JP6947972B2 - Manufacturing method of integrally molded body and integrally molded body - Google Patents

Description

The present invention relates to an integrally molded body and a method for producing the same.

By introducing the resin into the cavity with the insert member arranged in the cavity of the mold, an integrally molded body composed of the base material and the insert member can be molded. In Patent Document 1, one foamed resin sheet is reheated to be in a softened state and placed between a pair of split molds, and the foamed resin sheet is sucked under reduced pressure from both molds to obtain a foamed resin. A technique for forming a thick portion in a foamed molded product by secondary foaming a sheet is disclosed.

Japanese Unexamined Patent Publication No. 2001-310380

By the way, in some automobile interior members, it may be necessary to attach a sound absorbing material to a foam molded body (base material) made of a thermoplastic resin. In such a case, in general, after shaping the shape of the base material, integration is performed through a predetermined processing step, but there is a problem that the cost is high because a large amount of adhesive is used.

The present invention has been made in view of such circumstances, and an object of the present invention is to provide an integrally molded body in which a sound absorbing member is fixed to a base material without using an adhesive, and a method for producing the same.

According to the first aspect of the present invention, the foam molded body in the form of a sheet and a sound absorbing member which is a porous body are provided, the foam molded body has a predetermined surface, and the sound absorbing member is the foam molded body. An integrally molded body is provided that is fixed to a part of a predetermined surface by an anchor effect.

The integrally molded body according to the first aspect of the present invention is characterized in that the foam molded body has a first surface, and the sound absorbing member is fixed to the foam molded body by an anchor effect on a part of the first surface. do. That is, it has the effect that an integrally molded body having a sound absorbing effect can be molded without using an adhesive.

Hereinafter, various embodiments of the present invention will be illustrated. The embodiments shown below can be combined with each other.

Preferably, the foam molded body has a recess in a part of the predetermined surface, the sound absorbing member has an exposed surface, is housed in the recess, and the exposed surface is exposed from the foam molded body. The step at the boundary between the predetermined surface and the exposed surface is 1 to 20 mm.
Preferably, the step is 3 to 10 mm.
Preferably, the foam molded body has a recess in a part of the predetermined surface, the sound absorbing member has an exposed surface, is housed in the recess, and the exposed surface is exposed from the foam molded body. The step at the boundary between the predetermined surface and the exposed surface is 0 to 1 mm.

Further, according to the second aspect of the present invention, it is a method of manufacturing an integrally molded body using the first and second dies, which includes an insert step, an arrangement step, and a molding step, and the insert step includes an insert step, a placement step, and a molding step. , The insert member is mounted on the second mold, and in the arrangement step, the foamed resin in a molten state is placed between the first and second molds with the insert member mounted on the second mold. Provided is a method in which a foamed molded body made of the foamed resin and the insert member are fixed by an anchor effect to form an integrally molded body in the molding step of hanging down.

The molding method according to the second aspect of the present invention is characterized in that the insert member is mounted on the second mold and is fixed to the foam molded body by the anchor effect through the molding step. That is, according to the method, there is an effect that an integrally molded body having a sound absorbing effect can be molded without using an adhesive.

Preferably, the second mold is provided with a protrusion, the insert member is provided with an insertion hole, the protrusion is inserted into the insertion hole, and the insert member is mounted on the second mold.
Preferably, the molding step includes an expansion step, and the expansion step includes the first and second molds so that a gap larger than the thickness of the foamed resin is provided between the first and second molds. The foamed resin is expanded to the thickness of the gap by sucking the foamed resin under reduced pressure with both the first and second molds in a state where the molds are brought close to each other.
Preferably, the expansion step includes a first suction step, a mold proximity step, and a second suction step in this order, and in the first suction step, the foamed resin is sucked under reduced pressure by the first mold. The foamed resin is shaped into a shape along the cavity of the first mold, and in the mold proximity step, the first and first molds are provided so that the gap is provided between the first and second molds. The two molds are brought close to each other, and in the second suction step, the foamed resin is sucked under reduced pressure by the first and second molds to expand the foamed resin to the thickness of the gap.
Preferably, the insert member has a first thickness, and in the molding step, the foamed resin is expanded to the thickness of the gap and the insert member is compressed to a second thickness smaller than the first thickness. Then, an integrally molded body having the thickness of the gap is formed, and then the insert member compressed to the second thickness is restored to the first thickness with the passage of time.
Preferably, the value of (the second thickness) / (the first thickness) is 0.1 to 0.8.

