JPH0445907A - Manufacture of rigid urethane foamed product with skin - Google Patents

Manufacture of rigid urethane foamed product with skin

Info

Publication number
JPH0445907A
JPH0445907A JP2155930A JP15593090A JPH0445907A JP H0445907 A JPH0445907 A JP H0445907A JP 2155930 A JP2155930 A JP 2155930A JP 15593090 A JP15593090 A JP 15593090A JP H0445907 A JPH0445907 A JP H0445907A
Authority
JP
Japan
Prior art keywords
skin
layer
gas
skin material
mold
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
JP2155930A
Other languages
Japanese (ja)
Inventor
Akitoshi Nozawa
明敏 野沢
Kiyomi Nishida
清美 西田
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Tokai Chemical Industries Ltd
Original Assignee
Tokai Chemical Industries Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Tokai Chemical Industries Ltd filed Critical Tokai Chemical Industries Ltd
Priority to JP2155930A priority Critical patent/JPH0445907A/en
Publication of JPH0445907A publication Critical patent/JPH0445907A/en
Pending legal-status Critical Current

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  • Laminated Bodies (AREA)
  • Casting Or Compression Moulding Of Plastics Or The Like (AREA)

Abstract

PURPOSE:To prevent a skin material from swelling by forming the sakin material with a gas impermeable skin layer and a gas permeable dispersion layer provided at least on a part of the rear face of said skin layer when the gas impermeable skin material is disposed on one of divided mold to form a rigid urethane foamed body integrated with said skin material. CONSTITUTION:A skin layer and a dispersed layer are bonded together integrally by the laminating method by using, for example, and element such as polyvinyl chloride impermeable to gas for a gas impermeable skin layer 101 and an element such as slab foam composed of flexible foamed urethane for a dispersed layer 11. The dispersed layer is disposed in a mold 1 in a manner of facing the cavity side, and the rigid urethane foamed resin is injected. The gas generated when foam molding is carried out is dispersed uniformly in the dispersed layer and absorbed together with the gelatin of foamed resin to prevent the gas from concentrating locally between the skin material and a foam molded body.

Description

【発明の詳細な説明】 [産業上の利用分野] 本発明は表皮をもつ硬質ウレタン発泡品の製造方法に関
する。本発明の製造方法は、自動車の内装品、ニアコン
ディショナのフロントパネルなどの製造に利用すること
かで゛きる。
DETAILED DESCRIPTION OF THE INVENTION [Industrial Field of Application] The present invention relates to a method for manufacturing a rigid urethane foam product with a skin. The manufacturing method of the present invention can be used to manufacture interior parts of automobiles, front panels of near conditioners, etc.

[従来の技術] 例えば第4図に示すような室内用ニアコンディショナの
フロントパネルは、従来板金や樹脂から形成されていた
が、近年、硬質ウレタン発泡体の利用が検討されている
。硬質ウレタン発泡体を利用することにより、強度を維
持]ノつつ軽量化が達成でき、かつ断熱性も付与できる
からでおる。
[Prior Art] For example, the front panel of an indoor near conditioner as shown in FIG. 4 has conventionally been formed from sheet metal or resin, but in recent years, the use of rigid urethane foam has been considered. By using a hard urethane foam, it is possible to achieve weight reduction while maintaining strength, and it is also possible to provide heat insulation properties.

