JP2002292670A - How to process skin scraps - Google Patents

Abstract

(57) [Summary] [Problem] In a foamed molded article with a skin, the end of the skin is folded back along the outer peripheral portion of the molded foamed article, and is fused and integrated with the back surface of the foamed article. Provided is a method for easily trimming and removing a skin trim without damaging an inner foam. SOLUTION: A thermoplastic resin skin material 6 is arranged in one mold 19 having a folded frame 16 constituting a mold 30 and the mold is clamped. Then, foam beads 32 are filled in the mold 31 and steam heating is performed. The foamed beads 32 are foamed and fused together with each other, and the foamed beads 32 and the thermoplastic resin skin material 6 are fused and integrated with each other. After the foam molding in an integrated mold with the mold, the mold 30 is opened, and the foam molded article with the skin is kept attached to the one mold 19 or taken out from the one mold 19, and then a trimming jig (metal ), And trim the skin offcuts with a laser and remove it.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an in-mold foam molded article, in which part or all of the outer peripheral portion of a skin material which is fused and integrated with the surface of the in-mold foam molded article is folded inward to form a back surface of the in-mold foam molded article. The present invention relates to a method for treating a skin scrap of an in-mold foam molded article with a skin to be fused and integrated.

[0002]

2. Description of the Related Art Conventional techniques of this kind include, for example,
There is a simultaneous molding method of a skin material disclosed in Japanese Patent Application Laid-Open No. 62-108039. In this method, of a pair of male and female molds, after performing vacuum forming of the skin material along the female mold, foam molding is performed in a mold space formed between the male mold and the skin material, and molding is performed. In the simultaneous molding method of the skin material for integrally joining the foamed molded product and the skin material, the outer peripheral portion of the skin material is formed along the folded mold protruding into the mold from the outer periphery of the female mold during the vacuum molding of the skin material. Then, the mold is folded back from the outer peripheral edge to the back side, and at the time of foam molding, the folded portion of the skin material is integrally joined to the outer peripheral back surface of the foam molded article. However, as shown in FIGS. 9 and 10, in the vicinity of the end of the folded portion, the outer peripheral portion of the skin material is in an upright state with respect to the back surface of the foam molded product. When trimming the outer peripheral portion, it must be performed by a conventional manual operation or the like, and the trimming operation is difficult, so that a protruding ear portion having a predetermined length may remain.

On the other hand, for example, there is a method of trimming a skin in simultaneous molding of a skin material disclosed in Japanese Utility Model Application Laid-Open No. 61-201826. In this method, one mold for holding a skin and another mold combined with the mold to form a cavity for molding a substrate behind the skin are provided, and the other mold is held in one mold. By providing a cutting blade for trimming the periphery of the cut skin, when the two dies are matched, the skin held by one of the dies is trimmed by the engagement between the cutting blade and the groove. However, the present invention has a drawback that when the skin end is turned over, trimming cannot be performed inside the molded product from the outer periphery where the skin end is turned.

[0004]

DISCLOSURE OF THE INVENTION The present invention has been made in view of the above-mentioned problems, and the skin of the foamed molded article with a skin is formed at the end of the surface of the molded foamed article with a skin. A skin material comprising: a folded portion that is folded inward from the edge, one surface of which is fixed to the back surface of the foamed molded article with a skin, and a folded portion that is folded outward from the tip of the folded portion. An in-mold foam molded article with a skin, comprising:
It is an object of the present invention to provide a method for easily trimming a folded-back portion that has been folded outward from the tip of the folded portion inside an edge of a surface portion of the in-mold foam molded article.

[0005]

Means for Solving the Problems In order to achieve the above object, the means of claim 1 is characterized in that, at the time of thermoforming of a skin material, the entire periphery of the one mold surface or the opening edge of a part is measured. Along with a folding mold arranged to protrude inward, an outer peripheral portion of the skin material is folded inward to form a folded portion, and then the foam molding is performed, and one surface of the folded portion is subjected to in-mold foaming. After being fused and integrated on the back of the body, the mold is opened, and the outer peripheral portion is folded back outward from the tip of the folded portion of the foam molded article with the skin held by one mold. It is to cut the inner part from the outer periphery of the part with a laser.

