JP3738406B2

JP3738406B2 - Method for producing in-mold foam molded body with skin and molded body thereof

Info

Publication number: JP3738406B2
Application number: JP02681297A
Authority: JP
Inventors: 清松木; 頼輝柿本
Original assignee: Kaneka Corp
Current assignee: Kaneka Corp
Priority date: 1997-02-10
Filing date: 1997-02-10
Publication date: 2006-01-25
Anticipated expiration: 2017-02-10
Also published as: JPH10217269A

Description

【０００１】
【発明の属する技術分野】
この発明は、型内発泡成形体の表面に融着一体化される表皮材の外周部分を、内方へ折返して型内発泡成形体の裏面に融着一体化する表皮付き型内発泡成形体の製造方法及びその成形体に関する。
【０００２】
【従来の技術】
従来のこの種の技術としては、例えば、特開昭６２−１０８０３９号に開示されている表皮材の同時成形方法等がある。この方法は、図１８に示すように、雌雄一対の成形型２のうち、雌型９のキャビティ面２ａに沿って表皮材３の真空成形を行った後、雄型１０と表皮材３との間に形成されるキャビティ内（成形型内）４で発泡成形を行い、成形された発泡成形品（型内発泡成形体）５と前記表皮材３とを一体接合する表皮材３の同時成形方法において、前記表皮材３の真空成形時に、この表皮材３の外周部分を、前記キャビティ面２ａの開口端縁２ｂから内方へ突出させた折返し型（折返し用型）６に沿って、前記開口端縁２ｂから内方へ折返し成形しておき、前記発泡成形時に、前記発泡成形品（型内発泡成形体）５の裏面５ｂに表皮材３の折返し部７を一体接合するものである。
【０００３】
この方法においては、前記真空成形時に、表皮材３の外周部分を、折返し部７の先端７ｃから折返し型（折返し用型）６を巻き込むように外方へ折戻した状態にあらかじめ成形した後、この状態で発泡成形を行っている。また、得られた表皮材付発泡成形品（表皮付き型内発泡成形体）６１ａを脱型した後には、前記折返し部７の先端７ｃで表皮材３の不要な外周部分をトリミングするようにしている。
【０００４】
また、従来から、型内発泡成形体５の裏面５ｂの外周にインサート材が融着一体化される表皮付き型内発泡成形体において、表皮材３の外周部分を型内発泡成形体５の裏面５ｂ側に折返す場合には、前記インサート材を避けるようにして表皮材３の外周部分の所定範囲を切除した後、折返し部７を型内発泡成形体５の裏面５ｂに接着剤等で接着する工程が必要なことが知られている。
【０００５】
【発明が解決しようとする課題】
しかしながら、上記のような従来の同時成形方法においては、前記表皮材３の外周部分が、発泡成形品（型内発泡成形体）５の裏面５ｂに対して所定角度で前記折返し部７の先端７ｃから立設された状態となっているので、この折返し部７の先端７ｃで前記外周部分をトリミングする際には、所定長さの突出耳部が残ることがある。このような場合、表皮材付発泡成形品（表皮付き型内発泡成形体）の運搬や取付け作業等の際に、前記突出耳部が他の部材等に引っ掛かることが多いので、前記折返し部７がその先端７ｃから剥がれ易いという問題点がある。
【０００６】
また、上記のように、インサート材が融着一体化される場合に必要な折返し部７の所定範囲の切除工程や接着工程は、全て手作業で行う必要があるので、非常に手間がかかるという問題点がある。
【０００７】
この発明は、以上のような問題点に鑑みてなされたものであり、型内発泡成形体の裏面に折返して融着一体化される折返し部が剥がれにくいと共に、インサート材を取付ける場合でも手間がかからない表皮付き型内発泡成形体の製造方法及びその成形体を提供することを目的とする。
【０００８】
【課題を解決するための手段】
上記目的を達成するために、請求項１の表皮付き型内発泡成形体の製造方法の手段とするところは、成形型のキャビティ面に沿って表皮材を熱成形した後、この成形型内で発泡成形することによって、形成される型内発泡成形体の表面に前記表皮材を融着一体化する表皮付き型内発泡成形体の製造方法において、前記熱成形時に、前記キャビティ面の開口端縁から内方へ突出するように配置される折返し用型に沿って、前記表皮材の外周部分を内方へ折返して折返し部を形成した後、前記折返し用型を取外し、前記発泡成形時に、前記折返し部の一面を型内発泡成形体の裏面に融着一体化すると共に、この折返し部の先端から表皮材の外周部分が外方へ折戻された状態の折戻し部を前記折返し部の他面に重なるように押圧することにある。
【０００９】
請求項２の手段とするところは、前記折戻し部を熱成形時に、前記折返し部の先端から折返し用型を巻き込むように外方へ折戻した状態にあらかじめ成形しておくことにある。
【００１０】
請求項３の手段とするところは、前記表皮材の外周部分を発泡成形前に、前記押圧時に折戻し部の先端が折返し部の基端より内方に位置するようにあらかじめ切除しておくことにある。
【００１１】
請求項４の手段とするところは、前記開口端縁におけるキャビティ面と折返し用型のなす角度を、前記型内発泡成形体の裏面の外隅部角度よりあらかじめ大きくしておくことにある。
【００１２】
請求項５の手段とするところは、前記発泡成形時に、前記折返し部と折戻し部の少なくともいずれか一方にインサート材を接合することにある。
【００１３】
請求項６の手段とするところは、前記熱成形前に、前記折返し用型の先端にインサート材取付け用切欠部をあらかじめ設けておくことにある。
【００１４】
請求項７の表皮付き型内発泡成形体の手段とするところは、型内発泡成形体と、該型内発泡成形体の表面に融着一体化された表面部と、該表面部の端縁から内方へ折返されてその一面が前記型内発泡成形体の裏面に融着一体化された折返し部と、該折返し部の先端から外方へこの折返し部の他面に重なるように且つその先端が折返し部の基端より内方に位置するように折戻された折戻し部とからなる表皮材とを備えたことにある。
【００１５】
請求項８の手段とするところは、前記折戻し部が折返し部の他面に融着一体化されていることにある。
【００１６】
請求項９の手段とするところは、前記折返し部と折戻し部の少なくともいずれか一方にインサート材を接合したことにある。
【００１７】
請求項１０の手段とするところは、前記折返し部及び折戻し部が、前記型内発泡成形体の裏面に融着一体化したインサート材を避けるように折返し及び折戻しされていることにある。
【００１８】
請求項１１の手段とするところは、前記表皮材及び型内発泡成形体がポリオレフィン系樹脂からなることにある。
【００１９】
請求項１２の手段とするところは、前記表皮材、型内発泡成形体、及びインサート材がポリオレフィン系樹脂からなることにある。
【００２０】
【発明の実施の形態】
以下、この発明の実施形態を図面に基づいて説明する。なお、既述の従来技術と同じ構成については、同一符号を付してその説明を省略する。
【００２１】
図１乃至図７に示すように、第１実施形態に係る表皮付き型内発泡成形体１の製造方法は、成形型２のキャビティ面２ａに沿って表皮材３を例えば真空成形（熱成形）した後、この成形型内４で発泡成形することによって、形成される型内発泡成形体５の表面５ａ等に前記表皮材３を融着一体化するものである。
【００２２】
そして、この製造方法は、前記真空成形時に、前記キャビティ面２ａの開口端縁２ｂから内方へ突出するように配置される折返し用型６に沿って、前記表皮材３の外周部分を内方へ折返して折返し部７を形成した後、前記折返し用型６を取外し、前記発泡成形時に、前記折返し部７の一面７ａを型内発泡成形体５の裏面５ｂに融着一体化すると共に、この折返し部７の先端７ｃから表皮材３の外周部分が外方へ折戻された状態の折戻し部８を前記折返し部７の他面７ｂに重なるように押圧するものである。
【００２３】
即ち、図１に示すように、まず、前記成形型２の例えば下型を構成する雌型９に、キャビティ面２ａの開口端縁２ｂから内方へ所定長さ突出するように前記折返し用型６を配置する。
【００２４】
ここで、前記成形型２は、例えば上下方向に型締め及び型開き可能な前記雌型９と雄型１０とで構成されていると共に、雌型９が下型とされ、且つ、雄型１０が上型とされている。
【００２５】
前記雌型９は、例えば、横断面が凹状で且つ内部にチャンバー９ａが形成され、そのキャビティ面２ａ側には、前記チャンバー９ａと連通する複数の減圧孔９ｂが形成されている。そして、前記チャンバー９ａには、蒸気弁Ａ１、減圧弁Ｂ１、ドレイン弁Ｃ１がそれぞれ接続されている。
【００２６】
前記雄型１０は、例えば、横断面が凸状で且つ内部にチャンバー１０ａが形成され、例えばその突出部分には、前記チャンバー１０ａと連通する複数の蒸気孔１０ｂが形成されている。そして、前記チャンバー１０ａには、蒸気弁Ａ２、減圧弁Ｂ２、ドレイン弁Ｃ２がそれぞれ接続されており、前記成形型内４へ発泡ビーズ１１を充填するためのフィーダー１２が設けられている。
【００２７】
前記折返し用型６は、例えば図１及び図２に示すように、内方に平面視が矩形状の開口部６ａを有する矩形板状に形成され、外方へ取外しできるように所定箇所で複数個に分割可能となっている（図示せず）。この折返し用型６を前記雌型９上に載置又は磁着等により配置した際には、前記キャビティ面２ａの開口端縁２ｂから内方へ所定長さ突出するようになっている。なお、この折返し用型６を複数個に分割すると共に、それぞれをシリンダ機構等により内外へスライド自在に配置及び取外し可能としておいてもよい。
【００２８】
次いで、図３に示すように、前記表皮材３をあらかじめ加熱軟化させた状態で折返し用型６上に配置し、前記雌型９のチャンバー９ａに接続した減圧弁Ｂ１を開く等して、前記キャビティ面２ａに沿って表皮材３を例えば真空成形することによって、前記折返し用型６に沿ってこの表皮材３の外周部分を内方へ折返して折返し部７を形成すると共に、この折返し部７の先端７ｃから折返し用型６を巻き込むように外方へ折戻して折戻し部８を形成する。なお、この状態においては、前記雌型９や折返し用型６を、蒸気加熱又はヒータ（図示せず）等によりあらかじめ所定温度に加熱しておけば、表皮材３の熱成形をより効率良く行えるという利点がある。
【００２９】
この状態において、前記折返し用型６の先端６ｃの横断面形状をこの実施形態のように矩形状としておけば、前記折戻し部８は、前記折返し部７の先端７ｃから上方に折曲される垂直片８ｄと、該垂直片８ｄの上端から外方へ折曲される水平片８ｅとから構成される。なお、前記折返し用型６の先端６ｃの横断面形状は、矩形状の他、三角形状、台形状、円状、又は楕円状等とすることもできる。
【００３０】
前記表皮材３としては、例えば、塩化ビニル系樹脂や、あるいはポリエチレン系樹脂、ポリプロピレン系樹脂等のポリオレフィン系樹脂等からなる熱可塑性樹脂シート等が挙げられる。なお、この表皮材は、当該表皮付き型内発泡成形体１の表皮として使用されるので、その用途に応じて着色剤等により所望の色にあらかじめ着色しておけばよい。
【００３１】
なお、前記キャビティ面２ａに沿って表皮材３を熱成形する方法としては、この実施形態のような真空成形に限定されるものではなく、他に例えば加圧成形等を採用することもできる。また、このような加圧成形等を採用した場合には、前記表皮材３をキャビティ面２ａに沿って熱成形する際に、前記折戻し部８を形成しないで折返し部７だけを形成することもできる。
【００３２】
次に、図４に示すように、前記折返し用型６を例えば外方へ引き抜く等して取外した後、型締めして前記フィーダー１２から成形型内４へ発泡ビーズ１１を充填する。
【００３３】
この際には、前記成形型内４の空気を逃がし易くすると共に、前記表皮材３の折返し部７が下方へ折り込まれないようにするために、隙間を少し開けた状態（クラッキング状態）で型締めするのが望ましい。また、上記のように、前記表皮材３をキャビティ面２ａに沿って熱成形する際に、前記折戻し部８を形成しないで折返し部７だけを形成した場合には、折戻し部８となる表皮材３の外周部分が、折返し部７の先端７ｃから外方へ折戻されるようにして型締めすればよい。
【００３４】
前記発泡ビーズ１１を構成する合成樹脂としては、例えば、ポリオレフィン系樹脂やポリスチレン系樹脂等が挙げられる。
【００３５】
前記ポリオレフィン系樹脂としては、例えば、低密度ポリエチレン、中密度ポリエチレン、高密度ポリエチレン、直鎖状低密度ポリエチレン、エチレン−酢酸ビニル共重合体、プロピレンホモポリマー、エチレン−プロピレンランダム共重合体、エチレン−プロピレンブロック共重合体、エチレン−プロピレン−ブテンランダム３元共重合体、プロピレン−塩化ビニル共重合体、プロピレン−ブテン共重合体、プロピレン−無水マレイン酸共重合体、ポリ（ブテン−１）等のポリエチレン系樹脂やポリプロピレン系樹脂等が挙げられ、これらを単独で又は２種以上を混合して使用することができる。
【００３６】
このポリオレフィン系樹脂は、無架橋の状態のものが好ましいが、パーオキサイドや放射線等により架橋させたものであってもよい。
【００３７】
また、このポリオレフィン系樹脂に、他の熱可塑性樹脂を混合したものも使用できる。このような熱可塑性樹脂としては、前記ポリプロピレン系樹脂と混合する場合には、例えば低密度ポリエチレン、直鎖状低密度ポリエチレン、ビニル芳香族系ポリマー、ポリブテン、アイオノマー等が挙げられる。そして、前記ポリエチレン系樹脂と混合する場合には、例えばビニル芳香族系ポリマー、ポリブテン、アイオノマー等が挙げられる。なお、これらの場合の熱可塑性樹脂の配合量としては、ポリオレフィン系樹脂１００重量部に対して２０重量部以下、より好ましくは、５乃至１０重量部とするのが望ましい。
【００３８】
前記発泡ビーズ１１は、例えば、上記のような合成樹脂をあらかじめ粒子状に成形加工しておき、耐圧容器中でこの合成樹脂粒子に揮発性発泡剤を含有させ、攪拌しながら水中に分散させ、加圧下で所定の発泡温度まで加熱した後、この水分散物を低圧域に放出する方法等によって、予備発泡させた状態で製造しておけばよい。
【００３９】
この発泡ビーズ１１を型内発泡させる際の発泡倍率としては、３倍より小さい場合には、得られる型内発泡成形体の緩衝性等が低下する傾向があり、６０倍より大きい場合には、前記型内発泡成形体の収縮が大きくなると共に、柔らかくなり過ぎて強度等が低下する傾向があるので、３乃至６０倍、好ましくは５乃至５０倍、より好ましくは８乃至４５倍、特に好ましくは１０乃至３５倍が望ましい。このような発泡ビーズ７としては、例えば、エペランＰＰ（商品名，鐘淵化学工業社製，発泡倍率１５倍）等を好適に使用できる。
【００４０】
なお、前記発泡ビーズ１１は、あらかじめ内部に加圧ガスを浸透させて内圧を付与した状態で前記成形型内４へ充填してもよいし、また、加圧ガスを用いて圧縮した状態で充填してもよいし、あるいは、内圧の付与や圧縮を行うことなく、そのままの状態で充填してもよい。
【００４１】
また、この発泡ビーズ１１の型内発泡により得られる型内発泡成形体５と前記表皮材３との接着性を向上させるために、必要に応じて前記発泡ビーズ１１と接触するこの表皮材３の裏面３ｂ及び前記折返し部７の下方に面する一面７ａに、あらかじめ接着剤を塗布しておいてもよい。この接着剤としては、例えば、合成樹脂の有機溶媒溶液、樹脂エマルジョン、樹脂パウダー等が挙げられる。また、これらに使用される合成樹脂としては、例えば、エチレン−酢酸ビニル樹脂、ポリプロピレン、ポリエチレン、エチレン−プロピレン共重合体、塩素化ポリプロピレン、塩素化ポリエチレン、エチレン−プロピレン−ブテン３元共重合体、これらの混合物等のポリオレフィン系樹脂等が挙げられる。
【００４２】
次いで、図５に示すように、完全に型締めした後、前記雄型１０のチャンバー１０ａに接続した蒸気弁Ａ２を開いて水蒸気Ｓを前記蒸気孔１０ｂから成形型内４へ供給し、前記発泡ビーズ１１を加熱発泡させる。
【００４３】
なお、前記発泡ビーズ１１を加熱発泡させる際には、融着不良が発生しないように、必要に応じて、互いに融着する温度より低い温度での水蒸気Ｓによる予備加熱や、その状態で所定時間保持する蒸らし、更にはこの蒸らし後の真空引き等によるドレインの除去等をあらかじめ行っておいてもよい。
【００４４】
また、完全に型締めする時点としては、前記発泡ビーズ１１が成形型内４にほぼ満たされた時点で行うのが望ましく、この場合には、完全に型締めしてから発泡ビーズ１１を成形型内４に満たされるまで充填すればよい。このようにすれば、前記折返し部７が、成形型内４にほぼ満たされた多数の発泡ビーズ１１に支持されて下方に折り込まれないので、前記発泡成形後に、この折返し部７と前記折戻し部８との間に空洞が形成されるのを防止できるという利点がある。
【００４５】
この場合、前記折戻し部８の垂直片８ｄは、型締めするだけで前記折返し部７の先端７ｃから外方へ折曲されてこの折返し部７の他面７ｂに重なるように押圧される。また、前記水平片８ｅは、折返し部７の他面７ｂ及び雌型９上に重なるように押圧される。そして、この状態で発泡ビーズ１１を加熱発泡させるので、形成される型内発泡成形体５の表面５ａに表皮材３が融着一体化されると共に、型内発泡成形体５の裏面５ｂに前記折返し部７の一面７ａが融着一体化される。加えて、前記折戻し部８が上記のように押圧されると共に、蒸気加熱により折返し部７の他面７ｂに単に重なった状態又は融着一体化された状態に成形される。このように、折戻し部８は、単に折曲しただけでもよいし、前記表皮材３の材質や温度条件等によっては前記折返し部７の他面７ｂに融着一体化してもよい。
【００４６】
次いで、必要に応じて冷却した後、前記成形型２を型開きして脱型すれば、図６に示すように、前記発泡ビーズ１１の型内発泡により得られた型内発泡成形体５と、該型内発泡成形体５の表面５ａに融着一体化された表面部３ａと、該表面部３ａの端縁から内方へ折返されて前記型内発泡成形体５の裏面５ｂに融着一体化された折返し部７と、該折返し部７の先端７ｃから外方へこの折返し部７の他面７ｂに重なるように折戻された折戻し部８とからなる表皮材３とを備えた表皮付き型内発泡成形体１ａが得られる。
【００４７】
次に、表皮材３の不要な外周部分を、外観を損なわないようにするために前記折戻し部８の先端８ｃが折返し部７の基端７ｄ、即ち、前記表面部３ａの端縁より内方に位置するように適当な箇所で切除すれば、図７に示す表皮付き型内発泡成形体１を得ることができる。従って、このように切除するには、前記折戻し部８を、折返し部７の他面７ｂに融着一体化せずに単に折曲しただけの重なった状態となるように成形しておくのが望ましい。
【００４８】
以上のように、上記のように構成される表皮付き型内発泡成形体１を、前記成形型２を用いて一連の工程で製造できるので、前記型内発泡成形体５の裏面５ｂへの手作業による表皮材３の折返し接合工程が不要であるという利点がある。また、前記一連の工程により、前記折戻し部８を、折返し部７の他面７ｂに重ねるように、即ち、前記型内発泡成形体５の裏面５ｂに対して略平行となるように簡単に成形できるという利点がある。
