JPH0720623B2 - Method for manufacturing foamed molded products for automobile interiors - Google Patents

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for producing a foam-molded article for automobile interiors, more specifically an instrument pad for automobile interiors,
The present invention relates to a method for producing a foam-molded article for automobile interiors, such as a lower pad, a glove box lid, a console box, etc., which does not like adhesion of urethane foam on the back side of the insert.

[0002]

2. Description of the Related Art A foamed article for automobile interior, such as instrument pad, has a front curl portion at an outer peripheral end as shown in FIG.
As shown in FIG. 5, a method of manufacturing a foam-molded article having such a shape generally uses a pair of upper and lower molding dies B, and insert 10 in upper mold 3 (inner surface mold), On the other hand, the outer skin 5 is placed on the lower mold 4 (surface mold), urethane is injected between them, and foaming and curing are performed.

However, in this method, there is a gap of up to about 1 mm between the upper mold 3 and the back surface of the insert 10 in consideration of variations in molding dimensions at the time of insert molding. Urethane enters the gap and urethane foam adheres to the back surface of the insert. In order to prevent this, a soft urethane tape 11 or the like is previously attached to the back surface of the insert, and the cushion is used to sandwich it between the skin 5 and the insert 10 to prevent the urethane foam from leaking.

[0004]

However, in the above method, (a) it takes a lot of man-hours to attach the soft tape to the back surface of the insert. (B) Since there is a portion where the molding die and the urethane come into contact with each other, it is necessary to apply a wax coating treatment to the molding die, which deteriorates productivity. (C) In the above wax coating process, it is necessary to remove the solidified wax on a regular basis because the size of the molding die changes due to the deposition and deposition of wax on the mold, and the wax coating process adheres to the back surface of the skin and the insert surface. This may cause urethane peeling and lead to product defects.

In view of the above-mentioned circumstances, the present invention has been achieved as a result of earnestly studying in order to cope with the situation, and it is possible to perform insert pretreatment such as sticking a soft urethane tape on the back surface of the insert by the conventional method. It is an object of the present invention to provide a method for producing a foam-molded article in which urethane does not leak.

[0006]

In order to achieve the above object, a feature of the present invention is to inject urethane between a skin and an insert-molded article, and foam-cure the mixture to produce a foam-molded article. A seal flange having a thickness of 1.0 to 2.0 mm and being a surface substantially perpendicular to the operating direction of the upper die of the molding die is provided at the outer peripheral end of the insert molded article, and the flange and the skin are molded. It is a method for producing a foam-molded article for automobile interior, which is clamped by an upper mold and a lower mold.

[0007]

According to the above method, it is not necessary to apply a soft tape to the back surface of the insert or wax the molding die.
By providing a sealing flange thinner than the thickness of the insert body at the outer peripheral end of the insert molded product, it is possible to manufacture a foam molded product in which urethane does not leak to the back surface of the insert.

[0008]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Specific embodiments of the present invention will be described below with reference to the accompanying drawings. FIG. 1 is a schematic explanatory view showing a part of the shape of an insert molded product with a flange used in the present invention,
FIG. 2 is a cross-sectional view showing an essential part of the foam-molded product process, and FIG. 3 is a cross-sectional view after the flange-molded foam-molded product is released from the molding die.

In these figures, reference numeral 1 denotes an insert molded product, which is made of a thermoplastic resin such as PPG, ASG, or ABSG, and the outer peripheral end portion E of the insert molded product 1 has a thickness that allows injection molding, specifically 1.0 to
A sealing flange 2 having a thickness of 2.0 mm and arranged so as to be a surface substantially perpendicular to the operating direction of the upper die is provided. Here, when the thickness of the flange 2 is 1.0 mm or less, lack of thickness and deformation occur during insert molding. If the thickness of the flange 2 is 2.0 mm or more, trimming after foaming becomes difficult.

An adhesive agent is applied to the surface side of the insert molded product in order to secure the adhesive force with the urethane foam 6. When the insert-molded product 1 is formed into a predetermined shape as described above, the foam-molding step of the foam-molded product to be the product next is started. Means are used.

FIG. 2 shows an example of a foaming molding process using a pair of molding dies A composed of an upper mold 3 and a lower mold 4. The insert molded product 1 having the sealing flange 2 at one end is on the upper mold 3 side. On the other hand, after the powder slush molding of vinyl chloride or the like, or vacuum molding of a sheet material in which ABS resin and vinyl chloride resin are mixed, the outer skin 5 is set on the lower mold 4 side, and if necessary vacuum suction is performed. , Urethane 6
Is injected and allowed to foam-harden, and after foam-hardening is removed from the mold A, the flange is trimmed with a water jet or a hot blade press, and the flange of the insert end E and the unnecessary portion of the skin in the part are trimmed. Cut and remove (see Figure 3)

At this time, when the skin 5 is formed by powder slush molding, the thickness of the skin tends to be uneven, so that the flange portion and the skin are formed at the contact surfaces of the upper mold 3 and the lower mold 4 of the mold A. If a packing 7 having a predetermined size and having a cushioning property or the like is provided in a part of the sandwiched portion, the sealing will be more reliable. By removing the unnecessary portion in this manner, a foam molded article M having no urethane leakage on the back surface of the insert as shown in FIG. 4 can be obtained. Furthermore, the present invention is not limited to the instrument pad foam-molded product as shown in FIG. 4, but a lower pad, a glove box lid, a console box, etc. can be molded as necessary.

[0013]

As described above, according to the present invention, a thin sealing flange portion is formed on the outer peripheral end portion of the insert molded product with respect to the insert body so as to be a surface substantially perpendicular to the operating direction of the upper die of the molding die. By installing it on the insert, urethane leakage can be completely prevented without pretreatment with a soft urethane tape attached to a part of the insert, void defects due to urethane leakage can be completely eliminated, and urethane raw material loss can be greatly reduced. It becomes possible to do. Further, in the present invention, since the inner surfaces of the upper mold and the lower mold of the molding die are covered with the skin and the insert molding product with the flange, urethane does not leak during the injection foaming, so the wax coating treatment of the upper mold and the lower mold is performed. Is unnecessary and the cost can be significantly reduced.

[Brief description of drawings]

FIG. 1 is a schematic view of a flanged insert molded product used in the present invention.

FIG. 2 is a transverse cross-sectional view showing a main part of a foam molding process of a foam molding product process according to the present invention.

FIG. 3 is a cross-sectional view of a foamed molded product with a flange after the mold is released from the mold.

FIG. 4 is a partial cross-sectional view showing an example of a foam-molded article obtained by the present invention.

FIG. 5 is a transverse cross-sectional view showing a main part of a foam molding process of a conventional foam molded product process.

[Explanation of Codes] A Foaming Mold M Foaming Molded Product 1 Insert Molded Product 2 Flange 3 Upper Mold 4 Lower Mold 5 Skin 6 Urethane Foam 7 Packing

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Claims (1)

[Claims] 1. A method for producing a foam-molded article by injecting urethane between a skin and an insert-molded article and foam-curing the mixture to obtain a foam-molded article having a thickness of 1.0 to
A sealing flange having a surface of 2.0 mm and being substantially perpendicular to the operation direction of the upper mold of the foaming mold is provided, and the flange and the skin are clamped by the upper mold and the lower mold of the foaming mold. A method for producing a foam-molded article for automobile interiors, which comprises: