JPH1052826A - Foam molding method - Google Patents

Abstract

PROBLEM TO BE SOLVED: To effectively prevent leakage and to reduce a rate of defective by facilitating the setting in a foam molding, shortening a mold setting time to expedite shortening of a molding cycle, and eliminating a corner slope due to tension of a skin material at the time of sealing. SOLUTION: In order to conduct foam molding by mating one mold 1 in which a skin material 3 is disposed and the other mold 2 in which a core material 4 is disposed, an edge of the material 3 disposed in the one mold 1 is bent. A bent portion is maintained in a deflected state. A slide member 6 incorporated with the mold 1 is slid, and an end part 3a of a bent edge portion of the material 3 is locked to its end. Then, the other mold 2 is mated to the mold 1. Then, the member 6 is further slid while the part 3a of the material 3 remains locked to the end, and sealed. Foam material 5 is poured between the material 3 and a core material 4, and foam molded.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a foam molding method, and more particularly to an instrument panel, a glove box, and the like.
The present invention relates to a foam molding method for a foamed synthetic resin molded product used for automobile interior parts such as a console box.

[0002]

2. Description of the Related Art Conventionally, in foam molding of automobile interior parts such as an instrument panel, for example, as shown in FIG. And the other mold 2
The core material (insert material) 4 is arranged in
After the mold 2 is molded, a foam synthetic resin material such as urethane is injected between the two to integrally mold the skin material 3, the foam layer 5 and the core material 4. In the foam molding, the vicinity of the edge of the skin material and the joint portion of the core material are brought into surface contact with each other at the time of the foam molding, and the upper and lower molds 1 and 2 are press-bonded. Therefore, the foam material is injected between the core material 4 and the skin material 3. The foamed material leaks from the joint near the edge and hardens to form burrs, or isocyanate and polyol are mixed, and the gas generated during the chemical reaction to become urethane moves to the weaker pressure, and this When the urethane finishes reacting during the movement due to leakage, the gas remains as fine particles, and after molding, it has to be removed in a trimming process, which is not only very troublesome but also preferable in appearance. No more Defective products, there is a problem that results in a scrap.

For this reason, as shown in FIG. 5, as a technique for preventing the leakage of the foaming material at the joint portion of the skin material edge, the leakage of the foaming material is prevented by using a slide mold 1a as a foaming material forming die (Japanese Patent Laid-Open No. HEI 9-163556). JP-A-197443), a skin material and a core material are arranged in a foaming mold, and a foam material is injected between them to form an integral foam. At the joint between the skin material and the core material, as shown in FIG. It has been proposed to provide a ridge 10 or a sealing material (JP-A-4-247915) or a liquid thermoplastic resin (JP-B-7-10533).

[0004]

However, although each of the above-mentioned leak prevention structures is effective to some extent, it is necessary to set the skin material in advance to a seal shape or to set the shape of the core material other than the product surface. In addition to this, it takes a lot of time and labor, and at the time of foam molding, there is a problem that the edge of the skin material is pulled and opened between the core material joining surface and the dimensional accuracy is deteriorated.

On the other hand, as shown in FIG. 3, in a foaming mold in which one mold 1 in which a skin material 3 is arranged and another mold 2 in which a core material 4 is arranged, the skin material 3 is used.
The slide member 6 is provided at the bending position of the skin material edge of one mold 1 on which is disposed, and the member 6 is slid so that the bent edge tip 3a of the skin material 3 is brought into contact with the core material 4. Although some attempts have been made, since the skin material 3 is not bent, if there is a slit S between the bent edge tip 3a and the core material 4 as shown in FIG. When the skin material 3 is extruded toward the core material 4 by the sliding of the slide member 6 and is joined by being pulled, that is, FIG.
In the state described above, the corners are drooped due to the pulling by the slide member 6, and a part of the skin material 3 is thinned, so that there is a problem that defective products are easily caused.

SUMMARY OF THE INVENTION The present invention addresses the above-mentioned actual situation, and in particular, adopts a slide member and the shapes of the skin material and the core material to facilitate the setting, shorten the mold setting time, and shorten the molding cycle. It is another object of the present invention to promote the prevention and eliminate a dripping portion due to the tension of the skin material at the time of sealing, thereby reliably preventing leakage and reducing the defective rate.