【００４９】
そのため、表皮付き型内発泡成形体１の運搬や取付け作業等の際にも、前記折返し部７の先端７ｃや折戻し部８が他の部材等に引っ掛かりにくくなっているので、前記折返し部７が剥がれにくいという利点がある。また、表皮付き型内発泡成形体１の前記表面部３ａ側の外観を損なわないようにするために、前記表皮材３の外周部分を、折戻し部８の先端８ｃが折返し部７の基端７ｄより内方となるようにさえ切除しておけばよいので、この切除作業を特に注意を払うことなく簡単に行えるという利点がある。更に、前記折戻し部８と折返し部７が重なった部分においては、クッション性や補強効果がより高くなるという利点がある。
【００５０】
また、この実施形態のように、前記折戻し部８を真空成形等の熱成形時に、前記折返し部７の先端７ｃから折返し用型６を巻き込むように外方へ折戻した状態にあらかじめ成形しておけば、既述したように、完全に型締めするだけでこの折戻し部８を折返し部７の他面７ｂ等に重なるように簡単に押圧できるので、前記発泡ビーズ１１を成形型内４へ充填する際において、折戻し部８となる表皮材３の外周部分を、折返し部７の先端７ｃから外方へ折戻す手間を省くことができるという利点がある。
【００５１】
更に、当該表皮付き型内発泡成形体１における前記表皮材３及び型内発泡成形体５がポリオレフィン系樹脂からなる場合には、これら表皮材３と型内発泡成形体５の融着がより強固であると共に、いわゆるオールオレフィンであるためにリサイクルも容易であるという利点がある。
【００５２】
図８乃至図１０に示すように、第２実施形態に係る表皮付き型内発泡成形体２１の製造方法は、上記第１実施形態において、前記表皮材３の外周部分を発泡成形前に、前記押圧時に折戻し部８の先端８ｃが折返し部７の基端７ｄより内方に位置するようにあらかじめ切除しておくものである。
【００５３】
前記発泡成形前に切除しておく場合としては、前記真空成形等の熱成形を行う前にあらかじめ切除しておく場合、この熱成形と同時に切除する場合、及び熱成形してから前記発泡ビーズ１１を成形型内４へ充填するまでに切除する場合が含まれる。このうち、熱成形と同時に切除する方法としては、例えば、前記雄型１０の所定位置に下方に突出する切除用刃を設けると共に、前記折返し用型６の上面にこの切除用刃と嵌合する嵌合凹部をあらかじめ設けておき、前記熱成形時に型締めすることによって、前記切除用刃で表皮材３の外周部分を切除する方法等が挙げられる。また、前記雄型１０に、前記切除用刃よりも先端が鈍角な押圧突出部を設けておき、前記熱成形時に型締めした際に、この押圧突出部で表皮材３の所定位置を周囲より高い圧力で押圧して、他の部分よりも薄くなるように熱成形しておき、その後に表皮材３の外周部分を軽く引張るだけではぎ取れるようにしておいてもよい。更には、前記表皮材３の所定位置に点線状の孔を開けて、はぎ取り用の切除線（ミシン線）をあらかじめ形成しておいてもよい。
【００５４】
このように、折戻し部８の先端８ｃが折返し部７の基端７ｄより内方に位置するようにしておけば、表皮付き型内発泡成形体２１を製造した後には、表皮材３の不要な外周部分の切除作業が不要であるので、前記折戻し部８を折返し部７の他面７ｂに融着一体化してめくれ上がらないようにできるという利点がある。なお、図９及び図１０に示すように、前記折返し部７は、上記第１実施形態と比べて、上記のように切除されて比較的短くなった前記折戻し部８により押圧されて多少下方に折り込まれてもよい。
【００５５】
図１１に示すように、第３実施形態に係る表皮付き型内発泡成形体３１の製造方法は、上記第１又は第２実施形態において、前記開口端縁２ｂにおけるキャビティ面２ａと折返し用型６のなす角度Ｄ１を、前記型内発泡成形体５の裏面５ｂの外隅部角度Ｅよりあらかじめ大きくしておくものである。
【００５６】
このようにしておけば、前記真空成形等の熱成形時においては、前記開口端縁２ｂにおける表皮材３の折返し部７と表面部３ａとのなす角度Ｄ２を、既述の図４や図８に示す通常の場合よりも大きくできる。そのため、前記成形型内４への発泡ビーズ１１の充填の際に、前記型内発泡成形体５の裏面５ｂの外隅部となる部分にも発泡ビーズ１１が充填され易くなり、型内発泡成形体５の発泡成形を均一にできるという利点がある。
【００５７】
なお、前記発泡ビーズ１１の充填は既述と同様に行えばよいが、完全に型締めする際に、前記折返し部７が下方の所定位置まで折曲されるように充填しておき、次いで成形型内４に満たされるまで充填すればよい。
【００５８】
また、前記開口端縁２ｂにおけるキャビティ面２ａと折返し用型６のなす角度Ｄ１を大きくするには、例えばこの実施形態のように、前記折返し用型６の横断面形状を逆台形状等に形成してもよいし、あるいは前記折返し用型６をその先端６ｃ側が内方に向かって斜め上方に傾斜するように配置する等してもよい。
【００５９】
図１２及び図１３に示すように、第４実施形態に係る表皮付き型内発泡成形体４１の製造方法は、上記第２実施形態において、前記発泡成形時に、例えば前記折戻し部８上にインサート材１３を接合するものである。
【００６０】
この場合、前記真空成形等の熱成形前又は前記発泡ビーズ１１の充填前にインサート材１３を前記雄型１０の所定位置にあらかじめ配置しておき、発泡成形時、即ち、前記発泡ビーズ１１の型内発泡の際に、このインサート材１３を前記折戻し部８等に接着又は融着一体化して接合すればよい。
【００６１】
なお、このインサート材１３の接合位置としては、前記折戻し部８だけに限定されるものではなく、前記折返し部７でもよいし、あるいはこれら折戻し部８と折返し部７にまたがって接合してもよく、更には前記型内発泡成形体５の裏面５ｂにもまたがるように融着一体化してもよい。このうち、インサート材１３を前記折戻し部８だけに接合する場合には、既述したように、この折戻し部８を、めくれ上がらないように前記折返し部７に融着一体化するのが望ましい。
【００６２】
このように、前記インサート材１３を折返し部７と折戻し部８の少なくともいずれか一方に接合すれば、従来のような手作業による表皮材３の切除工程や接着工程が不要で手間がかからないという利点がある。また、これら折返し部７及び折戻し部８を形成した場合でも、インサート材１３の接合位置が特定の位置に限定されることはなく、前記型内発泡成形体５の裏面５ｂの外周付近において種々の位置に接合できるという利点がある。
【００６３】
また、上記のようにインサート材１３を接合した表皮付き型内発泡成形体４１においては、前記折返し部７や折戻し部８自体の強度が型内発泡成形体５の強度より高いので、このインサート材１３と前記折返し部７等との接合部分の強度がより高くなるという利点がある。
【００６４】
なお、前記インサート材１３としては、例えば、金属、木材、ＦＲＰや、あるいはポリエチレン、ポリプロピレン、ＡＢＳ樹脂等の熱可塑性樹脂、あるいはフェノール樹脂、ホルムアルデヒド樹脂等の熱硬化性樹脂等の種々の材質や形状のものが挙げられるが、前記表皮材３及び型内発泡成形体５がポリオレフィン系樹脂からなる場合には、インサート材１３もポリオレフィン系樹脂で構成しておくのが望ましい。このような場合には、上記と同様、表皮材３と型内発泡成形体５の融着がより強固であると共に、これら表皮材３や型内発泡成形体５とインサート材１３との融着もより強固であり、しかもリサイクルも容易であるという利点がある。
【００６５】
図１４乃至図１７に示すように、第５実施形態に係る表皮付き型内発泡成形体５１の製造方法は、上記第２実施形態において、前記真空成形（熱成形）前に、前記折返し用型６の先端６ｃにインサート材取付け用切欠部１４をあらかじめ設けておくものである。
【００６６】
即ち、図１４に示すように、前記折返し用型６の先端６ｃに例えば平面視が半円状のインサート材取付け用切欠部１４をあらかじめ設けておけば、図１５に示すように、前記真空成形時においては、このインサート材取付け用切欠部１４の内方に所定範囲の空間１５を開けて、前記折返し部７及び折戻し部８を折返し及び折戻しすることができる。
【００６７】
次いで、図１６及び図１７に示すように、既述と同様にして発泡成形する際には、インサート材１３を前記空間１５から型内発泡成形体５の裏面５ｂに取付けることができる。
【００６８】
このように、前記インサート材取付け用切欠部１４をあらかじめ設けておくだけで、このインサート材取付け用切欠部１４の内方に前記空間１５を開けて折返し部７等を形成できるので、インサート材１３を型内発泡成形体５の裏面５ｂに取付ける場合に、表皮材３の折返し等をこのインサート材１３を避けるようにして自動的に行うことができ、そのため従来のような手間がかからないという利点がある。
【００６９】
また、上記のように折返し部７及び折戻し部８が、前記型内発泡成形体５の裏面５ｂに融着一体化したインサート材１３を避けるように折返し及び折戻しされている表皮付き型内発泡成形体５１においては、前記インサート材１３を型内発泡成形体５の裏面５ｂに埋設するように融着一体化することもでき、そのためインサート材１３の取付け方の自由度を高くできるという利点がある。
【００７０】
更に、前記表皮材３及び型内発泡成形体５がポリオレフィン系樹脂からなる場合には、上記と同様、インサート材１３もポリオレフィン系樹脂で構成しておくのが望ましい。このような場合には、表皮材３と型内発泡成形体５の融着がより強固であると共に、型内発泡成形体５とインサート材１３の融着もより強固であり、しかもリサイクルも容易であるという利点がある。
【００７１】
以上、上記第１乃至第５実施形態においては、雌型９を下型とし、且つ、雄型１０を上型とする場合について説明したが、これに限定されるものではなく、これらが逆であってもよいし、あるいは水平方向等に型締め及び型開き可能であってもよい。また、前記雌型９のキャビティ面２ａには、必要に応じて皮シボ等の製品意匠模様用凹凸等をあらかじめ形成しておいてもよい。
【００７２】
【発明の効果】
以上のように、請求項１の表皮付き型内発泡成形体の製造方法の発明によれば、表皮付き型内発泡成形体を前記成形型を用いて一連の工程で製造できるので、前記型内発泡成形体の裏面への手作業による表皮材の折返し接合工程が不要であるという利点がある。また、前記一連の工程により、前記折戻し部を、折返し部の他面に重なるように押圧することによって、単に重なった状態又は融着一体化された状態となるように、即ち、前記型内発泡成形体の裏面に対して略平行となるように簡単に成形できるという利点がある。更に、表皮付き型内発泡成形体の表面側の外観を損なわないようにするために、前記表皮材の外周部分を、折戻し部の先端が折返し部の基端より内方となるようにさえ切除しておけばよいので、この切除作業を特に注意を払うことなく簡単に行えるという利点がある。
【００７３】
請求項２の発明によれば、前記折戻し部を熱成形時に、前記折返し部の先端から折返し用型を巻き込むように外方へ折戻した状態にあらかじめ成形しておくので、前記成形型を完全に型締めするだけで前記折戻し部を折返し部の他面等に重なるように簡単に押圧することができる。そのため、前記発泡ビーズを成形型内へ充填する際において、折戻し部となる表皮材の外周部分を、折返し部の先端から外方へ折戻す手間を省くことができるという利点がある。
【００７４】
請求項３の発明によれば、前記表皮材の外周部分を発泡成形前に、前記押圧時に折戻し部の先端が折返し部の基端より内方に位置するようにあらかじめ切除しておくので、表皮付き型内発泡成形体を製造した後には、表皮材の不要な外周部分の切除作業が不要であると共に、前記折戻し部を折返し部の他面に融着一体化してこの折戻し部をめくれ上がらないようにできるという利点がある。
【００７５】
請求項４の発明によれば、前記開口端縁におけるキャビティ面と折返し用型のなす角度を、前記型内発泡成形体の裏面の外隅部角度よりあらかじめ大きくしておくので、前記真空成形等の熱成形時においては、前記開口端縁における表皮材の折返し部と表面部とのなす角度を、既述の通常の場合よりも大きくできる。そのため、前記成形型内への発泡ビーズの充填の際に、前記型内発泡成形体の裏面の外隅部となる部分にも発泡ビーズが充填され易くなり、型内発泡成形体の発泡成形を均一にできるという利点がある。
【００７６】
請求項５の発明によれば、前記発泡成形時に、前記折返し部と折戻し部の少なくともいずれか一方にインサート材を接合するので、従来のような手作業による折返し部の切除工程や接着工程が不要で手間がかからないという利点がある。また、これら折返し部及び折戻し部を形成した場合でも、インサート材の接合位置が特定の位置に限定されることはなく、前記型内発泡成形体の裏面の外周付近において種々の位置に接合できるという利点がある。
【００７７】
請求項６の発明によれば、前記熱成形前に、前記折返し用型の先端にインサート材取付け用切欠部をあらかじめ設けておくので、このインサート材取付け用切欠部の内方に所定範囲の空間を開けて折返し部等を形成できる。即ち、インサート材を型内発泡成形体の裏面に取付ける場合に、表皮材の折返し等をこのインサート材を避けるようにして自動的に行うことができ、そのため手間がかからないという利点がある。
【００７８】
請求項７の表皮付き型内発泡成形体の発明によれば、前記型内発泡成形体と、前記表面部と折返し部と折戻し部とからなる表皮材とを備えているので、当該表皮付き型内発泡成形体の運搬や取付け作業等の際にも、前記折返し部の先端や折戻し部が他の部材等に引っ掛かりにくくなっており、そのため前記折返し部が剥がれにくいという利点がある。また、前記折戻し部と折返し部が重なった部分においては、クッション性や補強効果がより高くなるという利点がある。
【００７９】
請求項８の発明によれば、前記折戻し部が折返し部の他面に融着一体化されているので、折戻し部がめくれ上がらないという利点がある。
【００８０】
請求項９の発明によれば、前記折返し部と折戻し部の少なくともいずれか一方にインサート材を接合しているので、このインサート材と前記折返し部や折戻し部との接合部分の強度がより高くなるという利点がある。
【００８１】
請求項１０の発明によれば、前記折返し部及び折戻し部が、前記型内発泡成形体の裏面に融着一体化したインサート材を避けるように折返し及び折戻しされているので、前記インサート材を型内発泡成形体の裏面に埋設するように融着一体化することもでき、そのためインサート材の取付け方の自由度を高くできるという利点がある。
【００８２】
請求項１１の発明によれば、前記表皮材及び型内発泡成形体がポリオレフィン系樹脂からなるので、これら表皮材と型内発泡成形体の融着がより強固であると共に、いわゆるオールオレフィンであるためにリサイクルも容易であるという利点がある。
【００８３】
請求項１２の発明によれば、前記表皮材、型内発泡成形体、及びインサート材がポリオレフィン系樹脂からなるので、上記請求項１１の効果に加え、表皮材や型内発泡成形体とインサート材との融着がより強固であり、しかもリサイクルも容易であるという利点がある。
【図面の簡単な説明】
【図１】第１実施形態に係る表皮付き型内発泡成形体の製造方法において、雌型上に折返し用型を配置した状態を示す断面図。
【図２】図１の折返し用型の配置状態を示す平面図。
【図３】図１の表皮材を真空成形した状態を示す断面図。
【図４】成形型内に発泡ビーズを充填する様子を示す断面図。
【図５】発泡成形する様子を示す断面図。
【図６】表皮付き型内発泡成形体を脱型した状態を示す断面図。
【図７】図６の表皮材の不要な外周部分を切除した後の状態を示す断面図。
【図８】第２実施形態に係る表皮付き型内発泡成形体の製造方法において、成形型内に発泡ビーズを充填する様子を示す断面図。
【図９】発泡成形する様子を示す断面図。
【図１０】表皮付き型内発泡成形体を脱型した状態を示す断面図。
【図１１】第３実施形態に係る表皮付き型内発泡成形体の製造方法において、表皮材を真空成形した状態を示す断面図。
【図１２】第４実施形態に係る表皮付き型内発泡成形体の製造方法において、発泡成形時に、折戻し部にインサート材を接合する様子を示す断面図。
【図１３】表皮付き型内発泡成形体を脱型した状態を示す断面図。
【図１４】第５実施形態に係る表皮付き型内発泡成形体の製造方法において、先端にインサート材取付け用切欠部を設けた折返し用型の配置状態を示す平面図。
【図１５】表皮材を真空成形した状態を示す断面図。
【図１６】発泡成形時に、形成される型内発泡成形体の裏面にインサート材を融着一体化する様子を示す断面図。
【図１７】表皮付き型内発泡成形体を脱型した状態を示す断面図。
【図１８】従来例を示す断面図。
【符号の説明】
１，２１，３１，４１，５１表皮付き型内発泡成形体
２成形型
２ａキャビティ面
２ｂ開口端縁
３表皮材
３ａ表面部
４成形型内
５型内発泡成形体
５ａ表面
５ｂ裏面
Ｅ外隅部角度
６折返し用型
６ｃ先端
７折返し部
７ａ一面
７ｂ他面
７ｃ先端
７ｄ基端
８折戻し部
８ｃ先端
９雌型
１０雄型
１３インサート材
１４インサート材取付け用切欠部[0001]
BACKGROUND OF THE INVENTION
The present invention provides an in-mold foam-molded body with a skin, in which an outer peripheral portion of a skin material fused and integrated with the surface of an in-mold foam-molded body is folded inward to be fused and integrated with the back surface of the in-mold foam-molded body. The present invention relates to a manufacturing method and a molded product thereof.
[0002]
[Prior art]
