JPH03224707A - Manufacture of foam molding - Google Patents

Abstract

PURPOSE:To enable exterior components to be attached not necessitating another material and another process, and manufacture a foam molding by providing communicating holes that penetrate the inner and outer surface of skin, on the part to which the exterior component of the skin is attached, and injection foaming foam raw liquid into the inner and outer surface of the skin in the form of arranging the exterior components thereon. CONSTITUTION:As a material for skin, ones which excellently adhere to a foam body are used, and the skin is provided with holes 1a communicating with the inner and outer surface of the skin 1 on the part to which exterior components 3 are attached. A foam molding is manufactured by injection foaming foam raw liquid from the injection port of the foam raw liquid to the inner surface side of the skin, in a state of arranging the exterior components 3 on a predetermined position. At this time, in the part of the hole 1a provided in the skin 1, a foam body 4 invaded into the inner part thereof comes into contact with the inner surface of the exterior components 3 arranged on the outside of the skin 1, and thus adhesion between the exterior parts 3 and the foam body 4 is achieved.

Description

DETAILED DESCRIPTION OF THE INVENTION [Industrial Field of Application] The present invention relates to a method for producing a foam molded article. For more details,
Related to a method for producing a polyurethane foam molded product having a skin and an exterior component attached to at least a part of the outer surface of the skin [Prior art] Foam molded products with a skin have been used in various fields. (See, for example, Japanese Patent Laid-Open No. 82-184815).

For example, in polyurethane foam molded products with skins such as automotive instrument panels, safety pads for the same panels, and headrests, exterior parts such as anti-slip rubber sheets can be attached to the outer surface of the skin made of vinyl chloride resin. In this case, for example, you can use a different adhesive to adhere the exterior parts to the skin, or you can use adhesive to adhere the sheet metal base 0'2J to the exterior part ■ as shown in Figure 4. After molding the exterior part in the inserted state, the end of the sheet metal base 02 is placed so that it passes through the hole (Ila) provided in the skin (111), and the end is folded in the direction of the arrow in FIG. Conventionally, a method of attaching by bending and caulking has been adopted.

However, with the method using adhesive or the method using sheet metal base, the cost and weight increase due to the use of these separate parts, and additional processes such as gluing and caulking are required to attach the exterior parts. There is a problem of decreased sexuality.

[Problems to be Solved by the Invention] The present invention has been made in view of the problems in the conventional foam molded product manufacturing method, and is a foamed product in which attachment of exterior parts is achieved without requiring separate members or separate processes. The purpose is to provide a method for producing a molded body.

[Means for Solving the Problems] When manufacturing a foam molded article having a skin and an exterior component attached to at least a part of the outer surface of the skin, the present invention provides a method for manufacturing a foam molded article having a skin and an exterior component attached to at least a part of the outer surface of the skin. The present invention relates to a method for manufacturing a foam molded article, in which a hole is provided to communicate between the outer surface and the inner surface, and a foaming stock solution is injected into the inner surface of the skin with an exterior component placed in a predetermined position.

[Function] In the manufacturing method of the present invention, since a penetrating hole is provided in the part of the skin where the exterior component is attached, the foam also enters the hole and comes into direct contact with the inner surface of the exterior component.
The exterior component and the foam are bonded together with the skin in between. Therefore, the exterior component can be attached to the foam molded body without using a separate adhesive or mechanical fastening.

[Example] In the present invention, as the foaming stock solution, for example, a polyurethane foaming stock solution, a polypropylene foaming stock solution, a polystyrene foaming stock solution, a polyvinyl chloride foaming stock solution, etc. are used.

As the material for the skin, a material that adheres well to the foam from the foaming stock solution is used.

Specific examples of such materials include polyvinyl chloride molded articles in the case of polyurethane foams.