It is a perspective view which shows the integrally molded body 1 which concerns on 1st Embodiment of this invention. It is a perspective view which shows the integrally molded body 1 and is seen from the angle different from FIG. It is a front view which shows the integrally molded body 1 which concerns on 1st Embodiment of this invention. It is a top view which shows the integrally molded body 1 which concerns on 1st Embodiment of this invention. FIG. 4 is a cross-sectional view taken along the line AA in FIG. It is an exploded view which disassembled the integrally molded body 1 shown in FIG. 1 into a sound absorbing member 2 and a foam molded body 3. It is a schematic diagram which shows the foam molding machine 4 which can be used in the manufacturing method of an integrally molded body 1. It is a perspective view which shows the split mold 7. The split mold 7 is shown, and is a perspective view seen from a different angle from FIG. It is a top view which shows the split mold 7. FIG. 10 is a cross-sectional view taken along the line BB, showing a mode in which the split mold 7 is opened and the sound absorbing member 2 is attached to the mold 22. The mode in which the foamed resin sheet 3d is hung between the split dies 7 from the state of FIG. 11 is shown. From the state of FIG. 12, the split mold 7 is molded and the foamed resin sheet 3d is sucked onto the first mold 71 side. From the state of FIG. 13, the mode in which the foamed resin sheet 3d is also sucked onto the second mold 72 side is shown. The mode immediately after opening the split mold 7 from the state of FIG. 14 is shown. The mode in which time has passed from the state of FIG. 15 is shown. A cross-sectional photograph of the foam molded product 3 obtained in the examples of the present invention is shown. An example of the form of bubbles for explaining the calculation method of the tentative average bubble diameter is shown. FIG. 5 is a schematic view showing aspects of the sound absorbing member 2 and the foam molded body 3 when the integrally molded body 1 is molded by adopting the non-soft sound absorbing member 2 according to the first embodiment. It is sectional drawing (corresponding to FIG. 5) of the integrally molded body 1 which concerns on 2nd Embodiment of this invention. FIG. 5 is a schematic view showing aspects of the sound absorbing member 2 and the foam molded body 3 when the integrally molded body 1 is molded by adopting the non-soft sound absorbing member 2 according to the second embodiment.

1. 1. First Embodiment Hereinafter, the first embodiment of the present invention will be described. The various features shown in the embodiments shown below can be combined with each other. In addition, the invention is independently established for each feature.

1.1 Integral molded body 1
1 and 2 are perspective views showing an integrally molded body 1 according to the first embodiment of the present invention. Similarly, FIG. 3 is a front view, FIG. 4 is a plan view, and FIG. 6 is a cross-sectional view taken along the line AA in FIG. As shown in FIGS. 1 to 5, the integrally molded body 1 according to the first embodiment of the present invention is an integrally molded body formed by insert molding. That is, the integrally molded body 1 includes a sound absorbing member 2 which is an insert member, and a foam molded body 3 in which the sound absorbing member 2 is fixed by an anchor effect. The anchor effect is an effect in which the fixing force is enhanced by the other material entering into the fine irregularities on the surface of one material like the roots of a tree and hardening.

In particular, as shown in FIGS. 1 and 2, the foam molded product 3 has a sheet-like shape and has a first surface 31 and a second surface 32. Here, the first surface 31 (an example of the "predetermined surface" in the claims) is a surface on which the sound absorbing member 2 is attached. The second surface 32 is the back surface thereof, which is a surface that can be visually recognized by the user (so-called design surface) and has a flat shape. Further, the second surface 32 is also covered with a skin member such as a carpet 9 made of a non-woven fabric.

The average wall thickness of the foam molded product 3 is preferably 20 mm or less. This average wall thickness is, for example, 1 to 20 mm, and specifically, for example, 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16. , 17, 18, 19, 20 mm, and may be within the range between any two of the numerical values exemplified here.