As a conventional technique of this type, for example, there is a simultaneous molding method of a skin material disclosed in JP-A-62-108039. As shown in FIG. 18, in this method, after the skin material 3 is vacuum-formed along the cavity surface 2 a of the female die 9 of the pair of male and female molds 2, the male die 10 and the skin material 3 are separated. Simultaneous molding method of skin material 3 in which foam molding is performed in cavity (inside mold) 4 formed between them, and molded foam molded product (in-mold foam molding) 5 and skin material 3 are integrally joined In the vacuum forming of the skin material 3, the opening is formed along a folding die (folding die) 6 in which the outer peripheral portion of the skin material 3 protrudes inward from the opening edge 2 b of the cavity surface 2 a. The folded portion 7 of the skin material 3 is integrally joined to the back surface 5b of the foam molded product (in-mold foam molded product) 5 at the time of foam molding.
[0003]
In this method, at the time of the vacuum forming, after the outer peripheral portion of the skin material 3 is preliminarily molded in a state of being folded outward from the tip 7c of the folded portion 7 so as to wind the folded mold (folding mold) 6, Foam molding is performed in this state. In addition, after removing the obtained foamed product with skin material (in-mold foam-molded product with skin) 61a, an unnecessary outer peripheral portion of the skin material 3 is trimmed at the tip 7c of the folded portion 7. Yes.
[0004]
Conventionally, in an in-mold foam molded body with a skin in which an insert material is fused and integrated with the outer periphery of the back surface 5 b of the in-mold foam molded body 5, the outer peripheral portion of the skin material 3 is used as the back surface of the in-mold foam molded body 5. In the case of folding back to the 5b side, after cutting out a predetermined range of the outer peripheral portion of the skin material 3 so as to avoid the insert material, the folded portion 7 is bonded to the back surface 5b of the in-mold foam molded body 5 with an adhesive or the like. It is known that a process is required.
[0005]
[Problems to be solved by the invention]
However, in the conventional simultaneous molding method as described above, the outer peripheral portion of the skin material 3 is at a predetermined angle with respect to the back surface 5b of the foam molded product (in-mold foam molded body) 5 at the tip 7c of the folded portion 7. Therefore, when the outer peripheral portion is trimmed by the tip 7c of the folded portion 7, a protruding ear portion having a predetermined length may remain. In such a case, when the foamed article with skin material (in-mold foam-molded article with skin) is transported or attached, the protruding ear is often caught by another member or the like. However, there exists a problem that it is easy to peel from the front-end | tip 7c.
[0006]
In addition, as described above, it is necessary to perform all of the cutting process and the bonding process in the predetermined range of the folded-back portion 7 necessary when the insert material is fused and integrated, which is very troublesome. There is a problem.
[0007]
The present invention has been made in view of the above problems, and the folded portion that is folded and integrated on the back surface of the in-mold foam molded body is difficult to peel off, and even when the insert material is attached, it is troublesome. An object of the present invention is to provide a method for producing an in-mold foam-molded article with a skin and a molded article that is not applied.
[0008]
[Means for Solving the Problems]
In order to achieve the above object, the method of producing the in-mold foam-molded article with a skin according to claim 1 is that after the skin material is thermoformed along the cavity surface of the mold, In the method for producing an in-mold foam-molded body with a skin, wherein the skin material is fused and integrated with the surface of the in-mold foam-molded body to be formed by foam molding. A folding mold arranged so as to protrude inward from the outer peripheral portion of the skin material is folded inward to form a folded portion, and then the folding mold is removed, during the foam molding, One surface of the folded portion is fused and integrated with the back surface of the in-mold foam molded body, and the folded portion in a state in which the outer peripheral portion of the skin material is folded outward from the tip of the folded portion is the other portion of the folded portion. It is to press so as to overlap the surface.
[0009]
According to a second aspect of the present invention, the folded portion is preliminarily molded in a state of being folded outward so as to wind a folding mold from the tip of the folded portion during thermoforming.
[0010]
According to the third aspect of the present invention, the outer peripheral portion of the skin material is cut in advance so that the distal end of the folded portion is located inward from the proximal end of the folded portion before the foam molding. It is in.
[0011]
According to a fourth aspect of the present invention, an angle formed between the cavity surface at the opening edge and the folding mold is set in advance to be larger than an outer corner angle of the back surface of the in-mold foam molded body.
[0012]
The means of claim 5 is to join an insert material to at least one of the folded portion and the folded portion during the foam molding.
[0013]
The means of claim 6 is that a notch for attaching an insert material is provided in advance at the tip of the folding mold before the thermoforming.
[0014]
The in-mold foam-molded article with a skin according to claim 7 comprises means for in-mold foam-molded article, a surface part fused and integrated with the surface of the in-mold foam-molded article, and an edge of the surface part. A folded portion that is folded inward from one side and is fused and integrated with the back surface of the in-mold foam molded body, and overlaps the other surface of the folded portion outward from the tip of the folded portion and And a skin material comprising a folded portion folded back so that the tip is located inward from the proximal end of the folded portion.
[0015]
The means of claim 8 is that the folded portion is fused and integrated with the other surface of the folded portion.
[0016]
The means of claim 9 is that an insert material is joined to at least one of the folded portion and the folded portion.
[0017]
The means of claim 10 is that the folded portion and the folded portion are folded and folded so as to avoid the insert material fused and integrated with the back surface of the in-mold foam molded body.
[0018]
The means of claim 11 is that the skin material and the in-mold foam molded body are made of a polyolefin resin.
[0019]
The means of claim 12 is that the skin material, the in-mold foam molded product, and the insert material are made of a polyolefin resin.
[0020]
DETAILED DESCRIPTION OF THE INVENTION
Embodiments of the present invention will be described below with reference to the drawings. In addition, about the same structure as the prior art mentioned above, the same code | symbol is attached | subjected and the description is abbreviate | omitted.
[0021]
As shown in FIG. 1 to FIG. 7, the method for manufacturing an in-mold foam-molded body 1 with a skin according to the first embodiment is to form a skin material 3 along, for example, a cavity surface 2 a of the mold 2 by vacuum molding (thermoforming) After that, the skin material 3 is fused and integrated with the surface 5a of the in-mold foam molding 5 to be formed by foam molding in the molding die 4.
[0022]
In this manufacturing method, the outer peripheral portion of the skin material 3 is inwardly formed along the folding mold 6 arranged so as to protrude inward from the opening edge 2b of the cavity surface 2a during the vacuum forming. After folding back to form the folded portion 7, the folding mold 6 is removed, and at the time of foam molding, one surface 7a of the folded portion 7 is fused and integrated with the back surface 5b of the in-mold foam molded body 5, The folded portion 8 in a state where the outer peripheral portion of the skin material 3 is folded outward from the tip 7c of the folded portion 7 is pressed so as to overlap the other surface 7b of the folded portion 7.
[0023]
That is, as shown in FIG. 1, first, the folding mold 2 protrudes inward from the opening edge 2b of the cavity surface 2a to a female mold 9 constituting, for example, the lower mold of the mold 2 6 is arranged.
[0024]
