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JP2012228788A - Foamed molding, and method for manufacturing the same - Google Patents

Foamed molding, and method for manufacturing the same Download PDF

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JP2012228788A
JP2012228788A JP2011097088A JP2011097088A JP2012228788A JP 2012228788 A JP2012228788 A JP 2012228788A JP 2011097088 A JP2011097088 A JP 2011097088A JP 2011097088 A JP2011097088 A JP 2011097088A JP 2012228788 A JP2012228788 A JP 2012228788A
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skin material
mold
base material
nonwoven fabric
setting
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Nobuhiko Todaka
信彦 戸高
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Toyota Motor Corp
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Abstract

PROBLEM TO BE SOLVED: To facilitate setting the skin material to the mold in the foamed molding filled with the cushioning material made of the foam resin between the skin material and the base material.SOLUTION: Skin material 4 is made by providing a synthetic resin layer 7 on the surface of thermoplastic nonwoven fabric 6 and the skin material 4 is formed in a prescribed shape by hot press molding, vacuum forming, and vacuum pressure empty molding, etc. The back face of nonwoven fabric 6 of formed skin material 4 is cured by applying the polyester resin solution, and the mold 1 is closed by setting the base material 3 to a lower mold 1A, and setting the skin material 4 to a formed upper mold 1B. An instrument panel 2 is formed by injecting two liquid mixing foam urethane into a cavity between the base material 3 and the skin material 4 by a high pressure mixing nozzle 8, foaming and solidifying it. Setting of the skin material 4 to the mold 1 becomes easy by forming. In addition, the rigidity rises by applying the polyester resin solution on the back side of the nonwoven fabric 6 of the formed skin material 4, and curing it, and setting it to the mold 1 is facilitated.

Description

本発明は、自動車のインストルメントパネル等の表面にクッション性を有する意匠面を有する発泡成形品及びその製造方法に関するものである。   The present invention relates to a foam molded article having a design surface having cushioning properties on the surface of an instrument panel or the like of an automobile, and a method for producing the same.

例えば自動車のインストルメントパネルは、硬質の合成樹脂製の基材と、表面にシボが形成された意匠面を有する軟質の合成樹脂製の表皮材と、これらの間に介装されたクッション性を有する発泡樹脂との３層構造として、必要な強度を得ると共に、見映え及び質感を高めている。このような３層構造のインストルメントパネルは、例えば特許文献１に記載されているように、発泡成形用の金型に表皮材及び基材をセットし、キャビティ内に発泡樹脂を注入、発泡させることにより、これらを一体化することによって製造される。   For example, an instrument panel of an automobile has a base material made of a hard synthetic resin, a skin material made of a soft synthetic resin having a design surface with a texture on the surface, and a cushioning property interposed therebetween. As a three-layer structure with the foamed resin, the required strength is obtained and the appearance and texture are enhanced. In such an instrument panel having a three-layer structure, for example, as described in Patent Document 1, a skin material and a base material are set in a mold for foam molding, and a foamed resin is injected into the cavity and foamed. Therefore, it is manufactured by integrating them.

特開２００３−１１２３２７号公報JP 2003-112327 A

このように、表皮材及び基材を金型にセットして発泡成形を行なう場合、軟質の表皮材は、その形状を保持し難いため、金型の所定位置に正確に固定することが困難である。このため、表皮材を金型にセットする作業が煩雑で、生産性及び成形品質の低下の原因となっており、また、成形品の設計の自由度を制限することにもなっている。   Thus, when foam molding is performed with the skin material and the base material set in a mold, it is difficult to accurately fix the soft skin material at a predetermined position of the mold because it is difficult to maintain its shape. is there. For this reason, the work of setting the skin material on the mold is complicated, which causes a decrease in productivity and molding quality, and also limits the degree of freedom in designing the molded product.

本発明は、上記の点に鑑みてなされたものであり、表皮材の金型へのセットを容易にした発泡成形品及びその製造方法を提供することを目的とする。   The present invention has been made in view of the above points, and an object of the present invention is to provide a foam molded article that facilitates setting of a skin material to a mold and a method for manufacturing the same.

上記の課題を解決するために、本発明に係る発泡成形品の製造方法は、熱可塑性の不織布の表面に合成樹脂層を設けて表皮材とし、該表皮材を熱成形により所定形状に賦形し、賦形した前記表皮材、及び、基材を金型にセットし、前記表皮材と前記基材との間に発泡樹脂からなるクッション材を充填することを特徴とする。
また、本発明に係る発泡成形品は、熱可塑性不織布の表面に合成樹脂層を設け、熱成形により所定形状に賦形された表皮材と、基材と、賦形された前記表皮材と前記基材との間に充填されてこれらを一体に結合する発泡樹脂からなるクッション材とを備えていることを特徴とする。 In order to solve the above-described problems, a method for producing a foam molded article according to the present invention provides a skin material by providing a synthetic resin layer on the surface of a thermoplastic nonwoven fabric, and the skin material is shaped into a predetermined shape by thermoforming. The shaped skin material and the base material are set in a mold, and a cushion material made of foamed resin is filled between the skin material and the base material.
In addition, the foam molded article according to the present invention is provided with a synthetic resin layer on the surface of a thermoplastic nonwoven fabric, a skin material shaped into a predetermined shape by thermoforming, a base material, the shaped skin material, and the And a cushioning material made of a foamed resin that is filled between the base material and unites them together.

