JPH0574444B2 - - Google Patents

Description

[Detailed description of the invention]

(Industrial Application Field) The present invention relates to a foam molded product having a different skin part on a part of the surface of the product, more specifically a foam molded product having a part of the skin of a synthetic resin sheet made of cloth or wood. Molded products, foam molded products with parts of different colors, and specific products include methods for manufacturing foam molded products such as automobile interior parts such as automobile door trims, furniture, and building materials that have the above-mentioned characteristics. be. (Prior art) In recent years, foam molded products such as automobile interior parts, furniture, building materials, etc., as mentioned above, have been treated with fabric or different colored synthetic resins on a part of their surface due to consumer-oriented diversification and luxury. High demand. In the conventional structure and molding method of such a foam molded product, as shown in FIG.
A foam layer 25 and a shape-retaining layer 26 are integrated into a part of the base foam 23 formed by integrally laminating the foam layer 21 and the shape-retaining layer 22 on the back side of the skin 24 which is of a different color and material from the previous skin 20. Heterogeneous skin foam 27 laminated on
A structure has been proposed in which a locking metal fitting 28 protrudes from a shape-retaining layer 26 of a different skin foam 27 and is fixed therein. The manufacturing method is to mold the base foam 23 and the different skin foam 27 separately, and then fix the different skin foam 27 at a predetermined position on the base foam 23. (Problems to be Solved by the Invention) As described above, the foamed molded article according to the structure and manufacturing method of the prior art is a combination of separately molded foamed articles. Therefore, the dissimilar skin foam portion inevitably takes on a raised shape, creating a level difference between the surface of the base foam and the surface of the dissimilar skin foam, resulting in an unnatural feeling. In addition, due to the work involved in attaching the different skin foam parts and the molding accuracy of each foam, a gap inevitably occurs between the mating surfaces of both foam parts, making the separation line of the different skin parts unclear. . These drawbacks are truly serious problems for foamed molded products, for which good appearance is an important factor in determining commercial value, and an immediate solution has been desired. In addition, conventional manufacturing methods require three main steps: molding a base foam, forming a heterogeneous skin foam, and bonding both foams together. This method required a significantly larger number of man-hours than conventional molding, and the work efficiency was poor. The present invention has focused on these drawbacks of the prior art, and has developed a foaming method that eliminates unnatural bulges in dissimilar skin areas and gaps between mating surfaces, and reduces the number of man-hours required for production compared to conventional methods. The purpose is to provide a method for manufacturing molded products. (Means for Solving the Problems) Therefore, one feature of the present invention for achieving the above-mentioned object is that at least one section of the mold has a projecting wall that partitions the molding surface into a plurality of sections. A heterogeneous epidermis or board is arranged, a base epidermis or board is disposed in the other sections, and a fitting jig made of an elastic material and having a closing claw is installed at the overlapping portion of the end of the heterogeneous epidermis and the base epidermis and the protruding wall, respectively. After wearing it,
There is a method for manufacturing a foam molded product, which is made by injecting a urethane foam raw material into a mold, and removing the mold after the raw material has hardened.Another method is a method for manufacturing a foam molded product, in which the skin is covered with multiple types of skins. , a skin or board is disposed in one or more sections of the mold having a projecting wall that partitions the molding surface into a plurality of sections, and a skin or board different from the skin or board is provided in a section adjacent to the skin, and the skin or board is disposed in a section adjacent to the skin. After mounting the skin with a fitting part such as a groove formed at the boundary between the skin and the protruding wall with the end of the skin and the projecting wall sandwiched between the fitting part, injecting the urethane foam raw material into the mold,
The present invention provides a method for producing a foamed molded article by removing the shape after curing the raw material. (Function) By manufacturing a foamed molded product using the above method, the base epidermis and the different epidermis are integrally fixed by the urethane foam. In addition, during molding, the space between the skins is adjusted using a matching jig or a fitting part provided at the end of one skin.
They are tightly adhered without any gaps, and leakage of raw materials from between the skins is prevented. Furthermore, when a fixing jig is used, when the foamed molded product is removed from the mold, the fixing jig closes due to its elasticity and acts to fill the gap between the base skin and the different skin. Also, those with a foam layer on the back as the epidermis,
Alternatively, when molding is performed with a foam placed on the back surface of the skin, the foam layer on the back surface of the skin is crushed by the foaming pressure of the urethane foam during molding, and the foam layer is restored after the molded product is demolded. Therefore, the outer shape of the skin expands outward, filling the gap between the skins or the boards formed by the projecting walls of the mold. (Example) Specific examples of the present invention will be further described below. 1 and 2 are cross-sectional views of a mold showing each step in an embodiment of the method for manufacturing a foam molded product of the present invention, and FIG. 3 is a cross-sectional view of a mold manufactured by the method for manufacturing a foam molded product of the present invention. FIG. 2 is a cross-sectional view of a foam molded product. Reference numeral 1 in FIG. 1 denotes a mold used in the method for producing a foamed molded product of the present invention, which is comprised of a pair of upper mold 2 and lower mold 3. The lower mold 3 has a molding surface that molds the surface shape of the molded object, and the molding surface is partitioned into two molding surfaces by a protruding wall 4 provided annularly in the center of the molding surface, that is, It is partitioned into a base skin molding surface 5 and a dissimilar skin molding surface 6. A preformed base skin 7 is placed on the base skin molding surface 5 of the lower mold 3 of the mold 1 described above. The base skin 7 is preformed using PVC resin, ABS resin, or other synthetic resin raw material as the main raw material using slush molding, vacuum molding, injection molding, or other known molding methods, and is particularly made of solid layer PVC,
It is preferable to use a resin layer such as ABS laminated with a foam layer such as foamed PVC resin or foamed PE resin, since the surface becomes soft and the gap between the skins is filled. A dissimilar epidermis 8 having different properties from the previous base epidermis is provided on the dissimilar epidermis molding surface 6 of the lower mold 3. As the foreign epidermis, synthetic resin or cloth, etc., which is different in color from the base epidermis is generally used, and when cloth is used as the foreign epidermis, it is desirable to use stretchable cloth such as tricot, jersey, etc.
A foam sheet 9 made of polyurethane, PP resin, PE resin, etc. is laminated on the back side of the heterogeneous skin. Furthermore, depending on the design of the molded product, it is also possible to use a board made of synthetic resin, marble, wood pulp, or a laminate of these materials instead of the skin. When using a board for this part, it is necessary to mold it in advance by pressing or injection molding. Next, a matching jig 10 is attached to the overlapping portions of the projecting wall 4 and the end portions of the dissimilar epidermis 8 and the base epidermis 7, respectively, to fix the three members uniformly. It is desirable that the fitting jig be installed all around the projecting wall 4, but it may be done partially. The shape of this alignment jig 10 is not particularly limited as long as the claws 30 have the function of closing with elastic force. That is, the alignment jig 10 is made of an elastic resin material such as PVC resin, rubber, or polyurethane resin to form a C-shaped cross section with claws 30 and 31 as shown in FIGS. It is preferable that the body is formed into a U-shaped cross section with claws 32 as shown in FIG. It is also possible. The alignment jig 10 is installed by pushing open the claws of the alignment jig 10 and inserting it from above the projecting wall 4. Next, a hard urethane foam 11 whose composition is shown in Table 1 is injected into the cavity of the mold 1 in which the base skin 7, dissimilar skin 8, and mating jig 10 have been set as described above. (See Figure 2)

