JPH089171B2 - Method of manufacturing foamed molded product - Google Patents

Description

Description: TECHNICAL FIELD The present invention relates to a foamed molded article having different skin portions on a part of the product surface, more specifically, a synthetic resin sheet having a part of the surface of a cloth with a skin. As a foamed molded product having a part to be, or a foamed molded product having a partially different color portion, as a specific product,
The present invention relates to a method for manufacturing an automobile interior product such as an automobile door trim having the above-mentioned characteristics, a foamed molded product such as furniture and a building material.

(Prior Art) In recent years, foamed molded products such as automobile interior parts, furniture, and building materials, which have been exemplified above, have a demand for cloth and different color synthetic resin as part of the surface skin due to diversification and high quality of consumer orientation. Is high.

As shown in FIG. 6, the conventional structure and molding method of such a foam-molded article is such that the foam layer (2) is formed on the back surface of the skin (20).
1) and the shape-retaining layer (22) are integrally laminated, and a part of the base foam (23) is formed on the back surface of the skin (24) of a different color and material from the skin (20). 25) and the shape-retaining layer (26) are integrally laminated, and the dissimilar skin foam (27) is fixed with a locking metal fitting (28) protruding from the shape-retaining layer (26) of the dissimilar skin foam (27). A structure consisting of is proposed.

Then, the manufacturing method is such that the base foam (23) and the heterogeneous skin foam (27) are separately molded, and thereafter,
It is manufactured by fixing the heterogeneous skin foam (27) at a predetermined position of the base foam (23).

(Problems to be Solved by the Invention) The foamed molded article according to the structure and the manufacturing method of the prior art is
As described above, it is a product obtained by combining separately molded foamed molded products. Therefore, the heterogeneous skin foam portion inevitably has a swelled shape, and a step is generated between the surface of the base foam and the surface of the heterogeneous skin foam, resulting in an uncomfortable feeling. In addition, there was a drawback that a gap was created between the mating surfaces of the two foams due to the work of attaching the different skin foam parts and the molding accuracy of each foam, and the parting line of the different skin parts was unclear. .

These drawbacks are very serious problems for foamed molded products, in which good appearance and shape are important requirements for determining commercial value, and an urgent solution is desired.

Further, the conventional manufacturing method is a step of molding the base foam,
The process of molding different kinds of skin foams and the process of integrally bonding both foams are essentially divided into three processes, which require significantly more man-hours than ordinary foam-molded products. It was inefficient.

The present invention focuses on such drawbacks of the prior art, and has no unnatural swelling of different kinds of skin portion or a gap between mating surfaces, and can reduce the number of manufacturing steps as compared with the conventional method. An object is to provide a method for manufacturing a molded product.

(Means for Solving the Problems) Therefore, the feature of the present invention for achieving the above-mentioned object is to temporarily place a molding having a foot integrally formed on a molding surface of a mold that can be sealed. The molding surface is divided into molding surfaces of a plurality of compartments, at least one compartment of the molding surface is equipped with a different type of skin, and the other compartment is equipped with a base skin and then filled with a synthetic foam raw material in a molding die, It is a method for producing a foamed molded product in which the raw material is foamed and then released from the mold.

(Operation) By producing the foamed molded product by the above method, the base skin and the different skin are integrally fixed by the foamable synthetic resin.

Further, during molding, the foot of the molding is sandwiched between the base skin and the heterogeneous skin, and the foaming pressure of the raw material strongly presses the base skin, the heterogeneous skin, and the molding.

Therefore, the demolded molded article strongly holds the molding between different types of epidermis, the three parts are integrated, and the parting line between the epidermis is clearly shown.

(Examples) Specific examples of the present invention will be described below.

FIG. 1 and FIG. 2 are cross-sectional views of a molding die showing respective steps of an embodiment in the method for producing a foam-molded article of the present invention.
The figure is a perspective view of the molding, and FIG. 4 is a cross-sectional view of the foam-molded article manufactured by the method for manufacturing a foam-molded article of the present invention. In FIG. 1, (1) is a molding die used in the method for producing a foam-molded article of the present invention, which comprises a pair of upper die (2) and lower die (3). The lower mold (3) has a molding surface for molding the surface shape of the molded body, and an annular groove (4) is provided in the central portion, and the molding surface is two molding surfaces, that is, the base skin molding surface (5). ) And a different skin forming surface (6).

As the first step of the method for producing a foam-molded article of the present invention, a leg portion (8) whose tip portion is bent in an L shape is formed on the back surface of the semicircular head portion (7) as shown in FIG. ) Is temporarily placed with the foot (8) facing upward.