Here, the mold 2 is composed of, for example, the female mold 9 and the male mold 10 that can be clamped and opened in the vertical direction, the female mold 9 is a lower mold, and the male mold 10. Is the upper mold.
[0025]
For example, the female die 9 has a concave cross section and a chamber 9a formed therein, and a plurality of decompression holes 9b communicating with the chamber 9a are formed on the cavity surface 2a side. A steam valve A1, a pressure reducing valve B1, and a drain valve C1 are connected to the chamber 9a.
[0026]
The male mold 10 has, for example, a convex cross section and a chamber 10a formed therein. For example, a plurality of vapor holes 10b communicating with the chamber 10a are formed in the protruding portion. A steam valve A2, a pressure reducing valve B2, and a drain valve C2 are connected to the chamber 10a, and a feeder 12 for filling the foam beads 11 into the molding die 4 is provided.
[0027]
For example, as shown in FIGS. 1 and 2, the folding mold 6 is formed in a rectangular plate shape having an opening 6a having a rectangular shape when viewed from the inside, and a plurality of folding molds 6 are provided at predetermined locations so that the folding mold 6 can be removed outward. It can be divided into pieces (not shown). When the folding mold 6 is placed on the female mold 9 or arranged by magnetic attachment or the like, it protrudes inward from the opening edge 2b of the cavity surface 2a by a predetermined length. The folding mold 6 may be divided into a plurality of pieces and each may be arranged and removed slidably in and out by a cylinder mechanism or the like.
[0028]
Next, as shown in FIG. 3, the skin material 3 is placed on the folding mold 6 in a preheated and softened state, and the pressure reducing valve B1 connected to the chamber 9a of the female mold 9 is opened. For example, by forming the skin material 3 along the cavity surface 2a by vacuum forming, the outer peripheral portion of the skin material 3 is folded inward along the folding mold 6 to form the folded portion 7, and the folded portion 7 The folding part 6 is folded back outwardly so as to wind the folding-back mold 6 from the tip 7c. In this state, the skin material 3 can be thermoformed more efficiently if the female die 9 and the folding die 6 are heated to a predetermined temperature in advance by steam heating or a heater (not shown). There is an advantage.
[0029]
In this state, if the cross-sectional shape of the tip 6c of the folding mold 6 is rectangular as in this embodiment, the folding portion 8 is bent upward from the tip 7c of the folding portion 7. It is comprised from the vertical piece 8d and the horizontal piece 8e bent outward from the upper end of this vertical piece 8d. The cross-sectional shape of the tip 6c of the folding mold 6 may be a triangle, a trapezoid, a circle, an ellipse, or the like, in addition to a rectangle.
[0030]
Examples of the skin material 3 include a thermoplastic resin sheet made of a vinyl chloride resin, or a polyolefin resin such as a polyethylene resin or a polypropylene resin. In addition, since this skin material is used as the skin of the in-mold foam-molded body 1 with the skin, it may be colored in advance with a colorant or the like according to its use.
[0031]
The method of thermoforming the skin material 3 along the cavity surface 2a is not limited to the vacuum forming as in this embodiment, and other methods such as pressure forming may be employed. When such pressure molding or the like is adopted, when the skin material 3 is thermoformed along the cavity surface 2a, only the folded portion 7 is formed without forming the folded portion 8. You can also.
[0032]
Next, as shown in FIG. 4, the folding mold 6 is removed, for example, by pulling outward, and then the mold is clamped to fill the foam beads 11 from the feeder 12 into the mold 4.
[0033]
At this time, in order to facilitate the escape of the air in the mold 4 and to prevent the folded portion 7 of the skin material 3 from being folded downward, the mold is opened with a little gap (cracking state). It is desirable to tighten. Further, as described above, when the skin material 3 is thermoformed along the cavity surface 2a, if only the folded portion 7 is formed without forming the folded portion 8, the folded portion 8 is formed. The outer periphery of the skin material 3 may be clamped so that it is folded outward from the tip 7c of the folded portion 7.
[0034]
Examples of the synthetic resin constituting the foamed beads 11 include polyolefin resins and polystyrene resins.
[0035]
Examples of the polyolefin resin include low density polyethylene, medium density polyethylene, high density polyethylene, linear low density polyethylene, ethylene-vinyl acetate copolymer, propylene homopolymer, ethylene-propylene random copolymer, ethylene- Such as propylene block copolymer, ethylene-propylene-butene random terpolymer, propylene-vinyl chloride copolymer, propylene-butene copolymer, propylene-maleic anhydride copolymer, poly (butene-1), etc. A polyethylene resin, a polypropylene resin, etc. are mentioned, These can be used individually or in mixture of 2 or more types.
[0036]
This polyolefin-based resin is preferably in a non-crosslinked state, but may be crosslinked by peroxide or radiation.
[0037]
Moreover, what mixed the other thermoplastic resin with this polyolefin resin can also be used. Examples of such thermoplastic resins include, when mixed with the polypropylene resin, low density polyethylene, linear low density polyethylene, vinyl aromatic polymer, polybutene, and ionomer. And when mixing with the said polyethylene-type resin, vinyl aromatic polymer, polybutene, an ionomer etc. are mentioned, for example. In these cases, the amount of the thermoplastic resin blended is preferably 20 parts by weight or less, more preferably 5 to 10 parts by weight with respect to 100 parts by weight of the polyolefin resin.
[0038]
The foam beads 11 are, for example, previously molded into a particulate synthetic resin, containing a volatile foaming agent in the synthetic resin particles in a pressure vessel, and dispersed in water with stirring. After heating to a predetermined foaming temperature under pressure, the aqueous dispersion may be produced in a prefoamed state by a method such as discharging the aqueous dispersion to a low pressure region.
[0039]
When the foaming bead 11 is foamed in the mold, the foaming ratio is less than 3 times, the buffering property of the obtained in-mold foam molded product tends to decrease, and when it is larger than 60 times, Since the shrinkage of the in-mold foamed molded product increases and becomes too soft and the strength and the like tend to decrease, it is 3 to 60 times, preferably 5 to 50 times, more preferably 8 to 45 times, particularly preferably. 10 to 35 times is desirable. As such foamed beads 7, for example, Eperan PP (trade name, manufactured by Kaneka Chemical Co., Ltd., foaming magnification: 15 times) and the like can be suitably used.
[0040]
The foam beads 11 may be filled into the molding die 4 in a state in which a pressurized gas is infiltrated into the inside in advance and an internal pressure is applied. Alternatively, the foamed beads 11 are filled in a compressed state using a pressurized gas. Alternatively, it may be filled as it is without applying an internal pressure or compressing it.
[0041]
Moreover, in order to improve the adhesiveness between the in-mold foam molded product 5 obtained by in-mold foaming of the foam beads 11 and the skin material 3, the skin material 3 that contacts the foam beads 11 as necessary. An adhesive may be applied in advance to the back surface 3b and the one surface 7a facing below the folded portion 7. Examples of the adhesive include an organic solvent solution of a synthetic resin, a resin emulsion, and a resin powder. Moreover, as a synthetic resin used for these, for example, ethylene-vinyl acetate resin, polypropylene, polyethylene, ethylene-propylene copolymer, chlorinated polypropylene, chlorinated polyethylene, ethylene-propylene-butene terpolymer, Examples thereof include polyolefin resins such as a mixture thereof.
[0042]
Next, as shown in FIG. 5, after the mold is completely clamped, the steam valve A2 connected to the chamber 10a of the male mold 10 is opened to supply steam S from the steam hole 10b to the inside 4 of the mold, and the foaming is performed. The beads 11 are heated and foamed.