FIG. 6 is an exploded view of the integrally molded body 1 shown in FIG. 1 decomposed into a sound absorbing member 2 and a foam molded body 3. The sound absorbing member 2 is a porous body having a sound absorbing effect, and the material is not limited. However, it should be noted that the sound absorbing member 2 is a soft sound absorbing member 2 in the first embodiment. For example, an open cell foam sheet such as a urethane foam sheet is used. In particular, as shown in FIGS. 1 and 6, the sound absorbing member 2 is housed in the recess 31a of the first surface 31 of the foam molded body 3 and is fixed by the anchor effect. Further, the exposed surface 21 of the sound absorbing member 2 is exposed.

The value of (thickness of sound absorbing member 2) / (thickness of foamed molded body 3) is, for example, 0.1 to 0.99, and specifically, for example, 0.1, 0.2, 0.3. , 0.4, 0.5, 0.6, 0.7, 0.8, 0.9, 0.95, 0.96, 0.97, 0.98, 0.99, and is exemplified here. It may be within the range between any two of the given numerical values. The void ratio of the sound absorbing member 2 is, for example, 0.1 or more, and specifically, for example, 0.10, 0.15, 0.20, 0.25, 0.30, 0.35, 0. It is 40, 0.45, 0.50, 0.55, 0.60, 0.65, 0.70, 0.75, 0.80, 0.85, 0.90, and the numerical values exemplified here are used. It may be within the range between any two.

In particular, as shown in FIGS. 3 and 5, in the first embodiment, the exposed surface 21 is configured to protrude from the first surface 31. Further, in the first embodiment, the sound absorbing member 2 has a rectangular shape, but the sound absorbing member 2 is not limited to this, and various shapes such as a substantially circular shape and a substantially elliptical shape can be assumed depending on the application. ..

The step at the boundary between the exposed surface 21 and the first surface 31 is, for example, 1 to 20 mm, preferably 3 to 10 mm, and specifically, for example, 1, 2, 3, 4, 5, 6, 7, 8, and so on. It is 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20 mm, and may be within the range between any two of the numerical values exemplified here.

1.2 Configuration of Foam Molding Machine 4 Next, with reference to FIGS. 7 to 15, the foam molding machine 4 that can be used to carry out the method for manufacturing the integrally molded body 1 according to the first embodiment of the present invention will be described. .. FIG. 7 is a schematic view showing a foam molding machine 4 that can be used in the method for manufacturing the integrally molded body 1. The foam molding machine 4 includes a resin supply device 5, a T-die 6, and a split mold 7. The resin supply device 5 includes a hopper 51, an extruder 52, an injector 53, and an accumulator 54. The extruder 52 and the accumulator 54 are connected via a connecting pipe 81. The accumulator 54 and the T-die 6 are connected via a connecting pipe 82. The T-die 6 can also be implemented by using a cylindrical die core. Hereinafter, each configuration will be described in detail.

<Hopper 51, extruder 52>
The hopper 51 is used to put the raw material resin 3a into the cylinder 52a of the extruder 52. The form of the raw material resin 3a is not particularly limited, but is usually in the form of pellets. The raw material resin 3a is, for example, a thermoplastic resin such as polyolefin, and examples of the polyolefin include low-density polyethylene, linear low-density polyethylene, high-density polyethylene, polypropylene, ethylene-propylene copolymer and a mixture thereof. The raw material resin 3a is charged into the cylinder 52a from the hopper 51 and then melted by being heated in the cylinder 52a to become the molten resin 3b. Further, it is conveyed toward the tip of the cylinder 52a by the rotation of the screw arranged in the cylinder 52a. The screw is arranged in the cylinder 52a, and the molten resin 3b is kneaded and conveyed by its rotation. A gear device is provided at the base end of the screw, and the screw is rotationally driven by the gear device. The number of screws arranged in the cylinder 52a may be one or two or more.

