JPS63293011A - Monolithic foam molding method - Google Patents
Monolithic foam molding methodInfo
- Publication number
- JPS63293011A JPS63293011A JP62127761A JP12776187A JPS63293011A JP S63293011 A JPS63293011 A JP S63293011A JP 62127761 A JP62127761 A JP 62127761A JP 12776187 A JP12776187 A JP 12776187A JP S63293011 A JPS63293011 A JP S63293011A
- Authority
- JP
- Japan
- Prior art keywords
- foaming
- core material
- molding
- skin material
- mold
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Pending
Links
- 238000010097 foam moulding Methods 0.000 title claims description 8
- 239000011162 core material Substances 0.000 claims abstract description 34
- 239000000463 material Substances 0.000 claims abstract description 33
- 238000005187 foaming Methods 0.000 claims abstract description 32
- 238000000465 moulding Methods 0.000 claims abstract description 23
- 239000002994 raw material Substances 0.000 claims abstract description 17
- 239000006260 foam Substances 0.000 claims description 14
- JOYRKODLDBILNP-UHFFFAOYSA-N Ethyl urethane Chemical compound CCOC(N)=O JOYRKODLDBILNP-UHFFFAOYSA-N 0.000 abstract description 8
- 239000011550 stock solution Substances 0.000 abstract description 6
- 238000000034 method Methods 0.000 abstract description 5
- 238000010276 construction Methods 0.000 abstract 1
- 230000002950 deficient Effects 0.000 abstract 1
- 239000011800 void material Substances 0.000 abstract 1
- 230000007547 defect Effects 0.000 description 5
- 238000002347 injection Methods 0.000 description 4
- 239000007924 injection Substances 0.000 description 4
- 230000035699 permeability Effects 0.000 description 3
- 238000010586 diagram Methods 0.000 description 2
- 230000000694 effects Effects 0.000 description 2
- 238000005516 engineering process Methods 0.000 description 2
- 239000006261 foam material Substances 0.000 description 2
- 238000009423 ventilation Methods 0.000 description 2
- BZHJMEDXRYGGRV-UHFFFAOYSA-N Vinyl chloride Chemical compound ClC=C BZHJMEDXRYGGRV-UHFFFAOYSA-N 0.000 description 1
- 230000015572 biosynthetic process Effects 0.000 description 1
- 239000000919 ceramic Substances 0.000 description 1
- 230000008859 change Effects 0.000 description 1
- 230000006837 decompression Effects 0.000 description 1
- 210000000497 foam cell Anatomy 0.000 description 1
- 239000004088 foaming agent Substances 0.000 description 1
- 230000006872 improvement Effects 0.000 description 1
- 238000001746 injection moulding Methods 0.000 description 1
- 239000000123 paper Substances 0.000 description 1
- 230000009467 reduction Effects 0.000 description 1
- 239000011347 resin Substances 0.000 description 1
- 229920005989 resin Polymers 0.000 description 1
- 238000007788 roughening Methods 0.000 description 1
- 230000009466 transformation Effects 0.000 description 1
- 238000007666 vacuum forming Methods 0.000 description 1
- 239000002023 wood Substances 0.000 description 1
Landscapes
- Casting Or Compression Moulding Of Plastics Or The Like (AREA)
Abstract
Description
【発明の詳細な説明】
(産業上の利用分野)
本発明は、表皮材と芯材とを発泡成形型内にセットし、
該表皮材と芯材との間でウレタンなどの発泡原料を発泡
させて一体的に成形する一体発泡成形方法の改良に関す
る。DETAILED DESCRIPTION OF THE INVENTION (Industrial Application Field) The present invention involves setting a skin material and a core material in a foam mold,
The present invention relates to an improvement in an integral foam molding method in which a foaming raw material such as urethane is foamed between the skin material and the core material to integrally mold the skin material and the core material.
(従来の技術)
近年、自動車のインストルメントパネルなどの内装部品
には、表皮材、発泡体、芯材を順次積層させた一体発泡
成形品が数多く用いられている。(Prior Art) In recent years, many integral foam molded products in which a skin material, a foam material, and a core material are sequentially laminated have been used for interior parts such as automobile instrument panels.