硬質ウレタン発泡体を利用する場合、通常は別に形成さ
れた表皮材を表面に接合して美観および意匠性を付与し
ている。そして表皮材と硬質ウレタン発泡体との接合方
法としては、表皮材を成形金型内に配置して成形する一
体発泡成形を利用するのが便利である。例えば特開平2
−47022号公報には、裏面側に独立気泡構造の発泡
体層をもつ表皮材を金型内に配置して、硬質ウレタン発
泡樹脂を発泡させて一体化する製造方法が開示されてい
る13このように独立気泡構造の発泡体層を介在させる
ことにより、硬質ウレタン発泡樹脂が発泡体層内に含浸
しないので、表皮材の表面からの感触がソフトになる。
When using a rigid urethane foam, a separately formed skin material is usually bonded to the surface to give it an aesthetic appearance and design. As a method for joining the skin material and the rigid urethane foam, it is convenient to use integral foam molding in which the skin material is placed in a molding die and molded. For example, JP-A-2
Publication No. 47022 discloses a manufacturing method in which a skin material having a foam layer with a closed cell structure on the back side is placed in a mold, and a hard urethane foam resin is foamed and integrated.13 By interposing a foam layer with a closed cell structure in this way, the hard urethane foam resin does not impregnate into the foam layer, so the surface of the skin material feels soft to the touch.

[発明が解決しようとする課題] ところで、表皮材を金型内に配置して一体的に発泡成形
する方法において、表皮材が塩化ビニル樹脂製などガス
非透過性のものの場合には11表皮材と成形体の間に残
留するガスにより離型後に表皮材に部分的に脹れが生じ
る場合があった。例えば第4図に示すようなフ[1ント
バネルを硬質ウレタン発泡体から製造する場合、第5図
に示すように塩化ビニル樹脂製表皮材100に局部的に
脹れ101が生じる場合がある。この現象は硬質ウレタ
ン発泡品に顕著のものであり、半硬質ウレタン発泡品あ
るいは軟質ウレタン発泡品の場合には生じにくい。この
ことより、」−記(〕たような不具合は、硬質ウレタン
発泡体の独立気泡構造に起因するものであると考えられ
る。
[Problems to be Solved by the Invention] By the way, in a method of integrally foam-molding a skin material by placing it in a mold, if the skin material is made of a gas-impermeable material such as vinyl chloride resin, 11 skin materials are used. The skin material sometimes swells partially after being released from the mold due to gas remaining between the molded body and the molded body. For example, when a front panel as shown in FIG. 4 is manufactured from a hard urethane foam, local swelling 101 may occur in the vinyl chloride resin skin material 100 as shown in FIG. 5. This phenomenon is noticeable in hard urethane foam products, and is less likely to occur in semi-rigid urethane foam products or soft urethane foam products. From this, it is considered that the problems described in () are caused by the closed cell structure of the rigid urethane foam.

すなわち、発泡時には発泡樹脂は発生したガスによりセ
ルを形成して膨脂する。そして発泡途上で局部的にセル
が壊れ、セル内のカスか表出リ−る。
That is, during foaming, the foamed resin expands by forming cells with the generated gas. Then, during the foaming process, the cells are locally broken and the scum inside the cells leaks out.

この表皮材と発泡体との間に発生したガスは、発泡体が
連通気泡構造の場合には連通気泡を通じて発泡体側から
逃げることができるので、表皮材に脹れは生じない。し
か1ノ発泡体が硬質ウレタン発泡体のように独立気泡構
造の場合には、ガスは発泡体側から逃げることができず
、表皮材と発泡体の間に残留1−る。金型が閉じている
間は型面で押圧されているため脹れは牛しないが、発泡
品が離型されると金型からの押圧が解除されるために、
ガスは表皮材を内面から押圧し、その力が表皮材の形状
保持力に勝った場合に脹れが生じる。
If the foam has an open cell structure, the gas generated between the skin material and the foam can escape from the foam side through the open cells, so that the skin material does not swell. However, when the foam has a closed cell structure such as a rigid urethane foam, gas cannot escape from the foam and remains between the skin material and the foam. While the mold is closed, it will not swell because it is pressed by the mold surface, but when the foamed product is released from the mold, the pressure from the mold is released.
The gas presses the skin material from the inside, and when this force overcomes the shape retention force of the skin material, bulging occurs.

このように脹れが生じた場合には、表皮材あるいは発泡
体に貫通穴を形成してカスを扱き、再度加熱して表皮材
を平滑にする補修作業が必要となるので、T数が増大す
るとともに美観が損なわれる場合もある。
If swelling occurs in this way, it is necessary to repair by forming a through hole in the skin material or foam, handling the debris, and reheating to smooth the skin material, which increases the number of T. At the same time, the aesthetic appearance may be impaired.

