JP5808942B2 - Method for manufacturing shock absorbing pad and shock absorbing pad - Google Patents

Method for manufacturing shock absorbing pad and shock absorbing pad Download PDF

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JP5808942B2
JP5808942B2 JP2011105231A JP2011105231A JP5808942B2 JP 5808942 B2 JP5808942 B2 JP 5808942B2 JP 2011105231 A JP2011105231 A JP 2011105231A JP 2011105231 A JP2011105231 A JP 2011105231A JP 5808942 B2 JP5808942 B2 JP 5808942B2
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reinforcing member
main body
body portion
back surface
foamed resin
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JP2012236285A (en
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佳之 高橋
佳之 高橋
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Bridgestone Corp
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Bridgestone Corp
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Description

この発明は、成形金型の下型内に、プレート状の本体部分を有する補強部材を配置するとともに、前記本体部分の表面側に注入した液体状の発泡樹脂原料を、上型と下型との型締め姿勢で発泡させて、補強部材の本体部分の表面側に、樹脂発泡体を一体形成してなる、車両のドアパネル等に用いて好適な衝撃吸収パッドを製造する方法および、衝撃吸収パッドに関するものであり、とくに、発泡樹脂原料の発泡成形に際し、下型内に配置した補強部材の本体部分の裏面側への、発泡樹脂原料の流れ込みを防止して、製造する衝撃吸収パッドの品質の低下を防止する技術を提案するものである。   According to the present invention, a reinforcing member having a plate-shaped main body portion is disposed in a lower mold of a molding die, and a liquid foamed resin material injected into the surface side of the main body portion is divided into an upper mold and a lower mold. A method for producing a shock absorbing pad suitable for use in a vehicle door panel or the like, in which foaming is performed in a mold clamping posture and a resin foam is integrally formed on the surface side of the main body portion of the reinforcing member, and the shock absorbing pad In particular, when foamed resin raw material is foam-molded, the foamed resin raw material is prevented from flowing into the back side of the main body portion of the reinforcing member disposed in the lower mold, and the quality of the shock absorbing pad to be manufactured is improved. We propose a technique to prevent the decrease.

車両のドアパネルの内側に配設されて、車両の側面衝突時等の、乗員への衝撃を緩和するべく機能する衝撃吸収パッドは、プレート状の本体部分を有する、ポリプロピレン等の合成樹脂製の補強部材に、硬質ポリウレタンフォーム等の樹脂発泡体を一体的に設けて構成することができる。   The shock absorbing pad, which is disposed inside the vehicle door panel and functions to mitigate the impact on the occupant in the event of a side collision of the vehicle, has a plate-shaped main body reinforcement made of synthetic resin such as polypropylene. A resin foam such as a rigid polyurethane foam can be integrally provided on the member.

このような衝撃吸収パッドを製造するに当っては、たとえば、図６に示すような、平面視で長方形状をなす本体部分１２１の短辺側の周縁に、該本体部分１２１の表面１２１ａから立ち上がるとともに外側に折れ曲がって延びる取付け部分１２２を設けてなる補強部材１２０を用いる場合がある。
補強部材１２０の前記取付け部分１２２は、製造した衝撃吸収パッドを、車両のドアトリム等に取り付けるためのものであるが、本体部分１２１の表面１２１ａ側で発泡樹脂原料を発泡してなる樹脂発泡体を挟み込んで、該樹脂発泡体を補強部材１２０に一体的に固定するべくも機能する。 In manufacturing such a shock absorbing pad, for example, as shown in FIG. 6, the main body 121 has a rectangular shape in plan view, and rises from the surface 121 a of the main body 121 on the short side edge. In some cases, a reinforcing member 120 provided with a mounting portion 122 that bends and extends outward may be used.
The attachment portion 122 of the reinforcing member 120 is for attaching the manufactured shock absorbing pad to a vehicle door trim or the like. A resin foam formed by foaming a foamed resin raw material on the surface 121a side of the main body portion 121 is used. It also functions to sandwich and fix the resin foam to the reinforcing member 120 integrally.

そして、かかる補強部材１２０を用いて衝撃吸収パッドを製造するには、図７（ａ）に示すように、上型１０１と下型１０２とからなる成形金型１００の下型１０２内に、たとえば、その下型１０２の成形面に倣った形状の離型フィルム１１０を介して、前記補強部材１２０を配置するとともに、補強部材１２０の本体部分１２１の表面１２１ａ上に、液体状の発泡樹脂原料を注入し、しかる後、図７（ｂ）に示すように、上型１０１と下型１０２との型締め姿勢で、発泡樹脂原料を発泡させて、補強部材１２０の本体部分１２１の表面１２１ａ側に、樹脂発泡体１３０を一体形成することにより行うことができる。   And in order to manufacture an impact-absorbing pad using such a reinforcing member 120, as shown in FIG. 7A, for example, in a lower mold 102 made up of an upper mold 101 and a lower mold 102, The reinforcing member 120 is disposed through a release film 110 having a shape following the molding surface of the lower mold 102, and a liquid foamed resin material is applied on the surface 121a of the main body portion 121 of the reinforcing member 120. After the injection, as shown in FIG. 7B, the foamed resin material is foamed in the clamping posture of the upper mold 101 and the lower mold 102, and the surface of the reinforcing member 120 on the surface 121a side of the main body portion 121 is expanded. It can be performed by integrally forming the resin foam 130.