A second aspect of the present invention resides in that, when cutting the outer skin scraps of the folded portion, the folding mold is retracted from the laser cut portion.

According to a third aspect of the present invention, there is provided a folding mold which is disposed so as to protrude inward from the entire periphery of the one mold surface or the opening edge of a portion during thermoforming of the skin material. Along with this, the outer peripheral portion of the skin material is folded inward to form a folded portion, and then the folding mold is retracted from the inside of the opening end of the one mold surface, the mold is closed, and the foaming is performed. After performing molding and fusing one surface of the folded portion to the back surface of the foam in the mold, the mold is opened, and the outer peripheral portion from the tip of the folded portion of the foam molded product with a skin held in one mold is opened. Is to cut the inner portion from the outer periphery of the folded back portion with the laser folded back by laser.

According to a fourth aspect of the present invention, in the thermoforming, along the folding mold disposed so as to protrude inward from the entire periphery of the one mold surface or the opening edge of the portion. After the outer peripheral portion of the skin material is folded inward to form a folded portion, the folding mold is retracted from the inside of the opening end of the one mold surface, the mold is closed, and the foam molding is performed. After performing one surface of the folded portion by fusion bonding to the back surface of the in-mold foam, the mold is opened, and the skin-molded foam molded product having the folded portion formed thereon is released from one mold.
The present invention is to cut the inner portion from the outer periphery of the turned-back portion, which is fixed to the positioning jig and whose outer peripheral portion is turned outward from the tip of the turned-back portion, with a laser.

According to a fifth aspect of the present invention, there is provided a folding mold which is arranged so as to protrude inward from the entire periphery of the one mold surface or the opening edge of a portion during thermoforming of the skin material. Along with, after forming the folded portion by folding the outer peripheral portion of the skin material inward, the foam molding is performed, and one surface of the folded portion is fused and integrated with the back surface of the in-mold foam. Opened, the molded foam in the mold with the skin formed with the folded part is released from one mold, and then fixed to the positioning jig,
An object of the present invention is to cut the inner portion from the outer periphery of the folded portion in a state where the outer peripheral portion is folded outward from the tip of the folded portion by laser.

According to a sixth aspect of the present invention, the skin of the offcuts other than the folded portion is also cut by the laser.

According to a seventh aspect of the present invention, the laser used for cutting is a YAG laser.

The means of claim 8 is that the in-mold foam molded article is an olefin resin in-mold foam molded article.

The ninth aspect of the present invention resides in that the expanded molded article in an olefin resin mold is colorless (natural).

According to a tenth aspect of the present invention, the olefin-based resin molded foam is a polypropylene-based resin molded foam.

[0015] The means of claim 11 is that the skin material is an olefin-based thermoplastic elastomer sheet.

According to a twelfth aspect of the present invention, the olefin-based thermoplastic elastomer sheet is a polypropylene-based thermoplastic elastomer sheet.

According to a thirteenth aspect, the skin material is a colored olefin-based thermoplastic elastomer sheet.

According to a fourteenth aspect, the skin material is composed of at least one skin layer.

According to a fifteenth aspect, the skin material has at least one or more colored foamed resin layers.

[0020]

Embodiments of the present invention will be described below with reference to the drawings. 1 to 3 and 11 to 1
As shown in FIG. 3, the in-mold foam molded article 1 with a skin according to the embodiment includes, for example, an in-mold foam molded article 2 having a substantially U-shaped cross section, a surface portion 3, a folded portion 4 and a folded portion. A skin material 6 comprising a return portion 5 and a predetermined position L1 inside the base end 4a of the return portion 4 in the return portion 5 or a predetermined position L1 further inward from the base end 4a of the return portion 4 The position L2 is also cut with a laser, and the outer peripheral portion 8 is cut.
Is removed. The in-mold foam molded article 2 is obtained by subjecting foam beads made of a synthetic resin to foam molding (in-mold foaming) in a mold.

