JPH11333867A - Production of skin integrated molded product fitted with foam layer - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method for producing a skin integrated molded product fitted with a vehicle foam layer good in the fitting state of a boundary line even if the projected ribs on the inner surface of a mold are emilinated and having sufficient strength. SOLUTION: In a method for producing a skin integrated molded product fitted with a foam layer wherein a part forming a design surface on a resin layer and a part wherein the resin layer is covered with a surface sheet wherein the foam layer and a skin layer are integrated to form the design surface, the predetermined width part from the end edge of the surface sheet 1 is set to a non-foamed part 5 when the foam layer 3 is substantially removed and the surface sheet 1 is set to the cavity of a mold so that the skin 2 of the surface sheet 1 is provided along the inner surface of the mold of the skin layer forming part 12 and the non-foamed part 5 is held so as to divide the mold grooves 13 provided at the positions corresponding to both end parts of the inner surface of the mold of the skin layer forming part 12 and, subsequently, a resin 15 is injected into the cavity E1 on the rear side of the surface sheet of the mold and a resin 16 is injected into the cavity E2 coming into contact with the surface of the non-foamed part 5 of the mold to integrally bond and mold the surface sheet 1.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for producing a molded article of a skin with a foam layer, which is mounted on a vehicle interior or the like.

[0002]

2. Description of the Related Art In the case of an integrally molded article with a foam layer around an instrument panel, a door panel, or the like of an automobile, the elasticity of a urethane foam layer or the like on the back surface of the skin has conventionally been used in order to give a soft texture to the skin covering the surface. The foamed layer with the property is formed. FIG. 10 is a perspective view showing an example of such an integrally molded skin-equipped product with a foam layer. FIG. 11 shows the AA
It is a line sectional enlarged view. In the figure, reference numeral a denotes an injection-molded molded product main body, reference numeral b denotes a front cover sheet adhered to the entire surface of the molded product main body, and the front cover sheet b is integrally formed on a skin c and a back surface thereof. And a foam layer d. FIG.
FIG. 13 shows a perspective view, and FIG. 13 shows a cross section taken along the line BB of FIG. 13. In the example shown in FIG. By sandwiching the edge e of the front cover sheet b serving as the boundary into the groove f formed in the molded article main body a, the waving of the boundary line cannot be visually recognized.

[0003]

However, as shown in FIG. 14, a molding die for integrally attaching the above-mentioned facing sheet at the time of injection molding such a molded product is shown in FIG.
A convex rib i was formed on the inner surface of one of the pair of opening / closing dies g and h, and a mold groove 1 was formed on the inner surface of the other die.
Then, as shown in (a) in the figure, first, the skin c of the surface mounting sheet b is fitted from the inner surface of the mold to one side of the convex rib i, and the surface mounting sheet b is set in the molding die. (B) and (c), the resin s is injected from the side on which the facing sheet is set, and then the exposed portion resin t is injected from the other side as shown in (d). As described above, the two resins were bonded together in the mold groove 1 and cured. Here, when the width k of the convex rib i is made as small as possible, the groove f becomes narrower, and the edge e may not be conspicuous in appearance. However, when the width is made narrower, the strength decreases, and FIGS.
As shown in (1), there was a problem that a crack q was formed by the injection pressure of the resins s and t (arrows in the figure) and the resin was easily broken.

Further, in this molded product, the thickness n, p, etc. of the resin in that portion is locally reduced due to the edge e as shown in FIG. 17, so that when an external force r is applied as shown in FIG. There was a problem that sufficient rigidity could not be obtained and deformation was easy.
Therefore, it has been necessary to take measures by increasing the thicknesses n and p of these portions or reinforcing them with ribs.

[0005] For this reason, the present inventors abolished the convex ribs i and formed a concave surface m on the inner surface of one of the molds in which the facing sheet b fits, as shown in FIG. After injecting the resin s from the side of the facing sheet b,
It was considered that the resin t was injected from the other side. But,
Then, as shown in (b), the foaming layer d of the facing sheet b is crushed by the injection pressure of the resin from the other side, and the resin flows out to the surface side, so that the boundary line α becomes ambiguous and the aesthetic appearance is impaired. Have been.

[0006] The present invention solves the above-mentioned problems. Even if the convex ribs on the inner surface of the mold are abolished, the boundary line can be easily fitted.
It is still another object of the present invention to provide a method for producing a molded article integrally formed with a vehicle foam layer having sufficient strength.

