JPH064257B2 - Foam molded article having skin material and method for producing the same - Google Patents

Description

Description: TECHNICAL FIELD The present invention relates to a foam-molded article having a skin material and a method for producing the same, and more specifically to a foam-molded article having a skin material, for example, an instrument panel. In order to achieve this, when a skin material with a predetermined pattern is integrated with a base material made of foam through an adhesive, a release sheet is previously arranged in the base material forming die, and the A foamed molded article having a skin material and a method for producing the same, which omits the step of applying a mold release agent to the mold or removing the mold release agent, thus improving the production efficiency and obtaining a product of excellent quality. Regarding

[Background of the Invention] Recently, there has been a remarkable tendency toward high-grade automobiles. For example, in the instrument panel, a duct for cooling and warming air, a case for attaching an air conditioner, etc. are attached by in-mold molding, and a skin sheet with a grain pattern is attached to this, and a device to give a visual sense of unity Is a good example. In particular, in the instrument panel, it is desired that the skin material of the bent portion or the curved portion has a seam, and the texture is as if the skin material was stitched together to give a stitch.

When manufacturing an instrument panel having such a structure, a skin sheet having a predetermined pattern (skin grain pattern) is sewn on the surface, and the sewn skin sheet is sandwiched between a molding die including a male die and a female die. It is conceivable to perform foam molding to form the base material. In this case, in the foaming step, the foamable resin may leak from the stitching point,
In order to avoid this, the sutured portion must be sealed with a sealing tape or the like. On the other hand, the sewn skin sheet has a complicated shape to follow the outer shape of the instrument panel, and since the stitched portion has irregularities, there are problems such as wrinkles and swelling in the foaming process. is there.

In order to avoid this kind of inconvenience, it is naturally conceivable to bond the skin sheet and the base material to be integrated. However, depending on the material of the base material such as urethane or other hard foaming resin, a step of applying a release agent to the mold in advance is naturally required in order to smoothly release the mold. Moreover, the release agent remains attached to the base material to be molded, and when the skin sheet is attached to such a base material, the release agent is used as a solvent or a solvent in order to improve the adhesiveness between the base material and the skin sheet. It must be removed by sandblasting, which is a major obstacle to improving production efficiency.

[Object of the Invention] The present invention has been made in order to overcome the above-mentioned inconvenience, and is formed by a skin material and a mold to which a predetermined pattern is given in advance in order to produce a foam-molded article having the skin material. When the base material and the base material are integrated with each other via an adhesive, a mold release sheet is arranged in advance in the mold, and a foaming agent is injected into the sheet to foam and solidify the mold. A foamed molded article having a skin material, which can omit the step of applying a release agent and the step of removing the release agent to the production efficiency of this type of molded article and obtain a product of excellent quality, and It is an object to provide a manufacturing method thereof.

[Means for Achieving the Purpose] In order to achieve the above-mentioned object, the present invention relates to a composite sheet obtained by laminating a skin material and a foam sheet having elasticity and cutting the composite sheet into a predetermined shape at a predetermined portion. Is composed of a base material made of a hard foam having a surface to which a release agent is not attached, and an adhesive to the surface body without the release agent of the base material. It is characterized by being joined and integrated through.

In addition, the present invention forms a first base material, a second base material and the like with a hard foam resin material, and connects the respective base materials to each other through insert metal fittings, and further connects the connected base materials. It is characterized by being covered with a skin material.

Further, according to the present invention, a release sheet is provided between the first mold and the second mold, and then the release sheet is brought into close contact with any one of the molds, and further, the first molding is performed. Mold and second
The foamed resin material is injected into the cavity defined between the mold and the foam, and after the foam material is solidified, the mold is opened and the release sheet is peeled from the foam molded product. It is characterized in that the skin material is fixed to the foamed molded product.

[Embodiments] Next, preferred embodiments of a foam-molded article having a skin material and a method for producing the same according to the present invention will be described in detail below with reference to the accompanying drawings.

In FIG. 1, reference numeral 10 indicates a foam-molded article having a skin material according to the present invention, for example, an instrument panel for an automobile, and the instrument panel 10 is vinyl chloride or the like having an uneven pattern such as a leather grain. It is composed of a composite sheet 12 in which a foaming resin such as polyurethane having elasticity is attached to the skin material and a base material 14 made of a hard foaming resin such as urethane. The instrument panel 10
As can be easily understood from the figure, the glove box forming portion 18 for accommodating articles and the like, and the console portion 20 on which the vehicle-mounted stereo or air conditioner operation panel, shift lever, side brake lever, etc. are mounted. And an opening 22 through which the steering wheel shaft is inserted and in which a speedometer or the like is arranged is formed.