Examples of the skin material 6 include a thermoplastic resin sheet made of a vinyl chloride resin or a polyolefin resin such as a polyethylene resin or a polypropylene resin. Since the skin material 6 is used as the skin of the in-mold foam molded article 1 with the skin, the skin material 6 may be colored in advance to a desired color with a coloring agent or the like according to its use. The skin portion 3 of the skin material 6 is fixed to the surface of the in-mold foam molded body 2. The folded portion 4 is folded inward from the edge of the surface portion 3 and one surface thereof is fixed to the in-mold foam molded body 2. Examples of a method for fixing the surface portion 3 and the folded portion 4 to the in-mold foam molded body 2 include fusion by heat, adhesion by an adhesive, or a combination thereof. In FIG. 13, the folded-back portion 5 extends outward from the tip 4 b of the folded portion so as to overlap the other surface 4 c of the folded portion 4, and the tip thereof extends outward from the base end 4 a of the folded portion 4. It is folded back so as to protrude, and a predetermined position L <b> 1 inwardly of the base end 4 a of the return part 4 in the return part 5 or further the base end 4 a of the return part 4.
The predetermined inner position L2 is also cut by the laser, and the outer peripheral portion 8 is removed.

[0022]

DESCRIPTION OF THE PREFERRED EMBODIMENTS The above-mentioned polyolefin-based resin-molded foam molded article 2
Is obtained by foaming polyolefin resin foam beads in a mold. As the polyolefin resin, for example, low-density polyethylene, medium-density polyethylene, high-density polyethylene, linear low-density polyethylene,
Ethylene-vinyl acetate copolymer, propylene homopolymer, ethylene-propylene random copolymer, ethylene-propylene block copolymer, ethylene-propylene-butene random terpolymer, propylene-vinyl chloride copolymer, propylene-butene Copolymer, propylene-
Maleic anhydride copolymers, polyethylene resins such as poly (butene-1) and polypropylene resins, and the like;
These can be used alone or in combination of two or more.

The polyolefin resin is preferably in a non-crosslinked state, but may be crosslinked by peroxide or radiation.

A mixture of this polyolefin resin and another thermoplastic resin can also be used. When mixed with the polypropylene resin, examples of such a thermoplastic resin include low-density polyethylene, linear low-density polyethylene, vinyl aromatic polymer, polybutene, and ionomer. When mixed with the polyethylene resin, examples thereof include a vinyl aromatic polymer, polybutene, and an ionomer. The amount of the thermoplastic resin in these cases is preferably 20 parts by weight or less, more preferably 5 to 10 parts by weight, based on 100 parts by weight of the polyolefin resin.

The polyolefin resin foam beads are as follows:
For example, the above-mentioned polyolefin resin is formed into particles in advance, and a volatile foaming agent is contained in the polyolefin resin particles in a pressure vessel, dispersed in water with stirring, and subjected to a predetermined pressure. After heating to the foaming temperature of above, the aqueous dispersion may be manufactured in a prefoamed state by, for example, discharging the aqueous dispersion to a low pressure region. When the expansion ratio at the time of in-mold foaming of the polyolefin-based resin expanded beads is less than 3 times, the obtained polyolefin-based resin-in-mold foamed article tends to have a reduced buffering property and the like. When the size is large, the shrinkage of the foamed molded article in the polyolefin-based resin mold becomes large, and it tends to be too soft and the strength or the like tends to decrease. Therefore, it is 3 to 60 times, preferably 5 to 50 times, more preferably. It is preferably 8 to 45 times, particularly preferably 10 to 35 times. As such polyolefin resin foam beads, for example, Eperan PP (trade name, manufactured by Kaneka Chemical Co., Ltd., expansion ratio: 15) can be preferably used.

