the structure of a seal end portion of a skin-integrated foam-molded product of the present invention, and FIG. 2 is a sectional view of the other seal end portion. .

As shown in FIGS. 1 and 2, the present invention relates to a skin-integrated foam-molded article such as an instrument panel, and in particular, a synthetic resin foam layer 30 is provided between a base material 10 and a skin layer 20. Seal end S of the formed product
1, related to the structure of S2.

The substrate 10 serves as a strength member of a molded product, and is usually made of a hard synthetic resin injection molded product or the like. The skin layer 20 is made of a soft synthetic resin such as vinyl chloride resin. The synthetic resin foam layer 30 is made of a foamed synthetic resin such as polyurethane resin. As shown in the figure, the skin-integrated foam-molded article is obtained by setting the skin material 21 shaped into a predetermined shape by powder slush molding or vacuum molding in advance in the lower mold 41 of the foaming mold 40, and then the back surface of the skin material 21. A foam material 31 such as polyurethane resin is introduced into the upper mold 4
It is integrally foam-molded with the base material 10 set to 2.

In the structure of the present invention, first, as shown in the example of FIG. 1, the base material 10 and the skin layer 20 face each other with a width w of 5 mm or more at the portion which becomes the seal end S1 of the molded product. It is formed so as to have an overlapping portion W1.

As in this example, the seal end S1 of the molded product
By forming the base material 10 and the skin layer 20 so as to have the overlapping polymerized portions W1 having a width w of 5 mm or more, leakage of the foamed resin material 31 can be effectively stopped.

On the other hand, in the example of FIG. 2, at the seal end S2, the base material 10 and the skin layer 20 are opposed to each other with a width w of 5 mm or more through a synthetic resin foam layer 30 having a thickness d of 2 mm or less. It is formed to have a portion W2.

As in this example, when the base material 10 and the skin layer 20 are not directly polymerized at the seal end portion S2 and the synthetic resin foam layer 30 is interposed, the synthetic resin foam layer 30 is interposed. The thickness d of 30 is 2 mm or less, and the width w of the synthetic resin foam layer 30, the base material 10, and the skin layer 20 is 5
By molding so as to form the overlapping polymerized portions W2 having a size of not less than mm, leakage of the foam material forming the synthetic resin foam layer 30 in the middle portion can be suppressed as much as possible.

[0016]

As described above, according to the structure of the present invention, in the seal end portion of the molded product, as described above, the base material and the skin layer have a thickness of 2 mm or less (including 0 as shown in FIG. 1). Completely preventing or minimizing leakage of the foam material forming the synthetic resin foam layer at the time of molding by forming the resin foam layer so as to have opposed polymerized portions having a width of 5 mm or more. Is now possible.

Therefore, if the product is designed to have such a seal end, it is possible to reduce the number of man-hours required for the mold release process before the leakage of the burr, the mounting of the sealing material and the subsequent burr process. It enables efficiency improvement and cost reduction. At the same time, the bottom of the burr B rises due to leakage,
It is possible to improve molding defects called cell roughness and sink, which affect the appearance and function of the product.

[Brief description of drawings]

FIG. 1 is a partial cross-sectional view of a molding die for an opening of an instrument panel showing an example of a structure of a seal end portion of a skin-integrated foam-molded product of the present invention.

FIG. 2 is a sectional view of the other seal end portion of the same.

FIG. 3 is a cross-sectional view showing a molding state of an opening portion of a conventional instrument panel.

FIG. 4 is a sectional view of an opening of a conventional instrument panel molded product.

[Explanation of symbols]

 10 Base Material 20 Skin Layer 30 Synthetic Resin Foam Layer S1, S2 Seal Ends W1, W2 Polymerization Part w Width of Polymerization Part d Thickness of Synthetic Resin Foam Layer

Claims (1)

[Claims] 1. A synthetic resin in which the base material and the skin layer have a thickness of 2 mm or less at an end or an open end of a skin-integrated foam-molded article in which a synthetic resin foam layer is formed between the base material and the skin layer. A structure of a seal end portion of a skin-integrated foam-molded article, which has opposed polymerized portions having a width of 5 mm or more with a foam layer interposed therebetween.