[0007]

In order to achieve the above object,
The gist of the invention according to claim 1 is that a design surface is formed by covering a portion forming a design surface on the surface of the resin layer and a surface layer in which the resin layer is formed of at least a foam layer and a skin in an integrated manner. The method according to claim 1, further comprising: forming a predetermined width portion from an edge of the front cover sheet as a non-foamed portion from which the foam layer is substantially removed; The outer cover sheet is held by keeping the skin of the sheet along the inner surface of the mold of the skin layer forming portion and holding the non-foamed portion so as to divide the mold groove provided at a position corresponding to the end of the inner surface of the skin layer forming portion. It is set in a molding die, and then injects a resin into a cavity on the back surface side of the facing sheet in the molding die, and then injects a resin into a cavity in contact with a front surface side of the non-foamed portion, thereby forming the facing sheet. And stick them together In the manufacturing method of the foamed layer with integral skin molded article characterized by. Here, the “non-foamed portion from which the foamed layer has been substantially removed” refers to a material in which the foamed layer has been eliminated from the front cover sheet, or a foamed layer which has been crushed to minimize the foamed portion. According to a second aspect of the present invention, there is provided a method of manufacturing a molded article with a skin layer having a foam layer, wherein a clamping mechanism for clamping the tip of the non-foamed portion is provided at the bottom of the mold groove.

According to the first aspect of the present invention, after a predetermined width portion from the edge of the covering sheet is a non-foamed portion from which the foam layer is substantially removed, the skin of the covering sheet is formed into a mold of the covering layer forming portion. Along with the inner surface, the non-foamed portion is held in such a manner as to divide a mold groove provided at a position corresponding to an inner surface end of the skin layer forming portion, and the front cover sheet is set in a molding die. Inject resin into the cavity on the back side of the front cover sheet in the molding die, and then inject resin into the cavity in contact with the front side of the non-foamed portion.When the resin is injected during molding, the foam layer at the boundary is pushed. Since there is no crushing, the fit of the boundary line is improved even without the convex rib. Since the groove can be eliminated in the boundary area by eliminating the convex rib, sufficient strength can be maintained without increasing the thickness of the boundary area. As in the invention of claim 2, when a clamping mechanism for clamping the tip of the non-foamed portion is provided at the bottom of the mold groove, a portion where the front cover sheet forms the design surface and a portion where the resin layer surface forms the design surface are provided. Can be separated by the non-foamed portion, so that the specification of the injected resin can be changed between the surface mounting sheet side and the side on which the design surface is formed by the resin layer.

[0009]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, an embodiment of a method of manufacturing a molded article of a skin with a foam layer according to the present invention will be described in detail. Figure 1
Fig. 9 is an embodiment of the method for producing a skin-integrated molded article with a foamed layer according to the present invention. Figs. 1 and 2 are cross-sectional views of a facing sheet, Figs. FIG. 6 is a cross-sectional view of a molding die used in the present manufacturing method, and FIGS. 7 to 9 are cross-sectional views of a manufacturing process.

[0010] In the production of the foam layer with an integral skin molded article, a portion forming a design surface E ₂ in the resin layer surface, at least the foam layer and the skin layer resin layer is covered with the upper mounted sheet 1 is integrated design surface a portion forming a E _1, but making the integrally molded foamed layer with integral skin molded article. First, the outer cover sheet 1 as a skin with a foam layer is processed. The covering sheet 1 has a two-layer structure in which a foam layer 3 is formed on the back surface of a skin layer formed by the skin 2 as shown in FIG. 1 or a backing material 4 of a backing layer on the foam layer 3 as shown in FIG. Are attached together. The skin 2 is made of TPO (olefin-based thermoplastic elastomer), TPU (urethane-based thermoplastic elastomer) or PVC (vinyl chloride resin), and the foamed layer 3 is made of urethane foam, foamed polyethylene, foamed TPU, or the like. . The backing material 4 is selected from a resin film such as polypropylene or ABS.

The processing of the facing sheet 1 is performed by substantially removing the foamed layer 3 of a predetermined width portion from the edge of the facing sheet 1 so that the foaming layer 3 is not foamed at the edge of the facing sheet 1 as illustrated in FIG. The part 5 is formed. The method of removing the foam layer 3 is as follows.
When trimming the cover sheet with a predetermined press die, which is cut off with a cutter as shown in FIG. 3, as shown in FIG.
Is pressed and crushed to form a substantially non-foamed portion 5, or a non-foamed portion 5 without a foam layer is formed in advance when forming a front cover sheet. like,
When the method of pressing with a mold to crush the foam layer 5 during preforming is adopted, the removal of the foam layer 5 is easy and the workability is improved. The form after the removal of the foamed layer 3 is preferably such that, for example, as shown in FIG. 5, the thickness gradually becomes thinner at the corners, and the boundary α (FIG. 9) or the part beyond the boundary α is completely removed. This is because, at the time of injection molding, a problem that the resin 16 flows out to the surface side of the surface mounting sheet 1 does not occur (see FIG. 18). The same applies to the case where the backing material 4 is integrally adhered as described above as the surface mounting sheet 1 or the case where no backing material is used.