この一体発泡成形品の一般的な成形方法としては、予め
真空成形またはスラッシュ成形などで成形された表皮材
を発泡成形型の下型にセットし、プレス成形または射出
成形などで成形された芯材を上型にセットした後、ウレ
タンなどの発泡原料を表皮材と芯材との間に供給し、上
型と下型とを閉じて内部で発泡原料を発泡させ表皮材、
発泡体、芯材を積層させて一体品に形成するものである
。(参考文献:技術の友(トヨタ自動車株式会社トヨタ
技術会発行) 、 Vol。The general molding method for this integral foam molded product is to set the skin material, which has been formed in advance by vacuum forming or slush molding, into the lower mold of the foam mold, and then to form the core material, which is formed by press molding or injection molding. is set in the upper mold, a foaming raw material such as urethane is supplied between the skin material and the core material, the upper mold and the lower mold are closed, and the foaming material is foamed inside to form the skin material,
The foam and core material are laminated to form an integrated product. (Reference: Tomo of Technology (Published by Toyota Motor Corporation Toyota Engineering Society), Vol.
30 、No2 .1978 、P180〜P181)
ところで、発泡成形時には発泡原料から多量のガスが発
生する。そのため、発泡原料が発泡して型内(キャビテ
ィ)に充満していくと、ガスの逃げ場がなくなってエア
だまりか生じたり、または発泡体かガスを巻き込んでボ
イドの発生や発泡セルを荒くする等の問題かあった。30, No2. 1978, P180-P181)
By the way, during foam molding, a large amount of gas is generated from the foaming raw material. Therefore, when the foaming raw material foams and fills the mold (cavity), there is no place for the gas to escape, resulting in air pockets, or the foam or gas is drawn in, creating voids or roughening the foam cells. There was a problem.
そして、エアたまりやボイドなどによって、発泡体か充
分に型内に充満しないショート、または成形品の脱型後
に内部の高い圧力により剛性の弱い表皮材に生じるフク
レ等の欠陥を発生させるという問題かあった。There are also problems such as short-circuits where the foam does not fully fill the mold due to air pockets and voids, or defects such as blisters that occur in the less rigid skin material due to high internal pressure after demolding the molded product. there were.
従来、これらの問題を解決するために、発泡原料の注入
軌跡をかえたり、キャビティ内にスラブを張り付けて発
泡原料の発泡時の流れを制御してエアだまり等を防ぐよ
うにしたものがある。Conventionally, in order to solve these problems, there have been methods in which the injection locus of the foaming raw material is changed or a slab is pasted inside the cavity to control the flow of the foaming raw material during foaming and prevent air pockets.
また、前記問題を解消するために本出願人より特願昭6
l−274741)号に記載した技術がある。In addition, in order to solve the above problem, the present applicant has filed a patent application
There is a technique described in No. 1-274741).
この技術は、発泡体と芯材との間に通気性多孔質部材を
介装させることを特長とするものであり、この通気性多
孔質部材を介して成形時に発泡原料から発生した内部の
ガスを外部へ排出するものである。This technology is characterized by interposing an air permeable porous member between the foam and the core material, and the internal gas generated from the foam raw material during molding is absorbed through this air permeable porous member. is discharged to the outside.
(発明か解決しようとする問題点)
しかしながら、従来の発泡原料の注入軌跡なかえたり、
スラブを張り付けて流れを制御するものては、成形品の
形状に合わせて最適位置を設定しなければならなく、そ
のための検討か多大な作業となり、さらに個々の成形品
毎に行なわなければならなく、極めて生産性か悪く、コ
ストも高くなるという問題点かあった。(Problem to be solved by the invention) However, the injection trajectory of the conventional foaming raw material is changed,
When applying slabs to control flow, the optimal position must be set according to the shape of the molded product, which requires a great deal of study and work, and must be done for each individual molded product. However, there were problems in that productivity was extremely low and costs were high.
また、特願昭61−274740号に記載されているも
のでは、成形品毎に通気性多孔質部材を取付けなければ
ならず、°作業性かあまり良くなく、また製品コストも
高くなる等の問題点かあった。Furthermore, in the method described in Japanese Patent Application No. 61-274740, it is necessary to attach a breathable porous member to each molded product, which has problems such as poor workability and high product cost. There was a point.