Next, a method for producing the above-mentioned foamed molded article 1 in a polyolefin resin mold with a skin will be described. FIG.
As shown in FIG. 8 to FIG. 8, the method for manufacturing the foamed molded article 1 in a polyolefin resin mold with a skin according to the present embodiment includes one of the two molds 19 and 20 constituting the mold 30. After the TPO skin material 6 is disposed and the mold is clamped, the inside of the mold 31 is filled with polyolefin resin foam beads 32, and the polyolefin resin foam beads 32 are foamed by steam heating and fused together. The polyolefin resin foam beads 32 and the TPO skin material 6 are fused and integrated.

That is, as shown in FIG. 4, first, the TPO skin material 6 is placed in the one mold 19 and clamped.

Here, the molding die 30 comprises, for example, two dies 19 and 20 which can be clamped and opened in the vertical direction.

The one of the two dies 19, 20 has, for example, a concave cross section and a chamber 19a formed therein.
A plurality of decompression holes 19b communicating with the chamber 19a are formed. And, in the chamber 19a,
The steam valve A1, the pressure reducing valve B1, and the drain valve C1 are connected respectively.

The other mold 20 has, for example, a convex cross section and a chamber 20a formed therein.
On the 0c side, a plurality of steam holes 20b communicating with the chamber 20a are formed. A steam valve A2, a pressure reducing valve B2, and a drain valve C2 are connected to the chamber 20a, respectively, and a feeder 22 for filling polyolefin resin foam beads 32 into the mold 31 is provided. .

In order to arrange the TPO skin material 6 on the surface 19c of the one mold 19, the TPO skin material 6 is previously formed by vacuum molding or the like so as to conform to the shape of the surface 19c of the one mold 19. May be placed,
Alternatively, if it has flexibility, the inside of the mold 31
And may be arranged by performing vacuum molding or the like.

Here, in the case where the obtained foamed article 1 with a skin in the polyolefin-based resin mold requires, for example, an attachment for attaching to another member, the surface 20c of the other mold 20 is provided. An insert member (not shown) having a predetermined shape is arranged in advance, and when the polyolefin resin foam beads 32 are foamed in the mold, the insert member and the polyolefin resin foam molded article 2 are integrated. You may make it.

Next, as shown in FIG. 5, foamed polyolefin resin beads 32 are filled into the mold 31 from the feeder 22.

At this time, the surface 19c of the one mold 19
Is filled with the polyolefin resin foam beads 32 because the air in the mold 31 escapes only from the steam holes 20b of the other mold 20 when the mold is clamped. To facilitate the filling, the mold may be opened slightly to such an extent that the polyolefin resin foam beads 32 do not drop during filling, and the air may be released from the gap.

The polyolefin resin foam beads 32 may be filled into the molding die 31 in a state where a pressurized gas has been previously penetrated into the inside and an internal pressure has been applied. May be filled in a compressed state, or without applying or compressing the internal pressure,
It may be filled as it is.

Then, as shown in FIG. 6, the steam valve A2 connected to the chamber 20a of the other mold 20 is opened to supply steam S from the steam hole 20b to the inside 31 of the molding die. The foam beads 32 are foamed by heating.

At this time, before the polyolefin resin foam beads 32 are fully heated at a temperature higher than the temperature at which the polyolefin resin foam beads 32 fuse together, the polyolefin resin foam beads 32 are heated at a temperature lower than the fusion temperature. If the foam beads 32 are preheated in advance, the polyolefin resin foam beads 32 can be sufficiently heated without fusing to each other.

The temperature at which the polyolefin resin foam beads 32 are fused to each other means that the polyolefin resin foam beads 32 are placed in a mold 31 having a depth of about 50 mm.
When steam S at a predetermined temperature (predetermined pressure) is supplied to the inside of the mold 31 for 10 to 20 seconds, the polyolefin-based resin foam beads 32 are fused to each other, and the polyolefin-based resin mold foam 2 is formed. Means the lowest temperature at which the shape of the sheet can be maintained.