本発明によれば、表皮材を賦形することにより、表皮材の金型へのセットを容易に行うことができる。   According to the present invention, the skin material can be easily set in the mold by shaping the skin material.

本発明の一実施形態に係る発泡成形品であるインストルメントパネルが金型によって成形された状態を示す縦断面図である。It is a longitudinal cross-sectional view which shows the state by which the instrument panel which is a foaming molded article which concerns on one Embodiment of this invention was shape | molded with the metal mold | die. 図１に示すインストルメントパネルの賦形された表皮材の縦断面図である。It is a longitudinal cross-sectional view of the shaped skin material of the instrument panel shown in FIG. 図１に示すインストルメントパネルの変形例が金型によって成形された状態を示す縦断面図である。It is a longitudinal cross-sectional view which shows the state by which the modification of the instrument panel shown in FIG. 1 was shape | molded with the metal mold | die.

以下、本発明の一実施形態を図面に基づいて詳細に説明する。
図１は、金型１のキャビティ内において成形された発泡成形品であるインストルメントパネル２（以下、インパネ２という）を示している。インパネ２は、基材３と、基材３の表面の少なくとも一部を覆い、意匠面を形成する表皮材４と、基材３と表皮材４との間に介装されたクッション材５との３層構造となっている。 Hereinafter, an embodiment of the present invention will be described in detail with reference to the drawings.
FIG. 1 shows an instrument panel 2 (hereinafter referred to as an instrument panel 2) which is a foamed molded product molded in a cavity of a mold 1. The instrument panel 2 includes a base material 3, a skin material 4 that covers at least a part of the surface of the base material 3 and forms a design surface, and a cushion material 5 interposed between the base material 3 and the skin material 4. It has a three-layer structure.

基材３は、射出成形等によって成形されたＰＰ（ポリプロピレン）等の硬質の合成樹脂製の構造体であり、インパネ３の骨格及び外殻を形成する。表皮材４は、熱可塑性の不織布６を基布として、その表面を軟質の合成樹脂層７で覆って意匠面を形成している。クッション材５は、発泡ウレタン等の発泡樹脂を基材３と表皮材４との間に充填したものであり、これらを一体に結合して表皮材４にクッション性を与えている。   The base material 3 is a structure made of hard synthetic resin such as PP (polypropylene) formed by injection molding or the like, and forms a skeleton and an outer shell of the instrument panel 3. The skin material 4 uses a thermoplastic non-woven fabric 6 as a base fabric, and its surface is covered with a soft synthetic resin layer 7 to form a design surface. The cushion material 5 is a material in which a foamed resin such as foamed urethane is filled between the base material 3 and the skin material 4, and these are joined together to give the skin material 4 cushioning properties.

インパネ２の製造工程及び各部の詳細について以下に説明する。
先ず、次のようにして、図２に示す所定形状に賦形された表皮材４を製造する。目付け４０〜２００ｇ／ｍ２程度で曲げ剛性がＥＩｚ＝８ｇ・ｃｍ以上のポリエステル、ＰＥＴ（ポリエチレンテレフタレート）、ＰＰ（ポリプロピレン）等の熱可塑性樹脂からなる不織布６を基布とし、その表面を硬化後の厚さ１５〜２００μｍ程度の軟質ウレタンからなる表面層７で覆った合成皮革を用いる。表面層７の軟質ウレタンは、離型紙、シボロール等により、表面に凹凸を形成して意匠面とする。この合成皮革を予め裁断し、必要な縫製を施し、熱プレス成形、真空成形、真空圧空成形等の熱可塑性を利用した熱成形により賦形して図１に示す所定形状の表皮材を得る。 The manufacturing process of the instrument panel 2 and details of each part will be described below.
First, the skin material 4 shaped into a predetermined shape shown in FIG. 2 is manufactured as follows. A nonwoven fabric 6 made of a thermoplastic resin such as polyester, PET (polyethylene terephthalate) or PP (polypropylene) having a basis weight of about 40 to 200 g / m 2 and a bending rigidity of EIz = 8 g · cm or more is used as a base fabric, and its surface is cured The synthetic leather covered with the surface layer 7 made of soft urethane having a thickness of about 15 to 200 μm is used. The soft urethane of the surface layer 7 forms a design surface by forming irregularities on the surface with release paper, shibo roll, or the like. The synthetic leather is cut in advance, necessary sewing is performed, and is shaped by thermoforming using thermoplasticity such as hot press molding, vacuum forming, vacuum pressure forming, etc., to obtain a skin material having a predetermined shape shown in FIG.