本発明は1以上の問題点に鑑みてなされたものでり、そ
の目的とするところは、生産性を低下させることなく、
ショートやフクレ等の欠陥を防止することにある。The present invention has been made in view of one or more problems, and it is an object of the present invention to
The purpose is to prevent defects such as short circuits and blisters.
問題点を解決するための手段)
以上の問題点を解決して目的を達成するための手段とし
て、発泡成形型の上型または下型のいずれか一方の成形
面に表皮材を取付け、他方の型の成形面に通気性のある
材質で形成された芯材を、背面側に空間を形成させて取
付け、前記表皮材と芯材との間に発泡原料を供給した後
、前記上型と下型とを閉じてキャビティ内で前記発泡原
料を発泡させるとともに、前記芯材の背面側の空間を減
圧し前記キャビティ内を排気して成形するものである。As a means to solve the above problems and achieve the objective, a skin material is attached to the molding surface of either the upper mold or the lower mold of the foam mold, and the A core material made of a breathable material is attached to the molding surface of the mold with a space formed on the back side, and a foaming material is supplied between the skin material and the core material, and then the upper mold and the lower mold are The mold is closed and the foaming raw material is foamed within the cavity, and the space on the back side of the core material is depressurized and the inside of the cavity is evacuated for molding.
(作用)
このように通気性のある芯材の背面側の空間を減圧する
ことにより1発泡原料が発泡するとき発生したガスか芯
材を通って背面側に効率良く排出されるため、ガスによ
るエアだまりやボイドな発生させることがなくなり、シ
ョートやフクレ等の欠陥か防げる。(Function) In this way, by reducing the pressure in the space on the back side of the breathable core material, the gas generated when foaming raw material is foamed is efficiently discharged to the back side through the core material. Air pockets and voids are no longer generated, and defects such as short circuits and blisters can be prevented.
また、別部材を取付けることかないため生産性を低下さ
せたりコストを高くすることもない。Furthermore, since no separate member is attached, there is no reduction in productivity or increase in cost.
(実施例)
つぎに、本発明の実施例を図面に基づいて説明する。な
お、本実施例では自動車のインストルメントパネルの一
体発泡成形について説明する。(Example) Next, an example of the present invention will be described based on the drawings. In this example, integral foam molding of an automobile instrument panel will be explained.
まず、第1図は本発明に係る発泡成形型lを示すものて
、下型2と、下型2の側面に回動自在に支持され前記下
型2とともにキャビティを形“成する上型3と、上型3
の上面に設けられた拡開可ス屯な回転コア4,5とから
概略構成されている。First, FIG. 1 shows a foaming mold l according to the present invention, which includes a lower mold 2 and an upper mold 3 that is rotatably supported on the side surface of the lower mold 2 and forms a cavity together with the lower mold 2. and upper mold 3
It is generally composed of expandable, thick rotating cores 4 and 5 provided on the upper surface of the holder.
下型2の成形面は、塩化ビニール等て形成された表皮材
6が取付けられるようになっている。A skin material 6 made of vinyl chloride or the like is attached to the molding surface of the lower mold 2.
また、上型3には、通気性のある芯材7か取付けられ、
その芯材7の背面側は減圧キャビティ(空間)8が形成
されている。なお、芯材7としては1通気性かあり発泡
原料が漏れないものであればよく、例えば、紙、セラミ
ックス、木質材などが考えられる。In addition, a breathable core material 7 is attached to the upper mold 3,
A vacuum cavity (space) 8 is formed on the back side of the core material 7 . Note that the core material 7 may be any material as long as it has a permeability level of 1 and does not leak the foaming raw material, and examples thereof include paper, ceramics, and wood materials.
また、芯材7の全部分を通気性のある部材にする必要は
なく、第4図(a)、(b)に示すように一部分(斜線
で示すA′範囲)を通気性のある材質にし、他の部分(
B部分)は樹脂で成形したものてあってもよい。ここで
、第5図は、本実施例に用いられている芯材7のエア圧
と通気量の関係を示す図であり、I Kg/cm”のエ
ア圧で4〜69/分の通気性を有するものである。In addition, it is not necessary to make the entire core material 7 a breathable material; instead, as shown in FIGS. , other parts (
Part B) may be molded from resin. Here, FIG. 5 is a diagram showing the relationship between the air pressure and ventilation amount of the core material 7 used in this example, and shows that the air permeability is 4 to 69/min at an air pressure of I Kg/cm. It has the following.
