JPH0342216A - Foamed molded body having hollow part and preparation thereof - 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 (Industrial Field of Application) The present invention relates to improvements in a foam molded article having a hollow portion and a method for manufacturing the same.

(Prior Art) Conventionally, for example, as a lower panel constituting an automobile instrument panel, a hollow body is used as a core material in order to reduce the weight of the vehicle body, and a foam layer is integrally provided between the hollow body and the skin material. There is one set up in When manufacturing a foamed molded article having a hollow part in this way, generally, first, a skin material is placed in the lower part of the mold, and then, after supplying foamed molded feed onto the skin material, the hollow body is After placing it in the mold, and then clamping the upper mold and the lower mold of the mold,
By foaming the above-mentioned foam molding material, a foam molded article in which a foam layer is integrally interposed between the skin material and the hollow body is obtained.

(Problem to be Solved by the Invention) By the way, when producing a foam molded article with a hollow portion a as described above, it is necessary to remove gas generated from the foam molding material during the foaming process of the foam molding material. be. Gas venting for this purpose is usually performed in a gap formed at the outer peripheral joint between the skin material and the hollow body, and the generated gas is passed through the air vent hole formed on the mold mating surface of the mold to the atmosphere. It is designed to be released into the air.

However, when the above-mentioned degassing is performed in the gap formed at the outer peripheral joint between the skin material and the hollow body, a part of the foamed molding material is extruded from the gap by the action of foaming pressure, and this extruded foamed molding material There is a problem in that the foam gets around to the skin material side and adheres to the surface of the skin material, spoiling the appearance of the product (foamed molded product).

In addition, if a part of the foamed molding material adheres to the surface of the skin material in this way, the foamed molding material that has adhered to the skin material must be removed in a subsequent process, and this removal work, so-called deburring work, is extremely difficult. There was also the problem that the process was cumbersome and the production cycle time became long.

The present invention has been made in view of the above, and its purpose is to provide a suitable degassing means to the hollow body constituting the foamed molded product, thereby preventing the foamed molding material from reaching the skin material side. The objective is to surely obtain a product (foamed molded product) that prevents wraparound and does not damage the appearance. Furthermore,
It is also an attempt to shorten the production cycle time by eliminating the troublesome work of deburring. Another object of the present invention is to easily obtain a product (foamed molded product) that does not impair the appearance and can shorten the production cycle time without significantly modifying the equipment.

(Means for Solving the Problems) In order to achieve the above object, the solving means of the present invention as set forth in claim (1) provides a foamed molded body in which a foamed layer is provided between a hollow body and a skin material. In this case, a gas vent hole is formed on the contact surface of the hollow body that contacts the foam layer, and an air vent hole that communicates with the gas vent hole is formed on the opposite surface of the hollow body.

Furthermore, the solving means of the present invention as set forth in claim (2) provides a method for manufacturing a foamed molded article in which a foamed layer is provided between a hollow body and a skin material. A hollow body is prepared, each of which has an atmosphere opening hole communicating with the gas vent hole formed on the other side thereof.

Next, after a foamed molding material is supplied onto the skin material placed in the mold, the hollow body is placed in the mold with the gas vent hole facing toward the skin material.

Thereafter, by foaming the foam molding material, a foam molded article having a foam layer provided between the hollow body and the skin material is obtained.

(Function) With the above configuration, in the present invention as set forth in claim (1), a gas vent hole is provided on the contact surface of the hollow body that contacts the foam layer, and an atmosphere release hole that communicates with the gas vent hole is provided on the opposite contact surface. As a result, the gas generated during the foam layer formation process is released into the atmosphere from the gas vent hole through the atmosphere opening hole, and the foamed molding material is pushed out from the gas vent hole by the action of foaming pressure. A part of the foam is moved into the hollow part of the hollow body, thereby preventing the foam molding material from going around to the skin material side, thereby ensuring that a product (foam molded product) that does not spoil the appearance is obtained. Become. Furthermore, as mentioned above, since the foamed molding material is prevented from adhering to the surface of the skin material, the troublesome deburring work as a post-process is eliminated, and the production cycle time can be shortened.

