JP5047420B2 - Foam molded body having skin material on both sides and molding method thereof - Google Patents

Foam molded body having skin material on both sides and molding method thereof Download PDF

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JP5047420B2
JP5047420B2 JP2001015037A JP2001015037A JP5047420B2 JP 5047420 B2 JP5047420 B2 JP 5047420B2 JP 2001015037 A JP2001015037 A JP 2001015037A JP 2001015037 A JP2001015037 A JP 2001015037A JP 5047420 B2 JP5047420 B2 JP 5047420B2
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skin material
foam
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foaming
base material
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浩 鈴木
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Inoac Corp
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Description

【０００１】
【発明の属する技術分野】
この発明は、両面に表皮材を有する発泡成形体と、該成形体の成形方法に関するものである。
【０００２】
【従来の技術】
例えば乗用車における比較的高級な内装部材、例えばインストルメントパネルやコンソールを構成する部材としては、最下層となって外部から見えない部位に配されて剛性を有する基材と、車内に露出する最上層の表面となる表皮材と、これら基材と表皮材との間に中間層として介在するウレタン発泡体とからなる発泡成形体が多用される。この三層の発泡成形体は、表皮材にソフトな材質が選定されると共に、中間層のウレタン発泡体がクッションとして機能し、しかも最下層の基材が機械的な強度を負担するものであるために、視覚的にも触感的にも強度的にも優位性が認められるからである。従って前記インストルメントパネルの助手席側に設けられるグローブボックスその他セパレートシートの間に置かれる箱状のコンソールに関しても、該グローブボックスやコンソールの開口部に開閉自在に枢支される蓋部材に前記三層構層の発泡成形体が好適に使用されている。
【０００３】
【発明が解決すべき課題】
前述した三層構層の発泡成形体からなる蓋部材は、車内に露出する表面に前記表皮材が配され、またグローブボックス等の物品収容空間に指向する裏面には前記基材が配されるようになっている。このとき蓋部材の裏面となる基材は一般にフラットに形成されていて、該裏面の部位に何等かの物品を保持するような構造にはなっていない。ところで乗員が車内で使用する可能性のある物品は、ハイウェーカードや硬貨その他ボールペン等の細々とした物が多いが、車両内部のスペースは極めて限られているので、これら物品を整頓状態で収納しておく場所を見出すことは仲々困難である。このような見地で考えると、前記蓋部材の裏面に何等かの工夫をすればハイウェーカードや筆記具等の小さな物品を収納する余地はありそうであるが、現時点では該裏面の有効活用が図られたケースは存在していない。
【０００４】
【発明の目的】
本発明は、前述した課題を好適に解決するために提案されたものであって、例えば車両内部のスペースが限られていて各種物品を整頓状態で収納保持する余地が乏しいことに鑑み、前記グローブボックスやコンソール等の車両用内装部材の開口部を閉成する前記発泡成形体からなる蓋部材の裏面を物品収納部として有効活用することに着目したものであって、これを実現し得る両面に表皮材を有する発泡成形体と、該発泡成形体を好適に成形し得る方法とを提供することを目的とする。
【０００５】
【発明を解決するための手段】
前記課題を克服し、所期の目的を達成するため本発明に係る両面に表皮材を有する発泡成形体は、所要形状に成形されて剛性を有する基材と、前記基材を挟んで一方に設けた第１発泡体および他方に設けた第２発泡体と、所要形状に成形されて柔軟性を有し、前記第１発泡体の外側に設けた第１表皮材と、所要形状に成形されて柔軟性を有し、前記第２発泡体の外側に設けた第２表皮材とから構成され、前記基材は、前記第２表皮材の外周縁部に沿って外方へ露出する形状に成形され、前記第２表皮材には、前記基材と該第２表皮材との間に充満した弾性変形可能な前記第２発泡体側に向け突出して外側が凹み、該第２発泡体で裏側から支持される凹部が形成され、前記凹部の開口部分を挟んで対向する壁面に、該凹部の開口部分側へ突出する弾性変形可能なオーバーハング部が形成され、互いに対向する前記オーバーハング部間の距離は、前記凹部に収納する物品の幅より小さく設定されていることを特徴とする。この場合に、前記基材には所要数の通孔が穿設され、前記第１発泡体および第２発泡体は該通孔を介して繋がっている。また、前記基材は、前記第２表皮材の外周縁部に沿って外方へ露出している。
【０００６】
同じく前記課題を克服し、所期の目的を達成するために本発明は、基材、発泡体および表皮材の三層構造からなる車両用内装部材の開口部に開閉自在に設けられ、該開口部を閉成した状態では表面側を車内に露出させ、該開口部を開放した状態では裏面側を車内に露出させる蓋部材において、前記蓋部材は、蓋部材に必要な形状に成形されて剛性を有する基材と、基材を挟んで一方に設けた第１発泡体および他方に設けた第２発泡体と、蓋部材の表面側に必要な形状に成形されて柔軟性を有し、前記第１発泡体の外側に設けた第１表皮材と、所要形状に成形されて柔軟性を有し、前記第２発泡体の外側に設けられて蓋部材の裏面側となる第２表皮材とから構成され、前記基材は、前記第２表皮材の外周縁部に沿って外方へ露出する形状に成形され、前記第２表皮材には、前記基材と該第２表皮材との間に充満した弾性変形可能な前記第２発泡体側に向け突出して外側が凹み、該第２発泡体で裏側から支持される凹部が形成され、前記凹部の開口部分を挟んで対向する壁面に、該凹部の開口部分側へ突出する弾性変形可能なオーバーハング部が形成され、互いに対向する前記オーバーハング部間の距離は、前記凹部に収納する物品の幅より小さく設定されていることを特徴とする。この場合に前記三層構造からなる車両用内装部材は、グローブボックスやコンソールであって、各種物品を収容するための収容スペースが内部に画成されると共に、該スペースに連通する開口部が開設されている。
