JP5005464B2 - Foam mold and method for producing foam molded member with skin - Google Patents

Foam mold and method for producing foam molded member with skin Download PDF

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JP5005464B2
JP5005464B2 JP2007204680A JP2007204680A JP5005464B2 JP 5005464 B2 JP5005464 B2 JP 5005464B2 JP 2007204680 A JP2007204680 A JP 2007204680A JP 2007204680 A JP2007204680 A JP 2007204680A JP 5005464 B2 JP5005464 B2 JP 5005464B2
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skin
mold
molding die
product
holding surface
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裕造 伊藤
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Inoac Corp
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本発明は、表皮材をセットした第１成形型と基材をセットした第２成形型とを型閉めし、これら表皮材と基材との間で発泡体を発泡成形する発泡成形型と、この発泡成形型により表皮付き発泡成形部材を製造する方法に関するものである。   The present invention closes the first molding die on which the skin material is set and the second molding die on which the base material is set, and a foam molding die for foam molding of the foam between the skin material and the substrate, The present invention relates to a method for producing a foam-molded member with a skin using this foam-mold.

表皮付き発泡成形部材は、所要形状に形成された基材と、この基材の外面に配設される表皮材と、これら基材および表皮材の間に介在される発泡体とからなる３層構造に構成されたもので、自動車の乗員室内に設置される車両内装部材(インストルメントパネルやフロアコンソール等)や、椅子またはソファ等の各種家具として実用化されている。このような表皮付き発泡成形部材は、別工程において所要形状に予備成形した基材と、同じく別工程において所要形状に予備成形した表皮材とを、発泡成形型に夫々セットしたもとで該発泡成形型を型閉めし、これら基材と表皮材との間で発泡体を発泡成形することで製造される。ここで基材は、インジェクション成形技術等により成形されたものが多く採用される。また表皮材は、真空成形技術により樹脂シート材から成形されたもの、パウダースラッシュ成形技術により粉末樹脂から成形されたもの、スプレー成形技術によりポリウレタンから成形されたもの等が多く採用される。   The foam-formed member with a skin is a three-layered structure comprising a base material formed in a required shape, a skin material disposed on the outer surface of the base material, and a foam interposed between the base material and the skin material It has a structure and is put into practical use as a vehicle interior member (instrument panel, floor console, etc.) installed in the passenger compartment of an automobile, and various furniture such as a chair or a sofa. Such a foam-molded member with a skin is obtained by setting the base material preformed in a required shape in a separate process and the skin material preformed in a required shape in a separate process in a foaming mold, respectively. It is manufactured by closing the mold and foaming the foam between the base material and the skin material. Here, many substrates are formed by injection molding technology or the like. As the skin material, a material formed from a resin sheet material by a vacuum forming technique, a material formed from a powder resin by a powder slush forming technique, a material formed from polyurethane by a spray forming technique, and the like are often used.

図１０は、発泡成形型Ｍ１により表皮付き発泡成形部材１０を成形している状態を示した説明断面図である。この発泡成形型Ｍ１は、所要形状に予備成形された表皮材１６をセットし得る第１成形型３０と、所要形状に予備成形された基材１２をセットし得る第２成形型３２とを備えている。第１成形型３０にセットした表皮材１６の上面に所定量の発泡材を注入したもとで、基材１２をセットした第２成形型３２と該第１成形型３０とを型閉めすることで、表皮材１６と基材１２との間に画成された発泡空間内で発泡材を発泡させて発泡体１４を成形し、表皮付き発泡成形部材１０を製造することができる。   FIG. 10 is an explanatory cross-sectional view showing a state in which the foamed molding member 10 with the skin is being molded by the foaming mold M1. The foam mold M1 includes a first mold 30 that can set the skin material 16 preformed in a required shape, and a second mold 32 that can set the base material 12 preformed in the required shape. ing. The second molding die 32 on which the base material 12 is set and the first molding die 30 are closed with a predetermined amount of foam material injected into the upper surface of the skin material 16 set on the first molding die 30. Thus, the foamed material 14 is molded by foaming the foamed material in the foaming space defined between the skin material 16 and the base material 12, and the foamed molded member 10 with the skin can be manufactured.

図１１は、発泡成形型Ｍ１の第１成形型３０に、別の表皮成形型で予備成形した表皮材１６をセットする状態を示した説明断面図である。前述した表皮材１６は、厚さが１〜２ｍｍ程度であって柔軟性を有しているので形状保持性が低く、第１成形型３０の表皮セット面３４に被着セットする際に弛みや皺が形成され易いと共に、第１成形型３０と第２成形型３２とを型閉めする際もずれてしまうおそれがある。そこで、このような不具合の発生を防止するため、第１成形型３０には、表皮セット面３４の外側に隣接する表皮保持面３６に、表皮材１６の位置決めおよび固定保持のための係止凸部３８を複数個突設してある。また表皮材１６には、第１成形型３０にセットした際に表皮保持面３６に被着する非製品部２０を、該表皮材１６の予備成形時に製品部１８の外周に一体的に形成すると共に、前述した各係止凸部３８に係止し得る表皮凹部２２を該非製品部２０に形成しておく。従って、表皮材１６を第１成形型３０にセットする際には、製品部１８を表皮セット面３４に被着し、非製品部２０を表皮保持面３６に被着すると共に、各係止凸部３８を対応の表皮凹部２２へ係止させることで、第１成形型３０に対して表皮材１６を適切に装着保持するようになっている。なお非製品部２０は、表皮付き発泡成形部材１０において不要とされる部分であって、発泡成形型Ｍ１による発泡体１４の発泡成形完了後に製品部１８から切除される。このような発泡成形型に対する表皮材の位置決め固定に関しては、例えば特許文献１に開示されている。
特開２０００−３３６２６号公報 FIG. 11 is an explanatory cross-sectional view showing a state in which the skin material 16 preformed with another skin molding die is set in the first molding die 30 of the foam molding die M1. The above-mentioned skin material 16 has a thickness of about 1 to 2 mm and has flexibility, so that the shape retention is low, and when the skin material 16 is attached to the skin set surface 34 of the first mold 30, A wrinkle is likely to be formed, and there is a possibility that the first mold 30 and the second mold 32 may be displaced when the mold is closed. Therefore, in order to prevent the occurrence of such a problem, the first molding die 30 has an engagement protrusion for positioning and fixing and holding the skin material 16 on the skin holding surface 36 adjacent to the outside of the skin set surface 34. A plurality of portions 38 are projected. Further, the non-product part 20 that adheres to the skin holding surface 36 when the skin material 16 is set on the first mold 30 is integrally formed on the outer periphery of the product part 18 when the skin material 16 is preformed. At the same time, a skin recess 22 that can be locked to each locking protrusion 38 described above is formed in the non-product portion 20. Accordingly, when the skin material 16 is set on the first mold 30, the product portion 18 is attached to the skin setting surface 34, and the non-product portion 20 is attached to the skin holding surface 36, and each locking projection By locking the portion 38 to the corresponding skin recess 22, the skin material 16 is appropriately mounted and held on the first mold 30. The non-product part 20 is an unnecessary part in the foamed molded member 10 with a skin, and is cut out from the product part 18 after the foam molding of the foam 14 by the foam molding die M1 is completed. Such positioning and fixing of the skin material to the foaming mold is disclosed in, for example, Patent Document 1.
JP 2000-33626 A

前述した第１成形型３０の表皮保持面３６に突設された各係止凸部３８は、例えば直径が５〜１５ｍｍ、突出高さが５〜８ｍｍ程度とされる円柱形状や、一辺が５〜１５ｍｍ、突出高さが５〜８ｍｍ程度とされる角柱形状(四角形、六角形)等とされている。このため、表皮材１６の表皮凹部２２と係止凸部３８とが密着状態に係止されていた場合には、図１３に示すように、製造された表皮付き発泡成形部材１０を第１成形型３０から脱型する際に、表皮凹部２２が係止凸部３８に引掛かって両部２２,３８の円滑な離脱がなされない。従って、作業員が手作業にて各表皮凹部２２から各係止凸部３８を外さなければならず、表皮付き発泡成形部材１０の脱型作業が面倒で煩わしいものとなっていた。しかも、表皮付き発泡成形部材１０を無理矢理に引張った際には、非製品部２０のみならず製品部１８まで破れが進行して製品不良が発生する不都合もあった。   Each locking projection 38 protruding from the skin holding surface 36 of the first mold 30 described above has, for example, a cylindrical shape with a diameter of 5 to 15 mm and a protruding height of about 5 to 8 mm, or 5 sides. It is made into prismatic shape (square, hexagon) etc. which are -15 mm and protrusion height shall be about 5-8 mm. For this reason, when the skin recessed part 22 and the latching convex part 38 of the skin material 16 are latched | locked in the contact | adherence state, as shown in FIG. When the mold 30 is removed from the mold 30, the skin concave portion 22 is caught by the locking convex portion 38, and the both portions 22 and 38 are not smoothly detached. Therefore, an operator has to manually remove each locking projection 38 from each skin recess 22, which makes the work of removing the foamed molded member 10 with a skin troublesome and troublesome. In addition, when the foamed molded member 10 with the skin is forcibly pulled, there is a problem in that not only the non-product part 20 but also the product part 18 is broken and a product defect occurs.

また、第１成形型３０と第２成形型３２とを型閉めする際に基材１２と表皮材１６とが接触すると、第１成形型３０にセットした表皮材１６が表皮セット面３４側へ引張られ易い。このように、表皮材１６が表皮セット面３４側へ引張られると、図１２に示すように、非製品部２０が上方へ浮き上がったり捲り上がるようになるので、場合によっては係止凸部３８から各表皮凹部２２が外れてしまい、前述した表皮材１６のずれが一層助長されてしまう。このように表皮材１６がずれた状態で発泡体１４の発泡成形を行なった際には、製品不良が発生して製造効率の低下を招来することになる。   Further, when the base 12 and the skin material 16 come into contact with each other when the first molding die 30 and the second molding die 32 are closed, the skin material 16 set in the first molding die 30 is directed to the skin setting surface 34 side. Easy to be pulled. Thus, when the skin material 16 is pulled toward the skin set surface 34 side, as shown in FIG. 12, the non-product part 20 is lifted up or rolled up. Each skin recessed part 22 will remove | deviate, and the shift | offset | difference of the skin material 16 mentioned above will be promoted further. In this way, when the foam 14 is subjected to foam molding in a state where the skin material 16 is displaced, a product defect occurs, leading to a decrease in manufacturing efficiency.

一方、図１４に示すように、前述した表皮凹部２２を有する表皮材１６を成形する表皮成形型Ｓ１では、成形された表皮材１６を該表皮成形型Ｓから脱型するに際して非製品部２０を捲り上げようとすると、表皮凹部２２が成形凸部８８に引掛かって両部２２,８８の離脱が円滑になされない。従って、非製品部２０を無理矢理に引張りながら成形凸部８８から表皮凹部２２を外さなければならず、表皮材１６に変形や破れ等が発生し易くなっていた。   On the other hand, as shown in FIG. 14, in the skin molding die S <b> 1 for molding the skin material 16 having the skin recess 22 described above, the non-product part 20 is formed when the molded skin material 16 is removed from the skin molding die S. If it is going to be lifted up, the skin concave portion 22 is caught by the molding convex portion 88 and the both portions 22 and 88 are not smoothly detached. Accordingly, the skin concave portion 22 has to be removed from the molding convex portion 88 while forcibly pulling the non-product portion 20, and the skin material 16 is likely to be deformed or torn.

更に、前述したスプレー成形技術により成形される表皮材１６の場合には、図１５に示すように、成形凸部８８の周辺にポリウレタンを吹付けて非製品部２０および表皮凹部２２を成形するに際し、該成形凸部８８の上面に吹き付けられた該ポリウレタンが周囲へ流下してしまい、特に表皮凹部２２の底部分が薄くなり易い。このため、表皮材１６の脱型に際して、表皮凹部２２の底部分に破れが発生する不都合があった。   Further, in the case of the skin material 16 formed by the spray molding technique described above, as shown in FIG. 15, when the non-product part 20 and the skin concave part 22 are formed by spraying polyurethane around the molding convex part 88. The polyurethane sprayed on the upper surface of the molding convex portion 88 flows down to the surroundings, and in particular, the bottom portion of the skin concave portion 22 tends to become thin. For this reason, when the skin material 16 is demolded, the bottom portion of the skin concave portion 22 is broken.

従って本発明では、発泡成形型にセットした表皮材が型閉め時にずれることを防止すると共に、製造された表皮付き発泡成形部材の脱型を円滑に図り得るようにした発泡成形型と、この発泡成形型を使用することで製品不良の発生を防止すると共に製造効率を向上させるようにした表皮付き発泡成形部材の製造方法を提供することを目的とする。   Therefore, in the present invention, a foam molding die that prevents the skin material set in the foam molding die from being displaced when the mold is closed, and can smoothly remove the foam molded member with the manufactured skin, and the foam molding die. An object of the present invention is to provide a method for producing a foamed molded member with a skin, which prevents the occurrence of product defects by using a mold and improves the production efficiency.

前記課題を解決し、所期の目的を達成するため、本願の請求項１に記載の発明は、製品部および該製品部の外周に連続する非製品部を一体的に形成した表皮材を被着セット可能であり、前記製品部が被着される表皮セット面および前記非製品部が被着される表皮保持面を設けた第１成形型と、基材を被着セット可能な第２成形型とを備え、前記表皮材をセットした前記第１成形型と前記基材をセットした第２成形型とを型閉めし、これら表皮材と基材との間で発泡体を成形して表皮付き発泡成形部材を製造する発泡成形型において、
前記第１成形型の前記表皮保持面に凹設され、前記非製品部の該表皮保持面と対面する側に膨出形成された表皮凸部を係止する係止凹部と、
前記表皮保持面に設けられ、前記非製品部における端縁の該表皮保持面から離間する側への移動を規制する端縁保持部と、
前記第２成形型の前記表皮保持面に対向する型面から突出して設けられて前記係止凹部と対向し、前記第１成形型と第２成形型との型閉め時に、前記係止凹部に受容された前記表皮凸部を押える表皮当接部材とを有することを要旨とする。 In order to solve the above-mentioned problems and achieve the intended object, the invention according to claim 1 of the present application is to cover a skin material integrally formed with a product portion and a non-product portion continuous with the outer periphery of the product portion. A first molding die that is capable of being attached and set and has a skin set surface on which the product part is attached and a skin holding surface on which the non-product part is attached; A first molding die having the skin material set thereon and a second molding die having the base material set thereon are closed, and a foam is molded between the skin material and the base material. In a foam mold for producing a foam molded member with
A locking recess that is recessed in the skin holding surface of the first mold, and that locks the skin protrusion formed on the side facing the skin holding surface of the non-product part; and
An edge holding portion that is provided on the skin holding surface and regulates movement of the edge of the non-product portion to the side away from the skin holding surface;
Protruding from the mold surface facing the skin holding surface of the second molding die, facing the locking recess, and when the first molding die and the second molding die are closed, the locking recess It has a gist of having a skin contact member that presses the received skin convex part.

従って、請求項１に係る発明によれば、表皮材の非製品部に突設した表皮凸部が係止する係止凹部を第１成形型の表皮保持面に凹設したので、該係止凹部に表皮凸部を係止させることで表皮材を第１成形型に対して保持させ得ると共に、非製品部を表皮保持面から離間する方向へ引張ることで係止凹部から表皮凸部が抜け出て外れるので、製造された表皮付き発泡成形部材の脱型が容易となる。そして、表皮保持面にセットした非製品部の端縁を保持する端縁保持部を有するので、第１成形型と第２成形型とを型閉めする際に非製品部が表皮保持面から浮き上がることを防止できる。更に、係止凹部に受容して係止された表皮凸部を押える表皮当接部材を有するので、第１成形型と第２成形型とを型閉めする際に、表皮凸部を係止凹部に係止した状態に保持できる。すなわち、端縁保持部および表皮当接部材を設けたことにより、型閉めに際して第１成形型に表皮材を密着保持させることができ、該表皮材に弛みや皺等が形成されることを防止し得る。   Therefore, according to the first aspect of the present invention, since the locking recess that is locked by the skin protrusion protruding from the non-product portion of the skin material is recessed in the skin holding surface of the first mold, the locking The skin material can be held against the first mold by locking the skin convex part to the concave part, and the skin convex part is pulled out from the locking concave part by pulling the non-product part away from the skin holding surface. Therefore, it is easy to remove the produced foamed molded member with skin. And since it has the edge holding part which hold | maintains the edge of the non-product part set to the skin holding surface, when closing a 1st shaping | molding die and a 2nd shaping | molding die, a non-product part floats from a skin holding surface Can be prevented. Furthermore, since it has a skin contact member that receives and locks the skin protrusions received in the locking recesses, when closing the first molding die and the second molding die, the skin protrusions are locked into the locking recesses. Can be held in a locked state. That is, by providing the edge holding portion and the skin contact member, the skin material can be held in close contact with the first mold when the mold is closed, and the skin material is prevented from being slackened or wrinkled. Can do.

請求項２に記載の発明では、前記係止凹部は、前記表皮セット面側の第１壁面が、前記表皮保持面に対して垂直に形成されると共に、前記第１壁面と対向する第２壁面が、該係止凹部の底部から前記表皮保持面に向かうに従って第１壁面から離間するよう傾斜形成されることを要旨とする。
従って、請求項２に係る発明によれば、非製品部が表皮セット面の側へ引張られた際には表皮凸部が係止凹部の第１壁面に係止されるので、第１成形型にセットした表皮材のずれが防止される。また、表皮付き発泡成形部材を第１成形型から脱型するに際し、表皮保持面に被着されている非製品部を表皮セット面の側から引張ると、表皮凸部が第２壁面側へ変位して該表皮凸部と係止凹部との係止状態が解除されるので、表皮保持面からの非製品部の剥離が円滑になされて該表皮付き発泡成形部材の脱型が一層容易となる。 According to a second aspect of the present invention, the locking recess has a first wall surface on the skin set surface side that is formed perpendicular to the skin holding surface and a second wall surface that faces the first wall surface. However, it is formed so as to be inclined so as to be separated from the first wall surface from the bottom of the locking recess toward the skin holding surface.
Therefore, according to the invention according to claim 2, when the non-product part is pulled toward the skin set surface, the skin convex part is locked to the first wall surface of the locking concave part. Displacement of the skin material set in is prevented. When removing the foamed molded member with skin from the first mold, pulling the non-product part attached to the skin holding surface from the side of the skin set surface will cause the skin convex part to displace to the second wall surface side. Then, the locked state between the skin convex portion and the locking concave portion is released, so that the non-product portion is smoothly peeled from the skin holding surface, and the demolding of the foam molded member with the skin is further facilitated. .

請求項３に記載の発明では、前記表皮当接部材は、前記型面から出没方向に移動可能に配設されると共に、常には付勢手段により該型面から突出する方向へ付勢され、前記第１成形型と第２成形型との型閉め時に、前記基材と前記表皮材とが接触する前から前記表皮凸部を押えるよう設定されることを要旨とする。
従って、請求項３に係る発明によれば、第１成形型と第２成形型との型閉め時に、基材と表皮材とが接触する前から、係止凹部に受容して係止された表皮凸部を表皮当接部材で押えることができるので、基材と表皮材とが接触しても該表皮材のずれを好適に防止し得る。また、表皮当接部材が付勢手段の付勢力により表皮凸部を押えるようになり、該表皮凸部の潰れや裂け等を防止し得る。 In the invention according to claim 3, the skin contact member is arranged so as to be movable in and out of the mold surface, and is always urged in a direction protruding from the mold surface by the urging means, The gist of the invention is that when the first molding die and the second molding die are closed, the skin convex portion is set to be pressed before the base material and the skin material come into contact with each other.
Therefore, according to the invention according to claim 3, when the first molding die and the second molding die are closed, the base material and the skin material are received and locked in the locking recesses before they come into contact with each other. Since the skin convex portion can be pressed by the skin contact member, even if the base material and the skin material come into contact with each other, the skin material can be suitably prevented from shifting. Further, the skin contact member can press the skin convex portion by the biasing force of the biasing means, and the skin convex portion can be prevented from being crushed or torn.

請求項４に記載の発明では、製品部および該製品部の外周に連続する非製品部を一体的に形成した表皮材を、表皮セット面および表皮保持面を設けた第１成形型に、製品部を表皮セット面に被着すると共に非製品部を表皮保持面に被着した状態でセットし、基材をセットした第２成形型と前記第１成形型とを型閉めし、前記表皮材と基材との間で発泡体を成形して表皮付き発泡成形部材を製造する方法において、
前記非製品部の端縁を、前記表皮保持面に設けた端縁保持部で保持すると共に、前記非製品部に突設した表皮凸部を、前記表皮保持面に凹設された係止凹部に係止して、表皮材を第１成形型にセットし、
前記第１成形型と前記第２成形型とを型閉めする際に、前記係止凹部に受容された前記表皮凸部を、前記基材と前記表皮材とが接触する前から該第２成形型に設けた表皮当接部材で押えることを要旨とする。 In the invention according to claim 4, the skin material integrally formed with the product portion and the non-product portion continuous with the outer periphery of the product portion is applied to the first mold provided with the skin setting surface and the skin holding surface. The skin is set on the skin set surface and the non-product part is attached on the skin holding surface, the second molding die on which the base material is set and the first molding die are closed, and the skin material In a method for producing a foamed molded member with a skin by molding a foam between the substrate and the substrate,
An end portion of the non-product portion is held by an edge holding portion provided on the skin holding surface, and a skin concave portion protruding from the non-product portion is recessed in the skin holding surface. And set the skin material on the first mold,
When the first molding die and the second molding die are closed, the skin convex portion received in the locking recess is formed in the second molding before the base material and the skin material come into contact with each other. The gist is to press with a skin contact member provided on the mold.

従って、請求項４に係る発明によれば、第１成形型に対して表皮材をセットする際には、表皮材の非製品部に突設した表皮凸部を第１成形型の表皮保持面に凹設した係止凹部に係止させるようにしたので、第１成形型にセットした表皮材を保持し得る。また、表皮保持面にセットした非製品部の端縁を、該表皮保持面に設けた端縁保持部で保持するようにしたので、該非製品部の浮き上がりを防止し得る。更に、第１成形型と第２成形型とを型閉めする際には、係止凹部に受容して係止された表皮凸部を、第２成形型に設けた表皮当接部材で基材と表皮材とが接触する前から押えるようにしたので、基材と表皮材との接触後も係止凹部と表皮凸部との係止状態が保持され、第１成形型にセットした該表皮材のずれを防止し得る。従って、第１成形型にセットした表皮材に弛みや皺が形成されない状態で発泡体の成形を行なうことができ、発泡成形型で製造された表皮付き発泡成形部材の製品不良が発生することを防止して製造効率を向上させることができる。   Therefore, according to the invention which concerns on Claim 4, when setting a skin material with respect to a 1st shaping | molding die, the skin convex part which protruded in the non-product part of the skin material was used for the skin holding surface of a 1st shaping | molding die. Since it is made to latch in the latching recessed part provided in the inside, the skin material set to the 1st shaping | molding die can be hold | maintained. Further, since the edge of the non-product portion set on the skin holding surface is held by the edge holding portion provided on the skin holding surface, the non-product portion can be prevented from rising. Further, when closing the first molding die and the second molding die, the skin convex portion received and locked in the locking concave portion is formed by the skin contact member provided in the second molding die. And the skin material are pressed before they come into contact with each other, so that the latching state between the latching concave portion and the skin convex portion is maintained even after the contact between the base material and the skin material, and the skin set in the first mold Misalignment of the material can be prevented. Accordingly, the foam can be molded in a state in which no slack or wrinkles are formed on the skin material set in the first mold, and a defective product of the foam-molded member with the skin manufactured by the foam mold is generated. It is possible to improve the manufacturing efficiency.

本発明に係る発泡成形型によれば、該発泡成形型にセットした表皮材が型閉め時にずれることを防止すると共に、製造された表皮付き発泡成形部材の脱型を円滑に図り得る。
また、別の発明に係る表皮付き発泡成形部材の製造方法によれば、製品不良の発生を防止して製造効率を向上させながら表皮付き発泡成形部材を製造し得る。 According to the foam mold according to the present invention, it is possible to prevent the skin material set in the foam mold from shifting when the mold is closed, and to smoothly remove the manufactured foam molded member with a skin.
Moreover, according to the manufacturing method of the foam molding member with a skin which concerns on another invention, generation | occurrence | production of a product defect can be prevented and a foam molding member with a skin can be manufactured, improving manufacturing efficiency.

次に、本発明に係る発泡成形型および表皮付き発泡成形部材の製造方法につき、好適な実施例を挙げて、添付図面を参照しながら以下説明する。なお実施例では、図１０に示した表皮付き発泡成形部材１０を成形するための発泡成形型を例示する。従って、図１０〜図１３に示した発泡成形型Ｍ１と同一部材、部位については同一の符号を付して説明する。   Next, the manufacturing method of the foam mold according to the present invention and the foam-molded member with a skin will be described below with reference to the accompanying drawings with preferred examples. In addition, in an Example, the foam molding die for shape | molding the foam molding member 10 with a skin shown in FIG. 10 is illustrated. Therefore, the same members and parts as those of the foam molding die M1 shown in FIGS.

図１は、実施例の発泡成形型Ｍを、表皮付き発泡成形部材１０を製造している状態で示した断面図である。実施例の発泡成形型Ｍは、製品部１８および該製品部１８の外周に連続する非製品部２０が一体的に形成された表皮材１６を被着セット可能な第１成形型３０と、所要形状に予備成形されて表皮材１６の裏側に配設される基材１２を被着セット可能な第２成形型３２とを備えており、図示省略したヒンジ機構により第１成形型３０に対して第２成形型３２が開閉可能に構成されている。第１成形型３０は、図１および図３に示すように、表皮材１６における製品部１８の外面形状と合致する形状に形成されて該製品部１８が被着される表皮セット面３４と、この表皮セット面３４の外周に連続して形成されて非製品部２０が被着される表皮保持面３６とを設けてある。第２成形型３２は、図１および図３に示すように、基材１２の裏面形状に合致する形状に形成されて該基材１２が被着基材セット面４０と、基材セット面４０の外周に連続して形成されて前記第１成形型３０の表皮保持面３６に対向する型面４２とを設けてある。   FIG. 1 is a cross-sectional view showing a foam molding die M of the embodiment in a state where a foam molded member 10 with a skin is manufactured. The foam molding die M of the embodiment includes a first molding die 30 capable of adhering and setting a skin material 16 in which a product portion 18 and a non-product portion 20 continuous with the outer periphery of the product portion 18 are integrally formed. And a second molding die 32 that can be pre-formed into a shape and disposed on the back side of the skin material 16 and can be attached and set to the first molding die 30 by a hinge mechanism (not shown). The 2nd shaping | molding die 32 is comprised so that opening and closing is possible. As shown in FIGS. 1 and 3, the first mold 30 is formed in a shape that matches the outer surface shape of the product portion 18 in the skin material 16, and the skin set surface 34 to which the product portion 18 is attached, A skin holding surface 36 is provided which is continuously formed on the outer periphery of the skin setting surface 34 and to which the non-product portion 20 is attached. As shown in FIGS. 1 and 3, the second mold 32 is formed in a shape that matches the shape of the back surface of the base material 12, and the base material 12 is attached to the adherend base material setting surface 40 and the base material setting surface 40. A mold surface 42 that is formed continuously on the outer periphery of the first mold 30 and faces the skin holding surface 36 of the first mold 30 is provided.

実施例の発泡成形型Ｍでは、図１〜図３に示すように、第１成形型３０の表皮保持面３６に、該表皮保持面３６から凹んだ複数の係止凹部５０が、表皮セット面３４と表皮保持面３６との境界ラインから適宜離間した位置において、該境界ラインに沿って所要間隔毎に凹設されている。これに伴い、表皮材１６の非製品部２０には、後述すると共に図１〜図３に示すように、表皮保持面３６に凹設した各係止凹部５０に対応して係止可能な表皮凸部２４が形成されている。前述した各係止凹部５０は、表皮保持面３６に開口した形状が略矩形状とされる陥凹部であって、表皮セット面３４側の第１壁面５２が、表皮保持面３６に対して垂直に形成されると共に、表皮セット面３４と反対側に位置して第１壁面５２と対向する第２壁面５４が、該係止凹部５０の底部から表皮保持面３６に向かうに従って第１壁面５２から離間するよう傾斜形成されている。すなわち各係止凹部５０は、底部から表皮保持面３６に向けて拡開した形状に形成されている。   In the foam mold M of the embodiment, as shown in FIGS. 1 to 3, a plurality of locking recesses 50 recessed from the skin holding surface 36 are formed on the skin holding surface 36 of the first mold 30. In a position appropriately separated from the boundary line between the surface 34 and the skin holding surface 36, a recess is provided along the boundary line at every required interval. Accordingly, the non-product portion 20 of the skin material 16 has a skin that can be locked corresponding to each locking recess 50 provided in the skin holding surface 36 as described later and as shown in FIGS. A convex portion 24 is formed. Each of the locking recesses 50 described above is a recess having an approximately rectangular shape opened to the skin holding surface 36, and the first wall surface 52 on the skin setting surface 34 side is perpendicular to the skin holding surface 36. And the second wall surface 54 that is located on the opposite side of the skin setting surface 34 and faces the first wall surface 52 from the first wall surface 52 toward the skin holding surface 36 from the bottom of the locking recess 50. It is formed so as to be separated. That is, each locking recess 50 is formed in a shape that expands from the bottom toward the skin holding surface 36.

表皮材１６に形成された各表皮凸部２４は、図２および図３に示すように、非製品部２０の表皮保持面３６と対面する側に、対応の係止凹部５０の内壁形状と合致する外形形状に膨出形成されている。すなわち表皮凸部２４は、製品部１８に隣接した側の第１凸壁面２６が、非製品部２０の外面に対して垂直に形成されると共に、製品部１８と反対側に位置して第１凸壁面２６と対向する第２凸壁面２８が、該表皮凸部２４の頂部から非製品部２０の外面に向かうに従って第１凸壁面２６から離間するよう傾斜形成されている。なお、表皮凸部２４の突出高さは非製品部２０の厚さの３倍程度であり、かつ表皮凸部２４の厚さは非製品部２０の厚さと同一であるので、該表皮凸部２４の裏側は陥凹状に形成されている。   As shown in FIGS. 2 and 3, each skin convex portion 24 formed on the skin material 16 matches the inner wall shape of the corresponding locking concave portion 50 on the side facing the skin holding surface 36 of the non-product portion 20. The outer shape is formed to bulge. That is, the first convex wall surface 26 on the side adjacent to the product part 18 is formed perpendicular to the outer surface of the non-product part 20 and the first skin surface part 24 is located on the opposite side to the product part 18. A second convex wall surface 28 facing the convex wall surface 26 is formed so as to be separated from the first convex wall surface 26 toward the outer surface of the non-product portion 20 from the top of the skin convex portion 24. In addition, since the protrusion height of the skin convex part 24 is about 3 times the thickness of the non-product part 20, and the thickness of the skin convex part 24 is the same as the thickness of the non-product part 20, the skin convex part The back side of 24 is formed in a concave shape.