The polyolefin resin foam beads 32
Since the temperature at which the particles are fused to each other varies depending on the type of the polyolefin-based resin used, the temperature may be determined in advance, and then the temperature of the steam S at the time of the preliminary heating may be set. If the temperature of the water vapor S is too low, the effect of the preheating tends to be insufficient, so that the polyolefin resin foam beads 8
Are defined as T (° C.) when the temperature at which they are fused to each other is (T-3)
5) to T (° C), preferably (T-30) to (T-
3) (° C), more preferably (T-25) to (T-
5) It is desirable that the temperature be in the range of (° C.). Further, the pressure of the steam S may be appropriately adjusted so as to be in the above-mentioned temperature range.

After preheating as described above,
If the polyolefin-based resin foam beads 32 are steamed with steam S while maintaining the state for a predetermined time, the latent heat of the steam S supplied between the polyolefin-based resin foam beads 32 can be effectively used. For example, when the foamed polyolefin-based resin mold 2 having a large diameter is molded, there is an advantage that the polyolefin-based resin foam beads 8 can be more uniformly heated.

After the preheating, the steam may be steamed while the supply of steam S is continued, or the steam may be steamed while the supply of steam S is stopped and the drain valve C2 is opened as necessary. Is also good. The holding time during the steaming depends on the thickness of the foamed beads 32 in the polyolefin resin mold in the mold 31, the size and shape of the foamed polyolefin resin beads 32, the expansion ratio, and the like. When the thickness of the 32 layers of the resin foam beads is about 50 mm, the thickness is preferably about 3 seconds or more, preferably about 5 seconds or more, and more preferably about 10 seconds or more.

The polyolefin resin foam beads 32
Is steamed with steam S, a drain (moisture) exists between the polyolefin resin foam beads 32, and if the main heating is performed in this state, the polyolefin resin foam beads 32
It is desirable to remove the drain because mutual fusion failure may occur.

As a method for removing the drain, for example, as shown in FIG. 7, the pressure reducing valve B2 connected to the chamber 20a of the other mold 20 is opened to open the vapor hole 2
0b or a method in which the inside of the mold 31 is evacuated, or the mold 30 is slightly opened to open two molds 19 and 20.
A method of removing a drain from the gap by providing a gap between the foam holes 20b and passing high-temperature and dry air through the steam holes 20b at a temperature high enough to prevent the polyolefin resin foam beads 32 from being fused to each other.

Next, main heating is performed at a temperature not lower than the temperature at which the polyolefin resin foam beads 32 are fused to each other.
As shown in FIG. 8, the main heating is performed by opening the steam valve A2 and supplying steam S from the steam hole 20b to the inside of the molding die 31. At this time, as described above, if the inside of the mold 31 is evacuated to remove the drain after performing the steaming with the steam S as described above, the steam S for the main heating is more smoothly removed. Inside the mold 3
1 can be supplied.

The temperature of the steam S at this time may be at least the temperature at which the polyolefin-based resin foam beads 8 are fused to each other. Since the shrinkage of No. 2 tends to be too large, it is desirable that the temperature should not exceed 30 ° C., preferably 25 ° C. higher than the temperature at which the polyolefin resin foam beads 8 fuse together.

After the main heating as described above, it is desirable to maintain the state in order to sufficiently transfer the heat of the steam S to the polyolefin resin foam beads 32. The time required for holding at this time is, for example, about 2 seconds or more, preferably about 5 seconds or more for a polyolefin resin foamed bead 32 layer having a thickness of about 50 mm. Is too long, the resulting polyolefin-based resin molded foam 2
Since shrinkage occurs in the area, it may be set appropriately within a range in which such shrinkage does not occur.

Next, if the mold 30 is opened,
As shown in FIGS. 9 and 10, a polyolefin-based resin-molded foamed product 1 with a skin having a folded portion 5 is obtained.
Before opening the mold, the mold 30 may be cooled in advance. Next, before or after removing the molded polyolefin-based resin-molded foamed body 1 with a skin from the molding die 30, as shown in FIGS. Trimmed and removed.