【０００７】
更に同じく前記課題を克服し、所期の目的を達成するため本発明に係る両面に表皮材を有する発泡成形体の成形方法は、
予め所要形状に成形されて柔軟性を有する第１表皮材を第１発泡型のキャビテイにセットすると共に、
予め所要形状に成形されて柔軟性を有し、表面から裏面側へ凹む凹部および該凹部の開口部分に突出するオーバーハング部が形成された第２表皮材を、第２発泡型のキャビテイにセットして、該キャビテイに設けた凸部に前記凹部を整合させると共に該凸部に設けた凹部に前記オーバーハング部を整合させ、
所要形状に成形されて剛性を有しかつ所要数の通孔が穿設された基材を、前記第２表皮材の内側から前記キャビテイにセットし、
前記第１発泡型にセットした第１表皮材の内側に発泡原液を注入し、第１発泡型および第２発泡型を閉成して発泡原液の発泡反応を進行させることで、該反応が進行中の発泡原液を基材の通孔を介して第２表皮材の内側へも進入させ、
所要のキュアタイムを経過した後に両発泡型を開放して脱型することで、前記第１表皮材と基材との間に第１発泡体を充満させると共に、前記第２表皮材と基材との間に第２発泡体を充満させ、かつ第２表皮材には、弾性変形可能な前記第２発泡体により裏側から支持された前記凹部および前記オーバーハング部を備えた発泡成形体を成形するようにしたことを特徴とする。
【０００８】
また同じく前記課題を克服し、所期の目的を達成するため本発明に係る両面に表皮材を有する発泡成形体の成形方法は、
予め所要形状に成形されて柔軟性を有する第１表皮材を第１発泡型のキャビテイにセットすると共に、
予め所要形状に成形されて柔軟性を有し、表面から裏面側へ凹む凹部および該凹部の開口部分に突出するオーバーハング部が形成された第２表皮材を、第２発泡型のキャビテイにセットして、該キャビテイに設けた凸部に前記凹部を整合させると共に該凸部に設けた凹部に前記オーバーハング部を整合させ、
所要形状に成形されて剛性を有しかつ所要数の通孔が穿設された基材を、前記第２表皮材の内側から前記キャビテイにセットし、
第１発泡型および第２発泡型を閉成してから前記第１表皮材または第２表皮材の何れか一方の内側へ発泡原液を注入し、発泡反応の進行に伴い該発泡原液を前記基材の通孔を介して他方の第２表皮材または第１表皮材の内側へも進入させ、
所要のキュアタイムを経過した後に両発泡型を開放して脱型することで、前記第１表皮材と基材との間に第１発泡体を充満させると共に、前記第２表皮材と基材との間に第２発泡体を充満させ、かつ第２表皮材には、弾性変形可能な前記第２発泡体により裏側から支持された前記凹部および前記オーバーハング部を備えた発泡成形体を成形するようにしたことを特徴とする。
【０００９】
【発明の実施の形態】
次に、本発明に係る両面に表皮材を有する発泡成形体およびその成形方法につき、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。図１は、実施例に係る蓋部材１０の概略構成を示す斜視図であって、この蓋部材１０は、例えば前述した三層構造のインストルメントパネルに設けたグローブボックス(何れも図示せず)の開口部を開閉自在に閉成するようになっている。すなわち図１の(1)は前記グローブボックスの開口部を閉成した蓋部材１０の表面を示すものであり、また図１の(2)は斜め下方へ傾動して前記開口部を開放した蓋部材１０の裏面を示している。この図１(2)のＡ−Ａ線断面図が図２であり、また図１(2)のＢ−Ｂ線断面図が図３である。なお図面では、両面に表皮材を有する発泡成形体の好適例として車両用内装部材におけるグローブボックス等の蓋部材を挙げているが、これに限定されるものでないことは勿論である。
【００１０】
図２の実施例に係る発泡成形体(蓋部材)は、その両面に第１の表皮材１４および第２の表皮材１６を有すると共に、芯材としての基材１８が中間に設けられ、これら第１の表皮材１４と基材１８との間に第１の発泡体２０が、また第２の表皮材１６と基材１８との間に第２の発泡体２２が対応的に介在させられている。すなわち前記基材１８は、蓋部材１０として必要な形状に成形された剛性を有する合成樹脂製のシート状部材であって、該基材１８には所要数の通孔２４が整列的またはランダムなパターンで穿設されている。この基板１８の両側には、例えばウレタンその他の発泡原液を発泡させた第１発泡体２０および第２発泡体２２が存在し、これらの第１発泡体２０と第２発泡体２２とは前記基材１８に穿設した通孔２４を介して相互に繋がっている。
【００１１】
このように図示例に係る蓋部材１０は、従来の三層構造の車両用内装部材と異なり、一方の側の面だけでなく他方の側の面にも表皮材が設けられると共に、他方の側の表皮材と前記芯材となる基材との間にはウレタン等の発泡体が介在している。従って前記蓋部材１０によれば、その両側の面に良好な触感が得られることに加えて、適当な弾力でのクッション機能が両側に発揮されるものである。また図１の(1)に示すように、蓋部材１０の裏側となる第２表皮材１６に所要の凹部を予め成形しておくことで、この凹部に各種物品を着脱自在に収納保持し得るようになっている。例えば図１の(1)および図２に示した矩形状の凹部２６は、ハイウェーカードやクレジットカード等を平坦に収納保持するスペースであり、図３に示した断面が円弧状をなす凹部２８は、鉛筆やボールペン等の筆記具を収納保持するスペースである。同じく図３に示した断面が大径の円弧状をなす凹部３０は、各種異なる径の硬貨を夫々対応的に横向き状態で収納保持するスペースである。
【００１２】
これら凹部２６,２８,３０の開口部分には、図２および図３に示すように、何れも若干のオーバーハング部２６ａ,２８ａ,３０ａを設けておくのが好ましい。例えばカード等を収納保持する凹部２６のオーバーハング部２６ａは、庇状に両側から水平に延出する部位とすることが推奨される。また筆記具や硬貨を収納保持する凹部２８,３０については、各凹部の開口端を断面逆Ω状に形成することで前記オーバーハング部２８ａ,３０ａが得られる。前記カード、筆記具その他硬貨等を各対応の凹部に保持させるには、これら物品を該凹部の開口部上方に押し付け、前記オーバーハング部を変形させつつ強制的に押し込むことで挿入が完了する。挿入完了後は、これらオーバーハング部が各物品の上部に弾力的に当接するので、該物品は各凹部から容易に脱落することはない。
【００１３】
図示例に係る蓋部材１０では、これに収納される物品としてカード、筆記具、硬貨を例示したが、これに限定されるものでないことは勿論である。また、好適な実施例としてグローブボックスの開口部を閉成する蓋部材１０につき説明したが、これに限定されないことは前述の通りであって、例えば各種工具を前記凹部に圧入保持して携行するキャリングケース用本体等に応用可能である。このようにキャリングケースの本体に本願の「両面に表皮材を有する発泡成形体」を採用した場合は、物品収納用凹部が凹設される側の面に、開閉自在または着脱自在なケース蓋を設けることが推奨される。