従って、非製品部２０を表皮保持面３６に被着させるに際し、各係止凹部５０に対応の各表皮凸部２４を上方から突入すると、第１凸壁面２６が第１壁面５２に密着すると共に第２凸壁面２８が第２壁面５４に密着するようになる。そして、表皮凸部２４の第１凸壁面２６と係止凹部５０の第１壁面５２とが表皮保持面３６に対して垂直になっていることで、表皮材１６が表皮セット面３４の側へ引張られた際には、係止凹部５０と表皮凸部２４との係止度合がより強まるので、第１成形型３０にセットした表皮材１６が適切に保持される。また、表皮凸部２４の第２凸壁面２８と係止凹部５０の第２壁面５４とが前述のように傾斜形成されていることで、表皮保持面３６に被着されている非製品部２０を表皮セット面３４の側から該表皮保持面３６から離間するように捲り上げると、表皮凸部２４が第２壁面５４側へ変位して第１壁面５２と第１凸壁面２６との係止状態が解除されるので、係止凹部５０から表皮凸部２４が容易に外れるようになり、表皮保持面３６からの非製品部２０の剥離が円滑になされる。また、非製品部２０を表皮セット面３４と反対側へ引張った場合でも、係止凹部５０から表皮凸部２４が容易に外れるようになり、表皮保持面３６からの非製品部２０の剥離が円滑になされる。   Accordingly, when the non-product part 20 is attached to the skin holding surface 36, when each skin convex part 24 corresponding to each locking concave part 50 enters from the upper side, the first convex wall surface 26 comes into close contact with the first wall surface 52. The second convex wall surface 28 comes into close contact with the second wall surface 54. Then, the first convex wall surface 26 of the skin convex portion 24 and the first wall surface 52 of the locking concave portion 50 are perpendicular to the skin holding surface 36, so that the skin material 16 moves toward the skin set surface 34. When pulled, the degree of locking between the locking recess 50 and the skin protrusion 24 becomes stronger, so that the skin material 16 set on the first mold 30 is appropriately held. Further, the non-product part 20 attached to the skin holding surface 36 is formed by the second convex wall surface 28 of the skin convex part 24 and the second wall surface 54 of the locking concave part 50 being inclined as described above. Is raised from the skin setting surface 34 side so as to be separated from the skin holding surface 36, the skin convex portion 24 is displaced toward the second wall surface 54, and the first wall surface 52 and the first convex wall surface 26 are locked. Since the state is released, the skin convex part 24 can be easily detached from the locking concave part 50, and the non-product part 20 can be smoothly peeled from the skin holding surface 36. Further, even when the non-product part 20 is pulled to the side opposite to the skin set surface 34, the skin convex part 24 can be easily detached from the locking recess 50, and the non-product part 20 is peeled off from the skin holding surface 36. It is made smoothly.

また実施例の発泡成形型Ｍでは、図２および図３に示すように、表皮保持面３６に被着された非製品部２０の端縁２０Ａを保持して、該端縁２０Ａの表皮保持面３６から離間する側への移動を規制する端縁保持部６０が設けられている。この端縁保持部６０は、表皮保持面３６に被着された非製品部２０の端縁２０Ａが臨む位置の外側に沿って配設されるスペーサ６２と、このスペーサ６２の上面に固定されて該スペーサ６２から表皮セット面３４の方向へ延出する庇状保持片６４とで構成されている。前述したスペーサ６２は、表皮材１６の非製品部２０の厚さよりやや厚く設定されており、表皮保持面３６上に延出した庇状保持片６４と該表皮保持面３６との間には、非製品部２０の端縁２０Ａが挿入し得る間隙６６が形成されている。従って、非製品部２０を表皮保持面３６に被着するに際し、該非製品部２０の端縁２０Ａを前述した間隙６６内に差し込むことにより、表皮保持面３６に被着された非製品部２０の端縁２０Ａ部分が庇状保持片６４で保持され、非製品部２０の浮き上がりや捲り上がり等が防止されるようになる。   Moreover, in the foaming mold M of the embodiment, as shown in FIGS. 2 and 3, the edge 20A of the non-product portion 20 attached to the skin holding surface 36 is held, and the skin holding surface of the edge 20A is held. An edge holding portion 60 that restricts movement toward the side away from 36 is provided. The edge holding part 60 is fixed to the spacer 62 disposed along the outside of the position where the edge 20A of the non-product part 20 attached to the skin holding surface 36 faces, and is fixed to the upper surface of the spacer 62. It is constituted by a hook-shaped holding piece 64 extending from the spacer 62 in the direction of the skin set surface 34. The spacer 62 described above is set to be slightly thicker than the thickness of the non-product part 20 of the skin material 16, and between the hook-shaped holding piece 64 extending on the skin holding surface 36 and the skin holding surface 36, A gap 66 into which the end edge 20A of the non-product part 20 can be inserted is formed. Accordingly, when the non-product portion 20 is attached to the skin holding surface 36, the edge 20A of the non-product portion 20 is inserted into the gap 66 described above, whereby the non-product portion 20 attached to the skin holding surface 36 is inserted. The edge 20 </ b> A portion is held by the hook-shaped holding piece 64, and the non-product part 20 is prevented from being lifted or rolled up.

更に実施例の発泡成形型Ｍでは、図１〜図３に示すように、第２成形型３２の第１成形型３０における表皮保持面３６に対向する型面４２に、該型面４２から突出した複数の表皮当接部材７０を備えている。各表皮当接部材７０は、第１成形型３０と第２成形型３２との型閉め時に、表皮保持面３６に形成した各係止凹部５０に夫々対向する位置に配設されており、両成形型３０,３２を型閉めした際に係止凹部５０に受容して係止した表皮凸部２４を押えるようになっている。このような表皮当接部材７０を配設するため、第２成形型３２の型面４２には、図２に示すように、該型面４２に開口した円形状の通孔部４４と、第２成形型３２の裏側に開口して通孔部４４より大径の収容部４６とが、基材セット面４０と型面４２との境界ラインから適宜離間した位置において、該境界ラインに沿って所要間隔毎に貫通形成されている。また、収容部４６の開口部分には、キャップ４８が固定されている。   Furthermore, in the foam mold M of the embodiment, as shown in FIGS. 1 to 3, the mold surface 42 of the second mold 32 facing the skin holding surface 36 of the first mold 30 protrudes from the mold surface 42. The plurality of skin contact members 70 are provided. Each skin contact member 70 is disposed at a position facing each locking recess 50 formed in the skin holding surface 36 when the first molding die 30 and the second molding die 32 are closed. When the molding dies 30 and 32 are closed, the skin convex portion 24 received and locked in the locking recess 50 is pressed. In order to dispose such a skin contact member 70, the mold surface 42 of the second mold 32 is provided with a circular through hole 44 opened in the mold surface 42, as shown in FIG. (2) An accommodation portion 46 that opens to the back side of the mold 32 and has a larger diameter than the through-hole portion 44 is positioned along the boundary line at a position that is appropriately separated from the boundary line between the base material setting surface 40 and the mold surface 42. A penetration is formed at every required interval. A cap 48 is fixed to the opening portion of the housing portion 46.

表皮当接部材７０は、図２に示すように、第２成形型３２の型面４２に対して軸方向へのスライド移動が可能に配設された棒状部材であって、通孔部４４に挿通される外径とされて先端を球面状に形成した当接軸部７２と、この当接軸部７２より大径に形成されて収容部４６の直径より小さく形成されたフランジ部７４と、このフランジ部７４の当接軸部７２と反対側の端面に突設された係止部７６とから構成されている。この表皮当接部材７０は、第２成形型３２の外側から収容部４６に対して挿入して、通孔部４４を介して当接軸部７２を型面４２から外方へ突出した状態にセットされ、該型面４２に対して出没方向(該当接軸部７２の軸方向)への移動が可能に配設され、該型面４２からの突出量が変化するようになっている。   As shown in FIG. 2, the skin contact member 70 is a rod-shaped member disposed so as to be slidable in the axial direction with respect to the mold surface 42 of the second mold 32, and is formed in the through hole 44. A contact shaft portion 72 having an outer diameter to be inserted and having a tip formed in a spherical shape; a flange portion 74 formed to have a larger diameter than the contact shaft portion 72 and smaller than the diameter of the housing portion 46; The flange portion 74 includes a locking portion 76 that protrudes from the end surface opposite to the contact shaft portion 72. The skin contact member 70 is inserted into the housing portion 46 from the outside of the second molding die 32 so that the contact shaft portion 72 protrudes outward from the mold surface 42 through the through-hole portion 44. The mold surface 42 is arranged so as to be movable in the direction of protrusion and disengagement (the axial direction of the corresponding tangent portion 72), and the amount of protrusion from the mold surface 42 changes.

また、表皮当接部材７０をセットした収容部４６の内部には、図２に示すように、表皮当接部材７０のフランジ部７４と前述したキャップ４８との間に圧縮コイルバネ(付勢手段)８０が配設されており、該表皮当接部材７０は、常には圧縮コイルバネ８０の弾性力により型面４２から突出する方向に付勢されている。従って、表皮当接部材７０の先端部に対して外力が付与されていない場合には、図５に示すように、該表皮当接部材７０は型面４２から最大に突出した状態に保持され、表皮当接部材７０の先端部に軸方向に沿った外力が加わると、図６(ｂ)に示すように、該表皮当接部材７０は圧縮コイルバネ８０の弾性力に抗して型面４２から収容部４６内へ後退するようになる。   Further, as shown in FIG. 2, a compression coil spring (biasing means) is provided between the flange portion 74 of the skin contact member 70 and the above-described cap 48 inside the housing portion 46 in which the skin contact member 70 is set. 80 is disposed, and the skin contact member 70 is always urged in a direction protruding from the mold surface 42 by the elastic force of the compression coil spring 80. Therefore, when no external force is applied to the front end portion of the skin contact member 70, the skin contact member 70 is held in a state of projecting to the maximum from the mold surface 42, as shown in FIG. When an external force along the axial direction is applied to the tip of the skin contact member 70, the skin contact member 70 resists the elastic force of the compression coil spring 80 from the mold surface 42 as shown in FIG. Retreats into the accommodating portion 46.

