JP2016172368A - Molded article with foam and method for producing the same - Google Patents

Abstract

PROBLEM TO BE SOLVED: To obtain a molded article with foam having such a structure that unevenness is hard to occur in a surface skin.SOLUTION: A molded article 11 with foam has a surface 1a and a rear face 1b, and includes a resin base material 1G having a hole 1h formed therein, a surface skin 2 arranged so as to face the surface of the base material, a seal member 4 which is arranged on the surface of the base material and blocks the hole from the side of the surface, and a foam 3 which fills a space between the surface of the base material and the surface skin and is provided so as to cover the seal member. A circumferential portion of the hole 1h forming the hole 1h out of the base material 1G has such a shape as to project in a direction farther from the seal member 4.SELECTED DRAWING: Figure 8

Description

  The present invention relates to a molded article with a foam and a method for producing the same.

  As disclosed in Japanese Unexamined Patent Publication No. 2000-246742 (Patent Document 1), a molded product with a foam (resin molded product) is known. A molded article with a foam includes a hard substrate made of resin, a soft skin, and a foam provided therebetween, and is widely used for an instrument panel of an automobile or the like.

JP 2000-246742 A

  In the molded article with a foam, a foam is provided between the base material and the skin. The epidermis is bonded to the surface of the substrate via the foam. The shape of the skin is easily affected by the surface shape of the substrate (it is easy to follow the surface shape of the substrate). In some cases, a hole for mounting a panel (a seat surface for fixing a clip) is provided in the base material, and the surface of the base material may have an uneven shape in accordance with the shape of the hole. Conventionally, the skin has been affected by the surface shape of the substrate through the foam, so that unevenness may occur in the skin.

  An object of this invention is to provide the molded article with a foam provided with the structure where an unevenness | corrugation does not generate | occur | produce easily even if it is a case where the hole is provided in the base material, and its manufacturing method.

  The molded article with a foam according to the present invention has a front surface and a back surface, a resin base material in which a hole is formed, a skin disposed so as to face the surface of the base material, and the base A foaming member disposed on the surface of the material and filling the space between the surface and the skin of the base member and the sealing member that covers the hole from the surface side, and is provided to cover the sealing member A peripheral portion of the hole portion that forms the hole portion of the base material has a shape protruding in a direction away from the seal member.

  Preferably, when the edge portion located on the front surface side of the hole portion is a first opening end and the edge portion located on the back surface side of the hole portion is a second opening end, The two open ends are inclined with respect to the first open end.

  Preferably, a plurality of the hole portions are formed in the base material, and the second opening ends of each of the plurality of hole portions have a parallel relationship with each other.

  The method for producing a molded article with foam according to the present invention includes a step of preparing a base material having a front surface and a back surface and having a hole formed thereon, and a sealing member is disposed on the front surface of the base material. Covering the sealing member between the step of closing the hole from the surface side, the step of disposing the skin so as to face the surface of the base material, and the surface of the base material and the skin And a step of filling the foam with a foam, and a peripheral portion of the hole portion forming the hole portion of the base material has a shape protruding in a direction away from the seal member.

  According to said structure, the surrounding part of the hole part which forms the hole part of a base material has a shape which protrudes in the direction away from a sealing member. If the said structure is employ | adopted, since it is not necessary to make the surface of a base material uneven | corrugated shape according to the shape of a hole part, the structure where an unevenness | corrugation does not generate | occur | produce on an outer skin can be implement | achieved.