[0043]
In addition, when the foamed beads 11 are heated and foamed, preheating with steam S at a temperature lower than the temperature at which they are fused to each other or a predetermined time in that state, if necessary, so as not to cause poor fusion. Steaming to be held and further draining by vacuuming after the steaming or the like may be performed in advance.
[0044]
Further, it is desirable that the time when the mold is completely clamped is when the foamed beads 11 are almost filled in the mold 4. In this case, the foamed beads 11 are molded after the mold is completely clamped. It is sufficient to fill up to 4 of them. In this way, the folded portion 7 is supported by the large number of foam beads 11 substantially filled in the mold 4 and is not folded downward. Therefore, after the foam molding, the folded portion 7 and the folded portion are returned. There is an advantage that it is possible to prevent a cavity from being formed between the portions 8.
[0045]
In this case, the vertical piece 8d of the folded portion 8 is bent outward from the tip 7c of the folded portion 7 just by clamping and pressed so as to overlap the other surface 7b of the folded portion 7. Further, the horizontal piece 8 e is pressed so as to overlap the other surface 7 b and the female die 9 of the folded portion 7. Since the foam beads 11 are heated and foamed in this state, the skin material 3 is fused and integrated with the surface 5a of the in-mold foam molded body 5 to be formed, and the back surface 5b of the in-mold foam molded body 5 is One surface 7a of the folded portion 7 is fused and integrated. In addition, the folded portion 8 is pressed as described above, and is molded into a state where it is simply overlapped or fused and integrated with the other surface 7b of the folded portion 7 by steam heating. In this way, the folded portion 8 may be simply bent, or may be fused and integrated with the other surface 7b of the folded portion 7 depending on the material of the skin material 3, temperature conditions, and the like.
[0046]
Next, after cooling as necessary, if the mold 2 is opened and demolded, the in-mold foam molded body 5 obtained by in-mold foaming of the foam beads 11 as shown in FIG. The surface portion 3a fused and integrated with the surface 5a of the in-mold foam molded body 5, and the end portion of the surface portion 3a folded inward and fused to the back surface 5b of the in-mold foam molded body 5 A skin material 3 comprising an integrated folded portion 7 and a folded portion 8 folded outward from the tip 7c of the folded portion 7 so as to overlap the other surface 7b of the folded portion 7 is provided. An in-mold foam molded body 1a with a skin is obtained.
[0047]
Next, in order not to impair the appearance of the unnecessary outer peripheral portion of the skin material 3, the distal end 8c of the folded portion 8 is located inside the proximal end 7d of the folded portion 7, that is, the edge of the surface portion 3a. If it cuts in an appropriate location so that it may be located in the direction, the in-mold foam-molded body 1 with a skin shown in FIG. 7 can be obtained. Therefore, in order to excise in this way, the folded portion 8 is formed so as to be in an overlapped state where it is simply folded without being fused and integrated with the other surface 7b of the folded portion 7. Is desirable.
[0048]
As described above, since the in-mold foam-molded body 1 with the skin configured as described above can be manufactured in a series of steps using the mold 2, the hand to the back surface 5b of the in-mold foam-molded body 5 can be obtained. There is an advantage that the process of folding the skin material 3 by work is unnecessary. Further, by the series of steps, the folded portion 8 can be easily overlapped with the other surface 7b of the folded portion 7, that is, substantially parallel to the back surface 5b of the in-mold foam molded body 5. There is an advantage that it can be molded.
[0049]
For this reason, the tip 7c of the folded portion 7 and the folded portion 8 are less likely to be caught by other members or the like during the transportation or mounting of the in-mold foam molded body 1 with a skin. There is an advantage that is difficult to peel off. Moreover, in order not to impair the appearance on the surface portion 3 a side of the in-mold foam-molded body 1 with a skin, the distal end 8 c of the folded portion 8 is the base end of the folded portion 7. Since it is only necessary to excise so as to be inward from 7d, there is an advantage that this excision work can be easily performed without particular attention. Furthermore, in the part where the said folding | returning part 8 and the folding | returning part 7 overlapped, there exists an advantage that cushioning property and a reinforcement effect become higher.
[0050]
Further, as in this embodiment, the folded portion 8 is molded in advance so as to be folded outward from the tip 7c of the folded portion 7 so as to wind the folded mold 6 during thermoforming such as vacuum forming. In this case, as described above, it is possible to easily press the folded portion 8 so as to overlap the other surface 7b of the folded portion 7 only by completely clamping the mold. There is an advantage that it is possible to save the trouble of returning the outer peripheral portion of the skin material 3 to be the folded-back portion 8 outward from the tip 7c of the folded-back portion 7.
[0051]
Further, when the skin material 3 and the in-mold foam molded body 5 in the in-mold foam molded body 1 with the skin are made of a polyolefin-based resin, the fusion between the skin material 3 and the in-mold foam molded body 5 is stronger. In addition, since it is a so-called all-olefin, there is an advantage that recycling is easy.
[0052]
As shown in FIG. 8 to FIG. 10, the method for manufacturing the in-mold foam-molded body 21 with the skin according to the second embodiment is the above-described first embodiment. The tip 8c of the folded portion 8 is cut in advance so that the distal end 8c of the folded portion 8 is positioned inward from the proximal end 7d of the folded portion 7 when pressed.
[0053]
As for the case of cutting before foam molding, the foam beads 11 may be cut in advance before performing thermoforming such as vacuum molding, the case of cutting simultaneously with the thermoforming, and after thermoforming. This includes a case where the material is excised before being filled into the mold 4. Among them, as a method of cutting simultaneously with thermoforming, for example, a cutting blade protruding downward is provided at a predetermined position of the male mold 10 and the cutting blade is fitted to the upper surface of the folding mold 6. Examples include a method in which a fitting recess is provided in advance and the outer peripheral portion of the skin material 3 is cut with the cutting blade by clamping the mold during the thermoforming. Further, when the male mold 10 is provided with a pressing protrusion having an obtuse tip than the cutting blade, and when the mold is clamped at the time of the thermoforming, a predetermined position of the skin material 3 is moved from the periphery by the pressing protrusion. It may be pressed by high pressure and thermoformed so as to be thinner than the other parts, and then the outer peripheral part of the skin material 3 may be peeled off simply by lightly pulling. Further, a dotted line hole may be formed at a predetermined position of the skin material 3, and a cut-off line (sewing line) for stripping may be formed in advance.
[0054]
Thus, if the front end 8c of the folded back portion 8 is positioned inward from the base end 7d of the folded back portion 7, after manufacturing the in-mold foam-molded body 21 with the skin, the skin material 3 is unnecessary. Therefore, there is an advantage that the folded portion 8 can be fused and integrated with the other surface 7b of the folded portion 7 so as not to be turned up. As shown in FIGS. 9 and 10, the folded portion 7 is pressed slightly by the folded portion 8 that has been cut and relatively shortened as described above as compared with the first embodiment. It may be folded in.
[0055]