[0007]

That is, according to the present invention, which meets the above-mentioned object, according to the present invention, one of the molds on which the skin material is arranged and the other mold on which the core material is arranged are mold-matched to each other. In a foaming mold for injecting a foaming material during molding and molding a foamed product in which a skin material, a foam layer and a core material are integrated, a skin material edge bending position of one mold on which the skin material is arranged When foam molding is performed using a molding die in which a slide member that allows the front end of the skin material bent edge to abut on the core material is slidably disposed, the edge of the skin material arranged in one mold The folded portion is maintained in a state where the bent portion is deflected, and a slide member attached to the mold is slid so that the tip of the bent edge portion of the skin material is hooked to the tip thereof, and then the other is formed. After matching the mold The slide member, while was further slide was hooked to the bent edges of the skin material at its tip,
It is characterized in that a sealing material is sealed, a foam material is injected between the skin material and the core material, and foam molding is performed.

According to a second aspect of the present invention, a suitable means is added in carrying out the above method, and a bending portion is provided at a bent edge portion of a skin material, and a slide member is hooked at a tip end thereof. The present invention is characterized in that the hook-shaped hook portion is formed in advance.

[0009]

According to the present invention, the skin material is first placed on one mold while the slide member is not yet slid. Then, the slide member is slid to such an extent that the skin material can be hooked, and the front end of the skin material bending edge portion is hooked and maintained at the front end, and set.

[0010] In this state, the core material is then set in the other mold and lowered, and when the molds are matched, the slide member is slid again to completely touch the front end portion of the skin material bending edge to the core material. Touch and seal. Thus, by injecting the foam material and performing the foam molding, the trouble of trimming and deburring after foaming becomes unnecessary, and the molding cycle is shortened.

In particular, if the bending portion and the hooking portion are provided on the skin material as described in claim 2, the sliding member is slid until the front end of the skin material bending edge comes into contact with the core material. At this time, even when the skin material is pulled, the appearance is improved without causing any drooping at the corners, and the sealing is more complete so that the leakage of the foam material can be prevented.

[0012]

DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, specific embodiments of the present invention will be described with reference to the accompanying drawings.

FIGS. 1 and 2 show one embodiment of the foam molding method of the present invention. In the drawings, reference numeral 1 denotes a lower mold, 2 denotes an upper mold, and a foam molding die comprises the pair of molds 1 and 2 described above. In carrying out the present invention, a skin material 3 is arranged in a lower mold 1 and a core material 4 is arranged in an upper mold 2, and these upper and lower molds are matched with each other. A foamed resin material is injected between the skin material 3 and the core member 4 in a state where the tip portion 3a is joined to the core member 4, and foam molding is performed.

When the skin material 3 is placed (set) on the lower mold 1, a suction mechanism (not shown) connected to a suction source is provided, and the skin material 3 is sucked into the lower mold 1 by this vacuum suction. Crimp. Here, a flexible material such as a resin sheet or leather is used as the skin material 3, and a resin panel, a metal panel, or the like is used as the core material 4.

As the foam material 5, polyurethane, P
Foam materials such as VC and polyethylene can be used,
Most commonly it is polyurethane. By the way, as described above, the tip 3a of the bent edge portion of the skin material 3 is joined to the core material 4, the foam material 5 is injected between them, and the foam molding is performed. At the edge bending position of the skin material 3 of one of the molds 1 on which the material 3 is disposed, a slide member 6, for example, a slide plate, for bringing the bent edge tip 3 a into contact with the core material 4 is provided. Then, the bent edge tip 3a of the skin material 3 is brought into contact with the core material 4 by the slide member 6.

In this case, in order to more reliably join the skin material 3 to the core material 4 by the slide member 6, in a preferred embodiment, the skin material 3 is partially bent as shown in FIG. A portion 7 and a hook-shaped hooking portion 8 for hooking the slide member 6 on the end thereof are formed in advance. It is advantageous that the flexing portion 7 is slightly thinner than the other portions, and the thickness of the flexing portion 7 in the state before the extension is t when the thickness of the skin material 3 is t (0.2 to 1. 0) Let t.