Here, the composite sheet 12 and the base material 14 constituting the instrument panel 10 have a joint structure as shown in FIG.
That is, the composite sheet 12 is a sewn portion 16 in which portions previously cut into a plurality of paper patterns are sewn together to expose seams, and the sewn portion 16 has a shape that covers the surface of the base material 14. There is.

The suture portion 16 is shown in detail in FIG. As can be easily understood from the figure, the suturing portion 16 has a vinyl chloride sheet 24.
And two foamable resin layers 26 such as polyurethane having elasticity are laminated to make two composite sheets 28a, 28b contact each other by bending their ends, and a backing material 30 is arranged at the contact portion. They are sewn together with the sutures 32a and 32b so as to be integrated.

On the other hand, the substrate 14 is a main body 34, a console member 36,
It is formed separately from a visor portion 38 for a speedometer or the like. The glove box forming part 18, the console part 20, and the opening part 22 are internally provided with a bracket (not shown) for fitting a glove box, a vehicle-mounted stereo or an operation panel of an air conditioner, a speedometer and the like.

The instrument panel 10 to which the method for manufacturing a foam-molded article having a skin material according to the present invention is basically configured as described above. Next, the manufacturing process and effects thereof will be described.

The manufacturing process of the instrument panel 10 includes a manufacturing process of the composite sheet 12 which is a skin material and a manufacturing process of the base material 14.

First, a manufacturing process of the composite sheet 12 which is a skin material will be described. A foamable resin layer (26) having elasticity, such as polyurethane, is attached to a vinyl chloride sheet (24) having a pattern such as leather grain using a predetermined adhesive. Then, as shown in FIG. 4, the composite sheet 12 is cut according to the shapes of the main body 34, the console member 36, and the visor portion 38, and as shown in FIGS. 3 and 5, the suture thread 31a, After joining at 31b,
The short side is widened and sewn with different sutures 32a and 32b using the backing material 30, and is formed as a skin of the instrument panel 10.

Next, the manufacturing process of the base material 14 will be described. The main body 34, the console member 36, and the visor portion 38 that form the base material 14 are manufactured in the same process. Therefore,
Here, the main body 34 having the most complicated shape will be described. In this step, a step of forming a sheet S made of vinyl chloride for releasing the base material 14 from a forming die described later by a vacuum forming die, and positioning the formed sheet S in a forming die for foaming together with a bracket, Then, the mold is clamped and then foamed. This step will be described below.

A vacuum forming die 40 is shown in FIG. 6a. The vacuum forming die 40 has a lower die 42 and an upper die 44. The lower die 42 has a shape that follows the outer shape of the main body 34 that constitutes the instrument panel 10, and has a narrow recess 43 in a part thereof. The lower mold 42 has a plurality of suction ports for sucking and closely adhering the sheet S to be molded to the lower mold 42. The suction port is connected to a vacuum suction means (not shown). In addition, the upper mold 44 has a lower mold 42
A rod 46 is provided for insertion into the recess 43 of the. In this case, the vacuum forming die 40 may be provided with heating means.

Therefore, the sheet S stretched around the frame 47 is arranged between the lower mold 42 and the upper mold 44. At this time, the sheet S may be entirely heated by a heating means (not shown) in advance, and as described above, when the lower die 42 is provided with the heating means,
The sheet S may be lowered and brought into contact with the heated lower mold 42. As a result, the sheet S is softened so that the sheet S can easily follow the predetermined shape of the lower mold 42. At this time, the vacuum suction means connected to the lower die 42 is driven to bring the sheet S into close contact with the lower die 42 via the suction port 42a. Then, lower the upper mold 44,
The rod 46 is inserted into the recess 43. As a result, the sheet S is pulled by the rod 46, and the sheet S further adheres to the lower mold 42.

Next, when the lower die 42 has a heating means, it is deenergized, and after a predetermined time has passed, the molding is completed, the vacuum suction means is stopped, the upper die 44 is retracted, and then the above-mentioned The sheet S is released from the lower mold 42 (see FIG. 6c).