It is a perspective view which shows the molded article with a foam in a reference technique. It is sectional drawing which shows the molded article with a foam in a reference technique. It is a perspective view which shows the other form (state which decomposed | disassembled) the molded article with a foam in a reference technique. It is a perspective view which shows the mode at the time of assembling | attaching a panel to a base material regarding the other form of the molded article with a foam in a reference technique. It is a top view (figure which shows a mode that looked down at a hole from the direction of a panel) which shows a mode at the time of attaching a panel to a substrate about other forms of a molded article with a foam in reference technology. It is arrow sectional drawing along the VI-VI line in FIG. It is other sectional drawing which shows the molded article with a foam in a reference technique. 3 is a cross-sectional view showing a molded article with a foam according to Embodiment 1. FIG. It is a perspective view which shows the mode at the time of assembling | attaching a panel to a base material regarding the other form of the molded article with a foam in Embodiment 1. FIG. It is arrow sectional drawing along the XX line in FIG. It is sectional drawing for demonstrating the other hole provided in the base material of the molded article with a foam in Embodiment 1. FIG. 6 is a cross-sectional view for explaining still another hole provided in the base material of the molded article with foam in Embodiment 1. FIG. 6 is a cross-sectional view showing a molded article with a foam in a second embodiment. FIG. It is a perspective view which shows the base material used for the molded article with a foam in Embodiment 2. FIG. It is sectional drawing which shows the mode at the time of assembling | attaching a panel to a base material regarding the other form of the molded article with a foam in Embodiment 2. FIG. 6 is a cross-sectional view showing a molded product with a foam in a third embodiment. FIG. It is a perspective view which shows the base material used for the molded article with a foam in Embodiment 3. FIG.

[Reference technology]
Before describing the embodiment, reference techniques relating to the embodiment will be described below with reference to FIGS. In the description of the reference technique, the same parts and corresponding parts are denoted by the same reference numerals, and redundant description may not be repeated.

(Molded product with foam 10)
1 and 2 are a perspective view and a cross-sectional view, respectively, showing a molded article 10 with a foam according to the reference technique. The molded product 10 with a foam includes a substrate 1Z, a skin 2, a foam 3, and a seal member 4.

  The substrate 1Z has a front surface 1a and a back surface 1b, and is formed from a hard resin. The skin 2 is made of a soft resin such as polyvinyl chloride, and is disposed so as to face the surface 1a of the substrate 1Z. Although details will be described later, the substrate 1Z can also be used as one part of another form of the molded article 10 with foam (molded article 10A with foam shown in FIG. 3).

  The base 1Z is provided with an opening 1c (FIG. 1), and various devices such as a handle, an air bag, and a car navigation system can be mounted on the opening 1c. A plurality of holes 1h are also formed in the substrate 1Z. Although details will be described later, when the substrate 1Z is used as one component of the foamed molded article 10A (FIG. 3), the panel 5 (FIG. 3) is attached to the substrate 1Z using a plurality of holes 1h. .

  When the base material 1Z is used as one part of the molded article 10 with foam (FIGS. 1 and 2), the seal member 4 is disposed on the surface 1a of the base material 1Z. The hole 1h is closed from the surface 1a side by the seal member 4 (see FIG. 2). The seal member 4 prevents a material (for example, urethane) from leaking through the hole 1h when the foam 3 is formed. The foam 3 is filled between the surface 1a of the substrate 1Z and the skin 2 and is provided so as to cover the seal member 4.

(Molded product with foam 10A)
Depending on the specifications of the automobile, the panel 5 (FIG. 3) may be selected as a so-called optional product. Also in this case, the substrate 1Z can be used. Production efficiency can be improved by sharing parts.

  As shown in FIG. 3, the panel 5 has an opening 5c for mounting various devices such as a handle, an airbag, and a car navigation system. When using the panel 5, the arrangement | positioning location of the panel 5 is exposed among the surfaces 1a of the base material 1Z. The foam 3 and the seal member 4 are not provided at this arrangement location (see FIGS. 2 and 6), and a plurality of holes 1h are exposed.

  FIG. 4 is a perspective view showing a state when the panel 5 is assembled to the substrate 1Z. FIG. 5 is a plan view showing a state when the panel 5 is assembled to the substrate 1Z (a view showing a state where the hole 1h is looked down from the panel 5). FIG. 6 is a cross-sectional view taken along line VI-VI in FIG. As shown in FIGS. 4 to 6, in the molded article with foam 10 </ b> A, the panel 5 (FIG. 4) is attached to the base material 1 </ b> Z using the fixture 6.

(Hole 1h)
The hole 1h formed in the base material 1Z penetrates the base material 1Z in the thickness direction so as to reach the back surface 1b from the front surface 1a. The inner peripheral surfaces 1p to 1s forming the hole 1h in the substrate 1Z all have a flat surface shape. Edge portions A1 to A4 are formed on the surface 1a side of the hole 1h (inner peripheral surfaces 1p to 1s). Edge portions B1 to B4 are formed on the back surface 1b side of the hole 1h (inner peripheral surfaces 1p to 1s).