しかも各表皮当接部材７０は、図６(ａ)に示すように、第１成形型３０と第２成形型３２との型閉め途中、換言すると両成形型３０,３２の型閉めが完了する前に、係止凹部５０に係止した表皮凸部２４の裏側に当接するように設定されている。すなわち、表皮当接部材７０が係止凹部５０に受容して係止した表皮凸部２４の裏側に当接するタイミングは、第２成形型３２にセットした基材１２と第１成形型３０にセットした表皮材１６とが接触する前である。従って、第１成形型３０と第２成形型３２との型閉め時に、基材１２と表皮材１６とが接触する前から、各表皮当接部材７０が対応の表皮凸部２４に当接して該表皮凸部２４を押えるようになるので、型閉め時に基材１２と表皮材１６とが接触しても該表皮材１６のずれを好適に防止し得る。また、表皮当接部材７０が圧縮コイルバネ８０による付勢力により表皮凸部２４を弾力的に押えるようになるので、該表皮凸部２４の潰れや裂け等も防止し得るようになっている。   In addition, as shown in FIG. 6A, each skin contact member 70 is in the middle of closing of the first mold 30 and the second mold 32, in other words, the mold closing of both molds 30, 32 is completed. It is set so that it contacts the back side of the skin convex part 24 latched to the latching recessed part 50 before. That is, the timing at which the skin contact member 70 contacts the back side of the skin convex portion 24 received and locked in the locking recess 50 is set in the base 12 set in the second molding die 32 and the first molding die 30. This is before the skin material 16 is in contact. Accordingly, when the first molding die 30 and the second molding die 32 are closed, each skin contact member 70 comes into contact with the corresponding skin convex portion 24 before the base material 12 and the skin material 16 come into contact with each other. Since the skin convex portion 24 can be pressed, even if the base material 12 and the skin material 16 come into contact with each other when the mold is closed, the skin material 16 can be suitably prevented from shifting. Further, since the skin contact member 70 elastically presses the skin convex portion 24 by the urging force of the compression coil spring 80, the skin convex portion 24 can be prevented from being crushed or torn.

また各表皮当接部材７０は、図６(ａ)に示すように、係止凹部５０の第１壁面５２に沿うように突出するように設定されており、該表皮当接部材７０と第１壁面５２との間で表皮凸部２４の第１凸壁面２６を挟むよう構成されている。すなわち、表皮当接部材７０が係止凹部５０に受容して係止した表皮凸部２４の裏側を押すようになった際には、係止凹部５０の第１壁面５２に表皮凸部２４の第１凸壁面２６が押し付けられるようになり、これら係止凹部５０と表皮凸部２４との係止状態が好適に維持され、型閉めに際して表皮材１６のずれが発生することをより一層確実に防止し得る。   Further, as shown in FIG. 6A, each skin contact member 70 is set so as to protrude along the first wall surface 52 of the locking recess 50, and the skin contact member 70 and the first skin contact member 70. The first convex wall surface 26 of the skin convex portion 24 is sandwiched between the wall surface 52 and the wall surface 52. That is, when the skin contact member 70 presses the back side of the skin convex portion 24 received and locked in the locking concave portion 50, the skin convex portion 24 is formed on the first wall surface 52 of the locking concave portion 50. The first convex wall surface 26 is pressed, and the latching state between the latching concave portion 50 and the skin convex portion 24 is suitably maintained, and it is further ensured that the skin material 16 is displaced when the mold is closed. Can be prevented.

次に、前述のように構成された実施例の発泡成形型Ｍにより、表皮付き発泡成形部材１０を成形する工程を説明する。   Next, a process of molding the skin-formed foam molded member 10 using the foam mold M of the embodiment configured as described above will be described.

予め所定形状に予備成形された表皮材１６は、図４に示すように、発泡成形型Ｍの第１成形型３０にセットする。先ず、図４(ａ)に示すように、表皮材１６の非製品部２０を、第１成形型３０の表皮保持面３６に被着するに際し、端縁保持部６０の庇状保持片６４と表皮保持面３６との間に形成された間隙６６に、非製品部２０の端縁２０Ａを差し込む。これにより、非製品部２０の端縁２０Ａを、表皮保持面３６に設けた端縁保持部６０で保持させる。   The skin material 16 preliminarily molded into a predetermined shape is set in the first molding die 30 of the foam molding die M as shown in FIG. First, as shown in FIG. 4A, when the non-product part 20 of the skin material 16 is attached to the skin holding surface 36 of the first mold 30, the hook-like holding piece 64 of the edge holding part 60 and The edge 20 </ b> A of the non-product part 20 is inserted into a gap 66 formed between the skin holding surface 36. As a result, the edge 20 </ b> A of the non-product part 20 is held by the edge holding part 60 provided on the skin holding surface 36.

次いで、図４(ｂ)に示すように、非製品部２０の表皮保持面３６と対面する側に膨出形成された各表皮凸部２４を、表皮保持面３６に凹設された各係止凹部５０に係止させる。各係止凹部５０に各表皮凸部２４を受容して係止すると、非製品部２０が表皮保持面３６へ密着的に被着される。そして、非製品部２０に対する表皮保持面３６の被着が完了した後に、製品部１８を表皮セット面３４に沿って密着させる。これにより表皮材１６は、各表皮凸部２４が対応の各係止凹部５０に係止されるので、第１成形型３０に適切にセットされる。   Next, as shown in FIG. 4 (b), each skin convex portion 24 bulging and formed on the side facing the skin holding surface 36 of the non-product part 20 is provided with each locking recess recessed in the skin holding surface 36. Lock into the recess 50. When each skin convex portion 24 is received and locked in each locking recess 50, the non-product portion 20 is adhered in close contact with the skin holding surface 36. Then, after the attachment of the skin holding surface 36 to the non-product part 20 is completed, the product part 18 is brought into close contact with the skin set surface 34. As a result, the skin material 16 is appropriately set in the first mold 30 because each skin convex portion 24 is locked to the corresponding locking recess 50.

第１成形型３０に対する表皮材１６のセットが完了すると共に、第２成形型３２の基材セット面４０に対する基材１２のセットが完了したら、表皮材１６の上面に所定量の発泡材を注入した後、表皮材１６をセットした第１成形型３０に対して第２成形型３２を型閉めする。なお、型閉め前の第２成形型３２の型面４２には、図５に示すように、圧縮コイルバネ８０により付勢された各表皮当接部材７０が、該型面４２から最大に突出した状態に保持されている。   When the setting of the skin material 16 with respect to the first molding die 30 is completed and the setting of the base material 12 with respect to the base material setting surface 40 of the second molding die 32 is completed, a predetermined amount of foam material is injected into the upper surface of the skin material 16. After that, the second molding die 32 is closed with respect to the first molding die 30 on which the skin material 16 is set. As shown in FIG. 5, each skin contact member 70 biased by the compression coil spring 80 protrudes from the mold surface 42 to the maximum on the mold surface 42 of the second mold 32 before the mold is closed. Held in a state.

そして、第１成形型３０に対して第２成形型３２を閉成する際に、型閉めが完了する直前(型閉めの途中)に、図６(ａ)に示すように、各表皮当接部材７０の先端部を、係止凹部５０に受容して係止した表皮凸部２４に接触させる。すなわち、第２成形型３２にセットした基材１２と第１成形型３０にセットした表皮材１６とが接触する前から、各係止凹部５０に受容して係止した各表皮凸部２４を、各表皮当接部材７０で押える。   Then, when the second mold 32 is closed with respect to the first mold 30, immediately before the mold closing is completed (in the middle of mold closing), as shown in FIG. The distal end portion of the member 70 is brought into contact with the skin convex portion 24 received and locked in the locking recess 50. That is, before the base material 12 set on the second molding die 32 and the skin material 16 set on the first molding die 30 come into contact with each other, the respective skin convex portions 24 received and locked in the respective locking concave portions 50 are formed. Each skin contact member 70 is pressed.

各表皮凸部２４に各表皮当接部材７０が接触した後は、図６(ｂ)に示すように、第１成形型３０に対して第２成形型３２が閉成されるに伴い、表皮凸部２４を押えている各表皮当接部材７０は、圧縮コイルバネ８０の付勢力に抗して収容部４６内へ押されて後退する。そして、基材１２と表皮材１６とが接触した時点では、既に各表皮当接部材７０が対応の各表皮凸部２４を押えていると共に、端縁保持部６０が非製品部２０の端縁２０Ａを保持しているので、非製品部２０が表皮保持面３６から浮き上がったり捲れ上がることが防止される。更に、係止凹部５０の第１壁面５２と表皮凸部２４の第１凸壁面２６とは、図２に示すように、表皮凸部２４を押える表皮当接部材７０により相互密着した状態となるので、基材１２と接触した表皮材１６が表皮セット面３４側へ引張られても、各係止凹部５０と各表皮凸部２４との係止状態が適切に維持される。従って、型閉めに際して、非製品部２０が表皮保持面３６に密着的に保持されると共に製品部１８も表皮セット面３４に密着的に保持され、発泡体１４の発泡成形に際して表皮材１６に弛みや皺ができることを防止し得る。   After each skin contact member 70 comes into contact with each skin convex portion 24, as shown in FIG. 6 (b), as the second molding die 32 is closed with respect to the first molding die 30, the skin Each skin contact member 70 pressing the convex portion 24 is pushed into the accommodating portion 46 against the biasing force of the compression coil spring 80 and retracts. And when the base material 12 and the skin material 16 contact, each skin contact member 70 has already pressed each corresponding skin convex part 24, and the edge holding | maintenance part 60 is the edge of the non-product part 20. Since 20A is held, it is possible to prevent the non-product part 20 from floating or dripping from the skin holding surface 36. Further, as shown in FIG. 2, the first wall surface 52 of the locking recess 50 and the first convex wall surface 26 of the skin convex portion 24 are brought into close contact with each other by the skin contact member 70 that presses the skin convex portion 24. Therefore, even if the skin material 16 in contact with the base material 12 is pulled toward the skin set surface 34 side, the locking state between each locking recess 50 and each skin protrusion 24 is appropriately maintained. Accordingly, when the mold is closed, the non-product portion 20 is held in close contact with the skin holding surface 36 and the product portion 18 is also held in close contact with the skin set surface 34, and loosened by the skin material 16 during foam molding of the foam 14. It can prevent the wrinkles and wrinkles.