【００１４】
次に、両面に表皮材を有する発泡成形体の成形方法について、これを実施する型装置を例示しながら説明する。図４〜図８は、発泡成形体を成形する方法の実施に使用される発泡型３２の概略図である。この発泡型３２は、下型として機能する第１発泡型３４と、上型として機能する第２発泡型３６とから基本的に構成される。第１発泡型３４の内面には所要形状をなすキャビテイ３８が形成されると共に、第２発泡型３６の内面にも所要形状をなすキャビテイ４０が形成されている。なお第２発泡型３６のキャビテイ４０には、図１〜図３に関して説明した凹部２６,２８,３０を形成する凸部が対応的に設けられている。
【００１５】
図４において、第１発泡型３４および第２発泡型３６は全開状態にあるものとする。またスラッシュ成形等の別工程において、所要形状に予め成形されて柔軟性を有する第１表皮材１４および第２表皮材１６が準備してあるものとする。この状態で、第１表皮材１４を下型となる第１発泡型３４のキャビテイ３８にセットすると共に、第２表皮材１６を上型となる第２発泡型３６のキャビテイ４０にセットする。なお、第１発泡型３４および第２発泡型３６には適宜数の真空吸引孔(図示せず)が穿設され、該真空吸引孔の部位で各対応の第１表皮材１４および第２表皮材１６を各キャビテイに吸着させるようになっている。
【００１６】
また別工程において所要形状に成形した基材１８を予め準備し、図５に示す如く、この基材１８を前記第２表皮材１６の内側にセットする。基材１８は、その全面に亘り所要数の通孔２４が穿設されており、構造材として必要な剛性を有している。この場合に、第２表皮材１６の内側と基材１８との間には、後述するウレタン等の発泡材が発泡して充満されるだけの空間が画成されるようになっている。なお前記基材１８の外形寸法は、第２発泡型３６におけるキャビテイ４０の内側寸法と略等しくなるよう設定しておくことで、該基材１８を第２表皮材１６の内側へ脱落不能にセットすることができる。
【００１７】
次いで図６に示すように、下型となる第１発泡型３４にセットした第１表皮材１４の内側に、ウレタン等の発泡原液を図示しないノズル機構を使用して所要量だけ注入する。注入が完了したところで、図７に示すように、第１発泡型３４に対して第２発泡型３６を閉成し、第１表皮材１４の内側で前記発泡原液の発泡反応を進行させる。この原液の発泡反応の進行に伴い、発泡原液は基材１８に穿設してある多数の前記通孔２４を介して第２表皮材１６の内側へも進入し、ここでも発泡反応が進行する。そして所要のキュアタイムを経過した後に、図８に示すように第１発泡型３４から第２発泡型３６を開放して、図９の脱型を行なうことで、第１表皮材１４と基材１８との間に第１発泡体２０が充満され、また第２表皮材１６と該基材１８との間に第２発泡体２２が充満された発泡成形体１０が成形される。
【００１８】
すなわち図９に示す発泡成形体１０は、前記基材１８に予め所要数の通孔２４が穿設してあるために、第１表皮材１４の内側で発泡し始めた原液は第２表皮材１６の内側でも発泡反応を進行させ、最終的に第１表皮材１４および第２表皮材１６の両内側に充満して第１発泡体２０および第２発泡体２２となったものである。このとき第１発泡体２０および第２発泡体２２は、前記通孔２４を介して相互に密接に繋がっている。なお図４〜図８の工程を経て得られた発泡成形体１０は、その用途によって先に図１〜図３で説明した蓋部材１０に必要な成形がなされ、また各種工具や筆記具等を保持して携行し得る前記キャリングケース用本体等に成形される。
【００１９】
なお図４〜図８に示した工程では、第１発泡型３４および第２発泡型３６を開放した状態で発泡原液の注入を行なう所謂オープン注入方式を採用したが、これに限定されるものでなく、両発泡型３４,３６を閉成した状態で発泡原液を注入する所謂クローズド注入方式を採用してもよい。この場合は、図６および図７に関する前記工程が、例えば次の如く入れ換わるものである。すなわち第１発泡型３４に対して第２発泡型３６を閉成した後に、第１表皮材１４または第２表皮材１６の何れか一方の内側へ、当該の発泡型および表皮材に予め対応的に設けた注入孔(図示せず)を介してウレタン等の発泡原液を注入する。そして発泡反応の進行に伴い発泡原液を前記基材１８における通孔２４を介して他方の表皮材(第２表皮材１６または第１表皮材１４)の内側へも進入させる。その後の工程は、先に述べたクローズド注入方式を採用した場合と同じである。
【００２０】
【発明の効果】
以上に説明した如く、例えば車両内部の限られたスペース内では各種物品を整頓状態で収納保持する余地が乏しいことに鑑み、グローブボックスやコンソール等の開口部を閉成する蓋部材(発泡成形体)の裏面を物品収納部として有効活用したい、という点に本発明が端緒が存在している。そこで両面に表皮材を有する発泡成形体とすることで、従来は剛性のある基材の露出部であった部分にクッション性を付与し得ると共に、各種物品を整頓状態で保持し得る機能を持たせ得るようになったものである。また、このように両面に表皮材を有する発泡成形体を簡単かつ確実に成形し得る方法を提供し得たものである。
【図面の簡単な説明】
【図１】両面に表皮材を有する発泡成形体の一実施例に係る蓋部材の概略斜視図であって、(1)は該蓋部材の表面を示し、(2)は該蓋部材の裏面を示している。
【図２】図１(2)のＡ−Ａ線断面図である。
【図３】図１(2)のＢ−Ｂ線断面図である。
【図４】発泡成形方法の実施に使用する発泡型の概略断面図であって、第１発泡型および第２発泡型のキャビテイに第１表皮材および第２表皮材をセットした状態を示している。
【図５】発泡成形方法の実施に使用する発泡型の概略断面図であって、第２表皮材に基材をセットした状態を示している。
【図６】発泡成形方法の実施に使用する発泡型の概略断面図であって、第１表皮材の内側に発泡原液を注入した状態を示している。
【図７】発泡成形方法の実施に使用する発泡型の概略断面図であって、第１発泡型および第２発泡型を閉成した状態を示している。
【図８】発泡成形方法の実施に使用する発泡型の概略断面図であって、キュアタイムを経過した後に、第１発泡型および第２発泡型を開放した状態を示している。
【図９】発泡型から脱型して得られた両面に表皮材を有する発泡成形体の縦断面図である。
【符号の説明】
１０ 蓋部材(発泡成形体)
１４ 第１表皮材
１６ 第２表皮材
１８ 基材
２０ 第１発泡体
２２ 第２発泡体
２４ 通孔
２６,２８,３０ 凹部
２６ａ,２８ａ,３０ａ オーバーハング部
３４ 第１発泡型
３６ 第２発泡型
３８ キャビテイ
４０ キャビテイ [0001]
BACKGROUND OF THE INVENTION
The present invention relates to a foamed molded product having a skin material on both sides and a method for molding the molded product.