本発明はこのような事情に鑑みてなされたちのでおり1
、ガス非透過性の表皮材を型内に配置して硬質ウレタン
発泡樹脂により一体的に発泡成形する場合において、表
皮材の脹れを防止することを目的とする。
The present invention was made in view of these circumstances.1
The object of the present invention is to prevent the skin material from swelling when a gas-impermeable skin material is placed in a mold and integrally foam-molded with a hard urethane foam resin.

[課題を解決するための手段] 上記した表皮材の脹れは、全体に生じるものではなく局
部的に生じるのであり、脹れが生じない部分の面積の方
が一般に多い。本発明者らはこの現象に看目し、内部の
ガスが一部分に集中してその圧力が表皮材の強度に勝っ
たときに脹れが生じるものと仮定した。そして鋭意研究
の結果、ガスの集中を分散することにより脹れが防止で
きることを見出して本発明を完成したものである。
[Means for Solving the Problems] The above-mentioned swelling of the skin material does not occur all over, but locally, and the area of the portion where no swelling occurs is generally larger. The inventors of the present invention observed this phenomenon and hypothesized that swelling occurs when internal gas concentrates in one area and its pressure overcomes the strength of the skin material. As a result of extensive research, they discovered that swelling can be prevented by dispersing the concentration of gas, and completed the present invention.

すなわち本発明の表皮をもつ硬質ウレタン発泡品の製造
方法は、ガス非透過性の表皮材を分割型の一方の型面に
配置し型締め後分割型の他方の型面と表皮材との間に硬
質ウレタン発泡樹脂を注入して発泡させ表皮材と一体と
なった硬質ウレタン発泡体を形成する表皮をもつ硬質ウ
レタン発泡品の製造方法において、 表皮材はガス非透過性の表皮層と表皮層の裏面の少なく
とも一部に設けられた連通気泡構造あるいは網目構造の
ガス透過性の分散層とよりなり、表皮図を一方の型面に
対向させ分@層と他方の型面との間で硬質ウレタン発泡
樹脂を発泡させて硬質ウレタン発泡樹脂と表皮材との界
面で発生したガスを分散層内に分散して吸収するように
したことを特徴とする。
In other words, the method for producing a rigid urethane foam product with a skin according to the present invention involves placing a gas-impermeable skin material on one mold surface of a split mold, and after clamping the mold, disposing a gas-impermeable skin material between the other mold surface of the split mold and the skin material. In the manufacturing method of a hard urethane foam product having a skin, in which a hard urethane foam resin is injected and foamed to form a hard urethane foam that is integrated with the skin material, the skin material consists of a gas-impermeable skin layer and a skin layer. It consists of a gas-permeable dispersion layer with an open cell structure or a mesh structure provided on at least a part of the back surface of the It is characterized in that the urethane foam resin is foamed so that the gas generated at the interface between the hard urethane foam resin and the skin material is dispersed and absorbed within the dispersion layer.