<Injector 53>
The cylinder 52a is provided with an injector 53 for injecting a foaming agent into the cylinder 52a. Examples of the foaming agent injected from the injector 53 include a physical foaming agent, a chemical foaming agent, and a mixture thereof, and a physical foaming agent is preferable. As the physical foaming agent, inorganic physical foaming agents such as air, carbon dioxide, nitrogen gas, and water, organic physical foaming agents such as butane, pentane, hexane, dichloromethane, and dichloroethane, and their supercritical fluids are used. be able to. As the supercritical fluid, it is preferable to use carbon dioxide, nitrogen, etc., for nitrogen, the critical temperature is -149.1 ° C, the critical pressure is 3.4 MPa or more, and for carbon dioxide, the critical temperature is 31 ° C, the critical pressure. It is obtained by setting the pressure to 7.4 MPa or more. Examples of the chemical foaming agent include those that generate carbon dioxide gas by a chemical reaction between an acid (eg, citric acid or a salt thereof) and a base (eg, baking soda). The chemical foaming agent may be injected from the hopper 51 instead of being injected from the injector 53.

<Accumulator 54, T-die 6>
The foamed resin 3c formed by melt-kneading the molten resin 3b and the foaming agent is extruded from the resin extrusion port of the cylinder 52a and injected into the accumulator 54 through the connecting pipe 81. The accumulator 54 includes a cylinder 54a and a piston 54b slidable inside the cylinder 54a, and the foamed resin 3c can be stored in the cylinder 54a. Then, by moving the piston 54b after a predetermined amount of the foamed resin 3c is stored in the cylinder 54a, the foamed resin 3c is pushed out from the slit provided in the T die 6 through the connecting pipe 82 and hung down to be a foamed resin sheet. Form 3d.

<Split mold 7>
8 and 9 are perspective views of the split mold 7. The split mold 7 is a pair of split molds 7 including a first mold 71 and a second mold 72. The foamed resin sheet 3d (see FIGS. 7 and 12) is guided between the first mold 71 and the second mold 72. The first mold 71 is provided with a vacuum suction hole (not shown), and the foamed resin sheet 3d can be suctioned under reduced pressure to form a shape along the cavity 71b of the first mold 71. ing. Further, as shown in FIGS. 8 and 9, a pinch-off portion 71d is provided so as to surround the cavity 71b.

Similarly, the second mold 72 is provided with a vacuum suction hole (not shown), and the foamed resin sheet 3d can be suctioned under reduced pressure to form a shape along the cavity 72b of the second mold 72. It is possible. Further, as shown in FIGS. 8 and 9, a pinch-off portion 72d is provided so as to surround the cavity 72b.

In the first embodiment, the sound absorbing member 2 is mounted (fixed) on the sound absorbing member mounting portion 72e in the second mold 72, and insert molding described later is performed. The method of fixing the sound absorbing member 2 to the sound absorbing member mounting portion 72e is not particularly limited, and may be fixed with, for example, an adhesive tape or the like, or a protruding portion (not shown) may be provided on the second mold 72. Further, the sound absorbing member 2 may be fixed by providing an insertion hole (not shown) and inserting a protruding portion through the insertion hole.

1.3. Method for manufacturing integrally molded body 1 Here, a method for manufacturing the integrally molded body 1 according to the first embodiment of the present invention will be described with reference to FIGS. 11 to 15. The method of the first embodiment includes an insert step, a placement step, and an expansion step. Hereinafter, a detailed description will be given.

<Insert process>
In this step, in the split mold 7 in the open state shown in FIG. 11, the sound absorbing member 2 (“insert member” in the claims) is formed in advance at the sound absorbing member mounting portion 72e in the second mold 72. An example) is arranged (FIG. 11). As for the method of inserting into the second mold 72, a method of using a robot or the like may be used in addition to the method of mounting by a human hand.