[0002]
[Prior art]
For example, as a relatively high-grade interior member in a passenger car, for example, a member constituting an instrument panel or a console, a base material that is disposed in a lowermost portion that cannot be seen from the outside and has rigidity, and an uppermost layer that is exposed inside the vehicle A foam molded body is often used which is composed of a skin material that becomes the surface of the material and a urethane foam that is interposed as an intermediate layer between the base material and the skin material. In this three-layer foam molding, a soft material is selected for the skin material, the urethane foam in the intermediate layer functions as a cushion, and the lowermost base material bears mechanical strength. For this reason, superiority is recognized in both visual, tactile, and strength. Therefore, with respect to a glove box provided on the passenger side of the instrument panel and other box-like consoles placed between separate seats, the three lids are pivotally supported by the glove box and the opening of the console. A layered foam molded article is preferably used.
[0003]
[Problems to be Solved by the Invention]
In the lid member made of the three-layer foam molded body described above, the skin material is arranged on the surface exposed in the vehicle, and the base material is arranged on the back surface facing the article storage space such as a glove box. It is like that. At this time, the base material which becomes the back surface of the lid member is generally formed flat, and is not structured to hold any article on the back surface portion. By the way, there are many small items such as highway cards, coins and ballpoint pens that passengers may use in the car, but the space inside the vehicle is extremely limited, so these items must be stored in an orderly manner. It is difficult to find a place to keep. Considering this point of view, it seems that there is room for storing small articles such as highway cards and writing instruments if any device is provided on the back surface of the lid member, but at the present time, the back surface is effectively utilized. There are no cases.
[0004]
OBJECT OF THE INVENTION
The present invention has been proposed in order to suitably solve the above-described problems. For example, in view of the fact that the space inside the vehicle is limited and there is little room for storing and holding various articles in an organized state. Focusing on the effective use of the back surface of the lid member made of the foamed molded body that closes the opening of the interior member for a vehicle such as a box or console as an article storage unit, on both sides that can realize this It aims at providing the foaming molding which has a skin material, and the method which can shape | mold this foaming molding suitably.
[0005]
[Means for Solving the Invention]
In order to overcome the above-mentioned problems and achieve the intended purpose, a foamed molded article having a skin material on both sides according to the present invention is a base material that is molded into a required shape and has rigidity, and a base material sandwiched between the base material. The first foam provided and the second foam provided on the other side are molded into a required shape and have flexibility, and the first skin material provided outside the first foam is molded into the required shape. And a second skin material provided on the outside of the second foam, and the base material is exposed to the outside along the outer peripheral edge of the second skin material. molded, before Symbol second skin material, see concavely outwardly protrudes toward the elastically deformable second foam side was filled between the base material and the second skin material, the second foam in recess which is supported from the rear side is formed on a wall surface opposite to each other with respect to the opening portion of the recess, projecting into the opening portion side of the recess Is formed elastically deformable overhang portion, the distance between the overhang portions facing each other, characterized in that it is set smaller than the width of the article to be housed in the recess. In this case, a required number of through holes are formed in the base material, and the first foam and the second foam are connected via the through holes. Moreover, the said base material is exposed outside along the outer-periphery edge part of the said 2nd skin material.
[0006]
Similarly, in order to overcome the above-mentioned problems and achieve the intended purpose, the present invention is provided in an opening of a vehicle interior member having a three-layer structure of a base material, a foam and a skin material, and is openable and closable. When the cover is closed, the front side is exposed in the vehicle, and when the opening is opened, the back side is exposed in the vehicle. The first foam provided on one side with the base material interposed therebetween, the second foam provided on the other side, and formed into a required shape on the surface side of the lid member and have flexibility, A first skin material provided on the outer side of the first foam, and a second skin material molded into a required shape and having flexibility, and provided on the outer side of the second foam and serving as the back side of the lid member; consists, the substrate is formed into a shape which is exposed to the outside along the outer edge of the second skin material Is, wherein the second skin material, outer seen concave protrudes toward the second foamed body side elastically deformable filling the between the base material and the second skin material, the back side in the second foam recess to be supported is formed from, a wall surface opposite to each other with respect to the opening portion of the recess, elastically deformable overhang portion protruding toward the opening portion side of the concave portion is formed, between the overhang portion facing each other Is set to be smaller than the width of the article stored in the recess. In this case, the vehicle interior member having the three-layer structure is a glove box or a console, and a storage space for storing various articles is defined inside, and an opening communicating with the space is opened. Has been.
[0007]
Furthermore, in order to overcome the above-mentioned problem and achieve the intended purpose, a molding method of a foamed molded article having a skin material on both sides according to the present invention,
Set the first skin material, which is molded into the required shape in advance and has flexibility, into the first foaming type cavity,
A second skin material that has been formed into a required shape and has flexibility and has a recess recessed from the front surface to the back surface and an overhang projecting from the opening of the recess is set in the second foam type cavity And aligning the concave portion with the convex portion provided in the cavity and aligning the overhang portion with the concave portion provided in the convex portion,
A base material molded into a required shape and having rigidity and a required number of through holes is set in the cavity from the inside of the second skin material,
The reaction proceeds by injecting a foaming stock solution inside the first skin material set in the first foaming mold, closing the first foaming mold and the second foaming mold, and advancing the foaming reaction of the foaming stock solution. The foaming stock solution inside also enters the inside of the second skin material through the through hole of the base material,
After the required cure time has elapsed, both foaming molds are opened and removed to fill the first foam between the first skin material and the base material, and the second skin material and the base material. The second foam is filled with the second foam, and the second skin material is molded with a foam molded body provided with the concave portion and the overhang portion supported from the back side by the elastically deformable second foam. It was made to do.