本発明に用いられる表皮材は、ガス非透過性の表皮層と
、ガス透過性の分散層とh冒ら構成されている。ガス非
透過性の表皮層とは、空気や発泡がスなどのガスを全く
透過しないもの、あるいは透過しにくい材質のものをい
い、ポリ塩化ビニル、ポリオレフィン、ポリウレタン、
もしくはこれらの裏面側にPEFまたはゴム発泡体をラ
ミネートしたものなど、従来表皮材として用いられてい
るものを用いることができる。また、これらのガス非透
過性の材質から形成されたフィルムやシートの表面に、
織布あるいは不織布などが積層されたものを表皮層とし
て用いることもできる。分散層としでは、軟質発泡ウレ
タンからなるスラブフオームなとの連通気泡構造、ある
いは織布、不織布などの網「1構造をちら、空気あるい
は発泡ガスが自在に透過するものが用いられる1゜ 分散層は表皮層の裏面側全体に設けてもよいし、発泡ガ
スが集中しやすい部分に部分的に設けることもできる1
4また表皮層と分散層とは、接着、縫製など従来公知の
接合方法で接合することができるが、ラミネーI・法に
て一体的に接合することが好ましい。
The skin material used in the present invention is composed of a gas-impermeable skin layer, a gas-permeable dispersion layer, and a gas-permeable dispersion layer. Gas-impermeable skin layer refers to a material that does not permeate gas such as air or foam gas at all, or is made of a material that is difficult to permeate, such as polyvinyl chloride, polyolefin, polyurethane, etc.
Alternatively, materials conventionally used as skin materials, such as those laminated with PEF or rubber foam on the back side thereof, can be used. In addition, on the surface of films and sheets made of these gas-impermeable materials,
A laminated layer of woven or non-woven fabric can also be used as the skin layer. As the dispersion layer, a 1° dispersion layer is used that has an open-cell structure such as a slab foam made of soft urethane foam, or a net structure such as woven fabric or non-woven fabric through which air or foaming gas can freely permeate. may be provided on the entire back side of the skin layer, or may be provided partially in areas where foaming gas is likely to concentrate.
4.Although the skin layer and the dispersion layer can be joined by conventionally known joining methods such as adhesion and sewing, it is preferable to join them together by the lamination method.

上記表皮材は、表皮層が分割型の一方の型面に対向し分
散層がキャビティ側に向くように金型内に配置され、硬
質ウレタン発泡樹脂が注入されて従来と同様に発泡成形
が行なわれる。
The above skin material is placed in the mold so that the skin layer faces one mold surface of the split mold and the dispersion layer faces the cavity side, and hard urethane foam resin is injected and foam molding is performed in the same manner as before. It will be done.

[発明の作用および効果] 本発明の製造方法では、硬質ウレタン発泡樹脂は発泡に
より発泡セルを形成しながら膨張する。
[Operations and Effects of the Invention] In the manufacturing method of the present invention, the rigid urethane foam resin expands while forming foam cells by foaming.

そして分散層に到達した硬質ウレタン発泡樹脂では、局
部的にセルが壊れてセル内の発泡ガスが表出づ−る。こ
こで分散層は連通気泡構造または網目構造のカス透過性
であるので、ガスは分散N内に均一に拡散して分散し、
発泡樹脂のゲル化とともに吸収される。
When the hard urethane foam resin reaches the dispersion layer, the cells are locally broken and the foaming gas inside the cells is exposed. Here, since the dispersion layer has an open cell structure or a mesh structure and is permeable to scum, the gas is uniformly diffused and dispersed within the dispersion N.
It is absorbed as the foamed resin gels.

したがって本発明の製造方法によれば、表皮材と発泡成
形体との間に局部的にガスが集中することが防止される
ので、局部的にガスの圧力が高くなるのが防止され、離
型時に表皮材が部分的に脹れるのか防止される。したが
って補修作業が不要となり、美観に優れた発泡品が安定
して得られる、。
Therefore, according to the manufacturing method of the present invention, gas is prevented from locally concentrating between the skin material and the foamed molded product, so that the gas pressure is prevented from increasing locally, and mold release is prevented. Sometimes the skin material partially swells or is prevented. Therefore, there is no need for repair work, and a foamed product with excellent aesthetic appearance can be stably obtained.

[実施例] 以下、実施例により具体的に説明する。以下の実施例は
室内用ニアコンディショナのフロントパネルの製造に本
発明を適用したものである、。
[Example] Hereinafter, the present invention will be specifically explained using examples. In the following examples, the present invention is applied to the manufacture of a front panel of an indoor near conditioner.