<Placement process>
In this step, as shown in FIG. 12, one foamed resin sheet 3d formed by extruding the molten foam resin 3c from the slit of the T die 6 and hanging it is attached to the second surface 32. The carpet 9 is arranged between the split molds 7. That is, the first mold 71, the carpet 9, the foamed resin sheet 3d, the sound absorbing member 2, and the second mold 72 are arranged in this order. In the first embodiment, since the direct vacuum forming using the foamed resin sheet 3d extruded from the T die 6 as it is is performed, the foamed resin sheet 3d is not cooled to room temperature and solidified before molding. The solidified foamed resin sheet 3d is not heated before molding. Further, the foamed resin sheet 3d of the first embodiment has a substantially uniform temperature as a whole immediately after being extruded from the slit, and is gradually cooled from the surface by the atmosphere while being hung down. The temperature of the foamed resin sheet 3d of the first embodiment rises toward the center of the foamed resin sheet 3d in the thickness direction because it is less affected by cooling by the atmosphere toward the center of the foamed resin sheet 3d in the thickness direction. It has the property of lowering the viscosity. The wall thickness of the foamed resin sheet 3d is not particularly limited, but is, for example, 0.5 to 5.0 mm, preferably 1.0 to 3.0 mm. Specifically, the wall thickness is, for example, 0.5, 1.0, 1.5, 2.0, 2.5, 3.0, 3.5, 4.0, 4.5, 5.0 mm. It may be within the range between any two of the numerical values exemplified here.

<Expansion process>
In this step, as shown in FIGS. 13 and 14, the first die is in a state where the split die 7 is closed so that a gap G larger than the thickness of the foamed resin sheet 3d is provided between the split dies 7. The foamed resin sheet 3d is sucked under reduced pressure from both the mold 71 and the second mold 72. As a result, the foamed resin sheet 3d is expanded to the thickness of the gap G. Then, as shown in FIG. 14, the sound absorbing member 2 and the foamed resin sheet 3d are integrated. At this time, the soft sound absorbing member 2 is sandwiched between the expanded foamed resin 3d and the second sheet mold 72, and is temporarily compressed (see FIG. 14). The expansion step is not essential, and for example, the foamed resin sheet 3d may be crushed by the split mold 7 and molded so as to embed the sound absorbing member 2. In particular, a cylindrical foamed parison may be used instead of the foamed resin sheet 3d.

In the first embodiment, the first mold 71 is provided with the pinch-off portion 71d, and the second mold 72 is provided with the pinch-off portion 72d. When the first mold 71 and the second mold 72 are brought close to each other until the pinch-off portions 71d and 72d come into contact with each other, the space surrounded by the pinch-off portions 71d and 72d becomes a closed space S. The portion of the foamed resin sheet 3d in the closed space S becomes the foamed molded product 3. On the other hand, the portion of the foamed resin sheet 3d outside the closed space S becomes the burr 3f.

In the cavities 71b and 72b of the split mold 7, the gap G between the split molds 7 is formed over the entire portion of the foamed resin sheet 3d that becomes the foam molded body 3 (that is, the portion in the closed space S). It is configured to be substantially constant. When the foamed resin sheet 3d is sucked under reduced pressure by the split mold 7 in this state, the foamed resin sheet 3d expands to the thickness of the gap G to form the foamed molded product 3. The pinch-off portions 71d and 72d are not indispensable, and the first mold 71 and the second mold 72 may be brought close to each other in a non-contact manner so that a gap G is formed between the split molds 7. .. However, if decompression suction is performed by the split mold 7 in a state where the pinch-off portions 71d and 72d are brought into contact with each other to form the closed space S, the pressure in the closed space S tends to decrease, so that the foamed resin sheet 3d tends to expand. There is a merit.

The thickness of the gap G is not particularly limited, but is preferably 1.1 to 3.0 times the thickness of the foamed resin sheet 3d. Specifically, (thickness of gap G) / (thickness of foamed resin sheet 3d) is 1.1, 1.2, 1.3, 1.4, 1.5, 1.6, 1 .7, 1.8, 1.9, 2.0, 2.1, 2.2, 2.3, 2.4, 2.5, 2.6, 2.7, 2.8, 2.9 , 3.0, and may be within the range between any two of the numerical values exemplified here.

In the decompression suction by the split mold 7, the decompression suction by the first mold 71 is started first as shown in FIG. 13, and then the decompression suction by the first mold 71 is performed as shown in FIG. Decompression suction by the second mold 72 is started while maintaining the pressure. Of course, the present invention is not limited to this, and any of them may be started first or at the same time. Further, the decompression suction by the first mold 71 may be stopped first, the decompression suction by the second mold 72 may be stopped first, or the decompression suction by the split mold 7 may be stopped at the same time. .. The decompression suction by the split mold 7 may be started before the first mold 71 and the second mold 72 are brought close to each other, or may be started after the first mold 71 and the second mold 72 are brought close to each other.