本実施形態では、不織布６を目付け２００ｇ／ｍ２のポリエステルとし、その表面に約１００μｍのウレタンを塗布し、皮革状のシボを離型紙転写により付与して厚さ約１．２ｍｍとした合成皮革を用いている。また、賦形した表皮材４の不織布６の裏面にポリエステル樹脂溶液を１５０ｇ／ｍ２で塗布し、乾燥、硬化させることにより、その曲げ剛性をＥＩｚ＝１２ｇ・ｃｍ程度に高めている。なお、ポリエステル樹脂溶液の塗布は省略してもよい。 In this embodiment, the non-woven fabric 6 is made of polyester having a basis weight of 200 g / m 2 , urethane of about 100 μm is applied to the surface, and leather-like texture is applied by release paper transfer to a thickness of about 1.2 mm. Is used. Moreover, the bending rigidity is raised to about EIz = 12g * cm by apply | coating the polyester resin solution at 150 g / m < 2 > to the back surface of the nonwoven fabric 6 of the shaped skin material 4, and making it dry and harden | cure. The application of the polyester resin solution may be omitted.

次に、ＰＰ（ポリプロピレン）樹脂を射出成形した厚さ３ｍｍ程度の基材３に対して、クッション材５との接合面に火炎処理を施し、これを発泡成形用の金型１の下型１Ａにセットする。金型１の上型１Ｂに、表皮材４をセットする。このとき、表皮材４は、図２に示すように、所定の形状に予め賦形され、適度な曲げ剛性を有しているので、上型１Ｂに容易にセットすることができる。下型１Ａと上型１Ｂとを閉じて、基材３と表皮材４との間に形成された厚さ７ｍｍ程度のキャビティに、高圧混合ノズル８によって発泡樹脂として２液混合発泡ウレタンを射出、注入する。発泡樹脂がキャビティ内に発泡、充填され固化してクッション材５が成形される。発泡樹脂が固化した後、金型１を開いて、インパネ２を離型し、必要なトリミング等の仕上げ加工を行ない、インパネ２が完成する。完成したインパネ２は、合成皮革を用い、表面にシボ等の意匠面が設けられ、クッション性を有する表皮材４で覆われているので、質感が高く、見映えがよい。   Next, a flame treatment is applied to the joint surface with the cushion material 5 on the base material 3 having a thickness of about 3 mm obtained by injection-molding PP (polypropylene) resin. Set to. The skin material 4 is set on the upper mold 1 </ b> B of the mold 1. At this time, as shown in FIG. 2, the skin material 4 is pre-shaped into a predetermined shape and has an appropriate bending rigidity, so that it can be easily set in the upper mold 1B. The lower mold 1A and the upper mold 1B are closed, and a two-component mixed urethane foam is injected as a foamed resin by a high-pressure mixing nozzle 8 into a cavity having a thickness of about 7 mm formed between the base material 3 and the skin material 4. inject. The cushioning material 5 is formed by foaming, filling, and solidifying the foamed resin in the cavity. After the foamed resin is solidified, the mold 1 is opened, the instrument panel 2 is released, and necessary finishing processing such as trimming is performed to complete the instrument panel 2. The completed instrument panel 2 is made of synthetic leather, has a design surface such as grain on the surface, and is covered with a skin material 4 having cushioning properties, so that the texture is high and the appearance is good.

図３を参照して、賦形した表皮材４は、必要に応じて縫製して、縫い合せ部を内側に折込んだインステッチ部９を設け、また、飾りステッチ１０（アウトステッチ）を設けることができる。なお、図３において、図１に示すものと同様の部分には、同じ参照符号を付してある。この場合、不織布６のインステッチ部９及び飾りステッチ１０の裏側に漏れ止めテープ１１を貼付し、あるいは、漏れ止め用の樹脂を塗布する等の目止めを行うことにより、発泡成形時に発泡ウレタンが縫目から表皮材４の表面に漏出するのを防止する。賦形された表皮材４は、上型１Ｂ（図３には図示せず）へのセットが容易であり、確実に位置決めできるので、インステッチ部９及び飾りステッチ１０を正確に配置することができ、デザイン性の高いインパネ２を容易に製造することができる。   Referring to FIG. 3, the shaped skin material 4 is sewn as necessary, and is provided with an in-stitch portion 9 in which a stitched portion is folded inward, and a decorative stitch 10 (out-stitch) is provided. be able to. In FIG. 3, the same parts as those shown in FIG. In this case, the urethane foam is formed at the time of foam molding by applying a leak-proof tape 11 on the back side of the in-stitch part 9 and the decorative stitch 10 of the nonwoven fabric 6 or by applying a resin for leak-proofing. Leakage from the seam to the surface of the skin material 4 is prevented. Since the shaped skin material 4 is easy to set on the upper mold 1B (not shown in FIG. 3) and can be positioned reliably, the in-stitch portion 9 and the decorative stitch 10 can be accurately arranged. In addition, the instrument panel 2 with high design can be easily manufactured.