  Edge portions B2 and B4 located on the back surface 1b side are portions to be engaged with a fixture 6 (specifically, a shoulder portion 8b of the clip 8) described later, and the insertion direction of the fixture 6 (arrow AR) ) Extending in a direction orthogonal to (). Edge portions A2 and A4 corresponding to the edge portions B2 and B4 also extend in the same direction (see FIG. 6).

(Mounting tool 6)
Referring mainly to FIG. 4, the fixture 6 includes a base 7 and a clip 8. The pedestal 7 has a columnar shape, and recessed portions 7h are respectively provided on both side surfaces of the pedestal 7 (see FIG. 5). The clip 8 has a pair of clamping portions 8a, a pair of shoulder portions 8b, a pair of inclined portions 8c, and an insertion end portion 8d.

  The sandwiching portion 8 a is fitted into the recess 7 h of the pedestal 7. The shoulder portion 8b extends from the end portion of the clamping portion 7a so as to spread outward. The inclined portion 8c extends from the end portion of the shoulder portion 8b toward the position of the end portion 7s (FIG. 4) of the base 7. The insertion end 8d is located at the tip of the inclined portion 8c. The clip 8 is fixed to the pedestal 7 by fitting the holding portions 8a and 8a (FIG. 5) into the recesses 7h and 7h (FIG. 5) of the pedestal 7, respectively.

  Referring to FIGS. 4 and 6, when attaching panel 5 (FIG. 4) to base material 1 </ b> Z, fixture 6 is inserted into hole 1 h (arrow AR). The clip 8 is elastically deformed, and the shoulder portion 8b of the clip 8 is locked to the edge portions B2 and B4 located on the back surface 1b side of the substrate 1Z. Thereby, the panel 5 is fixed to the base material 1Z via the fixture 6.

  Referring again to FIG. 3, when the panel 5 is attached to the substrate 1Z, a plurality of attachments 6 (FIG. 4 and the like) are inserted into the plurality of holes 1h, respectively. Here, the shape of the surface 1a of the substrate 1Z varies depending on the design (such as the interior of an automobile), and there are curved portions and flat portions. The size and direction of the curve are also various.

  On the other hand, when fixing the panel 5 to the base material 1Z, due to structural reasons and work reasons (restrictions), the plurality of fixtures 6 have the same direction (arrow AR) in the plurality of holes 1h. Plugged in. Therefore, the plurality of hole portions 1h are designed in advance so as to open in substantially the same direction regardless of whether the portion is curved or flat. In other words, the plurality of holes 1h are designed in advance so that the plurality of fixtures 6 can be received in substantially the same direction.

  Referring to FIG. 7, the base material 1 </ b> Z in the reference technique can be used for a molded product 10 with a foam, and can also be used for a molded product 10 </ b> A with a foam (FIGS. 3 to 6). Have. However, since the base material 1Z has a plurality of holes 1h (seat surface for fixing clips) for attaching the panel 5 (FIG. 3), with respect to some holes 1h, The surface 1a of the base material 1Z located around the hole 1h according to the shape also has an uneven shape.

  The surface 1a of the substrate 1Z located around the hole 1h in accordance with the shape of the hole 1h is not limited to the plurality of holes 1h, and the surface 1a of the substrate 1Z has an uneven shape according to the shape of the hole 1h. May present. For example, depending on the layout of the panel 5, the design of the panel 5, the structural relationship between the panel 5 and the base material 1 </ b> Z (so-called contact), the panel 5 is placed in a specific direction (arrow AR direction) with respect to the base material 1 </ b> Z. ) In some cases. In such a case, according to the shape of the hole 1h, the surface 1a of the substrate 1Z located around the hole 1h may have an uneven shape.

  As shown in FIG. 7, when the base material 1 </ b> Z in the reference technology is adopted for the molded product 10 with foam, the skin 2 is placed on the base material 1 </ b> Z via the foam 3 in the peripheral portions of several holes 1 h. The surface of the skin 2 may be affected by the surface shape (uneven shape). If the degree of the unevenness is large, the foam 3 may sink and the skin 2 may partially sink. )

[Embodiment]
Hereinafter, embodiments will be described with reference to the drawings. The same parts and corresponding parts are denoted by the same reference numerals, and redundant description may not be repeated.