Further, the molded sheet S is set in the foam molding die 50. The foaming mold 50 has a lower mold 52 and an upper mold 54. The lower mold 52 is formed in a shape that directly follows the sheet S formed by the vacuum forming mold 40, and the lower mold 52 has a plurality of suction ports 52a for sucking and closely adhering the sheet S,
The suction port 52a is connected to a vacuum suction means (not shown). On the other hand, the upper mold 54 is a foaming resin material injection means (not shown).
Has an injection port 56 for injecting the foamable resin material. Further, on the molding surface of the foamable resin material of the lower mold 52 and the upper mold 54, in order to prevent the foamable resin material from leaking from the joint surface between the bracket as the insert metal fitting and the foamable resin material. 58a to 58e are provided. When the sheet S is set in the foaming mold 50, a glove box,
A bracket 60 for mounting an in-vehicle stereo, an operation panel of an air conditioner, a speedometer, etc. is placed on the seat S (see FIG. 7A). Then, as shown in FIG.
After the upper mold 54 is lowered with respect to the lower mold 52 and the two molds are clamped, the sheet S is brought into close contact with the lower mold 52 under the suction action of the vacuum suction means connected to the lower mold 52. In this case, the upper mold 54
It is also possible to apply a release agent on the mold surface. This is because, in the molded product corresponding to this surface, thereafter, the skin material and the like are not joined and the foamable resin material is effectively released from the upper mold. Then, a cavity defined between the lower mold 52 and the upper mold 54.
A foamable resin material is injected into 62 through the injection port 56 from the foamable resin material injection means, whereby a foamable resin layer 64 is formed. Then, after curing for a predetermined time, the mold is released as shown in FIG. 7c. That is, in this case, the vacuum suction means connected to the lower mold 52 is stopped and the upper mold 54
The mold is opened by retreating, and the foamable resin layer 64 in which the bracket 60 is embedded is taken out. Then, the sheet S
By peeling from the foamable resin layer 64, the base material 14 as a product is obtained.

As shown in FIG. 2, the base material 14 molded in this manner joins the main body 34, the console portion 20 and the visor portion 38 of the speedometer, which constitute the base material 14, to the instrument panel 10. The base material 14 is formed. At that time, this base material
In order that 14 of the sheet S can be easily understood from the peeling of the sheet S, at least one surface thereof is not coated with a release agent.

Next, an adhesive is applied to the composite sheet 12 manufactured as described above, and the composite sheet 12 and the base material 14 are attached to each other to complete the molded body of the instrument panel 10.

As described above, according to the present invention, since the foaming step is performed through the sheet S in the foaming step, it is necessary to apply the release agent to one surface of at least one of the foamable molds as in the conventional technique. It is possible to easily release the foamed molded product from the molding die. Further, when applying the adhesive to the base material 14 in order to bond the composite sheet 12 and the base material 14 made of the foamed molded product, no step of removing the release agent is required.

Next, FIG. 8 shows another embodiment of the present invention.

In the manufacturing process of this embodiment, the foaming process is performed via the sheet S, as in the above embodiment. In the manufacturing process of this embodiment, the molding of the sheet S and the foaming process are performed using a single foam molding die 70. This foam mold 70 is a lower mold 72
And the upper mold 74. The lower mold 72 is selected to have a shape in which the sheet S corresponds to the outer shape of the instrument panel 10 and a cavity corresponding to a foamable resin layer described later is defined when the foam molding mold 70 performs mold clamping. ing. The lower mold
72 is composed of blocks 72a, 72b and 72c that can be divided into three, and has a suction port 82 for sucking the sheet S to the lower mold 72 to bring it into close contact. The suction port 82 is connected to a vacuum suction means (not shown).

The upper mold 74 has an injection port 84 for injecting the foamable resin material by means of a foamable resin material injection means (not shown). At least the block 72b of the lower mold 72 has a heating unit (not shown), and has a function of driving the heating unit to heat the sheet S when the sheet S is molded.

First, as shown in FIG. 8A, the sheet S is placed above the lower mold 72 to be used for molding, and then lowered and hung down. At that time, the sheet S is heated by a heating means (not shown) of the lower mold 72. Next, as shown in FIG.
Moves down to clamp the mold with the lower mold 72. That is, a cavity 86 is defined between the lower mold 72 and the upper mold 74. Then, the vacuum suction means connected to the lower die 72 is driven, and the sheet S is sucked through the suction port 82, whereby the sheet S is sucked.
Is closely attached to the lower mold 72. After the molding process of the sheet S is completed after the curing for a predetermined time, the mold opening is performed as shown in FIG. 8c. In this case, the vacuum suction means connected to the lower mold 72 is in the operating state, and the sheet S remains in close contact with the lower mold 72.

Then, a foam molding process is performed. A bracket 88 for mounting a glove box, an in-vehicle stereo or an air conditioner operation panel, a speedometer, etc. on the lower mold 72 of the foam molding mold 70,
90 is attached. Then, as shown in FIG.
The mold 74 is clamped to the lower mold 72, and the foamable resin material is injected into the cavity 86 from the foamable resin material injection means (not shown) through the injection port 84. That is, the foamable resin layer 92 is formed. Then, curing is performed for a predetermined time, and the eighth
The upper mold 74 is retracted from the lower mold 72 as shown in FIG. In this case, the vacuum suction means connected to the lower mold 72 is stopped and the mold is opened to take out the foamable resin layer 92. Then, the sheet S is peeled off from the expandable resin layer 92 to complete the base material 14 as a product (see FIG. 8f).