上型3には、減圧キャビティ8と外部とを連通ずる通気
孔3aが形成されており、通気孔3aの出口側は吸引用
パイプ9か接続されている。また、吸引用パイプ9は、
減圧ポンプ10に接続されており、減圧ポンプIOの作
動により、吸引用パイプ9を介して減圧キャビティ8内
が減圧されることになる。A vent hole 3a is formed in the upper die 3 to communicate the vacuum cavity 8 with the outside, and the outlet side of the vent hole 3a is connected to a suction pipe 9. In addition, the suction pipe 9 is
It is connected to the vacuum pump 10, and the pressure inside the vacuum cavity 8 is reduced through the suction pipe 9 by the operation of the vacuum pump IO.
以上の構成に係る作用を説明する。The operation related to the above configuration will be explained.
第2図に示すように、上型3を開けて、下型2の成形面
に表皮材6を取付け、上型3の成形面に通気性のある芯
材7を取付けた後、発泡原料であるウレタン発泡原液1
1を注入機12から表皮材6上に供給する。As shown in FIG. 2, after opening the upper mold 3 and attaching the skin material 6 to the molding surface of the lower mold 2 and attaching the breathable core material 7 to the molding surface of the upper mold 3, A certain urethane foaming stock solution 1
1 is supplied onto the skin material 6 from the injection machine 12.
つづいて、第1図に示すように、上型3と下型2とを閉
じて、内部でウレタン発泡原液11を発泡させる。そし
て、ウレタン発泡原液11の発泡が完了する直前に、減
圧ポンプ10を作動させて、芯材7の背面側の減圧キャ
ビティ8を減圧することにより、ウレタン発泡原液11
か発泡するときにキャビティ内に発生したガスか芯材7
を通って吸引されることになる。そして、吸引されたガ
スは吸引用パイプ9を通って減圧ポンプ10から外部に
排出される。Subsequently, as shown in FIG. 1, the upper mold 3 and lower mold 2 are closed, and the urethane foaming stock solution 11 is foamed inside. Immediately before foaming of the urethane foaming stock solution 11 is completed, the vacuum pump 10 is operated to reduce the pressure in the vacuum cavity 8 on the back side of the core material 7.
The gas generated in the cavity during foaming or the core material 7
It will be sucked through. Then, the sucked gas passes through the suction pipe 9 and is discharged from the vacuum pump 10 to the outside.
成形か完了した後、第3図に示すように、上型3と回転
コアとを開けて、成形品13を下型2から取り出す。After the molding is completed, the upper mold 3 and rotating core are opened and the molded product 13 is taken out from the lower mold 2, as shown in FIG.
以上のようにして、発泡成形時にキャビティ内のガスを
排出することができるため、エアたまりの発生を防いで
ショートを防止し、さらに、内圧を低下できるため、脱
型時に生しる表皮材6のフクレを防止できることとなり
、インストルメントパネルの成形不良を大幅に低減する
ことができる。As described above, the gas in the cavity can be exhausted during foam molding, preventing the formation of air pockets and short circuits.Furthermore, it is possible to reduce the internal pressure, so the skin material 6 generated during demolding can be prevented. This means that blistering can be prevented, and molding defects of the instrument panel can be significantly reduced.
なお、本発明は上記実施例に限定されるものではなく、
目的、構成、効果を逸脱しない限り、いかなる変形、変
更も自由である。Note that the present invention is not limited to the above embodiments,
Any transformation or change is free as long as it does not deviate from the purpose, structure, or effect.
(発明の効果)
以上詳細に説明したように本発明は、一体発泡成形時に
芯材を介してキャビティ内を排気するようにしたため、
生産性を低下させることなく、エアたまり、ボイド、シ
ョートなどの成形不良を防止することかでき、さらに内
圧も低減して成形品の脱型時に生じるフクレも減少させ
ることかてきる。(Effects of the Invention) As explained in detail above, the present invention exhausts the inside of the cavity through the core material during integral foam molding, so that
It is possible to prevent molding defects such as air pockets, voids, and short circuits without reducing productivity, and it also reduces internal pressure and reduces blisters that occur during demolding of molded products.