A through hole is provided in the outer skin at the exterior component attachment portion. Chain holes are made, for example, during skin molding. There are no particular limitations on the shape, size, or number of the holes, but for example, if the holes are large and the exterior parts are soft, the pressure of the internal foam may cause the parts of the exterior covering the holes to break down. They tend to bulge outwards, making the surface uneven.Furthermore, if the number is small, poor appearance is likely to occur due to thermal expansion mismatch between the skin and exterior parts.
It is preferable that the pores be small and large in number in order to ensure smoothness of the surface of the exterior component and to prevent deformation due to stretching of the skin.

As the material for the exterior component, a material that adheres well to the foam made from the foaming stock solution is used. Specific examples of such materials include polyurethane foam, vinyl chloride rubber sheets, vinyl chloride sheets, nylon (polyamide), ABS resin, other general resins (excluding PP and PE), iron plates, etc. .

Next, an example of the method for manufacturing a foamed molded article of the present invention will be explained based on the drawings.

FIG. 1 is a schematic sectional view showing an example of the method for producing a foamed molded product of the present invention, FIG. 2 is an enlarged schematic sectional view showing pores in the skin, and FIG.
The figure is a schematic sectional view showing the skin, FIG. 3b is a plan view showing the exterior parts, FIG. 3c is a schematic sectional view showing the reinforcing material, and FIG. 4 is a schematic sectional view showing the conventional method of attaching the exterior parts.

In Fig. 1, the foamed molded product has a skin (1) shown in Fig. 3a and a frame (1) as a reinforcing material shown in Fig. 3c.
2), an exterior part (3) shown in Fig. 3b, and a foam (4).

As shown in FIG. 3a, the skin (1) is provided with a hole (la) that communicates the outer surface and the inner surface of the skin (1) at a portion where the exterior component (3) is attached.

The foamed molded article is produced by injecting a foaming solution into the inner surface of the skin (1) from the foaming solution injection port (5) and foaming with the exterior component (3) placed in a predetermined position. There are no particular limitations on the flow rate, pressure, temperature, etc. during injection of the foaming stock solution and molding, and the molding is carried out under normal conditions.

As shown in Figure 2, holes (
In the part la), the foam (4) that has entered the interior comes into contact with the inner surface of the exterior part (3) placed outside the skin (1), and here the exterior part (3) and the foam (4) Adhesion is made with. That is, the exterior component (3) and the foam (4) are adhered with the skin (1) interposed therebetween.

In addition, in the state shown in FIG. 1, since the foam is generated from the bottom to the top, there is a risk that air may remain in the holes (la) in FIG. 2, resulting in insufficient adhesion. Therefore, the above-mentioned foam molded product manufacturing operation is carried out in an upside-down state as shown in FIGS. 1 and 2, that is, the skin (1) is placed at the bottom of the mold, and the foaming stock solution is applied from above. It is preferable to carry out this by injection.

[Effects of the Invention] According to the method of the present invention, attachment of exterior parts to the skin can be achieved without using adhesives or mechanical fastening means. Therefore, not only is cost and weight reduced because no separate member is required, but productivity is improved because no separate process is required.

[Brief explanation of drawings]

FIG. 1 is a schematic sectional view showing an example of the method for producing a foamed molded product of the present invention, FIG. 2 is an enlarged schematic sectional view showing pores in the skin, and FIG.
The figure is a schematic sectional view showing the skin, FIG. 3b is a plan view showing the exterior parts, FIG. 3c is a schematic sectional view showing the reinforcing material, and FIG. 4 is a schematic sectional view showing the conventional method of attaching the exterior parts. (Main symbols in the drawings) (1) Two skins (LA): Holes (3): Exterior parts (4) Two foam patent applicant Daihatsu Motor Co., Ltd. Saizu Sai 2 Figure 768

Claims (1)

[Claims] 1. When manufacturing a foamed molded product having a skin and an exterior component attached to at least a part of the outer surface of the skin, a hole is provided in the portion of the skin where the exterior component is attached to communicate the outer surface and the inner surface of the skin. A foam molding manufacturing method in which a foaming solution is injected into the inner surface of the skin and foamed with the exterior parts placed in a predetermined position.