When the slide member 6 slides and moves the skin material 3 toward the core material 4, the flexure portion 7 and the latching portion 8 adjust the shape of the skin material 3 in accordance with the slide member 6. 3 and core 4
This is advantageous in making the seal between the two more complete.
If the skin material 3 is not flexed, FIG.
When the slit S is provided between the bent edge tip 3a and the core member 4 as shown in FIG. 5, the skin material 3 is pushed out toward the core member 4 by the slide of the slide member 6 as described above. When the member is pulled and joined, that is, when the state shown in FIG. 3B is obtained, the corner portion is drooped due to the pulling by the slide member 6 and a part of the skin material 3 is in a thin state. It is easy to invite. Therefore, it is very preferable to previously bend a part of the skin material 3 and to provide the hook 8 at the tip as shown in FIG.

Thus, in the present invention, the skin material 3 is arranged on one mold 1 and the slide member 6 is slid to the extent that the skin material 3 is hooked, and the setting of the skin material 3 on the mold 1 is completed. Is arranged, and is matched with the other set mold 2. At this time, since the bent edge tip 3a of the skin material 3 is not yet in contact with the core material 4,
The slide member 6 is again slid to the maximum extent, and the bent edge tip 3a is brought into close contact with the core material 4. Therefore, it is preferable that the slide length of the slide member 6 is set in accordance with the form of the foamed molded product and based on the mold matching between the bent edge tip portion 3a and the core member 4, so that a slight margin is preferably provided. When the bent edge portion 3a of the skin material 3 and the core material 4 are brought into contact with each other, the slide member 6 is sufficiently sealed by pressing the slide member 6, and a foaming material such as polyurethane is injected to perform foam molding. Do.

As described above, according to the present invention, the skin material edge is completely sealed, the effect on the product surface can be minimized, the trimming process can be streamlined, and the molding time can be shortened.

[0020]

According to the present invention, a slide is provided so that the front end of the bent edge portion of the skin material contacts the core material corresponding to the bent position of the skin material edge portion of the mold on which the skin material is arranged as described above. The member is disposed, and in the mold matching prior to foam molding, the front end of the bent edge portion of the skin material arranged in one mold is temporarily hooked by the slide member, and the other mold and mold in which the core material is arranged After the alignment, the sliding edge is further slid so that the tip of the bent edge of the skin material is brought into contact with the core material to inject the foam material, and the bent edge of the skin material is bent. Since the slide member is slid with the slide member maintained completely, it is possible to completely seal the slide member and completely prevent the leakage of the foamed material. Significantly simplified In addition, the skin material can be flexed and arranged in the mold set of the skin material and the core material, and can be set by the slide member. Has a remarkable effect on improving the appearance of In particular, by forming in advance a part of the flexure portion on the skin material and a hook-shaped hooking portion of the slide member at the tip portion, not only the setting of the skin material by the slide member but also a further sealing effect. Can be increased.

[Brief description of the drawings]

FIG. 1 is a schematic partial sectional view showing one embodiment of the foam molding method of the present invention.

FIG. 2 shows a preferred embodiment of a skin material in the foam molding method of the present invention, wherein (A) is a partial cross-sectional view of the skin material before stretching.
(B) is a partial cross-sectional schematic diagram in a state of the skin material in an extended state.

FIG. 3 shows a sliding mode of a comparative slide member;
(A) is a partial sectional view before sliding, and (B) is a schematic partial sectional view after sliding.

FIG. 4 is a sectional view showing an example of a known seal structure.

FIG. 5 is a sectional view showing another example of a known seal structure.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Lower mold 2 Upper mold 3 Skin material 4 Core material 5 Foam material 6 Slide member 7 Flexure part 8 Hook part

Continued on the front page (51) Int.Cl. ⁶ Identification code Agency reference number FI Technical display location B29L 31:58

Claims (2)

[Claims] 1. A mold in which a skin material is arranged and a mold in which a core material is arranged are matched with each other, and a foam material is injected between the skin material and the core material. And a foam molding method for molding a foam molded product in which the core material is integrated, wherein the edge of the skin material arranged in the one mold is bent, and the bent portion is maintained in a bent state, and the mold is formed. After sliding the slide member attached to, the front end of the bent edge portion of the skin material is hooked to the front end thereof, and then the other mold is mold-set. Then, the slide member is bent at the front end thereof. The foaming is characterized in that the edge portion is further slid while being hooked, the tip portion is brought into contact with the core material and sealed, and a foaming material is injected between the skin material and the core material to form the foam. Molding method. 2. The foam molding method according to claim 1, wherein a bending portion is formed at a bent edge portion of the skin material, and a hook-shaped hooking portion for hooking a slide member is formed at a tip of the bending portion.