Further, in the method of the present invention described in claim (2), after the foamed molding material is supplied onto the skin material placed in the mold, a gas vent hole is formed on one side and the gas vent hole is connected to the gas vent hole on the other side. The hollow bodies each having a communicating atmosphere vent hole are placed in the mold with the gas vent holes facing the skin material side, and then the foamed molding material is foamed to form the hollow bodies. Since a foamed molded product with a foam layer provided between it and the skin material can be obtained, a product (foamed molded product) that does not impair the appearance as described above and can shorten the production cycle time is a product that can be used with equipment. can be easily obtained without major modification.

(Example) Embodiments of the present invention will be described below based on the drawings.

1 to 3 show a foamed molded article according to an embodiment of the present invention, and in this embodiment, the foamed molded article is a lower panel A constituting an instrument panel of an automobile. The lower panel A includes a synthetic resin hollow body 1 as a core material molded, for example, by blow molding, a synthetic resin skin material 2 constituting a surface layer, and an integrated structure between the skin material 2 and the hollow body 1. It is formed with a foam layer 3 made of polyurethane or the like provided with a foam layer 3.

Further, as a feature of the present invention, on one side of the hollow body 1, that is, on the outer periphery of the contact surface 4 that contacts the foam layer 3, a plurality of gas vent holes 5, 5. ... are formed, and on the other side facing the contact surface 4, that is, in the substantially center of the anti-contact surface 6, an atmosphere vent hole 7 communicating with each of the gas vent holes 5 is formed. Further, two reinforcing ribs 8, 8 are formed on the anti-contact surface 6 of the hollow body 1 to prevent deformation of the contact surface 4 due to the action of foaming pressure when forming the foam layer 3. . Further, a portion of the foamed molding material is pushed out and adhered around each gas vent hole 5 in the hollow portion 1a of the hollow body 1 by the action of foaming pressure when the foamed layer 3 is formed.

Next, the manufacturing procedure of the lower panel A in which the foam layer 3 is integrally formed between the hollow body 1 and the skin material 2 constructed as described above will be explained based on FIGS. 4 to 6.

First, as mentioned above, there are multiple gas vent holes 5°5 on one side.
. . . prepares a hollow body 1 in which air vent holes 7 communicating with the gas vent holes 5 are respectively formed on the other side thereof, and sets the hollow body 1 into the upper die 12 of the mold 9.

Next, as shown in FIG. 4, after placing the skin material 2 on the lower die 10 of the mold 9, a foamed molding material 3' such as a polyurethane raw material is fed into the skin material 2 from the nozzle 11a of the supply device 11.
feed on top.

Thereafter, as shown in FIG. 5, the upper mold 12 and lower mold 10 of the mold 9 are clamped, and the hollow body 1 is placed in a state with each of the gas vent holes 5 facing the skin material 2 side. The outer peripheral joint portion of the hollow body 1 and the skin material 2 is arranged in a sealed state.

Thereafter, with the upper mold 12 and the lower mold 10 of the mold 9 being clamped, the foamed molding material 3- is foamed, thereby forming the hollow body 1 and the skin, as shown in FIG. A lower panel A is obtained in which a foam layer 3 is integrally formed with a material 2. When forming this foam layer 3, the foam molding material 3
The gas generated from
From there, it passes through the atmosphere opening hole 7, reaches the discharge passage 13 formed in the upper mold 12, and is discharged into the atmosphere. When the foaming of the foamed molding material 3' progresses and the space between the skin material 2 and the hollow body 1 is filled with the foamed molding material 3'', the excess foamed molding material 3' is released from each of the gases. It is pushed out from the hole 5 into the hollow part la of the hollow body 1.

As described above, in this embodiment, a plurality of gas vent holes 5, 5°, etc. are provided on the contact surface 4 of the hollow body 1 that contacts the foam layer 3, and a plurality of gas vent holes 5 are connected to the gas vent holes 5 on the opposite contact surface 6. Air vent hole 7
, the gas generated in the process of forming the foam layer 3 is transferred from each gas vent hole 5 to the atmosphere vent hole 7.
A part of the foamed molding material 3' that is extruded from each vent hole 5 by the action of foaming pressure can be moved into the hollow part la of the hollow body 1, thereby allowing the foamed molding material 3' to be released into the atmosphere through the foaming pressure. It is possible to reliably obtain a product (lower panel A) that does not spoil the appearance by preventing the foamed molding material 3' from going around to the skin material 2 side. Furthermore, as mentioned above, since the foamed molding material 3' is prevented from adhering to the surface of the skin material 2,
It is also possible to eliminate the troublesome deburring work as a post-process, thereby shortening the production cycle time.

