JPS61162335A - Resin molded shape with flexible skin layer - Google Patents

Abstract

(57) [Summary] This bulletin contains application data before electronic filing, so abstract data is not recorded.

Description

[Detailed Description of the Invention] Purpose of the Invention (Field of Industrial Application) The present invention relates to various resin molded products such as automobile interior parts and indoor equipment products, and more specifically, the present invention relates to various resin molded products such as automobile interior parts and indoor equipment products. The present invention relates to a resin molded product having a flexible skin layer.

(Prior art) In various resin molded products such as automobile interior parts and indoor equipment products, in order to give an excellent appearance and to hide defects such as scratches and color unevenness on the surface of the resin base material, the same surface is It is useful to decorate the surface with a flexible skin layer. Furthermore, in order to not only solve the problem of appearance but also to make the product soft to the touch, it is desirable to provide, for example, a foamed urethane resin layer on the surface of the base material.

In order to meet the above-mentioned demand, conventionally, as shown in FIG. After accommodating the fabric 14 in the mold, liquid urethane resin is injected through the injection port 15 formed on the joint surfaces of the upper and lower molds 11 and 12.
There was one in which a urethane resin layer 16 was laminated and molded between a resin base material I3 and a fabric I4. This molding method is made by a molding method called RIM molding in which the urethane resin is injected at a low pressure of several kg/cnl. There is a problem that it is easy to collapse. Furthermore, the conventional rim molding method includes a resin injection port 15 and a lower mold 12.
Since the fabric I4 is placed on the molding surface of the resin, the fabric 14 may be misaligned when resin is injected, the edges may get rolled up, and the urethane resin may be spread evenly between the resin base material 13 and the fabric 14. There is a problem that the quality of the product is deteriorated due to not being injected into the product.

In addition, as a conventional molding method, as shown in FIG. 11, a foamed resin sheet 17 is adhesively fixed to the surface of the resin base material I3,
The fabric 14 is adhered to the surface of the foamed resin sheet 17 and the edges of the fabric 14 are folded back and adhered to the back side of the resin base material 13 (fastened with a tacker 18 as shown in FIG. 12). There was also a tension processing method, but this conventional method had the problem of being troublesome to manufacture and making it impossible to reduce the cost of the product.

(Problems to be Solved by the Invention) The present invention solves the problems that exist in resin molded products manufactured by the conventional rim molding method or hand-stretching method, that is, the quality of the product deteriorates, the manufacturing is troublesome, and the product We are trying to solve the problem of not being able to reduce costs.

Structure of the Invention (Means for Solving the Problems) In order to solve the above problems, the present invention provides a foamed resin layer on the surface of a base material, and a flexible skin layer on the surface of the foamed resin layer. The foamed resin layer is applied to the base material or the flexible skin layer by spraying, and the adhesive force and foaming pressure of the foamed resin layer bond the base material, the foamed resin layer, and the flexible skin layer. It has this configuration.

(Function) The present invention employs the above means, so that only the foaming pressure of the foamed resin layer acts on the surface of the flexible skin layer.
The surface will not be crushed, and the adhesive force of the foamed resin layer will bond the foamed resin and the flexible skin layer, and the foaming pressure will cause the foamed resin to penetrate into the back side of the flexible skin layer. The foamed resin layer and the flexible skin layer are firmly joined by an anchor effect. In addition, since the foamed resin is spray applied to the base material or flexible skin layer and the base material is used as a mold, the thickness of the foamed resin layer is made uniform, and the flexible skin layer is prevented from shifting or being rolled up. etc. are eliminated, the quality of the product is improved and manufacturing can be performed easily.

(Example) Hereinafter, an example embodying the present invention will be described based on FIGS. 1 to 3.

Figure 1 shows the cross-sectional shape of an instrument panel cluster finish, which is one of the interior parts of an automobile. A base material injection molded from a resin such as chloride (hereinafter simply referred to as PVC resin), 2 is a foamed resin layer made of foamed urethane resin bonded and fixed to the outer surface of the same resin base material 1, and the softness of the product is I try to give a feeling.

This foamed urethane resin is made of a polymer polyol exhibiting high elasticity and an organic polyisocyanate (for example, JP-A-57-1
98722), and the two are mixed immediately before spray coating. Reference numeral 3 denotes a flexible skin layer made of fabric bonded and fixed to the surface of the foamed resin layer 2, and the surface is brushed to give a luxurious feel to the product.

Next, a method for manufacturing an instrument panel cluster finish will be explained with reference to FIGS. 2 and 3.