ところで、下型１０２内に配置する補強部材１２０が、単なる平板形状ではなく、たとえば、図６に示すような、本体部分１２１の裏面１２１ｂの一部を曲面としたり、本体部分１２１に取付け部分１２２を設けたこと等によって複雑な形状を有する場合は、補強部材１２０の寸法誤差を許容して、補強部材１２０を金型１００内に確実に配置するため、また、製造した衝撃吸収パッドで、発泡成形の終了後に時間の経過に伴って収縮する樹脂発泡体１３０を、補強部材１２０の寸法に整合させるため、金型内部のキャビティの、とくに上下方向の寸法を、補強部材１２０の同方向の寸法よりも若干大きくする必要があることから、下型１０２内に配置した補強部材１２０の本体部分１２１と、下型底面との間には僅かな隙間が形成されることになる。   By the way, the reinforcing member 120 arranged in the lower mold 102 is not a simple flat plate shape. For example, a part of the back surface 121b of the main body part 121 is curved as shown in FIG. In the case where the reinforcing member 120 has a complicated shape, the dimensional error of the reinforcing member 120 is allowed, and the reinforcing member 120 is surely arranged in the mold 100, and the produced shock absorbing pad is used for foaming. In order to match the resin foam 130 that shrinks with the passage of time after the completion of molding to the dimensions of the reinforcing member 120, the dimension of the cavity inside the mold, particularly the vertical dimension, is the same dimension of the reinforcing member 120. Therefore, a slight gap may be formed between the main body portion 121 of the reinforcing member 120 disposed in the lower mold 102 and the bottom surface of the lower mold. To become.

そのため、先に述べたような、衝撃吸収パッドの製造方法では、成形金型１００の下型１０２内に補強部材１２０を配置して、本体部分１２１の表面１２１ａ側に、発泡樹脂原料を注入した際に、液体状の発泡樹脂原料が、本体部分１２１の側縁から回り込んで、本体部分１２１の裏面１２１ｂ側に進入することがあり、この状態で発泡成形すると、製造された衝撃吸収パッドで、本体部分１２１の裏面１２１ｂの一部に、発泡樹脂材料が付着して、製品パッドの外観不良を招くという問題があった。
またこの場合は、補強部材１２０の裏面１２１ｂ側に付着した発泡樹脂材料の除去が必要となって、製造コストが嵩む他、樹脂発泡体１３０の一部を構成するべき発泡樹脂材料が、補強部材１２０の裏面１２１ｂに付着することに起因する、表面１２１ａ側の樹脂発泡体１３０の体積の不足によって、製品パッドの性能品質を十分に担保することができないという問題もある。 Therefore, in the method of manufacturing the shock absorbing pad as described above, the reinforcing member 120 is disposed in the lower mold 102 of the molding die 100, and the foamed resin material is injected into the surface 121a side of the main body 121. At this time, the liquid foamed resin raw material may wrap around from the side edge of the main body portion 121 and enter the back surface 121b side of the main body portion 121. If foam molding is performed in this state, the manufactured shock absorbing pad There is a problem that the foamed resin material adheres to a part of the back surface 121b of the main body 121 and causes a defective appearance of the product pad.
Further, in this case, it is necessary to remove the foamed resin material adhering to the back surface 121b side of the reinforcing member 120. In addition to increasing the manufacturing cost, the foamed resin material that should constitute a part of the resin foam 130 is the reinforcing member. There is also a problem that the performance quality of the product pad cannot be sufficiently secured due to the lack of volume of the resin foam 130 on the front surface 121a side due to adhering to the back surface 121b of 120.

なおここで、上記の製造方法で、補強部材１２０を下型１０２内に配置するに際し、本体部分１２１の裏面１２１ｂ側への、発泡樹脂原料の進入が生じないほどに、補強部材１２０を下型成形面に緊密に嵌合させて、本体部分１２１と下型底面との間への隙間の形成を防止することは、所定のライン速度の生産方式の下では困難であった。   Here, in the above manufacturing method, when the reinforcing member 120 is disposed in the lower mold 102, the reinforcing member 120 is moved to the lower mold so that the foamed resin material does not enter the back surface 121b of the main body 121. It has been difficult to prevent the formation of a gap between the main body portion 121 and the bottom surface of the lower mold by closely fitting with the molding surface under a production method with a predetermined line speed.

このような、発泡成形時の、本体部分１２１の裏面１２１ｂ側への発泡樹脂原料の回り込みに対処するべく、図８に示すように、下型１０２と離型フィルム１１０との間で、下型底面に、ゴム材料からなるシール部材１０３を、下型１０２内に配置される補強部材１２０の本体部分裏面１２１ｂの周縁に沿って一周させて設けたときは、補強部材１２０を下型１０２内に配置した後に、上型１０１と下型１０２との型締め状態で、補強部材１２０の取付け部分１２２を、上型１０１とゴムシール部材１０３との間に挟み込んで拘束することで、本体部分裏面１２１ｂの周縁をゴムシール部材１０３に押し当てることにより、ゴムシール部材１０３のシール機能に基いて、発泡樹脂原料の、本体部分１２１の裏面１２１ｂ側への進入を防止できると考えられる。   In order to cope with such a wraparound of the foamed resin raw material to the back surface 121b side of the main body 121 during foam molding, the lower mold is interposed between the lower mold 102 and the release film 110 as shown in FIG. When the sealing member 103 made of a rubber material is provided around the bottom surface of the reinforcing member 120 disposed in the lower mold 102 along the periphery of the back surface 121b, the reinforcing member 120 is placed in the lower mold 102. After the arrangement, the attachment portion 122 of the reinforcing member 120 is sandwiched between the upper die 101 and the rubber seal member 103 and restrained in a state where the upper die 101 and the lower die 102 are clamped. By pressing the peripheral edge against the rubber seal member 103, it is possible to prevent the foamed resin raw material from entering the back surface 121b of the main body portion 121 based on the sealing function of the rubber seal member 103. Considered.