発泡成形型Ｍの型閉め後、表皮材１６と基材１２との間に画成された発泡空間内で発泡体１４が成形されて表皮付き発泡成形部材１０の製造が完了したら、第２成形型３２を第１成形型３０から開放し、第１成形型３０から表皮付き発泡成形部材１０を脱型する。この脱型作業では、図７に示すように、第１成形型３０の表皮セット面３４から表皮付き発泡成形部材１０を取外した後、表皮保持面３６に密着している非製品部２０を該表皮製品部１８から剥離させる。このとき、前述したように、表皮凸部２４の第２凸壁面２８と係止凹部５０の第２壁面５４とが、頂部および底部から非製品部２０の外面に向かうに従って第１壁面５２から離間するよう傾斜形成されているので、表皮支持面３６に被着された非製品部２０を表皮セット面３４に隣接した側から引き上げると、表皮凸部２４が第２壁面５４側へ変位するため、第１壁面５２と第１凸壁面２６との係止状態が解除され、該表皮凸部２４は係止凹部５０から容易に外れる。換言すると、表皮付き発泡成形部材１０の脱型時には、基材１２を把持しながら該表皮付き発泡成形部材１０を第１成形型３０から離間させることにより、各表皮凸部２４が各係止凹部５０から簡単に外れて非製品部２０が表皮保持面３６から剥離されるので、作業者が各表皮凸部２４を各係止凹部５０から個別に外す作業が必要とされず、表皮付き発泡成形部材１０の脱型作業が円滑になされる。   After the foam molding die M is closed, when the foam 14 is molded in the foaming space defined between the skin material 16 and the base material 12 and the production of the foam molded member 10 with the skin is completed, the second molding is performed. The mold 32 is released from the first mold 30, and the foamed molded member 10 with the skin is removed from the first mold 30. In this demolding operation, as shown in FIG. 7, after removing the foamed molded member 10 with the skin from the skin setting surface 34 of the first mold 30, the non-product part 20 that is in close contact with the skin holding surface 36 is removed. The skin product part 18 is peeled off. At this time, as described above, the second convex wall surface 28 of the skin convex portion 24 and the second wall surface 54 of the locking concave portion 50 are separated from the first wall surface 52 from the top and bottom to the outer surface of the non-product portion 20. Since the non-product part 20 attached to the skin support surface 36 is pulled up from the side adjacent to the skin set surface 34, the skin convex part 24 is displaced to the second wall surface 54 side. The locking state between the first wall surface 52 and the first convex wall surface 26 is released, and the skin convex portion 24 is easily detached from the locking concave portion 50. In other words, at the time of demolding the foam-formed member 10 with the skin, each skin convex portion 24 becomes each locking recess by separating the foam-formed member 10 with the skin from the first mold 30 while holding the base material 12. Since the non-product part 20 is easily detached from the skin 50 and peeled off from the skin holding surface 36, the operator does not need to remove each skin convex part 24 individually from each locking concave part 50, and foam molding with a skin. The member 10 can be smoothly removed from the mold.

従って、前述した実施例の発泡成形型によれば、次のような作用効果を奏する。先ず、表皮材１６の非製品部２０に突設した表皮凸部２４が係止する係止凹部５０を第１成形型３０の表皮保持面３６に凹設したので、該係止凹部５０に表皮凸部２４を係止させることで、該第１成形型３０にセットした表皮材１６を適切に保持し得る。また、非製品部２０を表皮保持面３６から離間する方向へ引張ることで係止凹部５０から表皮凸部２４が抜け出て外れるので、製造された表皮付き発泡成形部材１０の脱型が容易となる。そして、表皮保持面３６にセットした非製品部２０の端縁２０Ａを保持する端縁保持部６０を有するので、第１成形型３０と第２成形型３２とを型閉めする際に非製品部２０が表皮保持面３６から浮き上がることを防止できる。更に、係止凹部５０に受容して係止された表皮凸部２４を押える表皮当接部材７０を有するので、第１成形型３０と第２成形型３２とを型閉めする際に、表皮凸部２４を係止凹部５０に係止した状態に保持できる。すなわち実施例の発泡成形型Ｍは、端縁保持部６０および表皮当接部材７０を設けたことにより、型閉めに際して非製品部２０を表皮保持面３６に密着保持させることができ、第１成形型３０にセットした表皮材１６に弛みや皺等が形成されることを防止し得る。   Therefore, according to the foaming mold of the embodiment described above, the following operational effects can be obtained. First, since the locking concave portion 50 that locks the skin convex portion 24 protruding from the non-product portion 20 of the skin material 16 is recessed in the skin holding surface 36 of the first mold 30, By locking the convex portion 24, the skin material 16 set in the first mold 30 can be appropriately held. In addition, by pulling the non-product part 20 in the direction away from the skin holding surface 36, the skin convex part 24 comes out and comes off from the locking concave part 50, so that the manufactured foamed molded member 10 with skin can be easily removed. . And since it has the edge holding | maintenance part 60 holding the edge 20A of the non-product part 20 set to the skin holding surface 36, when closing the 1st shaping | molding die 30 and the 2nd shaping | molding die 32, a non-product part 20 can be prevented from floating from the skin holding surface 36. Furthermore, since it has the skin contact member 70 which presses the skin convex part 24 received and latched in the latching recessed part 50, when closing the 1st shaping | molding die 30 and the 2nd shaping | molding die 32, it is skin convexity. The portion 24 can be held in a state of being locked in the locking recess 50. That is, the foam molding die M of the embodiment is provided with the edge holding part 60 and the skin contact member 70, so that the non-product part 20 can be held in close contact with the skin holding surface 36 when the mold is closed. It is possible to prevent slack and wrinkles from being formed on the skin material 16 set in the mold 30.

また、表皮保持面３６に凹設した係止凹部５０は、表皮セット面３４側の第１壁面５２が表皮保持面３６に対して垂直に形成されるので、非製品部２０が表皮セット面３４の側へ引張られた際には表皮凸部２４が係止凹部５０の第１壁面５２に係止されるので、第１成形型３０にセットした表皮材１６のずれが防止される。一方、表皮セット面３４と反対側に位置して第１壁面５２と対向する第２壁面５４が、係止凹部５０の底部から表皮保持面３６に向かうに従って該第１壁面５２から離間するよう傾斜形成されている。従って、表皮付き発泡成形部材１０を第１成形型３０から脱型するに際し、表皮保持面３６に被着されている非製品部２０を表皮セット面３４の側から引張ると、表皮凸部２４が第２壁面５４側へ変位して該表皮凸部２４と係止凹部５０との係止状態が解除されるので、表皮保持面３６からの非製品部２０の剥離が円滑になされて該表皮付き発泡成形部材１０の脱型がより一層容易となる。   Further, the locking recess 50 provided in the skin holding surface 36 is formed so that the first wall surface 52 on the skin setting surface 34 side is perpendicular to the skin holding surface 36, so that the non-product portion 20 is formed on the skin setting surface 34. When pulled to the side, the skin convex portion 24 is locked to the first wall surface 52 of the locking concave portion 50, so that the skin material 16 set in the first mold 30 is prevented from being displaced. On the other hand, the second wall surface 54 located opposite to the skin setting surface 34 and facing the first wall surface 52 is inclined so as to be separated from the first wall surface 52 from the bottom of the locking recess 50 toward the skin holding surface 36. Is formed. Therefore, when the non-product portion 20 attached to the skin holding surface 36 is pulled from the side of the skin setting surface 34 when the foamed molded member 10 with skin is removed from the first mold 30, the skin convex portion 24 is formed. Displacement toward the second wall surface 54 side releases the locked state between the skin convex portion 24 and the locking concave portion 50, so that the non-product portion 20 is smoothly peeled from the skin holding surface 36 and the skin is attached. Demolding of the foam molded member 10 is further facilitated.

また各表皮当接部材７０は、型面４２から出没方向に移動可能に配設されると共に、常には付勢手段により該型面４２から突出する方向に付勢されているので、該表皮当接部材７０が圧縮コイルバネ８０の付勢力により表皮凸部２４を押えるようになり、該表皮凸部２４の潰れや裂け等を防止し得る。また、第１成形型３０と第２成形型３２との型閉め時には、基材１２と表皮材１６とが接触する前から、係止凹部５０に受容して係止された表皮凸部２４を表皮当接部材７０で押えることができるので、基材１２と表皮材１６とが接触しても該表皮材１６のずれを好適に防止し得る。   Each skin contact member 70 is disposed so as to be movable in and out of the mold surface 42 and is always biased in a direction protruding from the mold surface 42 by the biasing means. The contact member 70 can press the skin convex portion 24 by the urging force of the compression coil spring 80, and the skin convex portion 24 can be prevented from being crushed or torn. Further, when the first molding die 30 and the second molding die 32 are closed, before the base material 12 and the skin material 16 come into contact with each other, the skin convex portion 24 received and locked in the locking concave portion 50 is removed. Since it can be pressed by the skin contact member 70, even if the base material 12 and the skin material 16 come into contact with each other, it is possible to suitably prevent the skin material 16 from shifting.