[Table] The injected hard urethane foam foams in the mold, but since the gap between the dissimilar skin 8 and the base skin 7 is closed by the mating jig 10, the hard urethane foam does not reach the surface of the foam molded product. Does not leak.
After the hard urethane foam 11 is cured, the upper mold 2 and lower mold 3 of the mold 1 are opened, and the foamed molded product is demolded.
At that time, the claws 30 of the mating member 10 close inwardly due to their elastic force, and the tension of the foam sheet 9 is released, causing the dissimilar skin 8 to expand. It fills the gap between the skin and the different epidermis, bringing them into close contact. Therefore, when demolding, there is no step gap between the base epidermis and the different epidermis, and a clear parting line is exposed. Next, other embodiments of the present invention will be described. FIG. 8 is a cross-sectional view of a mold showing a molding process in another embodiment of the method for producing a foamed molded product of the present invention, and corresponds to the process shown in FIG. 2 in the previously described embodiment. The manufacturing method of the foam molded product of this example differs from the above-mentioned example in that, in this example, a separate fitting jig is not used, and a groove-shaped fitting structure is provided at the end of the skin. The grooves sandwich the ends of the skin and the protruding wall in adjacent compartments to seal the end of the skin, thereby sealing the gap between the epidermis and the protruding wall or between the skins. That is, in this embodiment, the mold 40, the different skin 48, and the hard urethane foam 41 are completely the same, but the base skin 47 is provided with a fitting portion 50 at the end. To explain more specifically, the basal epidermis 4
In addition to a portion 60 attached to the base skin molding surface 45 of the mold 40 and a portion 61 disposed along the protruding wall 44, 7 has a concave shape at the tip of the portion 61 along the protruding wall toward the surface of the molded body. grooves are formed.
The shape of the groove, that is, the fitting part, is shown to be relatively deep in the embodiment, but it is shown in FIGS.
It is also possible to employ a fitting jig-like one as shown in the figure. Further, in the manufacturing method of this embodiment, the urethane foam 41 is injected after attaching the base skin 47 and the different type of epidermis 48 to the mold 40, as in the previous embodiment, but when each epidermis is attached to the mold, Then, the above-described fitting portion 50 of the base skin is fitted with the projecting wall 44 and the end of the dissimilar skin 48, and the base skin 47 and the projecting wall 44 are fitted.
The different epidermis 48 is sandwiched together. By doing so, the gaps between the skins are sealed, and the raw material does not leak out to the surface when the urethane foam is foamed. After the urethane foam has hardened, the molded product is demolded, but at this time the fitting portion 50 closes inward due to elastic force, and the foam layer expands to fill the gap between the projecting walls 44. In addition to the fitting between the groove and the end of the projecting wall and the skin or board according to the embodiment, as shown in FIG. This can also be done by fitting the groove 51 provided in the upper end of the dissimilar skin 48'. Although the above-mentioned two embodiments disclose embodiments of so-called closed injection in which the hard urethane foam is injected with the mold being sealed, the essence of the present invention is not limited to this in any way. Alternatively, so-called open injection may be adopted, in which the raw material is injected with the upper and lower molds open and then the upper and lower molds are sealed. Heterogeneous skins are usually unformed PP, PE,
It can be sufficiently molded using unformed cloth laminated with a foam sheet such as polyurethane resin, or synthetic resin, but depending on the external shape of the foam molding and the material of the skin, it may be necessary to preform partially or completely. There are some things. In the examples, the heterogeneous skin had a cushion layer on the back surface, and this cushion layer not only has a hardening that improves the feel of the molded product as described above, but also has a hardening effect when the molded product is removed from the mold. The cushion layer, which had been compressed by the raw material, expands and fills the gap between the projecting walls. Therefore, by setting the cushion layer to an appropriate thickness, it is possible to considerably compensate for the lack of elastic force of the mating jig, etc. In order to fill the gap between the projecting walls with the cushion layer, it is preferable that the cushion layer is made of urethane foam with closed cells that do not swell. In addition, in this example, hard urethane foam was selected as the urethane foam raw material injected into the mold,
Although a configuration was adopted in which the overall rigidity is maintained by the strength of the urethane foam itself, it is also possible to use a core and semi-rigid urethane foam as in the commonly known integral foam molding. (Effects) The method for producing a foamed molded product of the present invention employs a mold whose molding surface is partitioned into a plurality of sections by protruding walls, attaches different types of skin to the sections of the mold, and furthermore, In order to perform foam molding while the skin of the wall part is aligned and pressed together with a jig, the base skin and dissimilar skin are joined together by the urethane foam.
The foreign epidermis does not bulge out unnaturally,
An integral foam molded article can be produced. Furthermore, in the method for producing foam molded products of the present invention, the mating jig that fixes the boundary of the skin during demolding contracts due to its own elastic force, preventing gaps between the skins and making the parting line clear. This has the effect of making it possible to produce foam molded products with a beautiful appearance. In addition, the method for manufacturing a foamed molded product of the present invention has the effect that leakage of the urethane foam raw material from the gap between the skin and the protruding wall of the mold is prevented by a matching jig, etc., and as described above, the conventional manufacturing method has the following effect: a step of molding a base foam; a step of molding a heterogeneous skin foam;
Compared to the process of integrally bonding both foamed molded bodies, which are roughly divided into three steps, only one step is required to complete the molding, which has the effect of greatly improving work efficiency.