しかるに、適用車両に応じて設計される補強部材１２０が、十分な強度を発揮し得ない形状、厚み等である場合は、ゴムシール部材１０３に押圧される補強部材１２０の本体部分１２１が、図に破線で示す如く変形することから、シール部材１０３を配設してなお、本体部分１２１の側縁から、該本体部分１２１の裏面１２１ｂ側への発泡樹脂原料の進入が生じることになる。
この一方で、強度の小さい補強部材１２０であっても有効にシールするべく、ゴムシール部材１０３を、硬度の小さいゴム材料で形成すると、成形金型１００の使用に伴い、ゴムシール部材１０３の熱劣化が生じて、ゴムシール部材１０３によるシール機能を、長期間にわたって十分に発揮させることができない。 However, when the reinforcing member 120 designed according to the application vehicle has a shape, thickness, etc. that cannot exhibit sufficient strength, the main body portion 121 of the reinforcing member 120 pressed against the rubber seal member 103 is shown in the figure. Since deformation occurs as indicated by the broken line, the foamed resin raw material enters from the side edge of the main body portion 121 toward the back surface 121b of the main body portion 121 even when the seal member 103 is provided.
On the other hand, if the rubber seal member 103 is formed of a rubber material having a low hardness in order to effectively seal even the reinforcing member 120 having a low strength, the rubber seal member 103 is thermally deteriorated with the use of the molding die 100. As a result, the sealing function by the rubber seal member 103 cannot be sufficiently exhibited over a long period of time.

また、補強部材の形状によっては、発泡樹脂原料の注入および発泡成形に際して、補強部材を上型で拘束できないことがあり、この場合、本体部分１２１の裏面１２１ｂがゴムシール部材１０３に十分に押圧されないことから、ゴムシール部材１０３が圧縮変形せず、そのシール機能を有効に発揮させることができないので、ゴムシール部材１０３を用いるこの方法では、製品パッドの品質低下のおそれを十分に取り除くことができなかった。   In addition, depending on the shape of the reinforcing member, the reinforcing member may not be restrained by the upper mold when the foamed resin material is injected and foamed. In this case, the back surface 121b of the main body 121 is not sufficiently pressed against the rubber seal member 103. Therefore, since the rubber seal member 103 is not compressed and deformed and its sealing function cannot be effectively exhibited, this method using the rubber seal member 103 cannot sufficiently eliminate the risk of product pad quality deterioration.

この発明は、従来技術が抱えるこのような問題を解決することを課題とするものであり、それの目的とするところは、発泡樹脂原料の発泡成形に際し、下型内に配置した補強部材の本体部分の裏面側への、発泡樹脂原料の進入を有効に防止して、製造される衝撃吸収パッドの、外観不良等の品質低下のおそれを十分に取り除くことのできる、衝撃吸収パッドの製造方法および、衝撃吸収パッドを提供するにある。   An object of the present invention is to solve such problems of the prior art, and the object of the present invention is to provide a main body of a reinforcing member disposed in a lower mold during foam molding of a foam resin material. A method for producing an impact-absorbing pad that can effectively prevent the foamed resin material from entering the back side of the part and sufficiently eliminate the risk of deterioration in quality such as poor appearance of the produced impact-absorbing pad, and To provide shock absorbing pads.

この発明の、衝撃吸収パッドの製造方法は、上型および下型からなる成形金型の下型内に、プレート状の本体部分を有する補強部材を配置するとともに、補強部材の前記本体部分の表面上に発泡樹脂原料を注入し、上型と下型との型締め姿勢で、前記発泡樹脂原料を発泡させて、補強部材に、樹脂発泡体を一体に形成してなる衝撃吸収パッドを製造するに当り、補強部材を配置するのに先立って、該補強部材の、前記本体部分の裏面の周縁部分に、該裏面側から突出する凸部を形成し、補強部材の本体部分の裏面に、発泡樹脂材料からなるシール部材を、少なくとも、該裏面の周縁部分に形成された前記凸部を覆って、または前記凸部の外周側に該凸部の周囲を取り囲んで予め設け、前記本体部分の裏面に設けたシール部材が、下型の底面に、直接的または、離型フィルム等を介して間接的に接触する姿勢で、補強部材を下型内に配置した後、本体部分と下型底面との間での、シール部材の圧縮変形下で、前記本体部分の表面側に発泡樹脂原料を注入して、該発泡樹脂原料を発泡成形することにある。
なお、前記凸部を、前記周縁部分の全周にわたって形成することが好ましい。 According to the manufacturing method of the shock absorbing pad of the present invention, a reinforcing member having a plate-like main body portion is disposed in a lower die of an upper die and a lower die, and the surface of the main body portion of the reinforcing member is provided. A foamed resin raw material is injected into the upper mold and the lower mold, and the foamed resin raw material is foamed to produce a shock absorbing pad formed integrally with a resin foam on a reinforcing member. Before the reinforcing member is disposed, a convex portion protruding from the back surface side is formed on the peripheral portion of the back surface of the main body portion of the reinforcing member, and foam is formed on the back surface of the main body portion of the reinforcing member. A sealing member made of a resin material is provided in advance so as to cover at least the convex portion formed on the peripheral portion of the back surface or surround the convex portion on the outer peripheral side of the convex portion. The seal member provided on the bottom of the lower mold After placing the reinforcing member in the lower mold in a posture that directly or indirectly contacts through a release film or the like, under the compression deformation of the seal member between the main body portion and the lower mold bottom surface, by injecting a foaming resin material on the surface side of the body portion is to foam molding of the foamed resin material.
In addition, it is preferable to form the said convex part over the perimeter of the said peripheral part.