厚さQ、(3InInのガス非透過性のポリ塩化ビル製
シーl〜よりなる表皮層10の裏面に、厚さ2ro m
の連通気泡構造のスラブフオーム(rFl−68」丼上
M−’IP(株)製)からなる分散層11か一体的にフ
lノームラミネート法で接合された表皮材1を用意し、
真空成形により第1図に示す所定形状に賦形する。
Thickness Q, (3InIn gas-impermeable polychloride seal L~ on the back side of the skin layer 10, a thickness of 2rom
A skin material 1 is prepared, in which a dispersion layer 11 made of a slab foam with an open cell structure (rFl-68, manufactured by Donjo M-'IP Co., Ltd.) is integrally bonded by the flunorm lamination method,
It is formed into the predetermined shape shown in FIG. 1 by vacuum forming.

次に第2図に示すように、上型2oと下型21とよりな
る分割タイプの発泡成形型2を用意し、所定形状に賦形
された上記表皮材2を下型21の型面に、表皮層10が
型面側に、分散層11がキャビティ22側となるように
配置し、ざらに鉄製芯材3を配置して型締め後、所定量
の硬質ウレタン発泡樹脂をキャビティ22内に注入して
発泡成形する。
Next, as shown in FIG. 2, a split type foaming mold 2 consisting of an upper mold 2o and a lower mold 21 is prepared, and the skin material 2 shaped into a predetermined shape is placed on the mold surface of the lower mold 21. , the skin layer 10 is placed on the mold surface side and the dispersion layer 11 is placed on the cavity 22 side, and after roughly placing the iron core material 3 and clamping the mold, a predetermined amount of hard urethane foam resin is poured into the cavity 22. Inject and foam mold.

得られた発泡成形品は第3図に示すように、硬質ウレタ
ン発泡休4と表皮材1とからなり、硬質ウレタン発泡体
4は表皮材1の分散層11(スラブフオーム)と一体面
に接合されるとともに、表皮層10表面に脹れは生じて
いなかった。発泡成形時には、硬質ウレタン発泡樹脂は
発泡圧力が約3kg/cm2で発泡し、キャビティ22
内を充填するとともに、分散層11に含浸する。そして
局部的にセルが壊れて表出した発泡ガスは、分散層11
内に拡散して分散する。したがってガスが局部的に集中
するのが防止され、表皮層1oを押し上げるだけの圧力
に達しないため、脹れが生じなかったものと堆察される
As shown in FIG. 3, the obtained foam molded product is composed of a hard urethane foam 4 and a skin material 1, and the hard urethane foam 4 is integrally joined to the dispersion layer 11 (slab form) of the skin material 1. At the same time, no swelling was observed on the surface of the epidermal layer 10. During foam molding, the hard urethane foam resin is foamed at a foaming pressure of approximately 3 kg/cm2, and the cavity 22
At the same time, it is impregnated into the dispersion layer 11. Then, the foaming gas that is locally broken and exposed is transported to the dispersion layer 11.
Diffuse and disperse within. Therefore, the gas was prevented from being locally concentrated, and the pressure did not reach enough to push up the skin layer 1o, so it is assumed that no swelling occurred.

すなわち、得られたフロントパネルは軽量で表面の表皮
層]Oの美観に優れ、かつ硬質ウレタン発泡体4は充分
な強度を保持するとともに独立気泡による断熱作用を付
与している。
That is, the obtained front panel is lightweight and has an excellent appearance of the surface skin layer [O], and the hard urethane foam 4 maintains sufficient strength and provides a heat insulating effect due to closed cells.