また、実施例の表皮付き発泡成形部材の製造方法によれば、次のような作用効果を奏する。まず、第１成形型３０に対して表皮材１６をセットする際には、表皮材１６の非製品部２０に突設した表皮凸部２４を第１成形型３０の表皮保持面３６に凹設した係止凹部５０に係止させるようにしたので、第１成形型３０にセットした表皮材１６を適切に保持し得る。また、表皮保持面３６にセットした非製品部２０の端縁２０Ａを、該表皮保持面３６に設けた端縁保持部６０で保持するようにしたので、該非製品部２０の浮き上がりを防止し得る。更に、第１成形型３０と第２成形型３２とを型閉めする際には、係止凹部５０に受容して係止された表皮凸部２４を、第２成形型３２に設けた表皮当接部材７０で基材１２と表皮材１６とが接触する前から押えるようにしたので、基材１２と表皮材１６との接触後も係止凹部５０と表皮凸部２４との係止状態が保持され、第１成形型３０にセットした該表皮材１６のずれを防止し得る。従って、第１成形型３０にセットした表皮材１６に弛みや皺が形成されない状態で発泡体１４の成形を行なうことができ、発泡成形型Ｍで製造された表皮付き発泡成形部材１０の製品不良が発生することを防止して製造効率を向上させることができる。   Moreover, according to the manufacturing method of the foam-molded member with a skin of an Example, there exist the following effects. First, when setting the skin material 16 to the first mold 30, the skin convex portion 24 protruding from the non-product portion 20 of the skin material 16 is recessed in the skin holding surface 36 of the first mold 30. Since it was made to latch to the latching recessed part 50 which was made, the skin material 16 set to the 1st shaping | molding die 30 can be hold | maintained appropriately. Further, since the edge 20A of the non-product part 20 set on the skin holding surface 36 is held by the edge holding part 60 provided on the skin holding surface 36, the non-product part 20 can be prevented from being lifted. . Further, when the first mold 30 and the second mold 32 are closed, the skin protrusion 24 provided in the second mold 32 is provided with the skin protrusion 24 received and locked in the locking recess 50. Since the base member 12 and the skin material 16 are pressed by the contact member 70 before they come into contact with each other, the latching concave portion 50 and the skin convex portion 24 are in a locked state even after the base material 12 and the skin material 16 are in contact with each other. The deviation of the skin material 16 that is held and set in the first mold 30 can be prevented. Therefore, the foam 14 can be molded in a state where no slack or wrinkles are formed on the skin material 16 set in the first molding die 30, and the product failure of the foam-molded member 10 with the skin produced by the foam molding die M. It is possible to improve the production efficiency by preventing the occurrence of.

図８は、例えばスプレー成形技術により、表皮成形型Ｓの表皮成形面８２に、スプレーガン８４によりポリウレタンを吹き付けることで、表皮材１６を成形する状態を示した説明断面図である。この表皮成形型Ｓでは、表皮凸部２４を成形するための成形凹部８６が表皮成形面８２に陥凹的に形成されているため、吹き付けたポリウレタンは該成形凹部８６内へ適宜流動するようになり、形成された表皮凸部２４はむしろ非製品部２０より厚く形成されることが多い。従って、非製品部２０に突出した表皮凸部２４を備えた実施例の表皮材１６では、スプレー成形技術により成形される場合であっても各表皮凸部２４が適切に形成され、図１５に示した従来のような不都合が発生しない。また、成形された表皮材１６を表皮成形型Ｓから脱型するに際しては、図８(ｂ)に示すように、表皮凸部２４の形状に合わせて成形凹部８６が上方へ拡開した形状となっているため、非製品部２０を表皮成形面８２から捲り上げても表皮凸部２４が成形凹部８６に引掛かり難く、よって表皮成形型Ｓに対する表皮材１６の脱型が円滑になされる。   FIG. 8 is an explanatory cross-sectional view illustrating a state in which the skin material 16 is molded by spraying polyurethane onto the skin molding surface 82 of the skin molding die S with a spray gun 84 by, for example, spray molding technology. In the skin molding die S, the molding recess 86 for molding the skin projection 24 is formed in the skin molding surface 82 so that the sprayed polyurethane appropriately flows into the molding recess 86. Thus, the formed skin convex portion 24 is often formed to be thicker than the non-product portion 20. Therefore, in the skin material 16 of the embodiment provided with the skin convex portion 24 protruding to the non-product portion 20, each skin convex portion 24 is appropriately formed even in the case of being molded by the spray molding technique. The conventional inconvenience shown does not occur. Further, when the molded skin material 16 is removed from the skin molding die S, as shown in FIG. 8 (b), a shape in which the molding concave portion 86 is expanded upward in accordance with the shape of the skin convex portion 24. Therefore, even if the non-product part 20 is lifted from the skin molding surface 82, the skin convex part 24 is not easily caught by the molding concave part 86, so that the skin material 16 can be smoothly removed from the skin molding die S.

実施例では、端縁保持部６０の庇状保持片６４を、図３に示すように、表皮保持面３６に被着される非製品部２０の端縁２０Ａに亘って連続的に配設した形態としたが、所要長に形成された複数の庇状保持片６４を、所要間隔毎に断続的に配設した形態としてもよい。また端縁保持部６０の形態は、前述した細長プレート状のものに限定されず、非製品部２０の端縁２０Ａの適切な保持を図り得るものであれば、例えば針金状の棒状部材を所要間隔毎に配設した形態等としてもよい。また端縁保持部６０は、エアーシリンダやモータ等の作動機構により、表皮保持面３６に昇降移動可能に配設して、表皮成形面８２に表皮材１６の非製品部２０をセットした際に下降移動して、該非製品部２０の端縁２０Ａをクランプするようにしてもよい。   In the embodiment, as shown in FIG. 3, the hook-shaped holding pieces 64 of the edge holding portion 60 are continuously disposed over the edge 20 </ b> A of the non-product portion 20 that is attached to the skin holding surface 36. Although it was set as a form, it is good also as a form which arrange | positioned the some hook-shaped holding piece 64 formed in required length intermittently for every required space | interval. The shape of the edge holding portion 60 is not limited to the above-described elongated plate shape, and a wire-like rod-like member is required as long as it can appropriately hold the edge 20A of the non-product portion 20. It is good also as the form etc. which were arrange | positioned for every space | interval. Further, the edge holding portion 60 is arranged to be movable up and down on the skin holding surface 36 by an operating mechanism such as an air cylinder or a motor, and when the non-product portion 20 of the skin material 16 is set on the skin molding surface 82. The end 20A of the non-product part 20 may be clamped by moving downward.

実施例では、表皮当接部材７０を丸棒状の部材として例示したが、この表皮当接部材７０の形態はこれに限定されるものではない。すなわち表皮当接部材７０は、角棒状部材(四角形、六角形)としてもよい。   In the embodiment, the skin contact member 70 is exemplified as a round bar member, but the form of the skin contact member 70 is not limited to this. That is, the skin contact member 70 may be a square bar member (square, hexagonal).

実施例では、表皮当接部材７０を付勢する付勢手段８０として圧縮コイルバネを例示したが、この付勢手段８０は、表皮当接部材７０を適切に付勢し得るものであれば、例えばエアーダンパや油圧ダンパ等であってもよい。また表皮当接部材７０は、エアーシリンダやモータ等の作動機構により型面４２に対してスライド移動可能に配設して、表皮保持面３６との間で非製品部２０の端縁２０Ａを挟持するようにしてもよい。   In the embodiment, the compression coil spring is exemplified as the urging means 80 for urging the skin contact member 70. However, if the urging means 80 can appropriately urge the skin contact member 70, for example, An air damper, a hydraulic damper, or the like may be used. The skin contact member 70 is slidably disposed with respect to the mold surface 42 by an operating mechanism such as an air cylinder or a motor, and sandwiches the edge 20A of the non-product portion 20 with the skin holding surface 36. You may make it do.

実施例では、表皮材１６の非製品部２０に突設した表皮凸部２４の外形形状を、表皮保持面３６に凹設した係止凹部５０の形状と同一に形成した場合を例示したが、図９に示すように、該表皮凸部２４の第２凸壁面２８は、係止凹部５０の第２壁面５４に密着しない形状であってもよい。すなわち、少なくとも係止凹部５０の表皮セット面３４と反対側に位置する第２壁面５４を、該係止凹部５０の底部から前記表皮保持面３６に向かうに従って該表皮セット面３４から離間するよう傾斜形成してあれば、表皮凸部２４の第２凸壁面２８が図９に示すように非製品部２０に対して垂直に形成してあっても、非製品部２０を表皮セット面３４の側から捲った場合には表皮凸部２４が係止凹部５０の第２壁面５４側へ変位するので、表皮付き発泡成形部材１０の脱型時には係止凹部５０から表皮凸部２４を容易に離脱させ得る。   In the embodiment, the outer shape of the skin convex portion 24 projecting from the non-product portion 20 of the skin material 16 is exemplified to be the same as the shape of the locking concave portion 50 recessed in the skin holding surface 36. As shown in FIG. 9, the second convex wall surface 28 of the skin convex portion 24 may have a shape that does not adhere to the second wall surface 54 of the locking concave portion 50. In other words, at least the second wall surface 54 located on the opposite side of the locking recess 50 from the skin setting surface 34 is inclined so as to be separated from the skin setting surface 34 from the bottom of the locking recess 50 toward the skin holding surface 36. If it is formed, even if the second convex wall surface 28 of the skin convex portion 24 is formed perpendicular to the non-product portion 20 as shown in FIG. Since the skin convex part 24 is displaced to the second wall surface 54 side of the locking concave part 50 when it is rolled up, the skin convex part 24 is easily detached from the locking concave part 50 when the foamed molded member 10 with skin is removed. obtain.