[0008]
In addition, in order to overcome the above-mentioned problems and achieve the intended purpose, a molding method of a foamed molded article having a skin material on both sides according to the present invention,
Set the first skin material, which is molded into the required shape in advance and has flexibility, into the first foaming type cavity,
A second skin material that has been formed into a required shape and has flexibility and has a recess recessed from the front surface to the back surface and an overhang projecting from the opening of the recess is set in the second foam type cavity And aligning the concave portion with the convex portion provided in the cavity and aligning the overhang portion with the concave portion provided in the convex portion,
A base material molded into a required shape and having rigidity and a required number of through holes is set in the cavity from the inside of the second skin material,
After the first foaming mold and the second foaming mold are closed, a foaming stock solution is injected into one of the first skin material and the second skin material, and the foaming stock solution is added to the base as the foaming reaction proceeds. The inside of the other second skin material or the first skin material through the through-hole of the material,
After the required cure time has elapsed, both foaming molds are opened and removed to fill the first foam between the first skin material and the base material, and the second skin material and the base material. The second foam is filled with the second foam, and the second skin material is molded with a foam molded body provided with the concave portion and the overhang portion supported from the back side by the elastically deformable second foam. It was made to do.
[0009]
DETAILED DESCRIPTION OF THE INVENTION
Next, a foamed molded product having a skin material on both sides according to the present invention and a molding method thereof will be described below with reference to the accompanying drawings by giving preferred examples. FIG. 1 is a perspective view illustrating a schematic configuration of a lid member 10 according to an embodiment. The lid member 10 is a glove box (not shown) provided on, for example, the above-described instrument panel having a three-layer structure. The opening part of this is closed so that opening and closing is possible. That is, (1) in FIG. 1 shows the surface of the lid member 10 that closes the opening of the glove box, and (2) in FIG. 1 tilts downward obliquely to open the opening. The back surface of the member 10 is shown. 2 is a sectional view taken along line AA in FIG. 1 (2), and FIG. 3 is a sectional view taken along line BB in FIG. 1 (2). In the drawings, a lid member such as a glove box in a vehicle interior member is cited as a preferred example of a foam molded body having a skin material on both sides, but it is needless to say that the present invention is not limited to this.
[0010]
The foam molded body (lid member) according to the embodiment of FIG. 2 has a first skin material 14 and a second skin material 16 on both sides thereof, and a base material 18 as a core material is provided in the middle. A first foam 20 is interposed between the first skin material 14 and the base material 18, and a second foam 22 is interposed between the second skin material 16 and the base material 18 correspondingly. ing. In other words, the base material 18 is a sheet-like member made of synthetic resin and having a rigidity formed into a shape necessary for the lid member 10, and a required number of through holes 24 are arranged in the base material 18 in an aligned or random manner. It is drilled with a pattern. On both sides of the substrate 18 are, for example, a first foam 20 and a second foam 22 obtained by foaming urethane or other foaming stock solution. The first foam 20 and the second foam 22 are the above-mentioned bases. They are connected to each other through a through hole 24 formed in the material 18.
[0011]
As described above, the lid member 10 according to the illustrated example differs from the conventional three-layer vehicle interior member in that the skin material is provided not only on one side but also on the other side and the other side. A foamed material such as urethane is interposed between the outer skin material and the base material serving as the core material. Therefore, according to the lid member 10, in addition to obtaining a good tactile sensation on both sides, a cushion function with an appropriate elasticity is exhibited on both sides. Further, as shown in FIG. 1 (1), by forming a required recess in the second skin material 16 on the back side of the lid member 10 in advance, various articles can be detachably stored and held in the recess. It is like that. For example, the rectangular recess 26 shown in FIG. 1 (1) and FIG. 2 is a space for storing and holding a highway card, a credit card, etc. flat, and the recess 28 whose section shown in FIG. It is a space for storing and holding writing instruments such as pencils and ballpoint pens. Similarly, the concave portion 30 having an arc shape with a large cross section shown in FIG. 3 is a space for storing and holding coins of various different diameters in a horizontally oriented state.
[0012]
As shown in FIGS. 2 and 3, it is preferable to provide some overhangs 26a, 28a, 30a in the opening portions of the recesses 26, 28, 30. For example, it is recommended that the overhang portion 26a of the recess 26 for storing and holding a card or the like is a portion that extends horizontally from both sides in a bowl shape. For the recesses 28 and 30 for storing and holding writing instruments and coins, the overhang portions 28a and 30a can be obtained by forming the open ends of the recesses in an inverted Ω cross section. In order to hold the card, writing instrument and other coins in the corresponding recesses, the insertion is completed by pressing these articles above the openings of the recesses and forcibly pushing them in while deforming the overhangs. After the insertion is completed, these overhang portions elastically contact the upper portions of the respective articles, so that the articles do not easily fall out of the respective concave portions.
[0013]
In the lid member 10 according to the illustrated example, the card, the writing instrument, and the coin are exemplified as the articles stored therein, but it is needless to say that the present invention is not limited thereto. Further, as a preferred embodiment, the lid member 10 for closing the opening of the glove box has been described. However, the present invention is not limited to this. As described above, for example, various tools are press-fitted and held in the recess. It can be applied to a carrying case body. As described above, when the “foam molded body having a skin material on both sides” of the present application is adopted as the main body of the carrying case, a case lid that can be opened and closed or detached is provided on the surface on which the concave portion for storing articles is formed. It is recommended to provide it.
[0014]
Next, a method for forming a foamed molded article having a skin material on both sides will be described with reference to a mold apparatus for carrying out the method. 4 to 8 are schematic views of the foaming mold 32 used for carrying out the method of molding a foamed molded body. The foaming mold 32 is basically composed of a first foaming mold 34 that functions as a lower mold and a second foaming mold 36 that functions as an upper mold. A cavity 38 having a required shape is formed on the inner surface of the first foaming mold 34, and a cavity 40 having a required shape is also formed on the inner surface of the second foaming mold 36. Note that the cavity 40 of the second foamable 3 6, the convex portion forming the concave portion 26, 28, 30 described with respect to FIGS. 1 to 3 are provided correspondingly.