As shown in FIG. 11, the manufacturing method of the in-mold foam-molded body 31 with a skin according to the third embodiment is the same as that in the first or second embodiment described above. Is made larger than the outer corner angle E of the back surface 5b of the in-mold foam molded body 5 in advance.
[0056]
In this way, at the time of thermoforming such as vacuum forming, the angle D2 formed by the folded portion 7 of the skin material 3 and the surface portion 3a at the opening edge 2b is set as shown in FIGS. It can be made larger than the normal case shown in. Therefore, when the foam beads 11 are filled into the mold 4, the foam beads 11 are easily filled in the outer corners of the back surface 5 b of the mold foam 5. There is an advantage that the foam molding of the body 5 can be made uniform.
[0057]
The foam beads 11 may be filled in the same manner as described above, but when the mold is completely clamped, the folded portion 7 is filled so as to be bent to a predetermined position below, and then molded. What is necessary is just to fill until the inside 4 of a type | mold is filled.
[0058]
Further, in order to increase the angle D1 formed between the cavity surface 2a and the folding mold 6 at the opening edge 2b, for example, the cross-sectional shape of the folding mold 6 is formed in an inverted trapezoidal shape as in this embodiment. Alternatively, the folding mold 6 may be disposed such that the tip 6c side is inclined obliquely upward inward.
[0059]
As shown in FIG.12 and FIG.13, the manufacturing method of the in-mold foam-molded body 41 with a skin according to the fourth embodiment is the same as that in the second embodiment, for example, an insert on the folded portion 8 during the foam molding. The material 13 is joined.
[0060]
In this case, the insert material 13 is arranged in advance in a predetermined position of the male mold 10 before thermoforming such as vacuum forming or before filling the foamed beads 11, and at the time of foaming, that is, the mold of the foamed beads 11. In the case of inner foaming, the insert material 13 may be bonded or fused and joined to the folded portion 8 or the like.
[0061]
In addition, as a joining position of this insert material 13, it is not limited only to the said folding | returning part 8, The said folding | returning part 7 may be sufficient, or it joins across these folding | returning parts 8 and the folding | turning part 7. Alternatively, it may be fused and integrated so as to straddle the back surface 5b of the in-mold foam molded body 5. Of these, when the insert material 13 is joined only to the folded portion 8, as described above, the folded portion 8 is fused and integrated with the folded portion 7 so as not to be turned up. desirable.
[0062]
In this way, if the insert member 13 is joined to at least one of the folded portion 7 and the folded portion 8, it is unnecessary to take the labor of cutting and bonding the skin material 3 by a manual operation as in the prior art. There are advantages. Further, even when the folded portion 7 and the folded portion 8 are formed, the joining position of the insert material 13 is not limited to a specific position, and there are various positions near the outer periphery of the back surface 5b of the in-mold foam molded body 5. There is an advantage that it can be joined to the position.
[0063]
Further, in the in-mold foam molded body 41 with the skin joined with the insert material 13 as described above, the strength of the folded portion 7 and the folded portion 8 itself is higher than the strength of the in-mold foam molded body 5. There exists an advantage that the intensity | strength of the junction part of the material 13 and the said folding | turning part 7 grade | etc., Becomes higher.
[0064]
Examples of the insert material 13 include various materials and shapes such as metal, wood, FRP, thermoplastic resin such as polyethylene, polypropylene, and ABS resin, or thermosetting resin such as phenol resin and formaldehyde resin. In the case where the skin material 3 and the in-mold foam molded body 5 are made of a polyolefin resin, it is desirable that the insert material 13 is also made of a polyolefin resin. In such a case, similarly to the above, the fusion between the skin material 3 and the in-mold foam molded body 5 is stronger, and the skin material 3 or the in-mold foam molded body 5 and the insert material 13 are fused. Has the advantage of being stronger and more easily recycled.
[0065]
As shown in FIGS. 14 to 17, the method of manufacturing the in-mold foam-molded body 51 with the skin according to the fifth embodiment is the folding mold before the vacuum molding (thermoforming) in the second embodiment. 6 is provided with a notch portion 14 for attaching an insert material in advance at the tip 6c.
[0066]
That is, as shown in FIG. 14, if the tip 6c of the folding mold 6 is provided with an insert material mounting notch 14 having a semicircular shape in plan view in advance, as shown in FIG. In some cases, a space 15 in a predetermined range can be opened inside the insert material mounting notch 14, and the folded portion 7 and the folded portion 8 can be folded and folded.
[0067]
Next, as shown in FIGS. 16 and 17, when foam molding is performed in the same manner as described above, the insert material 13 can be attached from the space 15 to the back surface 5 b of the in-mold foam molded body 5.
[0068]
As described above, the insert material 13 can be formed by opening the space 15 inwardly of the insert material mounting notch 14 simply by providing the insert material mounting notch 14 in advance. Is attached to the back surface 5b of the in-mold foamed molded body 5, the skin material 3 can be turned back automatically so as to avoid the insert material 13, and therefore has the advantage that it does not take time and effort as in the prior art. is there.
[0069]
Further, as described above, the folded portion 7 and the folded portion 8 are folded and folded so as to avoid the insert material 13 fused and integrated with the back surface 5b of the in-mold foam molded body 5. In the foam molded body 51, the insert material 13 can be fused and integrated so as to be embedded in the back surface 5b of the in-mold foam molded body 5, and therefore, the advantage that the degree of freedom of the mounting of the insert material 13 can be increased. There is.
[0070]
Furthermore, when the skin material 3 and the in-mold foam molded body 5 are made of a polyolefin resin, it is desirable that the insert material 13 is also made of a polyolefin resin, as described above. In such a case, the fusion between the skin material 3 and the in-mold foam molded body 5 is stronger, the fusion between the in-mold foam molded body 5 and the insert material 13 is also stronger, and recycling is easy. There is an advantage of being.
[0071]
As described above, in the first to fifth embodiments, the case where the female mold 9 is the lower mold and the male mold 10 is the upper mold has been described. However, the present invention is not limited to this, and these are reversed. The mold may be clamped and opened in the horizontal direction or the like. Further, the cavity surface 2a of the female die 9 may be formed with product design pattern irregularities such as skin textures in advance if necessary.
[0072]
【The invention's effect】
As described above, according to the invention of the method for producing an in-mold foam-molded body with skin according to claim 1, the in-mold foam-molded body with skin can be produced in a series of steps using the molding die. There is an advantage that the step of folding and joining the skin material manually to the back surface of the foam molded body is unnecessary. Further, by the series of steps, the folded portion is pressed so as to overlap the other surface of the folded portion, so that it is simply overlapped or fused and integrated, that is, within the mold. There exists an advantage that it can shape | mold easily so that it may become substantially parallel with the back surface of a foaming molding. Furthermore, in order not to impair the appearance of the surface side of the in-mold foam-molded body with a skin, the outer peripheral portion of the skin material is even so that the tip of the folded portion is inward from the base end of the folded portion. Since it has only to be excised, there is an advantage that this excision work can be easily performed without paying special attention.