After being released from the mold 30, it is preferable to cure and dry at 50 to 80 ° C. for about 3 to 24 hours under normal pressure. Trimming after removal from the mold 30 can be performed either before or after curing and drying.

As described above, curing before or after demolding,
By trimming the outer edge portion 8 before or after curing and after drying, it is possible to obtain the polyolefin-based resin-molded foam 1 with a skin shown in FIGS.

As described above, the polyolefin resin foam beads 32 are preheated, steamed with steam S, and then fully heated. At the same time as the production, the polyolefin-based resin-type inner foam molded article 2 and the TPO skin material 6 can be firmly fused and integrated, and the polyolefin-based resin-type internal foam molded article 2 has polyolefin-based resin foam beads. Insulation molding of polyolefin resin with skin with good appearance of outer peripheral part of molded body, in which the end of the skin is folded back, and the outer edge part is trimmed inside the outer periphery of the molded body without occurrence of fusion failure of 32 The body 1 can be manufactured.

The polyolefin resin-in-foam molded article 1 with a skin shown in FIGS. 3, 10 and 13 is different from the above-mentioned embodiment in that the TPO skin material 6 is placed on the surface 19 c of the one mold 19 and the mold is formed. The folded frame 16 is retracted between the start of fastening and before the start of heating, and then the mold is further clamped to form the folded portion 4 and the folded portion 5 of the skin material 6 so as to be folded.

In the above embodiment, the one mold 19 is a concave mold (female mold) having a concave cross section.
And, the case where the lower mold is present has been described, but the present invention is not limited to this, and the one mold is a convex mold (male mold).
In addition, the other mold 20 may be a concave mold (female mold), or the one mold 19 may be an upper mold. Further, the mold 30 is opened in the vertical direction. However, the mold 30 may be opened in the horizontal direction.

Next, the present invention will be described in more detail with reference to examples, but is not limited to the examples according to the present invention.

[Examples 1 to 6] Of the female mold and the male mold constituting the mold, a skin material was placed on the female mold by vacuum molding, and then foamed in the mold. A flow path through which a heat medium flows is formed in a meandering state inside the portion forming the cavity surface of the female mold, and the cavity surface is maintained at the temperature shown in Table 1 by flowing steam through the flow path. did. The male mold was provided with a steam hole for supplying steam into the mold during foam molding, and a feeder for filling foam beads.

Here, a polyolefin-based thermoplastic resin sheet (TPO sheet) was used as the skin material, which was heated and softened, placed in the female mold, and shaped using a vacuum pump. As the expanded beads, Eperan PP (manufactured by Kaneka Chemical Industry Co., Ltd., trade name, expansion ratio 15 times, with an internal pressure of 2 kg / cm ² · G previously applied by air pressure in a pressure vessel), and after clamping the mold, The expanded beads were filled into the mold via the feeder. When the folded frame was retracted, it was performed after the filling was completed.

After filling the foam beads, steam (1.5 Kg / cm ² · G) is supplied from the steam holes formed in the male mold into the molding die to perform preheating, thereby steaming the foam beads. After the operation, the drain and the water vapor were sucked and removed using a vacuum pump. Thereafter, steam (vapor pressure 3.2 to 3.7 kg / cm ² · G) is again supplied from the vapor hole into the molding die, and the molding is fully heated. A molded article was obtained.

The skin end material of the in-mold foam molded article with skin is
In the case of trimming in a molding die, the mold was opened while holding the molded body in the female mold, and the skin trim was trimmed with a laser.

The skin end material of the foamed molded article with the skin was
In the case of trimming outside the molding die, the molded body was released from the female mold, and then the molded body was fixed to a positioning jig (die), and then the skin trim was trimmed with a laser.

[Comparative Examples 1 to 5] After obtaining a foamed molded article with a skin in the same manner as in Examples 1 to 6, except that the folded frame was not used in Comparative Example 1. The trim ends were trimmed outside the molding die.