[0015]
In FIG. 4, it is assumed that the first foaming mold 34 and the second foaming mold 36 are in a fully opened state. In another process such as slush molding, it is assumed that the first skin material 14 and the second skin material 16 which are molded in a required shape and have flexibility are prepared. In this state, the first skin material 14 is set in the cavity 38 of the first foaming mold 34 serving as the lower mold, and the second skin material 16 is set in the cavity 40 of the second foaming mold 36 serving as the upper mold. The first foaming mold 34 and the second foaming mold 36 are each provided with an appropriate number of vacuum suction holes (not shown), and the corresponding first skin material 14 and second skin material at the vacuum suction hole portions. The material 16 is attracted to each cavity.
[0016]
Further, a base material 18 formed into a required shape in another process is prepared in advance, and the base material 18 is set inside the second skin material 16 as shown in FIG. The base material 18 has a required number of through holes 24 formed on the entire surface thereof, and has a rigidity necessary as a structural material. In this case, a space is formed between the inside of the second skin material 16 and the base material 18 so as to be filled with a foam material such as urethane, which will be described later. The outer dimensions of the base material 18 are set so as to be substantially equal to the inner dimensions of the cavity 40 in the second foaming mold 36, so that the base material 18 is set so as not to fall off the second skin material 16. can do.
[0017]
Next, as shown in FIG. 6, a required amount of foaming stock solution such as urethane is injected into the inside of the first skin material 14 set in the first foaming mold 34 as the lower mold using a nozzle mechanism (not shown). When the injection is completed, as shown in FIG. 7, the second foaming mold 36 is closed with respect to the first foaming mold 34, and the foaming reaction of the foaming stock solution proceeds inside the first skin material 14. Along with the progress of the foaming reaction of the stock solution, the foaming stock solution also enters the inside of the second skin material 16 through the numerous through holes 24 formed in the base material 18, and the foaming reaction also proceeds here. . Then, after the required cure time has elapsed, the first foam material 14 and the base material are removed by releasing the second foaming mold 36 from the first foaming mold 34 as shown in FIG. The first foam 20 is filled between the first foam 20 and the second foam 22 is filled between the second skin material 16 and the base material 18.
[0018]
That is, since the foam molded body 10 shown in FIG. 9 has the required number of through holes 24 previously formed in the base material 18, the stock solution that has begun to foam inside the first skin material 14 is the second skin material. The foaming reaction also proceeds on the inner side of 16, and finally the inner sides of both the first skin material 14 and the second skin material 16 are filled into the first foam body 20 and the second foam body 22. At this time, the first foam body 20 and the second foam body 22 are closely connected to each other through the through hole 24. The foamed molded product 10 obtained through the steps shown in FIGS. 4 to 8 is formed into the lid member 10 described above with reference to FIGS. 1 to 3 according to its use, and holds various tools and writing tools. The carrying case main body and the like can be carried.
[0019]
In the steps shown in FIGS. 4 to 8, a so-called open injection method in which the foaming stock solution is injected while the first foaming mold 34 and the second foaming mold 36 are opened is used. However, the present invention is not limited to this. Alternatively, a so-called closed injection method may be employed in which the foaming stock solution is injected with both the foaming molds 34 and 36 closed. In this case, the steps relating to FIGS. 6 and 7 are replaced as follows, for example. That is, after the second foaming mold 36 is closed with respect to the first foaming mold 34, the foaming mold and the skin material are preliminarily associated with either the first skin material 14 or the second skin material 16. A foaming undiluted solution such as urethane is injected through an injection hole (not shown) provided in the container. Then, as the foaming reaction proceeds, the foaming stock solution is caused to enter the other skin material (second skin material 16 or first skin material 14) through the through holes 24 in the base material 18. The subsequent steps are the same as when the closed injection method described above is employed.
[0020]
【Effect of the invention】
As described above, in view of the lack of room for storing and holding various articles in an organized state within a limited space inside the vehicle, for example, a lid member (foam molded body) that closes an opening of a glove box, a console, or the like. The present invention has its origins in that it is desired to effectively use the back surface of () as an article storage unit. Therefore, by forming a foam molded body having a skin material on both sides, it is possible to impart cushioning properties to the exposed portion of the rigid base material and to hold various articles in an orderly manner. It has come to be able to be. In addition, the present invention can provide a method capable of easily and reliably forming a foamed molded article having a skin material on both sides.
[Brief description of the drawings]
FIG. 1 is a schematic perspective view of a lid member according to an embodiment of a foam molded body having a skin material on both sides, wherein (1) shows the surface of the lid member and (2) shows the back surface of the lid member Is shown.
FIG. 2 is a cross-sectional view taken along line AA in FIG.
3 is a cross-sectional view taken along line BB in FIG. 1 (2).
FIG. 4 is a schematic cross-sectional view of a foam mold used for carrying out the foam molding method, showing a state in which the first skin material and the second skin material are set in the cavities of the first foam mold and the second foam mold. Yes.
FIG. 5 is a schematic cross-sectional view of a foam mold used for carrying out the foam molding method, showing a state in which a base material is set on a second skin material.
FIG. 6 is a schematic cross-sectional view of a foaming mold used for carrying out the foam molding method, showing a state in which a foaming stock solution is injected into the first skin material.
FIG. 7 is a schematic cross-sectional view of a foam mold used for carrying out the foam molding method, showing a state in which the first foam mold and the second foam mold are closed.
FIG. 8 is a schematic cross-sectional view of a foaming mold used for carrying out the foaming molding method, and shows a state in which the first foaming mold and the second foaming mold are opened after the cure time has elapsed.
FIG. 9 is a longitudinal sectional view of a foamed molded article having a skin material on both sides obtained by demolding from a foaming mold.