なお、上実施形態において、表皮材４の表面層７は、上述の皮革状のシボを設けたものの他、ファブリック素材を用いることもでき、織物、編物等としてもよい。また、本実施形態では、一例として、本発明を自動車のインパネ２に適用した場合について説明しているが、本発明は、これにか要らず、他の発泡成形品にも同様に適用することができる。   In the above embodiment, the surface layer 7 of the skin material 4 can be made of a fabric material in addition to the above-described leather-like texture, or a woven fabric, a knitted fabric, or the like. In the present embodiment, as an example, the case where the present invention is applied to an instrument panel 2 of an automobile is described. However, the present invention is not limited to this, and is similarly applied to other foam molded products. Can do.

１…金型、２…インパネ（発泡成形品）、３…基材、４…表皮材、５…クッション材、６…不織布、７…合成樹脂層   DESCRIPTION OF SYMBOLS 1 ... Mold, 2 ... Instrument panel (foam molding product), 3 ... Base material, 4 ... Skin material, 5 ... Cushion material, 6 ... Nonwoven fabric, 7 ... Synthetic resin layer

Claims (4)

熱可塑性の不織布の表面に合成樹脂層を設けて表皮材とし、該表皮材を熱成形により所定形状に賦形し、賦形した前記表皮材、及び、基材を金型にセットし、前記表皮材と前記基材との間に発泡樹脂からなるクッション材を充填することを特徴とする発泡成形品の製造方法。   A synthetic resin layer is provided on the surface of the thermoplastic nonwoven fabric to form a skin material, the skin material is shaped into a predetermined shape by thermoforming, and the shaped skin material and the base material are set in a mold, A method for producing a foam-molded article, wherein a cushion material made of foamed resin is filled between a skin material and the base material. 賦形した前記表皮材の前記不織布の裏面にポリエステル樹脂溶液を塗布し、硬化させた後、前記表皮材を前記金型にセットすることを特徴とする請求項1に記載の発泡成形品の製造方法。   2. The production of a foam-molded article according to claim 1, wherein after the polyester resin solution is applied to the back surface of the non-woven fabric of the shaped skin material and cured, the skin material is set in the mold. Method. 熱可塑性不織布の表面に合成樹脂層を設け、熱成形により所定形状に賦形された表皮材と、基材と、賦形された前記表皮材と前記基材との間に充填されてこれらを一体に結合する発泡樹脂からなるクッション材とを備えていることを特徴とする発泡成形品。   A synthetic resin layer is provided on the surface of the thermoplastic nonwoven fabric, and a skin material formed into a predetermined shape by thermoforming, a base material, and the shaped skin material and the base material are filled between them. A foam molded product comprising a cushion material made of foamed resin that is integrally bonded. 賦形された前記表皮材の塑性不織布の裏面に、ポリエステル樹脂溶液が塗布されて硬化されていることを特徴とする請求項３に記載の発泡成形品。   The foam molded article according to claim 3, wherein a polyester resin solution is applied and cured on the back surface of the shaped plastic nonwoven fabric of the skin material.
JP2011097088A 2011-04-25 2011-04-25 Foamed molding, and method for manufacturing the same Withdrawn JP2012228788A (en)

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Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20130260079A1 (en) * 2012-03-27 2013-10-03 Toyota Motor Engineering & Manufacturing North America, Inc. Foam-filled panel and process for manufacture thereof
JP2017132275A (en) * 2016-01-25 2017-08-03 ダイキョーニシカワ株式会社 Interior article for vehicle
JP2018040089A (en) * 2016-09-09 2018-03-15 日本バイリーン株式会社 Surface material for injection molding

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20130260079A1 (en) * 2012-03-27 2013-10-03 Toyota Motor Engineering & Manufacturing North America, Inc. Foam-filled panel and process for manufacture thereof
US8993091B2 (en) * 2012-03-27 2015-03-31 Toyota Motor Engineering & Manufacturing North America, Inc. Foam-filled panel and process for manufacture thereof
JP2017132275A (en) * 2016-01-25 2017-08-03 ダイキョーニシカワ株式会社 Interior article for vehicle
JP2018040089A (en) * 2016-09-09 2018-03-15 日本バイリーン株式会社 Surface material for injection molding

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