[Embodiment 1]
(Molded product with foam 11)
FIG. 8 is a cross-sectional view showing the molded article 11 with foam in the first embodiment. The molded article 11 with a foam includes a substrate 1G, a skin 2, a foam 3, and a seal member 4. Although the molded article 11 with foam of this Embodiment comprises the instrument panel for vehicles, it is not restricted to this, The molded article 11 with foam is applied also to things other than the interior goods for motor vehicles. Can do. The same applies to a molded article with foam 11A, which will be described later.

  The substrate 1G has a front surface 1a and a back surface 1b, and is formed from a hard resin. The skin 2 is made of a soft resin such as polyvinyl chloride, and is disposed so as to face the surface 1a of the substrate 1G. The base material 1G can also be used as one part of another form of the molded article 11 with foam (molded article 11A with foam shown in FIG. 9).

  A plurality of holes 1h are formed in the substrate 1G (see the holes 1ha shown in FIG. 11 and the holes 1hb shown in FIG. 12). When the base material 1G is used as one part of a molded article with foam 11A (FIG. 9), the panel 5 (FIG. 9) is based on the hole 1h (and other holes 1ha, 1hb, and so on). It is attached to the material 1G.

  When the base material 1G is used as one component of the molded article 11 with foam (FIG. 8), the seal member 4 is disposed on the surface 1a of the base material 1G. The hole 1 h is closed from the surface 1 a side by the seal member 4. The seal member 4 prevents a material (for example, urethane) from leaking through the hole 1h when the foam 3 is formed. The foam 3 is provided between the surface 1a of the base material 1G and the skin 2 so as to cover the seal member 4.

  Here, the surface 1a of the substrate 1G has a flat surface shape (or a surface shape that curves very gently) unlike the above-described reference technique. On the other hand, the peripheral portion of the hole 1 h forming the hole 1 h in the base 1 </ b> G has a shape protruding in a direction away from the seal member 4. The base material 1 </ b> G of the present embodiment has an extending portion 1 m that extends in a direction away from the seal member 4. The extended portion 1m corresponds to “a peripheral portion of the hole 1h forming the hole 1h in the base 1G”.

(Production method)
In order to manufacture the molded article 11 with foam, the base material 1G is prepared, and the hole 1h is closed from the surface 1a side by the seal member 4. Next, the skin 2 is disposed so as to face the surface 1a of the substrate 1G. In a state where the base material 1G and the skin 2 are arranged in a mold (not shown), a material (such as urethane) of the foam 3 is filled between the surface 1a and the skin 2 of the base material 1G. The foamed molded article 11 is obtained by curing the material of the foam 3.

(Molded product with foam 11A)
Depending on the specifications of the automobile, the panel 5 (FIG. 9) may be selected as a so-called optional product. Also in this case, the substrate 1G can be used. Production efficiency can be improved by sharing parts. When using the panel 5, the arrangement | positioning location of the panel 5 is exposed among the surfaces 1a of the base material 1G. The foam 3 and the seal member 4 are not provided in this arrangement location (see FIGS. 8 to 12), and a plurality of holes 1h are exposed.

  FIG. 9 is a perspective view showing a state when the panel 5 is assembled to the base 1G. FIG. 10 is a cross-sectional view taken along line XX in FIG. In the molded article with foam 11A, the panel 5 is attached to the base material 1G using the fixture 6.

(Hole 1h)
The hole 1h formed in the base material 1G penetrates the base material 1G in the thickness direction so as to reach the back surface 1b from the front surface 1a. The inner peripheral surfaces 1p to 1s forming the hole 1h in the base 1G all have a flat surface shape. As described above, the base material 1 </ b> G has the extending portion 1 m extending in the direction away from the seal member 4. An inner peripheral surface 1p is formed inside the extending portion 1m. Edge portions A1 to A4 are formed on the surface 1a side of the hole 1h (inner peripheral surfaces 1p to 1s). Edge portions B1 to B4 are formed on the back surface 1b side of the hole 1h (inner peripheral surfaces 1p to 1s).

