JPS6340660B2 - - Google Patents

Description

Detailed Description of the Invention [Field of Industrial Application] The present invention relates to a method for manufacturing a foam molded product with an insert, and more specifically, when molding a foam molded product with an insert having an opening, the foam molding material The present invention relates to a method of manufacturing a foam molded product with an insert that can prevent leakage from the opening of the insert.

[Conventional technology]

Conventionally, for example, in safety pads attached to instrument panels installed inside automobiles, the opening of the insert coated with adhesive was covered with thin plastic to prevent burrs from forming from the urethane foam during foam molding. It has been practiced to cover the insert with a skin made of film, and to attach the skin made of plastic film to the insert by vacuum forming. At that time, a vacuum forming apparatus as shown in FIGS. 8 and 9 is used.

In FIGS. 8 and 9, 51 is a scissor lift that is an elevator, and this scissor lift 5
1 is provided with a mounting table 52 at the top and a support table 53 at the bottom. In addition, the mounting table 52
Support bodies 52a are provided at the four corners of the support base 53, and support bodies 53a are provided at the four corners of the support base 53 as well as the mounting base 52. Furthermore, each support 52a,
A leg body 54 is pivotally supported in an X-shape between the legs 53a, and is extendable and retractable. And the mounting table 5
2 is raised and lowered by a drive device (not shown).

Further, a vacuum forming mold 55 is fixed to the upper surface of the mounting table 52, and the upper part thereof serves as a molding part 56 on which an insert Wa having an opening Wd is placed. Further, the inside of the vacuum forming mold 55 is a space 57, and the forming part 56 has a space 57.
7 are formed, and a vacuum hole 60 is formed at the bottom to which a vacuum pipe 59 leading to a vacuum device (not shown) is connected.
is formed.

As a result, the vacuum forming mold 55 is moved to the scissor lift 5.
1 is activated, it is raised and lowered together with the mounting table 52, and a clamp 61 is disposed at the raised position, and the vacuum forming mold 55
The epidermis Wb is now stretched.

Then, when attaching the skin Wb to the insert Wa and closing the opening Wd, the scissor lift 51 is used.
is activated to lower the vacuum forming mold 51 and insert the insert Wa in which the opening Wd is formed.
is placed on the molding section 56. Next, insert Wa
Apply adhesive Wc to the surface of and allow it to dry to some extent.
Next, the outer layer of the plastic film was cut to a size larger than that to be vacuum formed.
While holding Wb by the clamp 61,
Uniform heating is performed using a heater (not shown) or the like.

After that, the scissor lift 51 is operated in reverse to raise the vacuum forming mold 55 and cover it with the epidermis Wb.
Wb is the outer peripheral surface of insert Wa and vacuum forming mold 55
After it is stretched uniformly between the contact area on the outer circumferential surface of the mold 55, vacuum is drawn from the vacuum hole 60 of the vacuum mold 55. Then, the heated skin Wb comes into contact with the vacuum forming mold 55 and the insert Wa, and is cooled while the skin Wb is heated.
is attached to the insert Wa by adhesive Wc,
The opening Wd is closed.

[Problem that the invention seeks to solve]

However, in such a vacuum forming apparatus, when attaching the skin Wb to the insert Wa,
After applying adhesive Wc to the surface of the insert Wa placed on the vacuum forming mold 55 and drying it to some extent,
The vacuum forming mold 55 is covered with a skin Wb cut to a size larger than the size to be vacuum formed, and the insert Wa and the skin Wb are pasted to close the opening Wd. Also epidermis Wb
Not only is the material cost wasted due to the Wb being pasted, but also the insert
Since the insert is attached using the adhesive Wc applied to the insert Wa, the opening Wd of the insert Wa cannot be completely sealed, which causes problems such as burrs caused by the foam molding material in the subsequent foam molding process. be.

Therefore, the present invention was made to solve the above-mentioned problems, and by forming a film on the opening of the insert, it is possible to eliminate wasteful material costs and completely seal the opening of the insert. It's about doing.