The design of the foamed molded article with the skin after trimming and the design of the outer peripheral portion were evaluated and the results are shown in Table 1.

[0061]

[Table 1]

[0062]

According to the method for treating a skin scrap of an in-mold foam molded article with a skin according to the present invention, the skin material is folded back along the outer peripheral portion of the in-mold foam molded article, and fused and integrated with the foam. After that, the skin trim can be easily trimmed and removed without damaging the foam with the skin. Significant cost reduction can be achieved because no manual operation is required.

[Brief description of the drawings]

FIG. 1 is a sectional view showing a state after an unnecessary outer peripheral portion of a skin material has been cut off in the molded body shown in FIG. 9;

FIG. 2 is a cross-sectional view showing the molded article shown in FIG. 9 after an unnecessary outer peripheral portion of a skin material has been cut off;

FIG. 3 is a cross-sectional view showing a state after cutting an unnecessary outer peripheral portion of a skin material of the molded body shown in FIG. 10;

FIG. 4 is a cross-sectional view showing a state in which a skin material is vacuum formed and a cracking mold is clamped.

FIG. 5 is a cross-sectional view showing a state in which foamed beads are filled in a mold.

FIG. 6 is a cross-sectional view showing a state in which foam beads are heated by a molding die.

FIG. 7 is a sectional view showing a state of removing a drain.

FIG. 8 is a sectional view showing a state in which a molded body is held by a molding die.

FIG. 9 is a cross-sectional view showing a state in which the foamed molded article with a skin is removed from the mold.

FIG. 10 is a cross-sectional view showing a state in which the foamed molded article with a skin shown in FIG.

11 is a cross-sectional view showing a state in which an unnecessary outer peripheral portion of the skin material of FIG. 9 is cut.

FIG. 12 is a cross-sectional view showing a state where an unnecessary outer peripheral portion of the skin material of FIG. 9 is cut;

13 is a cross-sectional view showing a state in which an unnecessary outer peripheral portion of the skin material of FIG. 10 is cut.

FIG. 14 is a cross-sectional view showing a state in which the folded frame is retracted during foam molding, and the molded body is held in the molding die.

[Explanation of symbols]

 REFERENCE SIGNS LIST 1 In-mold foam molded product with skin 2 In-mold foam molded product 1 Surface portion 2 Folded portion 4a Base end 4b Tip 5 Folded portion 1 Skin material 8 Skin material outer peripheral portion (skin cut material portion) 16 Folding frame 19 One side of gold Mold 19a Chamber 19b Decompression hole 19c Surface 20 The other mold 20a Chamber 20b Steam hole 20c Surface 22 Feeder 30 Mold 31 Mold inside 32 Foam beads A1 Steam valve A2 Steam valve B1 Pressure regulator B2 Pressure regulator C1 Drain valve C2 Drain valve L1 Skin cut off part (returned part) L2 Skin cut off part (returned part)

──────────────────────────────────────────────────続 き Continued on the front page (51) Int.Cl. ⁷ Identification symbol FI Theme coat ゛ (Reference) B29K 105: 04 B29L 9:00 B29L 9:00 B29C 67/22

Claims (15)