FIG. 6 is a sectional view of a molding die used in the present invention. The molding die is a low-pressure molding die, and a pair of opening and closing dies 10,
11 is provided. A concave skin layer forming portion 12 is provided on the inner surface of the cavity of one opening / closing mold 10 and the other opening / closing mold 1 is provided.
In FIG. 1, a mold groove 13 is formed in a portion of the skin layer forming portion 12 opposite to the inner end of the mold. The cover sheet 1 is set at the portion of the skin layer forming portion 12, and the design surface E is formed on the surface of the resin layer.
_The surface sheet region is made to have a convex shape from the part where the surface layer 2 is formed, and the skin layer forming portion depth T is set to be larger than the thickness S of the surface sheet 1 used (FIG. 7). in addition,
The opening / closing die 11 has a horizontal slide die 14 (slide mechanism) that can divide the bottom of the die groove 13 and move forward and backward in the direction of the arrow.
Is provided.

[0013] A non-foamed portion 5 from which the foam layer 3 is substantially removed is formed at a predetermined width from the edge of the front cover sheet by using the openable dies 10 and 11 as described above. Is set on the opening / closing die 10. The mold groove 13 in which the skin 2 of the skin 1 is arranged along the inner surface of the skin layer forming portion 12 of the opening and closing mold 10 and the non-foamed portion 5 is provided at a position facing the inner surface end of the skin layer forming portion 2. That is, the front cover sheet 1 is set in the molding die. In the present embodiment, the horizontal slide mold 14 is moved in advance so that the bottom of the mold groove 13 is opened, and the non-foamed portion 5 of the front cover sheet 1 is positioned in the mold groove 13. Activate to pinch and fix the tip of the non-foamed portion 5 (FIG. 7). By sandwiching and fixing the non-foamed portion 5 of the horizontal slide mold 14, the non-foamed portion 5
Wall is the appearance which is bisected into the cavity C ₁ and C ₂ of. The non-foamed portion 5 crosses from the design surface side to the back surface of the molded product.
Since the skin layer forming portion depth T is larger than the thickness S of the cover sheet 1 and the constant width portion of the foam layer 3 is removed from the edge of the cover sheet 1, the wall separating the cavity C ₂ is a non-foam portion 5. It has become. The non-foamed portion 5 is a mode in which the foamed layer is removed as described above. In addition to the case where only the skin 2 shown in FIG. And a backing material 4 (or only the skin 2).

Next, the cavity C on the back side of the front cover sheet
Resin 15 (molten resin) is injected into ₁ and low-pressure molding of the front cover sheet portion is performed (FIG. 8). Since the cavity C is divided by the non-foamed part 5, the resin 15 fills only the cavities C ₁ side of the mounting seat 1. By sandwiching and fixing the tip of the non-foamed portion of the horizontal slide die 14 as a slide mechanism, and by performing low-pressure molding, a change occurs in the non-foamed portion 5 that partitions the inside of the cavity C, but it does not become large. As described above, since the front cover sheet portion is formed first, as shown in FIG. 8, the periphery of the front cover sheet 1 has a beautiful bent shape without any restrictions, and the line of the boundary line α is linear. And the product will be able to shine. Outer seat 1
As described above, the foamed layer 3 is gradually squeezed at the corners, and the foamed layer 3 is removed at a portion exceeding the boundary line α, and the resin 15 is in contact with the non-foamed portion 5, so that a molded product is completed. At this point, the corner portion forming the boundary line α looks better.

Thereafter, the resin 16 is injected into the cavity C _{2 which} is in contact with the front side 5 a of the non-foamed portion 5. Since the foamed layer 3 is substantially removed from the non-foamed portion 5, even if the resin 16 is applied to the non-foamed portion 5 at the injection pressure, the portion does not become concave, and there is no fear that the resin 16 flows out to the surface side of the facing sheet 1. Absent. When the resin 16 fills the cavity C _2, end of the molding of the foam layer with an integral skin molded article (Figure 9). A portion making design surface E ₁ with the resin layer surface, design surface E over the resin layer with the upper mounted sheet 1
_An integral molded product with a foam layer and an integral molding of the part that forms ₁ is made. Here, by selecting a compatible material for the resin 16 and the cover sheet 1, fusion bonding with the resin 16 is achieved, and the cover sheet 1 is integrated. Further, the resin 15 is set to any color in the recycled materials, by performing two-color molding to choose the wood color design surface E ₂ virgin material only to the resin 16, it is also possible to reduce the cost. Since the resin 15 leaks into the cavity C ₂ by a wall of non-foamed portion 5 is blocked, because not come appear in the resin layer side to form a design surface E _2. Finally, if the mold is removed, a desired molded product in which the facing sheet 1 is integrally attached is obtained. Horizontal slide type 14
The tip portion of the non-foamed portion 5 which is sandwiched between the two and which appears on the back side of the molded product is subjected to a trimming process as necessary.