  Edge portions B2 and B4 located on the back surface 1b side are portions to be engaged with a fixture 6 (specifically, a shoulder portion 8b of the clip 8) described later, and the insertion direction of the fixture 6 (arrow AR) ) Extending in a direction orthogonal to (). As shown in FIG. 10, a first opening end is formed by edge portions A1 to A4 located on the surface 1a side of the hole 1h, and an edge portion B1 located on the back surface 1b side of the hole 1h. If the second opening end is formed by ~ B4, in the hole 1h, the second opening end (edge portions B1 to B4) is inclined with respect to the first opening end (edge portions A1 to A4). (See FIG. 10).

  When the panel 5 (FIG. 9) is attached to the substrate 1G, the fixture 6 is inserted into the hole 1h (arrow AR). The clip 8 is elastically deformed, and the shoulder 8b of the clip 8 is locked to the edge portions B2 and B4 located on the back surface 1b side of the base 1G. Thereby, the panel 5 is fixed to the base material 1G via the fixture 6.

  As described in the description of the reference technology, when the panel 5 is attached to the base 1G, the plurality of attachments 6 are inserted into the plurality of holes 1h, 1ha, 1hb, respectively. Here, the shape of the surface 1a of the base material 1G varies depending on the design (such as the interior of an automobile), and there are curved portions and flat portions. The size and direction of the curve are also various.

  Referring to FIG. 11, an extension portion 1 n is provided in addition to the extension portion 1 m for the portion of the base material 1 </ b> G where the hole portion 1 ha is formed. The extending part 1n also extends in a direction away from the seal member 4. The hole 1ha is designed to open in substantially the same direction as the hole 1h (FIG. 10). The second opening ends (edge portions B1 to B4) located on the back surface 1b side of the hole 1ha are parallel to the second opening ends (edge portions B1 to B4) located on the back surface 1b side of the hole 1h. is there. On the other hand, the shape of the surface 1a of the substrate 1G is different between the peripheral portion of the hole portion 1ha and the peripheral portion of the hole portion 1h.

  Referring to FIG. 12, the extending portion 1n is provided in addition to the extending portion 1m in the portion of the base material 1G where the hole portion 1hb is formed. The extending part 1n also extends in a direction away from the seal member 4. The hole 1hb is designed to open in substantially the same direction as the holes 1h and 1ha (FIGS. 10 and 11). The second opening ends (edge portions B1 to B4) located on the back surface 1b side of the hole 1hb are mutually in common with the second opening ends (edge portions B1 to B4) located on the back surface 1b side of the hole portions 1h and 1ha. Parallel. On the other hand, the shape of the surface 1a of the substrate 1G is different between the peripheral portion of the hole portion 1hb and the peripheral portions of the hole portions 1h and 1ha.

  In the base material 1G, as in the case of the base material 1Z described above, a plurality of holes 1h are designed in advance so as to open in substantially the same direction regardless of whether they are curved or flat. Has been. However, the base 1G has a shape in which the peripheral portions of the holes 1h, 1ha, 1hb forming the holes 1h, 1ha, 1hb of the base 1G protrude in the direction away from the seal member 4. Configuration is adopted. Thereby, unlike the case of the above-mentioned reference technique, the surface 1a of the base material 1G can be configured to have a flat surface shape (or a surface shape that curves very gently).

  As shown in FIG. 8, the peripheral portion of the hole 1 h forming the hole 1 h (and other holes 1 ha and 1 hb) in the base material 1 G has a shape protruding in a direction away from the seal member 4. By having it, the surface 1a of the base material 1G has a flat surface shape (or a surface shape that curves very gently). Even when the base material 1G is used for the molded article 11 with foam, in the base material 1G, it is not necessary to make the surface 1a of the base material 1G uneven according to the shape of the hole 1h. It is possible to realize a structure in which unevenness is less likely to occur in 2.

[Embodiment 2]
(Molded product with foam 12)
FIG. 13 is a cross-sectional view showing the molded article 12 with foam in the second embodiment. FIG. 14 is a perspective view showing a substrate 1J used for the molded article 12 with foam. The base material 1J used for the foamed molded article 12 differs from the above-described first embodiment (base material 1G) in the shape of the hole 1h (inner peripheral surface).