As described above, according to the present embodiment, since it is possible to perform the molding step of the sheet S and the foam molding step with a single foam molding die 70, the manufacturing process is shortened and the production efficiency is improved. Can be planned.

[Effects of the Invention] As described above, according to the present invention, when the skin material is integrated with the base material molded by the molding die via the adhesive,
The base material was molded via a release sheet.
Therefore, unlike the prior art, it is not necessary to apply a mold release agent to the mold or to remove the mold release agent after molding, and as a result, production efficiency is improved and a product with excellent quality is obtained. You can Moreover, the effect that the production cost can be suppressed can be obtained.

Although the present invention has been described with reference to the preferred embodiment, the present invention is not limited to this embodiment,
It goes without saying that various improvements and design changes can be made without departing from the scope of the present invention.

[Brief description of drawings]

FIG. 1 is a perspective explanatory view of an instrument panel to which the method for producing a foam-molded article having a skin material according to the present invention is applied, FIG. 2 is an exploded perspective view of the instrument panel shown in FIG. 1, and FIG. FIG. 4 is an enlarged perspective view of the instrument panel shown in FIG. 1 with a part of the seam portion omitted, FIG. 4 is an explanatory view of the division of the skin material forming the instrument panel shown in FIG. 1, and FIG. 6 (a) to 6 (c) are explanatory views of the vacuum forming process of the release sheet, and FIGS. 7 (a) to 7 (c) are illustrations of the instrument panel shown in FIG. Explanatory drawing of the foam molding step of the base material, and FIGS. 8A to 8F are explanatory drawings of the steps of another embodiment of the present invention. 10 ... Instrument panel 12 ... Composite sheet 14 ... Substrate 16 ... Stitching parts 32a, 32b ... Suture 34 ... Main body 38 ... Visor part 40 ... Vacuum mold 52 ... Lower mold 54 ... Upper mold 60 ... Bracket 64 ... Foamability Resin layer 72 ... Lower mold 74 ... Upper mold 82 ... Suction port 88, 90 ... Bracket 92 ... Expandable resin layer

Claims (11)

[Claims] 1. A skin material obtained by laminating a skin material and a foam sheet having elasticity and cutting the composite sheet cut into a predetermined mold shape so that seams are located at predetermined positions, and a release agent. A foam having a skin material, characterized in that the base material is made of a hard foam having a non-released surface, and a skin material is bonded and integrated with the release agent-free surface of the base material via an adhesive. Molding. 2. The foamed molded article according to claim 1, wherein the surface of the base material to be joined to the skin is formed as a surface without a release agent by a release sheet placed in the mold. Foam molded article having a skin material. 3. A first base material, a second base material and the like are molded from a hard foam resin material, and the respective base materials are connected to each other through insert metal fittings. A foamed molded article having a skin material characterized by being covered with the skin material. 4. The foam-molded article according to claim 3, wherein the insert fitting is embedded in a hard foam layer constituting any one of the base materials. 5. A mold release sheet is provided between the first mold and the second mold, and the mold release sheet is then brought into close contact with one of the molds, and further the first mold is formed. A foamed resin material is injected into the cavity defined between the mold and the second molding die to foam, and the mold is opened after solidification of the foamed material to separate the release sheet from the foam molded article. A method for producing a foam-molded article having a skin material, comprising fixing the skin material to the foam-molded article obtained in the above. 6. The method for manufacturing a foam-molded article having a skin material according to claim 5, wherein the release sheet is brought into close contact with either one of the molds in a heated state. 7. The method for producing a foam-molded article having a skin material according to claim 6, wherein the release sheet is heated by a heated mold. 8. The method for producing a foam-molded article according to any one of claims 5 to 7, wherein the mold-releasing sheet is sucked and adhered to one of the molds to inject the foamed resin material. A method for producing a foam-molded article having a skin material. 9. The manufacturing method according to claim 5, wherein an insert metal fitting for bonding the foamed molded product is previously placed on the release sheet, and the insert metal fitting is embedded in the foaming resin. A method for producing a foam-molded article having a skin material, comprising: 10. The manufacturing method according to claim 5, wherein the release sheet is suction-molded into a predetermined shape by a first molding die, and then the release sheet is formed into a foam molding die. A method for manufacturing a foam-molded article having a skin material, comprising setting and foam-molding a foam resin material. 11. The manufacturing method according to claim 5, wherein the release sheet is suction-molded into a predetermined shape by a molding die, and then a foaming resin material is injected into the same molding die to foam. A method for producing a foam-molded article having a skin material, the method comprising molding.