[Means for solving the problem] That is, in the method for manufacturing a foam molded product with an insert according to the present invention, when molding a foam molded product with an insert, an insert having an opening is placed in a vacuum molding mold. After placing the insert, a liquid capable of forming a film is sprayed around the opening of the insert to form a film. Next, the film formed around the opening is dried to close the opening of the insert. Thereafter, this insert is removed from the vacuum mold and set in a foam mold, and a foam molding material is injected into the foam mold to perform foam molding.

As the liquid that can form a film, any liquid that forms a film after drying can be used. For example, a liquid in which a synthetic resin material is dissolved in an organic solvent, and a liquid that is generally commercially available. Examples include sealants, paints, adhesives, and the like. Further, the thickness of the film formed at this time is suitably in the range of 20 to 200 μm in a dry state, and most preferably in the range of 50 to 150 μm. If the thickness of the film is less than 20 μm, there is a risk that the film will be torn when removing the insert from the vacuum molding mold, and if it is more than 200 μm, there is a problem that the material cost will increase.

In addition, when drying the film formed on the opening, either natural drying or forced drying can be used after the film is formed, and forced drying is suitable for speeding up the molding process. . The drying means at this time is not particularly limited, and examples thereof include a heater, an infrared light bulb, a heating plate, and the like.

〔Example〕

Hereinafter, one embodiment of the vacuum forming method according to the present invention will be described in detail based on the drawings.

Figures 1 to 6 are cross-sectional views showing the steps of the method for producing a foam molded product with an insert according to the present invention, and Figure 7 is a cross-sectional view of the foam molded product with an insert obtained according to the present invention. It is.

Figures 1 and 2 show the vacuum forming process, 1
is a vacuum forming mold, and the upper part of this vacuum forming mold 1 is an insert Wa in which an opening Wb is formed.
A molded part 2 is formed on which the material is placed, and a space 3 is formed at the bottom. A plurality of through holes 4a and 4b are formed in the molded part 2,
One of them is open to the molding surface of the molding part 2, and the other is open to the space 3. In addition, vacuum forming mold 1
A support stand 5 is provided on the bottom surface of the support stand 5, and a vacuum hole 7 to which a vacuum pipe 6 is connected is formed in the center of the support stand 5. Furthermore, legs 9a and 9b fixed to the floor 8 are provided on the bottom surface of the support stand 5, and support the vacuum forming mold 1.

Additionally, a spray gun 1 is placed above the vacuum forming mold 1.
A spray gun 10 sprays a liquid capable of forming a film on the opening Wb of the insert Wa placed in the vacuum mold 1 and its surroundings. M is sprayed to form a film Ma, and the dryer 11 removes the formed film.
Ma is becoming dry.

As shown in FIG. 2, the dryer 11 includes a box-shaped container 12 with an open bottom, a cylinder 13 provided at the center of the top of the container 12, and for raising and lowering the container 12. It consists of a heating plate 15 supported by a support member 14 at a corner inside the container 12, and when the cylinder 13 is activated and the container 12 is lowered, its lower end comes into contact with the vacuum mold 1. The molded part 2 is covered.

Further, FIGS. 4 to 6 show the foam molding process, and 20 is an upper mold, and in the center of the lower surface of this upper mold 20 is an insert Wa obtained by vacuum forming as shown in FIG. A holding part 21 is formed to hold a molded article W made of a film Ma and a film Ma, and a flat abutment surface 22 is formed around the holding part 21. Further, a lower mold 23 is disposed below the upper mold 20, and a space 24 in which the holding portion 21 of the upper mold 20 is accommodated and a molding surface 25 for performing foam molding are formed in the center of the upper surface of the lower mold 23. A contact surface 26 that contacts the contact surface 22 of the upper mold 20 is formed around the contact surface 26 . Furthermore, a syringe 27 is arranged in the space 24 of the lower mold 23 as shown in FIG.
A foamed molding material H such as urethane is injected into the molding surface 25.