Further, in the manufacturing method of the above embodiment, after the foamed molding material 3' is supplied onto the skin material 2 placed in the mold 9, a plurality of gas vent holes 5, 5. . . . The hollow body 1, in which the air vent holes 7 communicating with the gas vent holes 5 are formed on the other side thereof, is placed in the mold with the gas vent holes 5 facing the skin material 2 side. 9 and then foaming the foam molding material 3' to obtain the lower panel A in which the foam layer 3 is provided between the hollow body 1 and the skin material 2. A product (lower panel A) that does not impair the appearance and can shorten the production cycle time can be easily obtained without significantly modifying the equipment.

Further, in the above embodiment, each gas vent hole 5 is formed on the outer periphery of the contact surface 4 with the foam layer 3, and the atmosphere release hole 7 is formed at the center of the opposite contact surface 6, thereby separating the two. Therefore, a part of the foamed molding material 3' extruded into the hollow part 1a of the hollow body 1 from each of the gas vent holes 5 can be prevented from being discharged to the outside from the atmosphere opening hole 7. , the foamed molding material 3 extruded into this hollow part 1a
The strength of the outer periphery of the product can be ensured by the so-called surplus resin.

In addition, in the above-mentioned example, the case where the foamed molded product is the lower panel A constituting the instrument panel of an automobile is shown, but this is not limited to this, and the foamed product having a hollow part 1a other than other automobile interior parts or automobiles is Of course, it is also applicable to molded bodies.

(Effects of the Invention) As explained above, according to the present invention, gas vent holes are formed on the contact surface of the hollow body that contacts the foam layer, and air vent holes that communicate with the gas vent holes are formed on the opposite surface of the hollow body. So,
A part of the foamed molding material pushed out from the gas vent hole by the action of the foaming pressure can be moved into the hollow part of the hollow body, thereby preventing the foamed molding material from going around to the skin material side and damaging the appearance. It is possible to reliably obtain a product (foamed molded product) that does not cause sagging. Furthermore, since the foamed molding material is prevented from adhering to the surface of the skin material as described above, the troublesome deburring work as a post-process can be eliminated, and the production cycle time can be shortened.

Further, according to the method of the present invention, after the foamed molding material is supplied onto the skin material placed in the mold, a gas vent hole is formed on one side, and an atmosphere release hole communicating with the gas vent hole is formed on the other side. The formed hollow body is placed in the mold with the gas vent hole facing toward the skin material, and then the foam molding material is foamed to form a foam between the hollow body and the skin material. Since a foam molded product with layers is obtained, it is possible to easily produce a product (foam molded product) that does not impair the appearance as described above and can shorten the production cycle time without significantly modifying the equipment. Obtainable.

[Brief explanation of drawings]

The drawings show an embodiment of the present invention; FIG. 1 is a longitudinal sectional view of the lower panel, FIG. 2 is a perspective view of the lower panel viewed from the front side,
FIG. 3 is a perspective view of the lower panel seen from the back side, and FIGS. 4 to 6 are manufacturing process diagrams of the lower panel. 1...Hollow body 1a...Hollow part 2...Skin material 3...Foam layer 3''...Foam molding material 4...Contact surface 5...Gas vent hole 6...Reverse Contact surface 7... Atmospheric vent hole 9... Molding mold A... Lower panel (foamed molded product) 3... Foam layer 3''... Foamed molding material 4 - Contact surface 5... Gas vent hole 6...・・Anti-contact surface 7 ・Air vent hole 9 ・・Molding mold A・・Lower panel (foamed molded product) Figure 4 Figure 4 Figure 5

Claims (2)

[Claims] (1) A foamed molded article in which a foam layer is provided between a hollow body and a skin material, wherein the contact surface of the hollow body that contacts the foam layer has gas vent holes, and the opposite surface has gas vent holes. 1. A foamed molded article having a hollow portion, characterized in that each hole is formed with an atmosphere open hole that communicates with the punch hole. (2) A method for manufacturing a foamed molded article in which a foam layer is provided between a hollow body and a skin material, wherein one side has a gas vent hole and the other side has an air vent hole communicating with the gas vent hole. After preparing a hollow body in which each of A foam molded article having a hollow portion, characterized in that the foam molded article is placed in a mold and then foamed with the foam molding material to obtain a foam molded article in which a foam layer is provided between the hollow body and the skin material. manufacturing method.