When the foamed resin sheet 3d is sucked under reduced pressure by the split mold 7, the foaming of the foamed resin sheet 3d is promoted and the foamed resin sheet 3d expands. Since the foamed resin sheet 3d has the lowest viscosity (highest fluidity) near the center in the thickness direction, foaming near the center in the thickness direction is particularly promoted and the foamed resin sheet 3d expands. As a result, the foamed molded product 3 having a structure in which the average cell diameter in the layer near the center (central layer) in the thickness direction is large and the average cell diameter in the surface layer near the surface is small can be obtained. Such a foamed molded body 3 is lightweight and highly rigid because the central layer having a large average cell diameter has a sandwich structure sandwiched between surface layers having a small average cell diameter.

As shown in the cross-sectional photograph of FIG. 16, the foam molded body 3 obtained by the method of the first embodiment has a thickness of up to 10% from the surface of the foam molded body 3 with respect to the wall thickness of the foam molded body 3. When the layer is a surface layer and a layer having a thickness of 25 to 50% from the surface of the foamed molded product 3 is a central layer, the average cell diameter of the central layer becomes larger than the average cell diameter of the surface layer. The ratio of (average cell diameter of the central layer) / (average cell diameter of the surface layer) is not particularly limited, but is, for example, 1.2 to 10. Specifically, this ratio is, for example, 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9, 2.0, 2.5, 3.0, 3.5, 4.0, 4.5, 5.0, 5.5, 6.0, 7.0, 8.0, 9.0, 10.0, which are exemplified here. It may be in the range between any two of the numerical values.

The average cell diameter of the entire foam molded body 3 in the thickness direction is, for example, 100 to 2000 μm. Specifically, the average bubble diameter is, for example, 100, 200, 300, 400, 500, 600, 700, 800, 900, 1000, 1500, 2000 μm, and is between any two of the numerical values exemplified here. It may be within the range. The average cell diameter of the surface layer is, for example, 80 to 500 μm. Specifically, the average bubble diameter is, for example, 80, 100, 150, 200, 250, 300, 350, 400, 450, 500 μm, and is within the range between any two of the numerical values exemplified here. You may. The average bubble diameter of the central layer is, for example, 100 to 2000 μm. Specifically, the average cell diameter is, for example, 100, 200, 300, 400, 500, 600, 700, 800, 900, 1000, 1100, 1200, 1300, 1400, 1500, 1600, 1700, 1800, 1900. It is 2000 μm and may be within the range between any two of the numerical values exemplified here.

The average cell diameter is measured by the following method.
First, a cross-sectional photograph of the foam molded product 3 is taken at a magnification of 50 times as shown in FIG.
-Next, in the cross-sectional photograph, five reference lines R1 to R5 extending in the thickness direction are drawn. The distance between the reference lines is 500 μm.
-For each reference line, count the number of bubbles passing through the reference line in the layer to be measured (surface layer, central layer, or the entire thickness direction).
-Measure the maximum length in the thickness direction (the length at the part where the length in the thickness direction is the longest) for each bubble.
-Calculate the tentative average bubble diameter for each reference line according to Equation 1. Further, the average cell diameter is calculated by arithmetically averaging the tentative average cell diameters calculated for each reference line.
(Equation 1) Temporary average bubble diameter = total maximum length of all counted bubbles / number of counted bubbles

For example, in the example of FIG. 17, the number of bubbles through which the reference line R passes in the central layer is 6, and the maximum length of each bubble in the thickness direction is l1 to l6. Therefore, in this example, the tentative average bubble diameter of the central layer is calculated by (l1 + l2 + l3 + l4 + l5 + l6) / 6.

The expansion step is preferably performed by executing the first suction step, the mold proximity step, and the second suction step in this order. In the first suction step, the foamed resin sheet 3d is sucked under reduced pressure by the first mold 71 to shape the foamed resin sheet 3d into a shape along the cavity 71b of the first mold 71. In the mold proximity step, the first mold 71 and the second mold 72 are brought close to each other so that the gap G is provided between the split molds 7 (this state is shown in FIG. 13). In the second suction step, as shown in FIG. 14, the foamed resin sheet 3d is sucked under reduced pressure by the split mold 7 to expand the foamed resin sheet 3d to the thickness of the gap G.