  As shown in FIGS. 13 and 14, the base material 1J is provided with inner peripheral surfaces 1q1, 1q2, 1q3 and inner peripheral surfaces 1s1, 1s2, 1s3. The inner peripheral surfaces 1q2 and 1q3 have a shape bulging from the inner peripheral surface 1q1 toward the inner side (the inner peripheral surfaces 1s1, 1s2 and 1s3), and the inner peripheral surfaces 1s2 and 1s3 are formed from the inner peripheral surface 1s1. It has a shape that bulges toward the inner side (the inner peripheral surfaces 1q1, 1q2, and 1q3). An edge portion B2 is formed at the end of the inner peripheral surface 1q3 on the back surface 1b side, and an edge portion B4 is formed at the end of the inner peripheral surface 1s3 on the back surface 1b side. The edge portions B2 and B4 are portions that are locked to the fixture 6 shown in FIG. 15 (specifically, the shoulder portion 8b of the clip 8).

(Molded product with foam 12A)
FIG. 15 is a cross-sectional view showing another form (foamed molded article 12A) according to the second embodiment. Since the inner peripheral surfaces 1q3 and 1s3 bulge inward, the locking force with respect to the edge portions B2 and B4 of the fixture 6 (the shoulder portion 8b of the clip 8) can be improved.

[Embodiment 3]
(Molded product with foam 13)
FIG. 16 is a cross-sectional view showing the molded article 13 with foam in the third embodiment. FIG. 17 is a perspective view showing a substrate 1K used for the molded article 13 with foam. The base material 1K used for the molded product 13 with a foam is different from the above-described Embodiments 1 and 2 (base materials 1G and 1J) in the shape of the hole 1h (inner peripheral surface).

  The inner peripheral surfaces 1q1, 1q2, 1q3 (see FIG. 14) and the inner peripheral surfaces 1s1, 1s2, 1s3 (see FIG. 14) in the second embodiment all have a stepped shape. In the base material 1K, an inner peripheral surface 1q4 is formed instead of the inner peripheral surfaces 1q1 and 1q2, and an inner peripheral surface 1s4 is formed instead of the inner peripheral surfaces 1s1 and 1s2. The inner peripheral surfaces 1q4 and 1s4 have a tapered shape that tapers from the front surface 1a toward the back surface 1b. According to the said structure, it becomes easy to insert the fixture 6 in the hole 1h.

  Although the embodiment has been described above, the above disclosure is illustrative in all respects and is not restrictive. The technical scope of the present invention is defined by the terms of the claims, and is intended to include any modifications within the scope and meaning equivalent to the terms of the claims.

  1G, 1J, 1K, 1Z base material, 1a surface, 1b back surface, 1c, 5c opening, 1h, 1ha, 1hb hole, 1m, 1n extension, 1p, 1q, 1q1, 1q2, 1q3, 1q4, 1r , 1 s, 1 s 1, 1 s 2, 1 s 3, 1 s 4 inner peripheral surface, 2 skin, 3 foam, 4 seal member, 5 panel, 6 fixture, 7 base, 7 a, 8 a clamping portion, 7 h recessed portion, 7 s end portion, 8 clip 8b shoulder part, 8c inclined part, 8d insertion end part, 10, 10A, 11, 11A, 12, 12A, 13 molded product with foam, A1, A2, A3, A4, B1, B2, B3, B4 edge part , AR arrow (insertion direction).

Claims (4)

A resin base material having a front surface and a back surface, in which a hole is formed;
An epidermis arranged to face the surface of the substrate;
A sealing member disposed on the surface of the base material and closing the hole from the surface side;
A foam filled between the surface of the base material and the skin and provided to cover the sealing member, and
The peripheral portion of the hole portion forming the hole portion of the base material has a shape protruding in a direction away from the seal member.
Molded product with foam. The edge portion located on the surface side of the hole portion is a first opening end,
When the edge portion located on the back surface side of the hole portion is the second opening end,
The second opening end is inclined with respect to the first opening end;
The molded article with a foam according to claim 1. A plurality of the holes are formed in the base material,
The second open ends of each of the plurality of holes have a parallel relationship with each other,
The molded article with a foam according to claim 2. Preparing a base material having a front surface and a back surface and having a hole formed therein;
Disposing a sealing member on the surface of the substrate, and closing the hole from the surface side;
Arranging the epidermis so as to face the surface of the substrate;
Filling the foam between the surface of the base material and the skin so as to cover the sealing member,
The peripheral portion of the hole portion forming the hole portion of the base material has a shape protruding in a direction away from the seal member.
Manufacturing method of molded product with foam.

Images