また、この発明の衝撃吸収パッドは、補強部材が、該補強部材の本体部分の裏面の周縁部分に、該裏面側から突出する凸部を有し、補強部材の、プレート状の本体部分の裏面に、発泡樹脂材料からなるシール部材を、少なくとも、該裏面の周縁に設けられた前記凸部を覆って、または前記凸部の外周側に該凸部の周囲を取り囲んで設け、前記本体部分の表面側に、樹脂発泡体を一体に形成してなるものである。
なお、前記凸部を、前記周縁部分の全周にわたって形成してなることが好ましい。 In the impact absorbing pad of the present invention, the reinforcing member has a convex portion protruding from the back surface side at the peripheral portion of the back surface of the main body portion of the reinforcing member, and the back surface of the plate-shaped main body portion of the reinforcing member. Further, a sealing member made of a foamed resin material is provided so as to cover at least the convex portion provided on the peripheral edge of the back surface or to surround the convex portion on the outer peripheral side of the convex portion. A resin foam is integrally formed on the surface side.
In addition, it is preferable to form the said convex part over the perimeter of the said peripheral part.

この発明の、衝撃吸収パッドの製造方法によれば、成形金型の下型内に配置した補強部材の本体部分裏面の、少なくとも周縁部分に設けた、発泡樹脂材料からなる軟らかいシール部材が、圧縮変形状態で、本体部分の裏面と下型底面との間の空間を有効にシールするので、補強部材の本体部分の表面側に、発泡樹脂原料を注入するに際しての、本体部分の裏面側への発泡樹脂材料の回り込みを、該シール部材をもって効果的に阻止することができる。
この結果として、補強部材を、たとえば、上述したような、本体部分に取付け部分を設けた複雑な形状とした場合であっても、製造した衝撃吸収パッドの、補強部材の本体部分の裏面側に、発泡樹脂材料が固着することがなく、製品パッドの外観不良や、性能品質の低下を有効に防止することができる。 According to the manufacturing method of the shock absorbing pad of the present invention, the soft seal member made of the foamed resin material provided on at least the peripheral portion of the back surface of the main body portion of the reinforcing member disposed in the lower mold of the molding die is compressed. Since the space between the back surface of the main body portion and the bottom surface of the lower mold is effectively sealed in the deformed state, when the foamed resin raw material is injected into the front surface side of the main body portion of the reinforcing member, The wraparound of the foamed resin material can be effectively prevented by the seal member.
As a result, even if the reinforcing member has a complicated shape in which the mounting portion is provided on the main body portion as described above, for example, the manufactured shock absorbing pad is provided on the back side of the main body portion of the reinforcing member. Further, the foamed resin material does not stick, and it is possible to effectively prevent the appearance defect of the product pad and the deterioration of the performance quality.

またここでは、シール部材を、ゴム材料に比して十分に軟らかい発泡樹脂材料で形成したことから、下型内への発泡樹脂原料の注入に際し、上型で拘束できないような形状の補強部材であっても、軟らかい発泡樹脂製のシール部材が圧縮変形して、本体部分の裏面側への発泡樹脂材料の回り込みを有効に防止することができる。   Here, since the sealing member is formed of a foamed resin material that is sufficiently softer than the rubber material, a reinforcing member having a shape that cannot be restrained by the upper die when the foamed resin material is injected into the lower die. Even if it exists, the sealing member made of a soft foamed resin can be compressed and deformed, and the wraparound of the foamed resin material to the back side of the main body portion can be effectively prevented.

しかも、この製造方法では、補強部材の本体部分の表面側に注入されて、本体部分の裏面への回り込みを阻止された発泡樹脂原料が、発泡樹脂材料からなるシール部材に含浸されることになるので、製品パッドで、シール部材と補強部材との境界部分が、樹脂発泡体の一部で覆われることになって、製品パッドの良好な外観を確保することができる。
また、この製造方法では、本体部分の裏面側への発泡樹脂原料の流入を防止するシール部材を、成形金型の下型ではなく、補強部材それ自体に設けることから、衝撃吸収パッドを製造する度に、新たなシール部材によって、補強部材の本体部分の裏面側がシールされることになるので、繰返しの発泡成形に伴うシール部材の劣化という問題は生じない。 In addition, in this manufacturing method, the foamed resin material injected into the front surface side of the main body portion of the reinforcing member and prevented from entering the back surface of the main body portion is impregnated in the sealing member made of the foamed resin material. Therefore, the boundary portion between the sealing member and the reinforcing member is covered with a part of the resin foam in the product pad, and a good appearance of the product pad can be ensured.
Further, in this manufacturing method, the shock absorbing pad is manufactured because the sealing member for preventing the inflow of the foamed resin raw material to the back side of the main body portion is provided not on the lower mold of the molding die but on the reinforcing member itself. Since the back surface side of the main body portion of the reinforcing member is sealed with the new sealing member each time, the problem of deterioration of the sealing member due to repeated foam molding does not occur.

そして、この発明の衝撃吸収パッドによれば、上述したような製造方法によって製造することで、外観不良や、性能品質の低下のおそれを十分確実に取り除くことができる。   And according to the impact-absorbing pad of this invention, by manufacturing by the manufacturing method as mentioned above, the appearance defect and the possibility of deterioration of performance quality can be sufficiently removed.