[0073]
According to the invention of claim 2, since the folding part is preliminarily molded in a state of folding back outward so as to wind a folding mold from the tip of the folding part at the time of thermoforming, The folded portion can be easily pressed so as to overlap the other surface of the folded portion only by completely clamping the mold. Therefore, when filling the foamed beads into the mold, there is an advantage that it is possible to save the trouble of returning the outer peripheral portion of the skin material serving as the folded portion outward from the tip of the folded portion.
[0074]
According to the invention of claim 3, since the outer peripheral portion of the skin material is cut in advance so that the distal end of the folded portion is positioned inward from the proximal end of the folded portion before the foam molding, After producing the in-mold foam-molded body with a skin, it is not necessary to cut off the unnecessary outer peripheral portion of the skin material, and the folded portion is fused and integrated with the other surface of the folded portion. There is an advantage that it can be prevented from turning up.
[0075]
According to the invention of claim 4, the angle formed between the cavity surface at the opening edge and the folding mold is made larger in advance than the outer corner angle of the back surface of the in-mold foam molded product, At the time of thermoforming, the angle formed between the folded portion of the skin material and the surface portion at the opening edge can be made larger than the normal case described above. Therefore, when filling the foamed beads into the mold, the foamed beads are easily filled in the outer corners of the back surface of the foamed molded body. There is an advantage that it can be made uniform.
[0076]
According to the invention of claim 5, since the insert material is joined to at least one of the folded portion and the folded portion at the time of the foam molding, the cutting process and the bonding process of the folded portion by conventional manual work are performed. There is an advantage that it is unnecessary and hassle-free. Further, even when the folded portion and the folded portion are formed, the joining position of the insert material is not limited to a specific position, and can be joined to various positions in the vicinity of the outer periphery of the back surface of the in-mold foam molded body. There is an advantage.
[0077]
According to the invention of claim 6, since the notch for inserting the insert material is provided in advance at the tip of the folding mold before the thermoforming, a space within a predetermined range is provided inside the notch for attaching the insert material. The folded portion or the like can be formed by opening. That is, when the insert material is attached to the back surface of the in-mold foamed molded product, the skin material can be automatically folded and the like so as to avoid the insert material.
[0078]
According to the invention of the in-mold foam-molded body with a skin of claim 7, since the in-mold foam-molded body and a skin material comprising the surface portion, the folded portion, and the folded portion are provided, Also during transportation and attachment work of the in-mold foam molded product, the tip of the folded portion and the folded portion are less likely to be caught by other members and the like. Moreover, in the part which the said folding | returning part and the folding | returning part overlapped, there exists an advantage that cushioning property and a reinforcement effect become higher.
[0079]
According to invention of Claim 8, since the said folding | returning part is fusion-integrated and integrated with the other surface of the folding | returning part, there exists an advantage that a folding | returning part does not turn up.
[0080]
According to the invention of claim 9, since the insert material is joined to at least one of the folded portion and the folded portion, the strength of the joint portion between the insert material and the folded portion or the folded portion is further increased. There is an advantage that it becomes higher.
[0081]
According to the invention of claim 10, since the folded portion and the folded portion are folded and folded so as to avoid the insert material fused and integrated with the back surface of the in-mold foam molded article, the insert material Can be fused and integrated so as to be embedded in the back surface of the in-mold foam molded article, and therefore, there is an advantage that the degree of freedom in how to attach the insert material can be increased.
[0082]
According to the invention of claim 11, since the skin material and the in-mold foam molded body are made of polyolefin resin, the fusion between the skin material and the in-mold foam molded body is stronger and is a so-called all-olefin. Therefore, there is an advantage that recycling is easy.
[0083]
According to the invention of claim 12, since the skin material, the in-mold foam molded body, and the insert material are made of polyolefin resin, in addition to the effect of the above-mentioned claim 11, the skin material, the in-mold foam molded body and the insert material. There is an advantage that the fusion with the resin is stronger and the recycling is easy.
[Brief description of the drawings]
FIG. 1 is a cross-sectional view showing a state in which a folding mold is arranged on a female mold in the method for producing an in-mold foam molded body with a skin according to the first embodiment.
2 is a plan view showing an arrangement state of the folding mold of FIG. 1; FIG.
3 is a cross-sectional view showing a state in which the skin material of FIG. 1 is vacuum-formed.
FIG. 4 is a cross-sectional view showing a state in which foam beads are filled in a mold.
FIG. 5 is a cross-sectional view showing a state of foam molding.
FIG. 6 is a cross-sectional view showing a state where an in-mold foam molded body with a skin is removed.
7 is a cross-sectional view showing a state after removing an unnecessary outer peripheral portion of the skin material of FIG.
FIG. 8 is a cross-sectional view showing a state in which foam beads are filled in the mold in the method for producing an in-mold foam molded body with a skin according to the second embodiment.
FIG. 9 is a cross-sectional view showing a state of foam molding.
FIG. 10 is a cross-sectional view showing a state where an in-mold foam molded body with a skin is removed.
FIG. 11 is a cross-sectional view showing a state in which a skin material is vacuum-formed in a method for producing an in-mold foam molded body with a skin according to a third embodiment.
FIG. 12 is a cross-sectional view showing a state in which an insert material is joined to a folded portion at the time of foam molding in a method for producing an in-mold foam molded body with a skin according to a fourth embodiment.
FIG. 13 is a cross-sectional view showing a state where an in-mold foam molded body with a skin is removed.
FIG. 14 is a plan view showing an arrangement state of a folding mold in which a cutout portion for attaching an insert material is provided at the tip in a method for producing an in-mold foam-molded body with a skin according to a fifth embodiment.
FIG. 15 is a cross-sectional view showing a state in which a skin material is vacuum-formed.
FIG. 16 is a cross-sectional view showing a state in which an insert material is fused and integrated with the back surface of an in-mold foam molded body to be formed during foam molding.
FIG. 17 is a cross-sectional view showing a state where an in-mold foam molded body with a skin is removed.
FIG. 18 is a cross-sectional view showing a conventional example.
[Explanation of symbols]
1, 21, 31, 41, 51 In-mold foam molding with skin
2 Mold
2a Cavity surface
2b Open edge
3 Skin material
3a Surface part
4 Inside the mold
5 In-mold foam molding
5a Surface
5b Back side
E Outer corner angle
6 Folding type
6c Tip
7 Folding part
7a one side
7b Other side
7c Tip
7d proximal
8 Folding part
8c Tip
9 Female
10 Male
13 Insert material
14 Insert material mounting notch