As shown in FIG. 2, a large number of slides 5 are provided on the upper surface of the mold 4 and are reciprocally movable.
A plurality of clamps holding the flexible skin layer 3 are arranged on top,
At the time of application, a solution of a foamed urethane resin mixed with a polymer polyol and an organic polyisocyanate is uniformly applied to the upper surface of the flexible skin layer 3 (the side corresponding to the back surface of the molded product) by spraying. Immediately after the polymer polyol and organic polyisocyanate are mixed, they start reacting and foaming occurs. Just before this foaming is almost completed and the sagging disappears (3 sec to 60 sec), the resin base material 1 is moved downward while pressing against the upper surface of the foamed resin layer 2 as shown in FIG. Lower surface of skin layer 3 (surface of molded product)
is brought into contact with the molding surface 4a of the mold 4, and the resin base material 1 is stopped at a predetermined position. Subsequently, the slide 5 is moved inward to perform end treatment of the flexible skin layer 3. At this time, the resin base material 1, foam resin layer 2, and flexible skin layer 3 are bonded together by the adhesive force of the foam urethane resin, and the resin base material 1 acts as a mold, so the foam urethane resin Due to the foaming action, the gap between the resin base material 1 and the flexible skin layer 3 is maintained at a low pressure (approximately 0.2 kg/a+t to 0.9 kg/ct6), and as a result, the surface of the visible skin layer 3, i.e. This prevents the fabric surface (raised) from collapsing. In addition, since the urethane resin during the foaming process enters between the fibers on the back side of the fabric, wrinkles on the fabric surface are removed and the fabric is stretched under tension, and the foam resin layer 2 and fabric are firmly joined by the anchor effect. In addition, since in-mold molding is not used, the flexible skin layer 3 does not shift or get caught during the molding process, improving the quality of the product. The ends can be folded back and joined easily, making manufacturing simple.

Next, a separate method for manufacturing a resin molded product having a flexible skin layer 3 will be explained with reference to FIGS. 4 to 9.

In the manufacturing method shown in FIGS. 4 and 5, the manufacturing method (2) involves fitting a soft resin sheet, which has been previously formed into a desired shape by vacuum forming, onto the molding surface 4a of the mold 4, as the flexible skin layer 3. This embodiment differs from the above-mentioned embodiment in that a foamed urethane resin is applied by spraying to the back side of the same soft resin sheet, but other manufacturing methods are the same as in the above-mentioned embodiment. In addition, also in this case (2), there is no deterioration in the soft texture of the surface of the soft resin sheet, or there is no misalignment or entanglement, and the quality of the product is improved, and manufacturing is easy and the cost of the product can be reduced.

6 and 7 is a flexible fabric made of a fabricator, in which a foamed urethane resin is applied to the surface of the resin base material 1, and then the same resin base material 1 is held between clamps attached to the upper part of the slide 5. The resin base material 1 and the foamed resin layer 2 are placed in the mold 4 while maintaining appropriate tension and pressing against the skin layer 3.
and a flexible skin layer 3 are integrally molded.

8 and 9, a flexible skin layer 3 made of a soft resin sheet previously formed by vacuum forming is housed in the mold 4, while the surface of the resin base material 1 is After applying the foamed urethane resin by spraying, the resin base material 1 is moved to the soft resin sheet side so that the resin base material 1, the foamed resin layer 2, and the flexible skin layer 3 are integrally molded. There is.

Note that the present invention can also be embodied in the following embodiments.

(1) In the above embodiment, fabric or soft resin sheet was used as the flexible skin layer 3, but any material can be used as long as the skin layer has unevenness on the lower surface, such as underground woven fabric. can.

(2) In the above embodiment, the instrument panel cluster cover/inisoch was explained, but it can also be applied to console box lids, door trims, sun visors, ceilings, and other general household products (chair armrests), etc. be able to.

(3) In the above embodiments, a resin base material was used as the base material, but the base material may also be metal such as aluminum, iron, stainless steel, or wood such as veneer.

Effects of the Invention As detailed above, the present invention is a resin molded product having a flexible skin layer on the surface, which is provided with a foamed resin layer by spray coating, thereby preventing the surface of the flexible skin layer from collapsing due to molding pressure. In addition, the bond between the flexible resin layer and the foamed resin layer can be further strengthened not only by the adhesive force of the foamed resin but also by the anchoring effect caused by its penetration into the back surface of the flexible skin layer. Furthermore, the quality of the product can be improved by eliminating positional displacement and entrainment of the flexible skin layer during molding.

Furthermore, it is possible to easily fold back and join the ends of the skin layer, thereby simplifying manufacturing and reducing the cost of the product.

[Brief explanation of drawings]

FIG. 1 is a cross-sectional view showing an example in which the resin molded product having a flexible skin layer of the present invention is applied to an instrument panel cluster finish, which is one of the interior parts of an automobile, and FIG. FIG. 3 is a cross-sectional view showing one embodiment of the manufacturing method, FIGS. 4 and 5 are cross-sectional views for explaining the manufacturing method (2), and FIGS. 6 and 7 are sectional views for explaining the manufacturing method (2). 8 and 9 are sectional views for explaining the manufacturing method, and FIG. 10 is a sectional view for explaining the conventional method for manufacturing resin molded products. 11 and 12 are partial sectional views for explaining different methods of manufacturing conventional resin molded products.

Claims (1)

[Claims] 1. A foamed resin layer is provided on the surface of the base material, a flexible skin layer is provided on the surface of the foamed resin layer, and the foamed resin layer is sprayed onto the base material or the flexible skin layer. 1. A resin molded article having a flexible skin layer, characterized in that the base material, the foamed resin layer, and the flexible skin layer are bonded together by the adhesive force and foaming pressure of the foamed resin layer. 2. The resin molded article having a flexible skin layer according to claim 1, wherein the base material is formed of a synthetic resin such as urethane resin, ABS resin, or PVC resin. 3. The resin molded article having a flexible skin layer according to claim 1, wherein the foamed resin layer is made of foamed urethane resin. 4. The resin molded article having a flexible skin layer according to claim 1, wherein the flexible skin layer is made of cloth such as fabric, nonwoven fabric, or flocked cloth, or a resin sheet such as PVC or urethane.