また、発泡成形時に発生するガスを確実に排出てきるた
め1発泡剤を多く使用し発泡体を低密度にして、原材料
コストの低減や成形品の軽量化か図れる。Furthermore, in order to reliably discharge the gas generated during foam molding, a larger amount of foaming agent is used and the density of the foam is lowered, thereby reducing the cost of raw materials and the weight of the molded product.
第1図は、本発明の実施例の一体発泡成形型における発
泡原料を発泡させている状態での縦断面図、
第2図は、第1図で示す一体発泡成形型における発泡原
料の注入時の状態を示す縦断面図。
第3図は、第1図で示す一体発泡成形型における成形完
了後に成形品を取り出す状態を示す縦断面図、
第4図(a)、(b)は、それぞれ芯材を示す斜視図、
第5図は、芯材の通気性を示すエア圧力と通気量の関係
を示す図である。
1・・・発泡成形型
2・・・下型
3・・・上型
6・・・表皮材
7・・・芯材
8・・・減圧キャビティ(空間)
11・・・ウレタン発泡原液(発泡原料)特許出願人
トヨタ自動車株式会社第1図
第4図
第5図FIG. 1 is a vertical cross-sectional view of the integral foaming mold according to the embodiment of the present invention in a state in which the foaming raw material is being foamed, and FIG. 2 is a longitudinal cross-sectional view of the integral foaming mold shown in FIG. 1 during injection of the foaming raw material. FIG. 3 is a longitudinal cross-sectional view showing the state in which the molded product is taken out after completion of molding in the integral foaming mold shown in FIG. 1; FIGS. 4(a) and 4(b) are perspective views showing the core material, respectively; FIG. 5 is a diagram showing the relationship between air pressure and ventilation amount, which indicates the air permeability of the core material. 1... Foaming mold 2... Lower mold 3... Upper mold 6... Skin material 7... Core material 8... Decompression cavity (space) 11... Urethane foam stock solution (foaming raw material) ) Patent applicant
Toyota Motor Corporation Figure 1 Figure 4 Figure 5
Claims (1)
形面に表皮材を取付け、他方の型の成形面に通気性のあ
る材質で形成された芯材を、背面側に空間を形成させて
取付け、前記表皮材と芯材との間に発泡原料を供給した
後、前記上型と下型とを閉じてキャビティ内で前記発泡
原料を発泡させるとともに、前記芯材の背面側の空間を
減圧し前記キャビティ内を排気して成形することを特徴
とする一体発泡成形方法。(1) Attach a skin material to the molding surface of either the upper or lower mold of the foam mold, place a core material made of a breathable material on the molding surface of the other mold, and leave a space on the back side. After forming and attaching the material, and supplying the foaming raw material between the skin material and the core material, the upper mold and the lower mold are closed to foam the foaming material in the cavity, and the foaming material is foamed on the back side of the core material. An integral foam molding method characterized in that molding is performed by reducing the pressure in the space and evacuating the inside of the cavity.
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
JP62127761A JPS63293011A (en) | 1987-05-25 | 1987-05-25 | Monolithic foam molding method |
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
JP62127761A JPS63293011A (en) | 1987-05-25 | 1987-05-25 | Monolithic foam molding method |
Publications (1)
Publication Number | Publication Date |
---|---|
JPS63293011A true JPS63293011A (en) | 1988-11-30 |
Family
ID=14968036
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
JP62127761A Pending JPS63293011A (en) | 1987-05-25 | 1987-05-25 | Monolithic foam molding method |
Country Status (1)
Country | Link |
---|---|
JP (1) | JPS63293011A (en) |
Cited By (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
JPH05192940A (en) * | 1992-01-18 | 1993-08-03 | Eidai Co Ltd | Production of decorative panel |
-
1987
- 1987-05-25 JP JP62127761A patent/JPS63293011A/en active Pending
Cited By (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
JPH05192940A (en) * | 1992-01-18 | 1993-08-03 | Eidai Co Ltd | Production of decorative panel |
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