Then, by the foot portion (8) of the molding (9), the base skin forming surface (5) and the dissimilar skin forming surface (6), which are partitioned like walls, are preferably pre-molded by vacuum forming or slush forming. The base skin (10) and the heterogeneous skin (1) are attached in close contact with the molding surface of the lower mold (3) and the foot of the molding (9).

Here, the expressions of the base skin (10) and the heterogeneous skin (11) simply mean that the two skins have different properties, such as different colors, materials, weaves, and the like.
Known materials such as natural fibers on the other side of the synthetic resin such as S resin or their laminated bodies, laminated bodies with these foam layers and the like can be used.

Then, a disc-shaped press-fitting insert (13) having a hole in the center made of synthetic resin is overlaid on the different skin (6) overlaid on the L-shaped portion (12) of the molding (9). . In this state, the foaming material (15) such as rigid polyurethane foam material is injected onto each skin (10) (11) of the lower mold (3), and immediately the upper and lower molds (2) (3) are put together and the mold is hermetically sealed. To do.

At this time, the protrusion (14) is previously provided on the upper mold (2),
By bringing the tip of the protrusion (14) into contact with the pressing insert (13), the movement of the molding (8) during foaming of the raw material and
It is preferable because leakage of the raw material from between the molding (8) and the skins (10) and (11) is prevented. The raw material (5) that is filled and sealed in the molding die (1) foams and the volume expands, and the molding die (1)
The base epidermis (10) and the heterogeneous epidermis (11) are pressed against the legs (8) of the molding (9) with a strong force while spreading over the respective parts to integrate the three parts.

In this state, the inside of the molding die (1) is kept at a constant temperature to cure and cure the foaming raw material, and then the upper die (2) is opened and the molded product as shown in FIG. 4 is released from the mold.

In the above-mentioned examples, the molding die (1) was not provided with a core body serving as a shape-retaining material of the molded body, but when a relatively soft foaming raw material is used, synthetic resin, metal or the like is used. It is preferable to use a core.

Further, when the foamed molded product is molded according to the above-mentioned embodiment, if leakage of the raw material from the joint between the molding and the skin is a particular problem due to the peculiarity of the structure of the molding die, as shown in FIG. It is also effective to attach a jig (16) to the portion having a C-shaped cross section and, in some cases, a tab (5) for preventing the slipping out.

The above-described embodiment discloses an embodiment by so-called closed molding, in which the foaming synthetic resin raw material is injected in a state where the molding die is closed, but the essence of the present invention is not limited to this. Alternatively, so-called open molding may be adopted in which the upper and lower molds are sealed after the raw material is injected with the upper and lower molds open.

(Effect) The method for producing a foamed molded article of the present invention is such that the molding surface of the molding die is partitioned into a plurality of compartments as if it were partitioned by the legs of the molding, and the compartments are attached to each compartment to form the foamable raw material. Is injected and foamed, and when each epidermis is integrated by the synthetic resin, a molding is held between the epidermis by the foaming pressure on the door. Therefore, the method for producing a foam-molded article of the present invention is to produce a foam-molded article in which the base skin and the dissimilar skin are integrally molded and bonded and the dissimilar skin portion does not have an unnaturally raised shape or a step is formed. You can

In addition, the molding is firmly inserted in the gap between the different kinds of epidermis and the base epidermis so that a clear appearance can be obtained.

Further, as described above, the conventional manufacturing method requires three steps, that is, a step of molding a base foam, a step of molding a heterogeneous skin foam, and a step of integrally bonding both foam moldings. Compared with the above, the molding is completed in only one step, and there is an effect that work efficiency is greatly improved.

[Brief description of drawings]

1 and 2 are sectional views of a molding die showing each step of an embodiment of the method for producing a foam-molded article of the present invention, FIG. 3 is a perspective view of a molding, and FIG. 4 is the present invention. 4 is a cross-sectional view of the foam-molded product manufactured by the method for manufacturing a foam-molded product of FIG. 4, is a perspective view of the molding of FIG. 4, and FIG. 5 is a cross-sectional view of a molding die showing a step of a modified embodiment of the present invention. FIG. 6 is a sectional view of a conventional foam-molded product. (2) …… Upper mold (3) …… Lower mold (8) …… Foot (9) …… Mall (10) …… Base skin (11) …… Different skin (13) …… Presser insert (15) ) …… Foam synthetic resin raw material

Claims (1)

[Claims] 1. A molding having a foot integrally formed on a molding surface of a mold that can be sealed, and the molding surface is divided into a plurality of molding surfaces, and at least one of the molding surfaces is divided. A different type of skin is attached to the compartments, a base skin is attached to the other compartments, and then a foam synthetic resin raw material is filled in the molding die, and the raw material is foam-cured and then demolded. Production method.