When decompression suction by the split mold 7 is started after the split molds 7 are brought close to each other, the foamed resin sheet 3d comes into contact with the convex portion 72c of the second mold 72 before the foamed resin sheet 3d is formed. It ends up. Normally, the temperature of the split mold 7 is lower than the temperature of the foamed resin sheet 3d. Therefore, when the foamed resin sheet 3d comes into contact with the convex portion 72c of the second mold 72, the foamed resin sheet 3d is cooled and its viscosity becomes high. It rises and the followability of the split mold 7 to the cavities 71b and 72b deteriorates. On the other hand, when the expansion step is performed by executing the first suction step, the mold proximity step, and the second suction step in this order, the foamed resin sheet 3d has a shape along the cavity 71b of the first mold 71. Since the contact of the foamed resin sheet 3d with the split mold 7 before being shaped is minimized, the increase in the viscosity of the foamed resin sheet 3d is suppressed, and the foamed resin sheet 3d is divided into the split mold 7. Can be made to follow the cavities 71b and 72b of the above with high accuracy.

<Finishing process>
As shown in FIGS. 15 and 16, the split mold 7 is released after the expansion step. Immediately after release, the sound absorbing member 2 is compressed from the original thickness (an example of the "first thickness" in the claims) (an example of the "second thickness" in the claims). (Fig. 15). After a while, the thickness of the sound absorbing member 2 is restored from the second thickness to the first thickness (FIG. 16). Then, the foam molded product 3 is obtained by cutting off the burr 3f. The sound absorbing member 2 is fixed to the foam molded body 3 by the anchor effect, that is, the desired integrally molded body 1 can be obtained.

The value of (second thickness) / (first thickness) is, for example, 0.1 to 0.8, and specifically, for example, 0.1, 0.2, 0.3, 0. It is 4, 0.5, 0.6, 0.7, 0.8, and may be within the range between any two of the numerical values exemplified here.

2. Second Embodiment Next, the integrally molded body 1 according to the second embodiment of the present invention will be described.

It should be noted that the soft sound absorbing member 2 is adopted in the first embodiment, but the non-soft sound absorbing member 2 is adopted in the second embodiment. Examples of the non-soft sound absorbing member 2 include a non-woven fabric, a woven fabric, a sheet made of cotton, a non-breathable sheet having fine holes, and the like. The sound absorbing member 2 may be made of a material capable of selectively absorbing sound having a specific frequency. By the way, in the second embodiment, since the sound absorbing member 2 is not compressed in the expansion step and restored after the split mold 7 is released, the exposed surface 21 of the sound absorbing member 2 and the first surface 31 of the foam molded body 3 are not restored. It is characterized in that the step between the two and the above is smaller than that of the above embodiment. Especially ideally, it can be a continuous flat surface.

However, in reality, it is conceivable that a step will occur at the boundary between both sides. The step is, for example, 0 to 3 mm, preferably 0 to 1 mm, and specifically, for example, 0, 0.1, 0.2, 0.3, 0.4, 0.5, 0.6, 0. It is 7, 0.8, 0.9, 1.0, 1.5, 2.0, 2.5, 3.0 mm, even if it is within the range between any two of the numerical values exemplified here. good.

Since the non-soft sound absorbing member 2 is used, when the integrally molded body 1 is molded, as shown in FIG. 18, the contact portion 33 with the sound absorbing member 2 is compressed and the bubbles are crushed in the thickness direction. .. Then, the integrally molded body 1 taken out from the split mold 7 is finished according to the mold thickness.

3. 3. Modification Example The integrally molded body 1 according to the first and second embodiments described above can also be implemented by the following aspects.

First, particularly in the soft sound absorbing member 2, the sound absorbing member 2 may be integrated with the foam molded body 3 to form the integrally molded body 1 by the anchor effect without forming the recess 31a.

Secondly, the second surface 32, which is the design surface, may be implemented without being covered with the carpet 9 (skin member).