[Explanation of symbols]
10 Lid member (foam molding)
14 First skin material 16 Second skin material 18 Base material 20 First foam 22 Second foam 24 Through-hole
26, 28, 30 Recess
26a, 28a, 30a Overhang part 34 1st foam type 36 2nd foam type
38 Cavity
40 Cavity

Claims (7)

所要形状に成形されて剛性を有する基材(18)と、
前記基材(18)を挟んで一方に設けた第１発泡体(20)および他方に設けた第２発泡体(22)と、
所要形状に成形されて柔軟性を有し、前記第１発泡体(20)の外側に設けた第１表皮材(14)と、
所要形状に成形されて柔軟性を有し、前記第２発泡体(22)の外側に設けた第２表皮材(16)とから構成され、
前記基材(18)は、前記第２表皮材(16)の外周縁部に沿って外方へ露出する形状に成形され、
前記第２表皮材(16)には、前記基材(18)と該第２表皮材(16)との間に充満した弾性変形可能な前記第２発泡体(22)側に向け突出して外側が凹み、該第２発泡体(22)で裏側から支持される凹部(26,28,30)が形成され、
前記凹部(26,28,30)の開口部分を挟んで対向する壁面に、該凹部(26,28,30)の開口部分側へ突出する弾性変形可能なオーバーハング部(26a,28a,30a)が形成され、
互いに対向する前記オーバーハング部(26a,28a,30a)間の距離は、前記凹部(26,28,30)に収納する物品の幅より小さく設定されている
ことを特徴とする両面に表皮材を有する発泡成形体。A base material (18) which is molded into a required shape and has rigidity,
A first foam (20) provided on one side of the substrate (18) and a second foam (22) provided on the other;
A first skin material (14) which is molded into a required shape and has flexibility and is provided outside the first foam (20);
A second skin material (16) formed on the outer side of the second foam (22), which is molded into a required shape and has flexibility.
The base material (18) is molded into a shape exposed outward along the outer peripheral edge of the second skin material (16),
The front Stories second skin material (16), and protrudes toward the full the elastically deformable second foam (22) side between said substrate (18) second skin material (16) outside seen concave recess is supported from the back side in the second foam (22) (26, 28, 30) is formed,
Overhanging portions (26a, 28a, 30a) that are elastically deformable projecting toward the opening portion side of the recesses (26, 28, 30) on the wall surfaces facing the opening portions of the recesses (26, 28, 30) Formed,
The distance between the overhang portions (26a, 28a, 30a) facing each other is set to be smaller than the width of the article stored in the recess (26, 28, 30). Foam molded body having. 前記基材(18)には所要数の通孔(24)が穿設され、前記第１発泡体(20)および第２発泡体(22)は該通孔(24)を介して繋がっている請求項１記載の両面に表皮材を有する発泡成形体。  The base material (18) is provided with a required number of through holes (24), and the first foam (20) and the second foam (22) are connected via the through holes (24). The foaming molding which has a skin material on both surfaces of Claim 1. 基材、発泡体および表皮材の三層構造からなる車両用内装部材の開口部に開閉自在に設けられ、該開口部を閉成した状態では表面側を車内に露出させ、該開口部を開放した状態では裏面側を車内に露出させる蓋部材(10)において、
前記蓋部材(10)は、
蓋部材(10)に必要な形状に成形されて剛性を有する基材(18)と、
基材(18)を挟んで一方に設けた第１発泡体(20)および他方に設けた第２発泡体(22)と、
蓋部材(10)の表面側に必要な形状に成形されて柔軟性を有し、前記第１発泡体(20)の外側に設けた第１表皮材(14)と、
所要形状に成形されて柔軟性を有し、前記第２発泡体(22)の外側に設けられて蓋部材(10)の裏面側となる第２表皮材(16)とから構成され、
前記基材(18)は、前記第２表皮材(16)の外周縁部に沿って外方へ露出する形状に成形され、
前記第２表皮材(16)には、前記基材(18)と該第２表皮材(16)との間に充満した弾性変形可能な前記第２発泡体(22)側に向け突出して外側が凹み、該第２発泡体(22)で裏側から支持される凹部(26,28,30)が形成され、
前記凹部(26,28,30)の開口部分を挟んで対向する壁面に、該凹部(26,28,30)の開口部分側へ突出する弾性変形可能なオーバーハング部(26a,28a,30a)が形成され、
互いに対向する前記オーバーハング部(26a,28a,30a)間の距離は、前記凹部(26,28,30)に収納する物品の幅より小さく設定されている
ことを特徴とする車両用内装部材の蓋部材。Opened and closed at the opening of a vehicle interior member consisting of a three-layer structure of a base material, foam, and skin material. When the opening is closed, the front side is exposed to the interior of the vehicle and the opening is opened. In the lid member (10) that exposes the back side in the vehicle in the
The lid member (10)
A base material (18) which is molded into a shape necessary for the lid member (10) and has rigidity,
A first foam (20) provided on one side with a substrate (18) in between, and a second foam (22) provided on the other;
A first skin material (14) which is molded into a required shape on the surface side of the lid member (10) and has flexibility and is provided outside the first foam (20);
A second skin material (16) which is molded into a required shape and has flexibility and is provided on the outer side of the second foam (22) and which is the back side of the lid member (10);
The base material (18) is molded into a shape exposed outward along the outer peripheral edge of the second skin material (16),
The second skin material (16) protrudes outwardly toward the elastically deformable second foam (22) filled between the base material (18) and the second skin material (16). but seen concave recess is supported from the back side in the second foam (22) (26, 28, 30) is formed,
Overhanging portions (26a, 28a, 30a) that are elastically deformable projecting toward the opening portion side of the recesses (26, 28, 30) on the wall surfaces facing the opening portions of the recesses (26, 28, 30) Formed,
A distance between the overhang portions (26a, 28a, 30a) facing each other is set smaller than a width of an article stored in the recess (26, 28, 30). Lid member. 前記三層構造からなる車両用内装部材は、グローブボックスやコンソールである請求項３記載の車両用内装部材の蓋部材。The lid member for a vehicle interior member according to claim 3, wherein the vehicle interior member having the three-layer structure is a glove box or a console. 予め所要形状に成形されて柔軟性を有する第１表皮材(14)を第１発泡型(34)のキャビテイ(38)にセットすると共に、
予め所要形状に成形されて柔軟性を有し、表面から裏面側へ凹む凹部(26,28,30)および該凹部(26,28,30)の開口部分に突出するオーバーハング部(26a,28a,30a)が形成された第２表皮材(16)を、第２発泡型(36)のキャビテイ(40)にセットして、該キャビテイ(40)に設けた凸部に前記凹部(26,28,30)を整合させると共に該凸部に設けた凹部に前記オーバーハング部(26a,28a,30a)を整合させ、
所要形状に成形されて剛性を有しかつ所要数の通孔(24)が穿設された基材(18)を、前記第２表皮材(16)の内側から前記キャビテイ(40)にセットし、
前記第１発泡型(34)にセットした第１表皮材(14)の内側に発泡原液を注入し、第１発泡型(34)および第２発泡型(36)を閉成して発泡原液の発泡反応を進行させることで、該反応が進行中の発泡原液を基材(18)の通孔(24)を介して第２表皮材(16)の内側へも進入させ、