In the manufacturing process configured as described above, when molding a foam molded product with an insert, the insert Wa having the opening Wb formed therein is inserted into the molding part 2 of the vacuum mold 1 as shown in FIG. Place it on the table and evacuate it from the vacuum pipe 6. At that time, the air in the through holes 4a, 4b and the space 3 of the vacuum forming mold 1 is exhausted from the vacuum hole 7, creating a vacuum state.
The insert Wa is sucked into the vacuum forming mold 1 and set in a proper position in close contact with the mold. Thereafter, the spray gun 10 is moved to the vicinity of the vacuum mold 1, and a liquid M capable of forming a film, such as a sealant, is sprayed onto the opening Wb of the insert Wa and its surroundings.
At this time, the liquid M penetrates into every corner of the opening Wb. Then, spray a predetermined amount of liquid M,
As shown in Figure 2, the opening Wb of the insert Wa
A film Wa of a predetermined thickness is formed on the surface.

Next, the spray gun 10 is retreated from the vicinity of the vacuum forming mold 1, and the cylinder 13 of the dryer 11 is activated as shown in FIG. cover. Thereafter, the inside of the container 12 is heated by heating the heating plate 15. At this time, the organic solvent and the like in the film Ma formed in and around the opening Wb of the insert Wa evaporates and dries, thereby completely closing the opening Wb. The thickness of the film Ma at this time was about 100μ.

Next, the cylinder 13 of the dryer 11 is operated in reverse to raise the container 12 and open the molding section 2 of the vacuum mold 1, and the molded product W consisting of the insert Wa and the film Ma is removed from the molding section 2. remove. At that time, insert Wa as shown in Figure 3.
A molded article W consisting of and film Ma is obtained.

The released molded product W is then transferred to a foam molding process. In the foam molding process, as shown in FIG. 4, the molded product W is held in the holding part 21 of the upper mold 20, and as shown in FIG.
A predetermined amount of foamed molding material H such as urethane is injected into the molding surface 25.

After that, as shown in FIG. 6, the upper mold 20 and the lower mold 2
3 is closed in the mold and placed in an oven as in the conventional manner, maintained at a temperature of, for example, 40 to 60°C, and left for a predetermined period of time. At that time, the foamed molding material H is
5 and the molded article W are uniformly foamed. After foam molding has been carried out for a predetermined period of time, the upper mold 20 and the lower mold 23 are opened, and the insert Wa
The integrally molded foamed product P is released from the mold and taken out.

This allows the insert to open as shown in Figure 7.
A foam molded product P is obtained in which a molded product W made of Wa and a film Ma and a foam Ha are integrally molded.

[Effects of the Invention] As explained above, in the method for manufacturing a foam molded product with an insert according to the present invention, a liquid capable of forming a film is sprayed onto the opening of an insert placed in a vacuum mold to form a film. Since the opening is closed by forming the opening, it is possible to significantly reduce the cost of materials for closing the opening.

In addition, in the method for manufacturing a foam molded product with an insert according to the present invention, a film is formed by spraying a liquid capable of forming a film onto the opening of the insert, so that the liquid reaches every corner around the opening. Since it permeates and forms a film, the opening of the insert can be completely sealed, which has the effect of preventing the formation of burrs due to the foam molding material in the subsequent foam molding process.

In addition, in the method for manufacturing a foam molded product with an insert according to the present invention, since the opening of the insert is closed by spraying a liquid capable of forming a film, there is no need to perform any trimming work as in the conventional method. This has the effect of simplifying the foam molding work.

[Brief explanation of drawings]

1 to 6 are cross-sectional views showing the steps of the method for manufacturing a foam molded product with an insert according to the present invention. FIG. 7 is a sectional view of a foam molded article with an insert obtained according to the present invention. Figures 8 and 9
The figure is a sectional view of a vacuum forming process in a conventional method for manufacturing a foam molded product with an insert. 1... Vacuum forming mold, 2... Molding section, 10... Spray gun, 11... Dryer, 15... Heating plate,
20... Upper mold, 21... Holding part, 23... Lower mold,
24... Space portion, 25... Molding surface, 27... Injector, W... Molded product, Wa... Insert, Wb...
...Aperture, M...Liquid capable of forming a film, Ma
...Film, H...Foamed molding material, Ha...Foam,
P...Foam molded product.

Claims (1)

[Claims] 1. After placing an insert with an opening in a vacuum forming mold, spray a liquid capable of forming a film around the opening of the insert to form a film, and dry the film to close the opening of the insert. The insert is then removed from the vacuum mold and placed in a foam mold.
A method for producing a foam molded article with an insert, which comprises injecting a foam molding material into the foam mold and performing foam molding.