Claims

成形型のキャビティ面に沿って表皮材を熱成形した後、この成形型内で発泡成形することによって、形成される型内発泡成形体の表面に前記表皮材を融着一体化する表皮付き型内発泡成形体の製造方法において、
前記熱成形時に、前記キャビティ面の開口端縁から内方へ突出するように配置される折返し用型に沿って、前記表皮材の外周部分を内方へ折返して折返し部を形成した後、前記折返し用型を取外し、前記発泡成形時に、前記折返し部の一面を型内発泡成形体の裏面に融着一体化すると共に、この折返し部の先端から表皮材の外周部分が外方へ折戻された状態の折戻し部を前記折返し部の他面に重なるように押圧することを特徴とする表皮付き型内発泡成形体の製造方法。A skin-attached die in which the skin material is fused and integrated with the surface of the in-mold foam molded product by thermoforming the skin material along the cavity surface of the molding die and then foam-molding in the molding die. In the method for producing an inner foam molded article,
At the time of the thermoforming, along the folding mold arranged so as to project inward from the opening edge of the cavity surface, the outer peripheral portion of the skin material is folded inward to form a folded portion, The folding mold is removed, and at the time of foam molding, one surface of the folded portion is fused and integrated with the back surface of the in-mold foam molded body, and the outer peripheral portion of the skin material is folded outward from the tip of the folded portion. A method for producing an in-mold foam-molded article with a skin, wherein the folded portion in a state of being pressed is pressed so as to overlap the other surface of the folded portion.

前記折戻し部を熱成形時に、前記折返し部の先端から折返し用型を巻き込むように外方へ折戻した状態にあらかじめ成形しておくことを特徴とする請求項１記載の表皮付き型内発泡成形体の製造方法。2. The in-mold foam with a skin according to claim 1, wherein the folded portion is preliminarily molded in a state of being folded outward so as to wind a folding mold from the tip of the folded portion during thermoforming. Manufacturing method of a molded object.

前記表皮材の外周部分を発泡成形前に、前記押圧時に折戻し部の先端が折返し部の基端より内方に位置するようにあらかじめ切除しておくことを特徴とする請求項１又は２記載の表皮付き型内発泡成形体の製造方法。3. The outer peripheral portion of the skin material is cut out in advance so that the front end of the folded portion is positioned inward from the proximal end of the folded portion before the foam molding before foam molding. For producing an in-mold foam-molded article with a skin.

前記開口端縁におけるキャビティ面と折返し用型のなす角度を、前記型内発泡成形体の裏面の外隅部角度よりあらかじめ大きくしておくことを特徴とする請求項１乃至３のいずれか記載の表皮付き型内発泡成形体の製造方法。The angle formed between the cavity surface at the opening edge and the folding mold is set in advance to be larger than the outer corner angle of the back surface of the in-mold foam molded body. A method for producing an in-mold foam molded body with a skin.

前記発泡成形時に、前記折返し部と折戻し部の少なくともいずれか一方にインサート材を接合することを特徴とする請求項１乃至４のいずれか記載の表皮付き型内発泡成形体の製造方法。The method for producing an in-mold foam-molded article with a skin according to any one of claims 1 to 4, wherein an insert material is joined to at least one of the folded portion and the folded portion during the foam molding.

前記熱成形前に、前記折返し用型の先端にインサート材取付け用切欠部をあらかじめ設けておくことを特徴とする請求項１乃至４のいずれか記載の表皮付き型内発泡成形体の製造方法。The method for producing an in-mold foam-molded article with a skin according to any one of claims 1 to 4, wherein a notch for attaching an insert material is provided in advance at the tip of the folding mold before the thermoforming.

型内発泡成形体と、
該型内発泡成形体の表面に融着一体化された表面部と、該表面部の端縁から内方へ折返されてその一面が前記型内発泡成形体の裏面に融着一体化された折返し部と、該折返し部の先端から外方へこの折返し部の他面に重なるように且つその先端が折返し部の基端より内方に位置するように折戻された折戻し部とからなる表皮材と
を備えたことを特徴とする表皮付き型内発泡成形体。In-mold foam molding,
A surface portion fused and integrated with the surface of the in-mold foam molded body, and one surface of the surface portion is folded inward from the edge of the surface portion and fused and integrated with the back surface of the in-mold foam molded body. A folded portion and a folded portion that is folded back outwardly from the tip of the folded portion so as to overlap the other surface of the folded portion and so that the tip is located inward from the proximal end of the folded portion. An in-mold foam-molded article with a skin, characterized by comprising a skin material.

前記折戻し部が折返し部の他面に融着一体化されていることを特徴とする請求項７記載の表皮付き型内発泡成形体。The in-mold foam-molded article with a skin according to claim 7, wherein the folded portion is fused and integrated with the other surface of the folded portion.

前記折返し部と折戻し部の少なくともいずれか一方にインサート材を接合したことを特徴とする請求項７又は８記載の表皮付き型内発泡成形体。The in-mold foam-molded article with a skin according to claim 7 or 8, wherein an insert material is joined to at least one of the folded portion and the folded portion.

前記折返し部及び折戻し部が、前記型内発泡成形体の裏面に融着一体化したインサート材を避けるように折返し及び折戻しされていることを特徴とする請求項７又は８記載の表皮付き型内発泡成形体。9. With the skin according to claim 7 or 8, wherein the folded portion and the folded portion are folded and folded so as to avoid an insert material fused and integrated with the back surface of the in-mold foam molded body. In-mold foam molding.

前記表皮材及び型内発泡成形体がポリオレフィン系樹脂からなることを特徴とする請求項７又は８記載の表皮付き型内発泡成形体。The in-mold foam-molded article with a skin according to claim 7 or 8, wherein the skin material and the in-mold foam-molded article are made of a polyolefin resin.

前記表皮材、型内発泡成形体、及びインサート材がポリオレフィン系樹脂からなることを特徴とする請求項９又は１０記載の表皮付き型内発泡成形体。The in-mold foam-molded article with a skin according to claim 9 or 10, wherein the skin material, the in-mold foam-molded body, and the insert material are made of a polyolefin-based resin.