所要のキュアタイムを経過した後に両発泡型(34,36)を開放して脱型することで、前記第１表皮材(14)と基材(18)との間に第１発泡体(20)を充満させると共に、前記第２表皮材(16)と基材(18)との間に第２発泡体(22)を充満させ、かつ第２表皮材(16)には、弾性変形可能な前記第２発泡体(22)により裏側から支持された前記凹部(26,28,30)および前記オーバーハング部(26a,28a,30a)を備えた発泡成形体(10)を成形するようにした
ことを特徴とする両面に表皮材を有する発泡成形体の成形方法。Set the first skin material (14), which has been molded into the required shape in advance and has flexibility, into the cavity (38) of the first foaming mold (34),
The recesses (26, 28, 30) that have been molded into a required shape in advance and have flexibility, are recessed from the front surface to the back surface side, and the overhang portions (26a, 28a) that protrude into the opening portions of the recesses (26, 28, 30) , 30a) is set in the cavity (40) of the second foaming mold (36), and the concave portion (26, 28) is formed on the convex portion provided on the cavity (40). , 30) and align the overhang portion (26a, 28a, 30a) with the concave portion provided in the convex portion,
A base material (18) molded into a required shape and having rigidity and having a required number of through holes (24) is set in the cavity (40) from the inside of the second skin material (16). ,
The foaming stock solution is injected inside the first skin material (14) set in the first foaming mold (34), and the first foaming mold (34) and the second foaming mold (36) are closed to form the foaming stock solution. By allowing the foaming reaction to proceed, the foaming stock solution in which the reaction is in progress also enters the inside of the second skin material (16) through the through hole (24) of the base material (18),
After the required cure time has elapsed, the first foam (20) is opened between the first skin material (14) and the base material (18) by opening both foaming molds (34, 36) and removing the mold. ), The second foam material (22) is filled between the second skin material (16) and the base material (18), and the second skin material (16) is elastically deformable. The foam molded body (10) provided with the concave portions (26, 28, 30) and the overhang portions (26a, 28a, 30a) supported from the back side by the second foam (22 ) is molded. A method for forming a foamed molded article having a skin material on both sides. 予め所要形状に成形されて柔軟性を有する第１表皮材(14)を第１発泡型(34)のキャビテイ(38)にセットすると共に、
予め所要形状に成形されて柔軟性を有し、表面から裏面側へ凹む凹部(26,28,30)および該凹部(26,28,30)の開口部分に突出するオーバーハング部(26a,28a,30a)が形成された第２表皮材(16)を、第２発泡型(36)のキャビテイ(40)にセットして、該キャビテイ(40)に設けた凸部に前記凹部(26,28,30)を整合させると共に該凸部に設けた凹部に前記オーバーハング部(26a,28a,30a)を整合させ、
所要形状に成形されて剛性を有しかつ所要数の通孔(24)が穿設された基材(18)を、前記第２表皮材(16)の内側から前記キャビテイ(40)にセットし、
第１発泡型(34)および第２発泡型(36)を閉成してから前記第１表皮材(14)または第２表皮材(16)の何れか一方の内側へ発泡原液を注入し、発泡反応の進行に伴い該発泡原液を前記基材(18)の通孔(24)を介して他方の第２表皮材(16)または第１表皮材(14)の内側へも進入させ、
所要のキュアタイムを経過した後に両発泡型(34,36)を開放して脱型することで、前記第１表皮材(14)と基材(18)との間に第１発泡体(20)を充満させると共に、前記第２表皮材(16)と基材(18)との間に第２発泡体(22)を充満させ、かつ第２表皮材(16)には、弾性変形可能な前記第２発泡体(22)により裏側から支持された前記凹部(26,28,30)および前記オーバーハング部(26a,28a,30a)を備えた発泡成形体(10)を成形するようにした
ことを特徴とする両面に表皮材を有する発泡成形体の成形方法。Set the first skin material (14), which has been molded into the required shape in advance and has flexibility, into the cavity (38) of the first foaming mold (34),
The recesses (26, 28, 30) that have been molded into a required shape in advance and have flexibility, are recessed from the front surface to the back surface side, and the overhang portions (26a, 28a) that protrude into the opening portions of the recesses (26, 28, 30) , 30a) is set in the cavity (40) of the second foaming mold (36), and the concave portion (26, 28) is formed on the convex portion provided on the cavity (40). , 30) and align the overhang portion (26a, 28a, 30a) with the concave portion provided in the convex portion,
A base material (18) molded into a required shape and having rigidity and having a required number of through holes (24) is set in the cavity (40) from the inside of the second skin material (16). ,
After the first foaming mold (34) and the second foaming mold (36) are closed, the foaming stock solution is injected into one of the first skin material (14) and the second skin material (16), As the foaming reaction proceeds, the foaming stock solution enters the other second skin material (16) or first skin material (14) through the through hole (24) of the base material (18),
After the required cure time has elapsed, the first foam (20) is opened between the first skin material (14) and the base material (18) by opening both foaming molds (34, 36) and removing the mold. ), The second foam material (22) is filled between the second skin material (16) and the base material (18), and the second skin material (16) is elastically deformable. The foam molded body (10) provided with the concave portions (26, 28, 30) and the overhang portions (26a, 28a, 30a) supported from the back side by the second foam (22 ) is molded. A method for forming a foamed molded article having a skin material on both sides. 前記第２発泡型(36)を、前記第１発泡型(34)から上方へ開放させ、
下向きの前記キャビテイ(40)の内形寸法と同じ外形寸法に形成された前記基材(18)を、該キャビテイ(40)の対向する内壁部に該基材(18)の対向する外壁部を当接させた状態でセットする請求項５または６記載の両面に表皮材を有する発泡成形体の成形方法。Opening the second foaming mold (36) upward from the first foaming mold (34);
The base material (18) formed to have the same external dimensions as the internal shape dimension of the downwardly facing cavity (40), and the opposing outer wall portion of the base material (18) is formed on the opposing inner wall portion of the cavity (40). The method for forming a foamed molded article having a skin material on both sides according to claim 5 or 6, wherein the foamed article is set in a state of contact.
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