【図面の簡単な説明】[Brief explanation of the drawing]

第1図〜第3図は本発明の一実施例の製造方法に環し、
第1図は表皮材の要部断面図、第2図は表皮材を型内に
配置した状態を示す要部断面図、第3図は得られた発泡
成形品の要部断面図である1、第4図はフロン1〜パネ
ルの斜視図、第5図は服れが生じた状態で示す第4図の
断面図でおる。 1・・・表皮材  2・・・発泡成形型  3・・・芯
材4・・・硬質ウレタン発泡成形体 10・・・表皮層(ポリ塩化ビニル) 11・・・分散層(スラブフオーム) 20・・・上型 21・・・下型 22・・・キrビテ
ィ特許出願人   東海化成工業株式会社代理人   
 弁理士   大川 宏
1 to 3 illustrate a manufacturing method according to an embodiment of the present invention,
Fig. 1 is a cross-sectional view of the main part of the skin material, Fig. 2 is a cross-sectional view of the main part showing the state in which the skin material is placed in the mold, and Fig. 3 is a cross-sectional view of the main part of the obtained foam molded product. , FIG. 4 is a perspective view of the front panel 1 to the panel, and FIG. 5 is a cross-sectional view of FIG. 4 showing a state where wear has occurred. 1... Skin material 2... Foaming mold 3... Core material 4... Hard urethane foam molded product 10... Skin layer (polyvinyl chloride) 11... Dispersion layer (slab foam) 20 ... Upper mold 21 ... Lower mold 22 ... Kirbiti patent applicant Tokai Kasei Kogyo Co., Ltd. agent
Patent attorney Hiroshi Okawa

Claims (1)

【特許請求の範囲】[Claims] (1)ガス非透過性の表皮材を分割型の一方の型面に配
置し型締め後該分割型の他方の型面と該表皮材との間に
硬質ウレタン発泡樹脂を注入して発泡させ該表皮材と一
体となった硬質ウレタン発泡体を形成する表皮をもつ硬
質ウレタン発泡品の製造方法において、 前記表皮材はガス非透過性の表皮層と該表皮層の裏面の
少なくとも一部に設けられた連通気泡構造あるいは網目
構造のガス透過性の分散層とよりなり、該表皮層を前記
一方の型面に対向させ該分散層と前記他方の型面との間
で前記硬質ウレタン発泡樹脂を発泡させて該硬質ウレタ
ン発泡樹脂と該表皮材との界面で発生したガスを分散層
内に分散して吸収するようにしたことを特徴とする表皮
をもつ硬質ウレタン発泡品の製造方法。
(1) A gas-impermeable skin material is placed on one mold surface of the split mold, and after the mold is clamped, a hard urethane foam resin is injected between the other mold surface of the split mold and the skin material and foamed. In the method for manufacturing a rigid urethane foam product having a skin that forms a rigid urethane foam integral with the skin material, the skin material is provided on a gas-impermeable skin layer and at least a portion of the back surface of the skin layer. The hard urethane foam resin is formed between the dispersion layer and the other mold surface, with the skin layer facing the one mold surface, and the hard urethane foam resin is formed between the dispersion layer and the other mold surface. A method for manufacturing a hard urethane foam product having a skin, characterized in that gas generated at the interface between the hard urethane foam resin and the skin material is dispersed and absorbed in a dispersion layer by foaming.
JP2155930A 1990-06-14 1990-06-14 Manufacture of rigid urethane foamed product with skin Pending JPH0445907A (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
JP2155930A JPH0445907A (en) 1990-06-14 1990-06-14 Manufacture of rigid urethane foamed product with skin

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
JP2155930A JPH0445907A (en) 1990-06-14 1990-06-14 Manufacture of rigid urethane foamed product with skin

Publications (1)

Publication Number Publication Date
JPH0445907A true JPH0445907A (en) 1992-02-14

Family

ID=15616621

Family Applications (1)

Application Number Title Priority Date Filing Date
JP2155930A Pending JPH0445907A (en) 1990-06-14 1990-06-14 Manufacture of rigid urethane foamed product with skin

Country Status (1)

Country Link
JP (1) JPH0445907A (en)

Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPS5748886U (en) * 1980-09-05 1982-03-18
JP3081711B2 (en) * 1992-08-18 2000-08-28 オリンパス光学工業株式会社 camera

Patent Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPS5748886U (en) * 1980-09-05 1982-03-18
JP3081711B2 (en) * 1992-08-18 2000-08-28 オリンパス光学工業株式会社 camera

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