この発明の製造方法を示す縦断面工程図である。It is a longitudinal cross-sectional process drawing which shows the manufacturing method of this invention. 図１に示す製造方法の実施に用いる補強部材を、シール部材を配設した状態で示す裏面側斜視図である。It is a back surface side perspective view which shows the reinforcement member used for implementation of the manufacturing method shown in FIG. 1 in the state which has arrange | positioned the sealing member. 図１に示す製造方法によって製造した衝撃吸収パッドの裏面側斜視図である。It is a back surface side perspective view of the shock absorption pad manufactured by the manufacturing method shown in FIG. 補強部材へのシール部材の他の配設例を示す裏面側斜視図および、その斜視図のＡ−Ａ線に沿う要部拡大断面図である。It is the back surface side perspective view which shows the other example of arrangement | positioning of the sealing member to a reinforcement member, and the principal part expanded sectional view which follows the AA line of the perspective view. 補強部材へのシール部材のさらに他の配設例を示す裏面側斜視図および、その斜視図のＢ−Ｂ線に沿う要部拡大断面図である。It is the back surface side perspective view which shows other example of arrangement | positioning of the sealing member to a reinforcement member, and the principal part expanded sectional view which follows the BB line of the perspective view. 従来の、衝撃吸収パッドの製造方法の実施に用いる補強部材を示す斜視図である。It is a perspective view which shows the reinforcement member used for implementation of the manufacturing method of the conventional impact-absorbing pad. 従来の、衝撃吸収パッドの製造方法を示す縦断面工程図である。It is a longitudinal cross-sectional process drawing which shows the manufacturing method of the conventional impact-absorbing pad. 従来の製造方法の問題点を誇張して示す縦断面図である。It is a longitudinal cross-sectional view which exaggerates and shows the problem of the conventional manufacturing method.

以下に図面を参照しつつ、この発明の実施の形態について説明する。
図１に示すところにおいて、図中１は、衝撃吸収パッドの製造に用いる成形金型を、また、１０は、成形金型１の内部に配置した補強部材を、そして、２０は、成形金型１の内部で発泡樹脂原料を発泡させてなる樹脂発泡体をそれぞれ示す。 Embodiments of the present invention will be described below with reference to the drawings.
In FIG. 1, reference numeral 1 denotes a molding die used for manufacturing an impact absorbing pad, 10 denotes a reinforcing member disposed inside the molding die 1, and 20 denotes a molding die. 1 shows resin foams obtained by foaming a foamed resin raw material inside 1.

ここで、成形金型１は、図に示すところでは、断面が略チャンネル状の成形面を有する下型２と、型締め姿勢で下型２に嵌まり込む上型３とからなるものであり、下型２と上型３との型締め姿勢では、それらの間に成形キャビティ４が画成される。
なお図１に示すところでは、発泡成形後の成形品の容易な取り出しを実現するため、下型２に、たとえば真空成形法によって、下型２の成形面に倣った形状に成形した離型フィルム５を設けているが、この離型フィルム５は、この発明に必須の構成ではない。 Here, as shown in the figure, the molding die 1 includes a lower mold 2 having a molding surface having a substantially channel-shaped cross section, and an upper mold 3 that fits into the lower mold 2 in a clamping position. In the clamping posture between the lower mold 2 and the upper mold 3, a molding cavity 4 is defined between them.
As shown in FIG. 1, in order to realize easy removal of the molded product after foam molding, a release film formed on the lower mold 2 by, for example, a vacuum molding method so as to follow the molding surface of the lower mold 2 5 is provided, but the release film 5 is not an essential component of the present invention.

ここにおいて、補強部材１０は、ポリプロピレン、ナイロン、ポリエチレン、ＡＢＳ樹脂その他の合成樹脂材料にて形成することができるが、生産コストの観点からは、補強部材１０をポリプロピレン製とすることが好ましい。
またここでは、補強部材１０として、図２に斜視図で例示するように、平面視で長方形状をなす本体部分１１の、一方の長辺寄りの部分を、図の上方側となる裏面１１ｂ側に盛り上げて塑性変形させ、また、本体部分１１の短辺側の周縁に、該本体部分１１の、図の下方側となる表面１１ａから立ち上がるとともに外側に折れ曲がって延びるそれぞれの取付け部分１２を設けてなるものを用いている。 Here, the reinforcing member 10 can be formed of polypropylene, nylon, polyethylene, ABS resin, or other synthetic resin material, but from the viewpoint of production cost, the reinforcing member 10 is preferably made of polypropylene.
Further, as illustrated in the perspective view of FIG. 2, as the reinforcing member 10, a portion closer to one long side of the main body portion 11 having a rectangular shape in plan view is a back surface 11 b side that is an upper side of the drawing. Each of the mounting portions 12 is provided at the peripheral edge on the short side of the main body portion 11 so as to rise from the surface 11a on the lower side of the figure 11 and bend and extend outward. Is used.

そしてまた、金型１の成形キャビティ４内で発泡樹脂原料を発泡成形してなる樹脂発泡体２０は、たとえば、ポリヒドロキシ化合物とポリイソシアネート化合物とを主成分とする硬質ポリウレタンフォームからなるものとすることができ、さらにこれに、触媒、発泡剤、整泡材、難燃剤等の助剤を含むものとすることもできる。   The resin foam 20 formed by foaming a foamed resin material in the molding cavity 4 of the mold 1 is made of, for example, a rigid polyurethane foam mainly composed of a polyhydroxy compound and a polyisocyanate compound. Further, it may contain auxiliary agents such as catalysts, foaming agents, foam stabilizers, flame retardants and the like.