[Claims] An in-mold foam molded by thermoforming a skin material along one of two mold surfaces of a mold and then foam-molding in the mold. A method for producing an in-mold foam molded article with a skin in which the skin material is fused and integrated with the surface of the molded article, and at the time of the thermoforming,
An outer peripheral portion of the skin material was folded inward along a folding die arranged so as to protrude inward from the entire periphery of the one mold surface or the opening edge of the portion to form a folded portion. Then, after performing the foam molding and fusing and integrating one surface of the folded portion to the back surface of the in-mold foam, the mold is opened and the folded portion of the in-mold foam molded product with the skin held by one mold is opened. A method for treating skin scraps, in which a laser cuts an inner portion from the outer periphery of a folded-back portion in which an outer peripheral portion is folded outward from a tip. (2) When cutting off the skin trimmings of the folded portion,
The method according to claim 1, wherein the folded frame is retracted from the laser cut portion. 3. An in-mold foam formed by subjecting a skin material to thermoforming along one of the two mold surfaces of a forming mold and then performing foam molding in the forming mold. A method for producing an in-mold foam molded article with a skin in which the skin material is fused and integrated with the surface of the molded article, and at the time of the thermoforming,
An outer peripheral portion of the skin material was folded inward along a folding die arranged so as to protrude inward from the entire periphery of the one mold surface or the opening edge of the portion to form a folded portion. Then, the folding mold is retracted from the inside of the opening end of the one mold surface, the mold is closed, the foam molding is performed, and one surface of the folded portion is fused and integrated with the back surface of the foam in the mold. After that, the mold is opened, and the inner part from the outer periphery of the folded back portion in a state where the outer peripheral portion is folded back outward from the tip of the folded portion of the in-mold foam molded product with the skin held by one mold is opened. How to treat skin scraps by laser cutting. 4. An in-mold foam molded by subjecting a skin material to thermoforming along one of two mold surfaces constituting a molding die and then performing foam molding in the molding die. A method for producing an in-mold foam molded article with a skin in which the skin material is fused and integrated with the surface of the molded article, wherein, during the thermoforming, the inner periphery of the one mold surface or an opening edge of a part of the mold surface is formed. After the outer peripheral portion of the skin material is folded inward along a folding mold arranged so as to protrude inward, a folded portion is formed, and then the folding mold is placed inside the open end of the one mold surface. The mold is closed, the mold is closed, the foam molding is performed, and one surface of the folded portion is fused and integrated with the back surface of the foam in the mold, and then the mold is opened, and the inside of the mold with the skin formed with the folded portion is formed. After releasing the molded foam from one mold, fix it to the positioning jig and fold it. The inner portion of the outer peripheral folded back portion of the state where the tip peripheral portion from and portions are folded back outwardly, cutting with laser, the processing method of the skin scrap. 5. An in-mold foam molded by thermoforming a skin material along one of two mold surfaces of a molding die and then performing foam molding in the molding die. A method for producing an in-mold foam molded article with a skin in which the skin material is fused and integrated with the surface of the molded article, and at the time of the thermoforming,
An outer peripheral portion of the skin material was folded inward along a folding die arranged so as to protrude inward from the entire periphery of the one mold surface or the opening edge of the portion to form a folded portion. Then, after performing the foam molding and fusing and integrating one surface of the folded portion to the back surface of the in-mold foam, the mold is opened, and the foam molded product with the skin having the folded portion formed therein is formed into one mold. After being released from the mold, it is fixed to a positioning jig, and the inner portion from the outer periphery of the folded back portion in a state where the outer peripheral portion is folded back outward from the tip of the folded portion is cut with a laser, a method of treating skin scraps. . 6. The method according to claim 1, 2, 3, 4, or 5, wherein the skin of the offcuts other than the folded portion is also cut by a laser. 7. The method according to claim 1, wherein the laser used for cutting is a YAG laser. 8. The method according to claim 1, wherein the in-mold foam molding is an olefin resin in-mold foam molding. 9. The olefin-based resin-molded foam molded article is colorless (natural).
The method for treating skin scraps according to 7 and 8. 10. The method according to claim 8, wherein the olefin-based resin-molded foam is a polypropylene-based resin-molded foam. 11. The method according to claim 1, wherein the skin material is an olefin-based thermoplastic elastomer sheet.
The method for treating a skin material according to 8, 9, and 10. 12. The method according to claim 11, wherein the olefin-based thermoplastic elastomer sheet is a polypropylene-based thermoplastic elastomer sheet. 13. The method according to claim 11, wherein the skin material is a colored olefin-based thermoplastic elastomer sheet. 14. A skin material comprising at least one skin layer.
8, 9, 10, 11, 12, and 13, the method for treating skin scraps 15. A skin material having at least one colored foamed resin layer.
The method for treating a skin material according to 7, 8, 9, 10, 11, 12, 13, or 14.