JPH0857875A - Manufacture of integrally skinned foam molded article - Google Patents

Abstract

PURPOSE: To provide a method for manufacturing an integrally skinned foam molded article having a groove part on the surface at favorable quality such as void-free quality of the like simply and economically. CONSTITUTION: By pouring liquid foaming material P between base material 21 and skin material 31, onto the surface side of which a groove-like bend part 32 is formed by bending the predetermined part of the surface to the base material side in the form of a groove, and then expanding P, an integrally skinned foam moulded article, in which the base material and the skin material are made into an integral body and on the surface of which a groove part is provided under the condition that the flow passage 12 of foaming material is formed between the swollen shaped part of the base material and the groove- like bend part of the skin material by forming the base material opposing the groove-like bend part into the swollen shape 22, which swells to the side opposite to the skin material.

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 skin-integrated foam-molded article in which a liquid foam material is injected between a skin material and a base material and foamed to integrate the skin material and the base material.

[0002]

2. Description of the Related Art In the foam-in-mold product with integral skin, as in the instrument panel of an automobile shown in FIG. 4, a marking line or a decorative line formed of a concave groove portion 81 on a predetermined surface portion is formed due to design requirements. There was something that was done. As shown in FIG. 5 showing the 5-5 cross section of FIG. 4, this groove portion 81 is formed by a groove-shaped bent portion 84 formed by bending a predetermined portion of the skin material 82 toward the base material 83 in a groove shape. It Reference numeral 85 is a synthetic resin foam layer foam-molded from a liquid foam material.

In order to manufacture a skin-integrated foam product in which a concave groove portion 81 is formed in the predetermined surface portion, the skin having the predetermined surface portion bent in advance in a concave groove shape toward the base material side is formed by powder slush molding or vacuum molding. The material 82 is set on the mold surface of the cavity mold 86 as shown in FIG. 6, the base material 83 is set on the mold surface of the core mold 87, and the polyurethane foam injected between the base material 83 and the skin material 82. This is performed by integrally foaming a liquid foam material P such as a raw material with the base material 83 and the skin material 82.

However, the skin material 82 and the base material 83 come close to each other in the concave groove portion 84 of the skin material and the skin material 82 and the base material 8
The gap 88 between the three becomes small, and since the viscosity of the liquid foam material P increases as the foaming progresses, the narrow gap 88
When the liquid foam material P passes through the portion, its flow is obstructed. As a result, there is a problem that the quality of the molded product is likely to be deteriorated, for example, air is trapped in the liquid foam material P to generate a void (air trap).

Conventionally, as means for solving the above problem, a cushion seal member (not shown) for increasing the injection amount of the liquid foaming material P or for closing the gap 88 between the base material and the groove-like bent portion of the skin material. It has been proposed to attach () to the skin material 82 or the base material 83 in advance, or to carry out so-called multi-point injection in which a separate liquid foam material is injected into a portion where voids are expected to occur.

However, the increase in the injection amount causes an increase in the weight of the molded product, an increase in the price of the molded product, and a decrease in the heat aging property. On the other hand, when attaching the cushion seal member,
There is a problem that the attachment work is additionally required, and the price of the molded product is increased by using the cushion seal member. Further, in the case of multi-point injection, since the injection head of the liquid foam material is moved to a plurality of injection locations, the injection head is damaged quickly, and the cavity mold and the core mold cannot be closed during multi-point injection, There is a problem that the closed mold becomes slow and new voids are easily generated.

[0007]

SUMMARY OF THE INVENTION In view of the above points, the present invention is a method for easily and economically producing a skin-integrated foam-molded article having a groove on the surface with good quality without voids. Is provided.

[0008]

According to the present invention, there is provided a base material and a skin material having a predetermined groove on the surface of the base material which is bent in a concave groove shape to form a concave groove-shaped bent portion on the front surface side. When a liquid foaming material is injected into and foamed, the base material and the skin material are integrated to produce a skin-integrated foam-molded article having a groove portion on the surface, and a groove-shaped bent portion of the skin material is used. The base material facing to the swelling shape that swells to the side opposite to the skin material, and forms a flow path for the foamed material between the swelled shape portion of the base material and the groove-shaped bent portion of the skin material. The feature is that

[0009]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention will be described in detail below with reference to the accompanying drawings. FIG. 1 is a sectional view of a molding die showing an example of manufacturing a skin-integrated foam-molded product of the present invention, and FIG.
FIG. 3 is a cross-sectional view showing an example of a skin-integral foam-molded article obtained by carrying out the present invention.

First, manufactured by the practice of this invention,
The skin-integrated foam-molded article 10 shown in FIG. 3 will be described.
The skin-integrated foam-molded product 10 is manufactured for an automobile instrument panel, and has a synthetic resin foam layer 41 integrally between a base material 21 and a skin material 31.
Further, a decorative line composed of the concave groove portion 11 is formed on the surface.

The base material 21 is a strength member of a molded product, and is made of a hard synthetic resin injection molded product, a fiber reinforced resin molded product, a metal press molded product, or the like, and is formed into a shape according to the shape of the molded product. Has been done. Further, in the base material 21, a portion corresponding to the concave groove portion 11 on the surface of the molded product 10 is the skin material 3
It has a concave bulging shape 22 that bulges to the side opposite to 1. Due to the bulging shape 22, the concave groove portion 11 on the surface of the molded product is formed.
The distance d between the portion of the base material 21 corresponding to (4) and the groove-like bent portion 32 of the skin material, which will be described later, is set to a desired value as described later.