ここにおいて、衝撃吸収パッドを製造するに当っては、補強部材１０を下型２内に配置するに先立って、はじめに、補強部材１０の本体部分１１の、下型２内への配置姿勢で下型２の底面２ａ側に向く裏面１１ｂに、図２に示すように、発泡樹脂材料からなるストリップ状部材を、裏面１１ｂの周縁に沿って一周させて予め貼着すること等によって、シール部材１３を設けておく。
この場合、シール部材１３は、図２に示すように、補強部材１０の本体部分１１の裏面１１ｂの、少なくとも周縁を覆って設ける必要があるが、一部を周縁の内側に入り込ませて設けることもでき、たとえば、図示は省略するが、シート状の部材を、裏面１１ｂの全体を覆って貼着させることで、シール部材を設けることもできる。 Here, in manufacturing the shock absorbing pad, prior to disposing the reinforcing member 10 in the lower mold 2, first, the main body portion 11 of the reinforcing member 10 is placed in the lower posture in the lower mold 2. As shown in FIG. 2, a strip-shaped member made of a foamed resin material is attached to the back surface 11b facing the bottom surface 2a side of the mold 2 around the periphery of the back surface 11b and pasted in advance. Is provided.
In this case, as shown in FIG. 2, the seal member 13 needs to be provided so as to cover at least the peripheral edge of the back surface 11 b of the main body portion 11 of the reinforcing member 10, but a part thereof is provided so as to enter the inside of the peripheral edge. For example, although illustration is omitted, a seal member can be provided by attaching a sheet-like member to cover the entire back surface 11b.

次いで、型開きした成形金型１の下型２内に、図１（ａ）に示すように、上述した補強部材１０を、本体部分１１の裏面１１ｂに設けたシール部材１３を下型２の底面２ａに接触させた状態で配置して、本体部分１１の表面１１ａ側に、液体状の発泡樹脂原料を注入する。   Next, as shown in FIG. 1 (a), the sealing member 13 provided on the back surface 11 b of the main body portion 11 is placed in the lower mold 2 of the lower mold 2 as shown in FIG. It arrange | positions in the state made to contact the bottom face 2a, and inject | pours a liquid foamed resin raw material into the surface 11a side of the main-body part 11. FIG.

そしてここでは、図１（ｂ）に示すように、上型３と下型２を型締め状態で、補強部材１０の取付け部分１２を、上型３と下型２との間に挟みこんで下型２側に押し付けることにより、本体部分１１の裏面１１ｂの周縁を覆って設けたシール部材１３を、たとえば、下型２の成形面上に配設した離型フィルム５を介して、下型底面２ａに押し当てて、本体部分１１と下型底面２ａとの間で、シール部材１３を圧縮変形させる。   Here, as shown in FIG. 1 (b), the upper die 3 and the lower die 2 are clamped, and the attachment portion 12 of the reinforcing member 10 is sandwiched between the upper die 3 and the lower die 2. The sealing member 13 provided so as to cover the peripheral edge of the back surface 11b of the main body portion 11 by being pressed against the lower die 2 side, for example, via the release film 5 disposed on the molding surface of the lower die 2. The seal member 13 is compressed and deformed between the main body portion 11 and the lower mold bottom surface 2a by pressing against the bottom surface 2a.

このとき、本体部分１１の裏面１１ｂの周縁に設けた、圧縮下のシール部材１３が、本体部分１１の表面１１ａ側の側縁から回り込んで流動する発泡樹脂原料の、裏面１１ｂ側への進入を防止するべく機能するので、発泡樹脂原料の発泡成形が終了するまでの間は、シール部材１３によって取り囲まれた、本体部分裏面１１ｂと離型フィルム５との間の空間に、発泡樹脂原料が存在しない状態が確実に維持されることになる。
なおこの発明では、シール部材１３を、ゴム材料に比して軟らかい発泡樹脂材料にて形成したことにより、補強部材１０が、十分な強度を発揮し得ない形状、厚み等であっても、本体部分裏面１１ｂ側への樹脂発泡原料の回り込みを招くおそれのある、補強部材１０の大きな変形は生じない。 At this time, the foamed resin raw material that flows around the side edge on the front surface 11a side of the main body portion 11 provided on the periphery of the back surface 11b of the main body portion 11 flows into the back surface 11b side. Therefore, the foamed resin material is surrounded by the sealing member 13 in the space between the main body part back surface 11b and the release film 5 until the foaming of the foamed resin material is finished. The state that does not exist is surely maintained.
In the present invention, the sealing member 13 is formed of a foamed resin material that is softer than the rubber material, so that the reinforcing member 10 has a shape, thickness, etc. that cannot exhibit sufficient strength. The large deformation of the reinforcing member 10 that may cause the resin foam raw material to wrap around the partial back surface 11b does not occur.

しかる後は、図１（ｂ）に示すように、成形金型１の型締めの下、注入した発泡樹脂原料を発泡・膨張させて成形・固化させ、それによって、補強部材１０の本体部分１１の表面１１ａ側に樹脂発泡体２０が一体形成された衝撃吸収パッドを、たとえば、離型フィルム５の下面側への、加圧空気の吹き込み等に基く離型作用によって、型開きした成形金型１から取り出す。   Thereafter, as shown in FIG. 1B, under the mold clamping of the molding die 1, the injected foamed resin raw material is foamed and expanded to be molded and solidified, whereby the main body portion 11 of the reinforcing member 10 is obtained. A molding die in which a shock absorbing pad integrally formed with the resin foam 20 on the surface 11a side thereof is opened by, for example, a releasing action based on blowing of pressurized air or the like to the lower surface side of the release film 5 Remove from 1.