実施例の発泡成形型を、表皮材と基材との間で発泡体を成形している状態で示した説明断面図である。It is explanatory sectional drawing which showed the foaming mold of the Example in the state which shape | molds the foam between a skin material and a base material. 第１成形型の表皮保持面に凹設した係止凹部に非製品部に突設した表皮凸部を係止させ、非製品部の端縁を端縁保持部で保持すると共に、第２成形型に配設した表皮当接部材で係止凹部に係止した表皮凸部を押えた状態を示した部分断面図である。The skin convex portion protruding from the non-product portion is locked to the locking recess provided in the skin holding surface of the first mold, and the edge of the non-product portion is held by the edge holding portion, and the second molding is performed. It is the fragmentary sectional view which showed the state which pressed down the skin convex part latched by the latching recessed part with the skin contact member arrange | positioned at the type | mold. 表皮材の非製品部に設けた表皮凸部、第１成形型の表皮保持面に設けた係止凹部および端縁保持部と、第２成形型の型面に設けた表皮当接部材を示した斜視図である。The skin convex part provided in the non-product part of the skin material, the locking concave part and the edge holding part provided in the skin holding surface of the first mold, and the skin contact member provided on the mold surface of the second mold FIG. 第１成形型に表皮材を被着する状態を示した説明断面図であって、(ａ)は、非製品部の端縁を端縁保持部の間隙に差し込む状態を示し、(ｂ)は、非製品部に突設した表皮凸部を表皮保持面に凹設した係止凹部に受容して係止した状態を示している。It is explanatory sectional drawing which showed the state which adheres a skin material to a 1st shaping | molding die, Comprising: (a) shows the state which inserts the edge of a non-product part in the clearance gap between edge holding parts, (b) The state is shown in which the skin convex portion protruding from the non-product portion is received and locked in the locking concave portion provided in the skin holding surface. 表皮材をセットした第１成形型に対し、基材をセットした第２成形型を近接させた状態を示した説明断面図である。It is explanatory sectional drawing which showed the state which made the 2nd shaping | molding die which set the base material adjoined with respect to the 1st shaping | molding die which set the skin material. 型閉め途中の状態を示した説明断面図であって、(ａ)は、型閉めの途中において基材と表皮材とが接触する前から、第２成形型に設けた表皮当接部材が係止凹部に係止した表皮凸部を押える状態を示し、(ｂ)は、型閉めが進行することで、基材が表皮材に接触すると共に、表皮当接部材が表皮凸部を押えながら後退する状態を示している。It is explanatory sectional drawing which showed the state in the middle of mold closing, Comprising: (a) is related with the skin contact member provided in the 2nd shaping | molding die before the base material and skin material contacted in the middle of mold closing. (B) shows a state in which the skin convex part locked to the concave part is pressed, and (b) shows that the base material comes into contact with the skin material as the mold closing progresses, and the skin contact member retreats while holding the skin convex part. It shows the state to do. 製造された表皮付き発泡成形部材を第１成形型の表皮セット面から脱型する状態を示した説明断面図である。It is explanatory sectional drawing which showed the state which demolds the manufactured foam molding member with a skin from the skin set surface of a 1st shaping | molding die. (ａ)は、スプレー成形技術により、表皮成形型において実施例の表皮材を成形する状態を示した説明断面図であり、(ｂ)は、成形された表皮材の非製品部を端縁側から捲り上げて表皮材を脱型するに際し、表皮凸部が容易に外れることを示した説明断面図である。(a) is explanatory sectional drawing which showed the state which shape | molds the skin material of an Example in a skin mold by spray molding technology, (b) is a non-product part of the molded skin material from an edge side. It is explanatory sectional drawing which showed that a skin convex part remove | deviates easily when raising and removing a skin material. 非製品部に突設した表皮凸部の別形態例を示した説明断面図である。It is explanatory sectional drawing which showed the example of another form of the skin convex part protrudingly provided in the non-product part. 従来の発泡成形型を、表皮材と基材との間で発泡体を成形している状態で示した説明断面図である。It is explanatory sectional drawing which showed the conventional foaming mold in the state which shape | molds the foam between a skin material and a base material. 第１成形型の表皮セット面および表皮保持面に、製品部および非製品部からなる表皮材をセットする状態を示した説明断面図である。It is explanatory sectional drawing which showed the state which sets the skin material which consists of a product part and a non-product part to the skin set surface and skin holding surface of a 1st shaping | molding die. 型閉めに際して基材と表皮材とが接触することで非製品部が表皮保持面から浮き上がり、係止凸部と表皮凹部との係合が解除される状態を示した説明断面図である。It is explanatory sectional drawing which showed the state from which a non-product part floats up from a skin holding surface because a base material and a skin material contact at the time of mold closing, and engagement with a latching convex part and a skin recessed part is cancelled | released. 製造された表皮付き発泡成形部材を第１成形型から脱型する状態を示した説明断面図である。It is explanatory sectional drawing which showed the state which demolds the manufactured foam molding member with a skin from a 1st shaping | molding die. 表皮成形型から表皮材を脱型する状態を示した説明断面図である。It is explanatory sectional drawing which showed the state which removes a skin material from a skin shaping | molding die. スプレー成形技術により、表皮成形型において従来の表皮材を成形する状態を示した説明断面図である。It is explanatory sectional drawing which showed the state which shape | molds the conventional skin material in a skin mold by spray molding technique.

符号の説明Explanation of symbols

１０ 表皮付き発泡成形部材，１２ 基材，１４ 発泡体，１６ 表皮材，１８ 製品部
２０ 非製品部，２０Ａ 端縁，２４ 表皮凸部，３０ 第１成形型，３２ 第２成形型
３４ 表皮セット面，３６ 表皮保持面，４２ 型面，５０ 係止凹部，５２ 第１壁面
５４ 第２壁面，６０ 端縁保持部，７０ 表皮当接部材，８０ 圧縮コイルバネ(付勢手段) DESCRIPTION OF SYMBOLS 10 Foam molding member with skin, 12 base material, 14 foam, 16 skin material, 18 product part 20 non-product part, 20A edge, 24 skin convex part, 30 1st molding die, 32 2nd molding die 34 skin set Surface, 36 skin holding surface, 42 mold surface, 50 locking recess, 52 first wall surface 54 second wall surface, 60 edge holding member, 70 skin contact member, 80 compression coil spring (biasing means)

Claims (4)

製品部および該製品部の外周に連続する非製品部を一体的に形成した表皮材を被着セット可能であり、前記製品部が被着される表皮セット面および前記非製品部が被着される表皮保持面を設けた第１成形型と、基材を被着セット可能な第２成形型とを備え、前記表皮材をセットした前記第１成形型と前記基材をセットした第２成形型とを型閉めし、これら表皮材と基材との間で発泡体を成形して表皮付き発泡成形部材を製造する発泡成形型において、
前記第１成形型の前記表皮保持面に凹設され、前記非製品部の該表皮保持面と対面する側に膨出形成された表皮凸部を係止する係止凹部と、
前記表皮保持面に設けられ、前記非製品部における端縁の該表皮保持面から離間する側への移動を規制する端縁保持部と、
前記第２成形型の前記表皮保持面に対向する型面から突出して設けられて前記係止凹部と対向し、前記第１成形型と第２成形型との型閉め時に、前記係止凹部に受容された前記表皮凸部を押える表皮当接部材とを有する
ことを特徴とする発泡成形型。 A skin material integrally formed with a product portion and a non-product portion continuous on the outer periphery of the product portion can be attached and set, and a skin set surface to which the product portion is attached and the non-product portion are attached A first molding die provided with a skin holding surface and a second molding die on which a base material can be attached and set, and the first molding die on which the skin material is set and the second molding on which the base material is set In a foam molding mold for closing a mold and producing a foam molded member with a skin by molding a foam between the skin material and the base material,
A locking recess that is recessed in the skin holding surface of the first mold, and that locks the skin protrusion formed on the side facing the skin holding surface of the non-product part; and
An edge holding portion that is provided on the skin holding surface and regulates movement of the edge of the non-product portion to the side away from the skin holding surface;
Protruding from the mold surface facing the skin holding surface of the second molding die, facing the locking recess, and when the first molding die and the second molding die are closed, the locking recess A foam molding die comprising: a skin contact member that presses the received skin convex portion. 前記係止凹部は、前記表皮セット面側の第１壁面が、前記表皮保持面に対して垂直に形成されると共に、前記第１壁面と対向する第２壁面が、該係止凹部の底部から前記表皮保持面に向かうに従って第１壁面から離間するよう傾斜形成される請求項１記載の発泡成形型。   In the locking recess, the first wall surface on the skin set surface side is formed perpendicular to the skin holding surface, and the second wall surface facing the first wall surface extends from the bottom of the locking recess. The foaming mold according to claim 1, wherein the foaming mold is inclined so as to be separated from the first wall surface toward the skin holding surface. 前記表皮当接部材は、前記型面から出没方向に移動可能に配設されると共に、常には付勢手段により該型面から突出する方向へ付勢され、前記第１成形型と第２成形型との型閉め時に、前記基材と前記表皮材とが接触する前から前記表皮凸部を押えるよう設定される請求項１または２記載の発泡成形型。   The skin contact member is disposed so as to be movable from the mold surface in the protruding and retracting direction, and is always urged by the urging means in a direction protruding from the mold surface, so that the first molding die and the second molding die The foaming mold according to claim 1 or 2, wherein the mold is set so as to press the skin convex portion before the base material and the skin material come into contact with each other when the mold is closed. 製品部および該製品部の外周に連続する非製品部を一体的に形成した表皮材を、表皮セット面および表皮保持面を設けた第１成形型に、製品部を表皮セット面に被着すると共に非製品部を表皮保持面に被着した状態でセットし、基材をセットした第２成形型と前記第１成形型とを型閉めし、前記表皮材と基材との間で発泡体を成形して表皮付き発泡成形部材を製造する方法において、
前記非製品部の端縁を、前記表皮保持面に設けた端縁保持部で保持すると共に、前記非製品部に突設した表皮凸部を、前記表皮保持面に凹設された係止凹部に係止して、表皮材を第１成形型にセットし、
前記第１成形型と前記第２成形型とを型閉めする際に、前記係止凹部に受容された前記表皮凸部を、前記基材と前記表皮材とが接触する前から該第２成形型に設けた表皮当接部材で押える
ことを特徴とする表皮付き発泡成形部材の製造方法。 A skin material integrally formed with a product portion and a non-product portion continuous on the outer periphery of the product portion is attached to a first mold having a skin set surface and a skin holding surface, and the product portion is attached to the skin set surface. In addition, the non-product part is set in a state of being attached to the skin holding surface, the second molding die on which the base material is set and the first molding die are closed, and the foam is formed between the skin material and the base material. In the method of producing a foamed molded member with a skin by molding
An end portion of the non-product portion is held by an edge holding portion provided on the skin holding surface, and a skin concave portion protruding from the non-product portion is recessed in the skin holding surface. And set the skin material on the first mold,
When the first molding die and the second molding die are closed, the skin convex portion received in the locking recess is formed in the second molding before the base material and the skin material come into contact with each other. A method for producing a foamed molded member with a skin, characterized by pressing with a skin contact member provided on a mold.
JP2007204680A 2007-08-06 2007-08-06 Foam mold and method for producing foam molded member with skin Expired - Fee Related JP5005464B2 (en)

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