In the method of manufacturing the integrally molded skin-formed product with the foam layer, the non-foamed portion 5 located in the mold groove 13 is not crushed by the injection pressure of the resin 16 and is not deformed. There is no danger that 16 will flow out to the front side. Therefore, the boundary line does not undulate, and the boundary line α can be beautifully finished. In particular, when molding is performed by sandwiching the front end of the non-foamed portion with the horizontal slide mold 14, the corner portion of the facing sheet 1 is neatly bent in a cross-sectional view, and the boundary line α has a line shape without waving. , Products shine. Since the thickness of the resins 15 and 16 does not locally decrease at the boundary portion as in the related art, necessary rigidity and mechanical strength can be maintained. Of course, since the convex rib i as shown in FIG. 16 is abolished, the problem that a crack q runs on the convex rib is also solved.

Further, the type of the resin to be injected into the molding die is made different with the mold groove 13 as a boundary. That is, the resin 15 hidden by the surface mounting sheet 1 and the resin 16 forming the design surface E ₂ are different types. For example, by using a recycled product of an arbitrary color for the resin 15 and using a virgin material of a predetermined color for the resin 16, it is possible to maintain the high quality while reducing the cost.

The present invention is not limited to the embodiment described above, but can be variously modified within the scope of the present invention depending on the purpose and application. Cover sheet 1, non-foamed part 5, openable type 1
The shape, size, etc. of 0, 11, etc. can be appropriately selected according to the application.

[0019]

As described above, according to the method for producing a skin-integrated molded article with a foamed layer of the present invention, the boundary between the surface on which the design surface is formed on the surface of the resin layer and the skin is clean and well-fitted. It has excellent effects such as sufficient strength.

[Brief description of the drawings]

FIG. 1 is a cross-sectional view of a covering sheet constituting a molded article of a skin with a foam layer according to the present invention.

FIG. 2 is a cross-sectional view of a cover sheet having a different form from FIG.

FIG. 3 is a cross-sectional view showing a processing state of the front cover sheet.

FIG. 4 is a cross-sectional view illustrating a processing state of a front cover sheet having a form different from that of FIG. 3;

FIG. 5 is a cross-sectional view showing a processing state of a surface mounting sheet having a different form from FIGS. 3 and 4;

FIG. 6 is a cross-sectional view of a molding die used for an integrally molded article with a foam layer of the present invention.

FIG. 7 is a cross-sectional view showing a manufacturing process for producing a skin-integrated molded article with a foam layer.

FIG. 8 is a cross-sectional view showing a manufacturing process for producing a skin-integrated molded article with a foam layer.

FIG. 9 is a cross-sectional view showing a manufacturing process for producing a skin-integrated molded article with a foam layer.

FIG. 10 is a perspective view showing an example of a molded article of a skin with a foam layer.

FIG. 11 is a sectional view taken along line AA of FIG. 10;

FIG. 12 is a perspective view showing another example of a molded article of a skin with a foam layer.

FIG. 13 is a sectional view taken along line BB of FIG. 12;

FIG. 14 is an explanatory sectional view showing a molding step according to a conventional technique.

FIG. 15 is a partially enlarged view of FIG.

FIG. 16 is a partially enlarged view of FIG.

FIG. 17 is a cross-sectional view of a conventional integrated molded article with a foam layer and a skin.

FIG. 18 is an explanatory sectional view showing a molding step according to a conventional technique.

[Description of Signs] 1 Front cover sheet 2 Skin 3 Foam layer 4 Backing material 5 Non-foamed section 10, 11 Open / close type 12 Skin layer forming section 13 Mold groove 14 Horizontal slide type 15, 16 Resin C, C ₁ , C ₂ cavity E _1, E ₂ design surface

Claims (2)

[Claims] A portion forming a design surface on the surface of the resin layer;
A portion that forms a design surface by covering the resin layer with a surface sheet integrally formed with at least a skin layer made of a foam layer and a skin,
In the method for manufacturing a skin-integrated molded article with a foam layer, which is integrally molded, a predetermined width portion from an edge of the surface sheet is a non-foamed portion from which the foam layer is substantially removed, and then the skin of the surface sheet is formed. Along the inner surface of the mold of the skin layer forming portion, and holding the non-foamed portion so as to divide the mold groove provided at a position corresponding to the end of the inner surface of the skin layer forming portion to form the surface mounting sheet in the molding die. And then inject resin into the cavity on the back side of the front cover sheet in the mold,
A method for producing a skin-integrated molded article with a foamed layer, wherein a resin is injected into a cavity in contact with a surface side of the non-foamed portion, and the cover sheet is integrally adhered and molded. 2. The method according to claim 1, further comprising a clamping mechanism for clamping the tip of the non-foamed portion at the bottom of the mold groove.