このようにして製造した衝撃吸収パッド３０では、発泡成形時の、シール部材１３による上述したようなシール機能に基き、本体部分１１の裏面１１ｂに発泡樹脂材料が付着することがないので、上記の製造方法によれば、図３に示すように、製品パッド３０の外観不良や、性能品質の低下を有効に防止することができる。
しかも、この製造方法では、上述した発泡成形工程の際に、本体部分１１の側縁に達した発泡樹脂原料が、本体部分１１の裏面１１ｂの、発泡樹脂材料からなるシール部材１３に浸み込んだ状態で固化するので、製品パッド３０で、補強部材１０とシール部材１３との境界部分が、樹脂発泡体２０の一部によって覆われることになって、製品パッドの外観を十分良好なものとすることができる。 In the shock absorbing pad 30 manufactured in this way, the foamed resin material does not adhere to the back surface 11b of the main body portion 11 based on the sealing function as described above by the sealing member 13 during foam molding. According to the manufacturing method, as shown in FIG. 3, it is possible to effectively prevent a defective appearance of the product pad 30 and a decrease in performance quality.
Moreover, in this manufacturing method, the foamed resin raw material that has reached the side edge of the main body portion 11 penetrates into the sealing member 13 made of the foamed resin material on the back surface 11b of the main body portion 11 during the above-described foam molding step. Since the product pad 30 is solidified, the boundary between the reinforcing member 10 and the seal member 13 is covered with a part of the resin foam 20 in the product pad 30, and the appearance of the product pad is sufficiently good. can do.

なおここで、シール部材１３は、たとえば、軟質ポリウレタンフォームからなるスラブウレタンで形成することが、下型２内に補強部材１２を配置した際に、シール部材１３の圧縮変形に基くシール機能をより効果的に発揮させる上で好ましい。
また同様の観点から、シール部材１３の厚みは、１ｍｍ〜３ｍｍ、なかでも１ｍｍ〜２ｍｍとすることが好ましく、そして、シール部材１３の硬さは、５０Ｎ〜１５０Ｎ、とくに７０Ｎ〜１２０Ｎとすることが好ましい。ここでいう「硬さ」は、ＪＩＳ Ｋ６４０１に規定されるものであって、とくに、２５％圧縮時の硬さを意味する。 Here, the sealing member 13 can be formed of, for example, slab urethane made of a flexible polyurethane foam, so that when the reinforcing member 12 is disposed in the lower mold 2, a sealing function based on the compressive deformation of the sealing member 13 can be further improved. It is preferable for effective display.
From the same viewpoint, the thickness of the seal member 13 is preferably 1 mm to 3 mm, and more preferably 1 mm to 2 mm, and the hardness of the seal member 13 is 50 N to 150 N, particularly 70 N to 120 N. preferable. “Hardness” here is defined in JIS K6401, and particularly means the hardness at 25% compression.

ところで、補強部材の強度を高めるために、補強部材を下型２内に配置するに先立って、補強部材の、本体部分の裏面の周縁部分に予め、図４に示すように、該周縁部分の全周にわたって裏面４１ｂ側から突出する凸部４２を形成する。この場合は、シール部材４３を、凸部４２を覆って設ける。
このような補強部材４０に樹脂発泡体を一体化させる場合は、成形金型で、本体部分裏面４１ｂの凸部４２に対応させて下型成形面に設けた溝部分が、金型キャビティの、高さの低い箇所に位置することになるが、上述したように、シール部材４３を、凸部４２を覆って設けることにより、発泡成形工程で、発泡樹脂原料が、まだ粘度の低い状態で本体部分裏面４１ｂ側に流れ込むおそれがある場合に、そのような発泡樹脂原料が溜まり易い前記溝部分に、シール部材４３が位置することになるので、発泡樹脂原料の、本体部分４１の裏面４１ｂへの回り込み、ひいては、製品パッドの外観不良等をより有効に防止することができる。 By the way, in order to increase the strength of the reinforcing member, prior to disposing the reinforcing member in the lower mold 2, as shown in FIG. forming a convex portion 42 that protrudes from the back surface 41b side along the entire circumference. In this case, the sealing member 43, Ru provided to cover the convex portion 42.
When integrating the resin foam with such a reinforcing member 40, the groove portion provided in the lower mold surface corresponding to the convex portion 42 of the main body part back surface 41b is a mold die, Although it is located at a low height, as described above, by providing the sealing member 43 so as to cover the convex portion 42, the foamed resin raw material is still in the state of low viscosity in the foam molding process. When there is a possibility of flowing into the partial back surface 41b side, the sealing member 43 is located in the groove portion where the foamed resin raw material tends to accumulate. It is possible to more effectively prevent wraparound and, in turn, defective appearance of the product pad.

一方、このように、シール部材４３を、凸部４２を覆って貼り付けるには若干の習練が必要であり、また、発泡成形工程で、発泡樹脂原料が反応して粘度がある程度高くなった後に、発泡樹脂原料が本体部分の裏面に到達する場合は、シール部材の配設位置がそれほど問題とはならないので、シール部材を容易に貼り付けるとの観点からは、図５に示すように、補強部材５０の、本体部分裏面５１ｂの周縁部分に全周にわたって設けた凸部５２の外周側に、その凸部５２の周囲を取り囲んで、シール部材５３を設ける。 On the other hand, in this way, a little training is required to attach the sealing member 43 so as to cover the convex portion 42, and after the foamed resin raw material reacts and the viscosity increases to some extent in the foam molding process. When the foamed resin raw material reaches the back surface of the main body portion, the position of the sealing member is not so problematic. From the viewpoint of easily sticking the sealing member, as shown in FIG. member 50, the outer periphery of the convex portion 52 provided along the entire circumference on the peripheral portion of the body portion rear surface 51b, surrounds the periphery of the convex portion 52, Ru provided a seal member 53.