[Brief explanation of the drawing]

1 and 2 are cross-sectional views of a mold showing each step of an embodiment of the method for manufacturing a foam molded product of the present invention, and FIG. 3 is a cross-sectional view of a mold manufactured by the method for manufacturing a foam molded product of the present invention. FIG. 4 is a cross-sectional view of a foam molded product;
5 are cross-sectional views of the matching jig, FIGS. 6 and 7 are front views of the matching jig, and FIG.
The figure is a sectional view of a mold showing steps in another embodiment of the present invention, and FIG. 9 shows another embodiment of a fitting structure between a groove in the skin or board end and an adjacent skin end. FIG. 10 is a partial cross-sectional view of a foam molded product manufactured by a conventional technique. 2... Upper mold, 3... Lower mold, 4, 44... Projection wall,
7,47,47'...basal epidermis, 8,48,4
8'... Different type of skin, 9... Foam sheet laminated on different type of skin, 10... Fitting jig, 11,
41...Hard urethane foam, 30, 31, 3
2, 33...claw, 50...fitting part.

Claims (1)

[Scope of Claims] 1 A mold having a protruding wall that partitions a molding surface into a plurality of compartments has a different type of epidermis arranged in at least one section, a base epidermis arranged in the other divisions, and each of the different type of epidermis and the base epidermis After attaching a fitting jig made of an elastic material and having a closing claw to the overlapping part of the end and the protruding wall, a urethane foam raw material is injected into the mold,
A method for producing a foamed molded article, which comprises demolding the raw material after curing. 2. A board is arranged in at least one section of a mold having a projecting wall that partitions the molding surface into a plurality of sections, a skin is arranged in the other sections, and an elastic layer is provided at the overlapping parts of the ends of the board and the skin and the projecting wall. 1. A method for producing a foamed molded product, which comprises: attaching a mating jig made of material and having closing claws, injecting a urethane foam raw material into a mold, and removing the mold after the raw material has hardened. 3. In a method for manufacturing a foam molded product whose surface is covered with multiple types of skin or board, the skin or board is placed in one or more compartments of a mold having a projecting wall that partitions the molding surface into multiple compartments, A state in which a skin or board that is different from the skin or board in adjacent compartments and has a fitting part formed at the boundary with the skin or board is sandwiched between the skin or the end of the board and the projecting wall by the fitting part. 1. A method for manufacturing a foam molded article, which comprises: injecting a urethane foam raw material into a mold, and removing the foam after the raw material has hardened.