4. Conclusion As described above, according to the present embodiment, it is possible to provide an integrally molded body in which a sound absorbing member is fixed to a base material without using an adhesive, and a method for manufacturing the same.

Although the embodiments according to the present invention have been described, they are presented as examples and are not intended to limit the scope of the invention. The novel embodiment can be implemented in various other forms, and various omissions, replacements, and changes can be made without departing from the gist of the invention. The embodiment and its modifications are included in the scope and gist of the invention, and are included in the scope of the invention described in the claims and the equivalent scope thereof.

1: Integral molded body 2: Sound absorbing member 21: Exposed surface 22: Mold 3: Foam molded body 3a: Raw material resin 3b: Molten resin 3c: Foamed resin 3d: Foamed resin sheet 3f: Burr 31: First surface 31a: Recess 32: Second surface 33: Contact part 4: Foam molding machine 5: Resin supply device 51: Hopper 52: Extruder 52a: Cylinder 53: Injector 54: Accumulator 54a: Cylinder 54b: Piston 6: T-die 7: Split mold 71: First mold 71b: Cavity 71d: Pinch-off portion 72: Second mold 72b: Cavity 72c: Convex portion 72d: Pinch-off portion 72e: Sound absorbing member mounting location 81: Connecting pipe 82: Connecting pipe 9: Carpet G: Gap S: Closed space

Claims (9)

A sheet-shaped foam molded body and a porous sound absorbing member are provided.
A predetermined surface is provided on a part of the foam molded product, and the foam molded product is provided with a predetermined surface.
The sound absorbing member is an integrally molded body composed of an open cell foam sheet, which is fixed by entering the surface of the predetermined surface of the foamed molded product and being cured. The foamed molded product has a recess in a part of the predetermined surface.
The sound absorbing member is
With an exposed surface
It said stowed and said exposed surface to recess Ru is configured to protrude from the foamed molded, integrally molded body according to claim 1. The step at the boundary between the predetermined surface and the exposed surface is 3 to 10 mm.
The integrally molded body according to claim 2. The foamed molded product has a recess in a part of the predetermined surface.
The sound absorbing member is
With an exposed surface
It is configured to be housed in the recess and the exposed surface to be exposed from the foamed product.
The step at the boundary between the predetermined surface and the exposed surface is 0 to 1 mm.
The integrally molded body according to claim 1. A method for manufacturing an integrally molded body using the first and second dies.
It has an insert process, a placement process, and a molding process.
In the insert step, the insert member is mounted on the second mold, and the insert member is attached.
In the arrangement step, with the insert member mounted on the second mold, a molten foam resin is hung between the first and second molds.
In the molding step, the foam molded body made of the foamed resin and the insert member are fixed by an anchor effect to form an integrally molded body .
The molding step includes an expansion step.
In the expansion step, the first and second molds are brought close to each other so that a gap larger than the thickness of the foamed resin is provided between the first and second molds. By sucking the foamed resin under reduced pressure with both molds, the foamed resin is expanded to the thickness of the gap.
The insert member has a first thickness and
In the molding process,
The foamed resin is expanded to the thickness of the gap and the insert member is compressed to a second thickness smaller than the first thickness to form an integrally molded body having the thickness of the gap.
A method in which the thickness of the insert member compressed to the second thickness is then restored over time. The second mold has a protrusion, and the insert member has an insertion hole.
The protrusion is inserted into the insertion hole, and the insert member is mounted on the second mold.
The method according to claim 5. The expansion step includes a first suction step, a mold proximity step, and a second suction step in this order.
In the first suction step, the foamed resin is sucked under reduced pressure by the first mold to shape the foamed resin into a shape along the cavity of the first mold.
In the mold proximity step, the first and second molds are brought close to each other so that the gap is provided between the first and second molds.
In the second suction step, the foamed resin is sucked under reduced pressure by the first and second molds to expand the foamed resin to the thickness of the gap.
The method according to claim 5 or 6. In the previous Symbol molding process,
The insert member which is compressed before Symbol second thickness is repaired with time until the first thickness,
The method according to claim 5 or 6. The value of (the second thickness) / (the first thickness) is 0.1 to 0.8.
The method according to claim 8.

Images