なおこの場合、補強部材５０を下型２内に配置した際に、シール部材５３が、本体部分裏面５１ｂと下型底面２ａとの間で圧縮された状態で、凸部５２が、下型底面２ａに接するか、または、凸部５２と下型底面３との間に多少クリアランスが生じるように、シール部材５３の厚みＴおよび、凸部５２の突出高さＨのそれぞれを選択することができる。   In this case, when the reinforcing member 50 is disposed in the lower mold 2, the sealing member 53 is compressed between the main body partial back surface 51b and the lower mold bottom surface 2a, and the convex portion 52 is formed on the lower mold bottom surface. Each of the thickness T of the sealing member 53 and the protruding height H of the convex portion 52 can be selected so as to be in contact with 2a or to have some clearance between the convex portion 52 and the bottom surface 3 of the lower mold. .

１ 成形金型
２ 上型
３ 下型
３ａ 下型底面
４ 成形キャビティ
５ 離型フィルム
１０，４０，５０ 補強部材
１１，４１，５１ 本体部分
１１ａ，４１ａ，５１ａ 表面
１１ｂ，４１ｂ，５１ｂ 裏面
１２ 取付け部分
４２，５２ 凸部
１３，４３，５３ シール部材
２０ 樹脂発泡体
３０ 製品パッド DESCRIPTION OF SYMBOLS 1 Molding die 2 Upper mold 3 Lower mold 3a Lower mold bottom face 4 Molding cavity 5 Release film 10, 40, 50 Reinforcing member 11, 41, 51 Main body part 11a, 41a, 51a Surface 11b, 41b, 51b Back surface 12 Mounting part 42,52 Convex portion 13,43,53 Seal member 20 Resin foam 30 Product pad

Claims (4)

上型および下型からなる成形金型の下型内に、プレート状の本体部分を有する補強部材を配置するとともに、補強部材の前記本体部分の表面上に発泡樹脂原料を注入し、上型と下型との型締め姿勢で、前記発泡樹脂原料を発泡させて、補強部材に、樹脂発泡体を一体に形成してなる衝撃吸収パッドを製造するに当り、
補強部材を配置するのに先立って、該補強部材の、前記本体部分の裏面の周縁部分に、該裏面側から突出する凸部を形成し、
補強部材の本体部分の裏面に、発泡樹脂材料からなるシール部材を、少なくとも、該裏面の周縁部分に形成された前記凸部を覆って、または前記凸部の外周側に該凸部の周囲を取り囲んで予め設け、
前記本体部分の裏面に設けたシール部材が、下型の底面に接触する姿勢で、補強部材を下型内に配置した後、本体部分と下型底面との間での、シール部材の圧縮変形下で、前記本体部分の表面側に発泡樹脂原料を注入して、該発泡樹脂原料を発泡成形する、衝撃吸収パッドの製造方法。 A reinforcing member having a plate-like main body portion is disposed in a lower die of an upper die and a lower die, and a foamed resin material is injected onto the surface of the main body portion of the reinforcing member, In producing a shock absorbing pad by foaming the foamed resin raw material in a mold clamping posture with a lower mold and integrally forming a resin foam on a reinforcing member,
Prior to placing the reinforcing member, the reinforcing member, the peripheral portion of the back surface of the body portion, forming a protrusion protruding from the rear surface side,
A sealing member made of a foamed resin material is provided on the back surface of the main body portion of the reinforcing member, covering at least the convex portion formed on the peripheral edge portion of the back surface , or surrounding the convex portion on the outer peripheral side of the convex portion. Enclosed in advance,
After the sealing member provided on the back surface of the main body portion is in contact with the bottom surface of the lower mold and the reinforcing member is disposed in the lower mold, the compression deformation of the seal member between the main body portion and the lower mold bottom surface is performed. A method for producing an impact-absorbing pad, comprising: injecting a foamed resin raw material into the surface side of the main body portion and foam-molding the foamed resin raw material. 前記凸部を、前記周縁部分の全周にわたって形成する、請求項１に記載の衝撃吸収パッドの製造方法。The manufacturing method of the impact-absorbing pad according to claim 1, wherein the convex portion is formed over the entire circumference of the peripheral edge portion. 補強部材が、該補強部材の本体部分の裏面の周縁部分に、該裏面側から突出する凸部を有し、
補強部材の、プレート状の本体部分の裏面に、発泡樹脂材料からなるシール部材を、少なくとも、該裏面の周縁に設けられた前記凸部を覆って、または前記凸部の外周側に該凸部の周囲を取り囲んで設け、補強部材の前記本体部分の表面側に、樹脂発泡体を一体に形成してなる衝撃吸収パッド。 The reinforcing member has a convex portion protruding from the back surface side at the peripheral edge portion of the back surface of the main body portion of the reinforcing member,
On the back surface of the plate-shaped main body portion of the reinforcing member, a sealing member made of a foamed resin material covers at least the convex portion provided on the periphery of the rear surface , or the convex portion on the outer peripheral side of the convex portion. An impact absorbing pad formed by integrally forming a resin foam on the surface side of the main body portion of the reinforcing member. 前記凸部を、前記周縁部分の全周にわたって形成してなる、請求項３に記載の衝撃吸収パッド。The impact-absorbing pad according to claim 3, wherein the convex portion is formed over the entire circumference of the peripheral portion.
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