The skin material 31 is made of vinyl chloride resin or the like shaped into a molded product by powder slush molding or vacuum molding, and is laminated on the base material 21 with a synthetic resin foam layer 41 interposed therebetween. ing. This skin material 3
1, a groove-shaped bent portion 32 that forms the groove portion 11 on the surface of the molded product is formed at a predetermined surface portion. The groove-shaped bent portion 32 is formed by bending a predetermined surface portion of the skin material 31 toward the base material 21 side, and forms a desired distance d between the bulging shape 22 of the base material 21. There is.

The synthetic resin foam layer 41 is made of a foamed synthetic resin such as polyurethane foam, and is for imparting a soft feeling or cushioning property to the surface of the molded article 10. As will be described later, the synthetic resin foam layer 41 is formed integrally with the base material 21 and the skin material 31 by foaming a liquid foam material between the base material 21 and the skin material 31.

Next, an example of manufacturing the above-mentioned skin-integrated foam-molded article by the manufacturing method of the present invention using the base material 21 and the skin material 31 having the above-mentioned shape will be described. FIG. 1 is a cross-sectional view of a molding die during manufacturing thereof. The mold 50 used is
It is composed of a cavity mold 61 and a core mold 71. The cavity mold 61 has a concave mold surface 62 on which the skin material 31 is set, and a convex portion 63 into which the concave groove-shaped bent portion 32 of the skin material fits is formed at a predetermined portion of the mold surface 62. There is. In addition,
The cavity mold 61 has a structure in which upper parts 64 and 65 are divided so that a molded product can be easily released from the mold.

On the other hand, the core die 71 has a convex mold surface 72 on which the base material 21 is set, and a concave portion into which the bulging shape 22 of the base material 21 is fitted in a predetermined portion of the mold surface 72. 73 is formed. The core mold 71 and the cavity mold 61 are closed molds to form the molding cavity 51 therein.

On the die surface 62 of the cavity die 61, the skin material 31 is formed, and the groove-shaped bent portion 32 thereof is a convex portion 63 of the die surface.
The core surface 71 of the core mold 71 and the mold surface 72 of the core mold 71.
Then, the base material 21 is set so that the bulging shape 22 portion thereof is fitted.

Then, a liquid foaming material P such as a polyurethane foaming raw material is injected into the skin material 31 to form a cavity mold 6.
1 and the core mold 71 are closed. Due to the closing mold, the inner surface of the concave groove-shaped bent portion 32 of the skin material and the inner surface of the bulging shape 22 of the base material face each other, and the liquid foam material flows between the inner surface of the concave groove-shaped bent portion 32 and the inner surface of the bulged shape 22 portion. The path 12 is formed. FIG. 2 is an enlarged cross-sectional view around the concave groove-shaped bent portion 32 and the bulging shape 22 portion.

A concave groove-shaped bent portion 32 in the flow passage 12
The distance d between the inner surface and the inner surface of the bulging shape 22 part is 80% or more of the distance e between the skin material 31 and the base material 21 in the other general parts, and at least 5 mm or more is the liquid foam material. This is preferable because the smooth distribution of the liquid foam material P can be ensured during the foaming of P.

Next, the liquid foam material P is foamed.
Due to the foaming, the liquid foaming material P increases in viscosity, and the concave groove-shaped bent portion 32 of the skin material and the bulging shape 2 of the base material are increased.
The space between the base material 21 and the skin material 31 is filled through the flow passage 12 between the two parts. At this time, since the flow passage 12 has a sufficient gap, the thickened liquid foam material P flows smoothly without being obstructed when passing through the flow passage 12.
As a result, the liquid foam material P is filled between the skin material 31 and the base material 21 without entraining air, and the self-adhesiveness of the liquid foam material P makes the synthetic resin foam integrated with the skin material 31 and the base material 21. Form a layer (41 in FIG. 3).

Thereafter, the cavity mold 61 and the core mold 71 are opened, and the molded product is released from the mold to obtain the skin-integrated foam molded product 10 shown in FIG. The skin-integrated foam-molded article 10 thus obtained has good quality without voids and the like.

[0021]

As shown and described above, according to the manufacturing method of the present invention, the skin-integrated foam-molded article having the groove portion on the surface can be obtained by simply foaming the liquid foam material between the skin material and the base material. It can be manufactured with good quality without voids. Therefore, it is not necessary to attach the cushion seal member, increase the injection amount of the liquid foaming material, or inject multiple points, which has been conventionally performed to prevent voids, etc. A molded product can be obtained.

[Brief description of drawings]

FIG. 1 is a cross-sectional view of a molding die showing a production example of a skin-integrated foam-molded article of the present invention.

FIG. 2 is an enlarged cross-sectional view of a main part thereof.

FIG. 3 is a cross-sectional view showing an example of a skin-integrated foam-molded article obtained by carrying out the present invention.

FIG. 4 is a perspective view showing an example of an instrument panel.

FIG. 5 is a sectional view taken along line 5-5.

FIG. 6 is an enlarged partial cross-sectional view of a molding die showing a manufacturing method according to a conventional method.

[Explanation of symbols]

 11 Recessed Groove on Molded Product Surface 21 Base Material 22 Bulging Shape 31 Skin Material 32 Recessed Groove-Shaped Part 61 Cavity Type 71 Core Type P Liquid Foam Material

Claims (1)

[Claims] 1. A liquid foaming material is injected between a base material and a skin material in which a predetermined surface portion is bent toward the base material in a concave groove shape and a concave groove-shaped bent portion is formed on the surface side. By foaming,
When manufacturing the skin-integrated foam-molded article having a groove portion on the surface by integrating the base material and the skin material, the base material facing the groove-shaped bent portion of the skin material is opposite to the skin material. A skin-integrated foam-molded article characterized in that a foamed material flow path is formed between the bulge-shaped portion of the base material and the concave groove-shaped bent portion of the skin material so as to bulge to the side. Production method.