Mold goods and insert molding method

• US 20070148411A1
• Filed: 12/27/2006
• Published: 06/28/2007
• Est. Priority Date: 12/28/2005
• Status: Active Grant

• Current Assignee: Nihon Plast Company Limited
• Original Assignee: Nihon Plast Company Limited
• Inventors: Yamada, Shuji
• Granted Patent: US 8,388,875 B2
• Time in Patent Office: Days
• US Class Current: 428/172
• CPC Class Codes: B29C 44/0461 by having different chemical compositions in different places, e.g. having different concentrations of foaming agent, feeding one composition after the other
• CPC Class Codes: B29C 44/08 using several expanding or moulding steps
• CPC Class Codes: B29C 44/12 Incorporating or moulding on preformed parts, e.g. inserts or reinforcements
• CPC Class Codes: B29C 45/1671 with an insert
• CPC Class Codes: B29C 67/246 Moulding high reactive monomers or prepolymers, e.g. by reaction injection moulding [RIM], liquid injection moulding [LIM] casting monomers B29C39/006, mixing construction B29B7/74
• CPC Class Codes: B29C 70/78 Moulding material on one side only of the preformed part
• CPC Class Codes: B29K 2075/00 Use of PU, i.e. polyureas or polyurethanes or derivatives thereof, as moulding material
• CPC Class Codes: B29K 2105/04 cellular or porous
• CPC Class Codes: B29L 2031/3005 Body finishings
• CPC Class Codes: B29L 2031/3008 Instrument panels
• CPC Class Codes: B29L 2031/3035 Sun visors
• CPC Class Codes: B29L 2031/3041 Trim panels
• CPC Class Codes: B29L 2031/3047 Steering wheels
• CPC Class Codes: B32B 27/065 of foam
• CPC Class Codes: B32B 27/40 comprising polyurethanes
• CPC Class Codes: B32B 5/22 characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed layer formed of natural mineral fibres or particles next to a foam layer B32B19/047, next to a layer made of particles B32B19/048, or next to a fibrous or filamentary layer B32B19/06; paper layer or cardboard layer next to a paper layer or cardboard layer B32B29/005, next to a foam layer B32B29/007, next to a fibrous or filamentary layer B32B29/02, or next to a particulate layer B32B29/04
• CPC Class Codes: Y10T 428/24612 Composite web or sheet
• CPC Class Codes: Y10T 428/249981 Plural void-containing components
• CPC Class Codes: Y10T 428/249989 Integrally formed skin

Abstract

For a skin, a non-formed polyurethane resin layer at the surface side and a foamed polyurethane resin layer between the non-foamed polyurethane resin layer and a base member are configured to form an integral and uniform layer over and extent from an injection point to a distant point on a surface of the base member, so that an integral skin foam in which such skin layer and foamed layer are laminated can be molded, under an atmospheric pressure, in a single process, allowing for manufacture of a laminate article with a high degree of uniformity over an appreciable wide range of the article, as well as for provision of a laminate mold goods having the skin and foamed layers formed with a high uniformity along the base member, over the length in a flow direction of skin forming material.

Claims

1. A mold goods having a flexible skin integrally molded along a surface of a base member, the mold goods comprising:

a skin having a combination of a non-foamed polyurethane resin layer at a side of a surface thereof, and a foamed polyurethane resin layer between the non-foamed polyurethane resin layer and a base member, configured to form an integral and uniform layer over an extent from an injection point to a distant prescribed point on a surface of the base member.

2. The mold goods as claimed in claim 1, wherein the mold goods is a cover panel for an air bag apparatus, and wherein the extent to the distant prescribed point in which the integral and uniform layer is formed has formed therein a swelling opening presumptive portion configured to form an opening with a pressure of an air bag deployed in opposition to a passenger.

3. A mold goods having a flexible skin integrally molded along a surface of a base member, the mold goods comprising:

a skin having a combination of a first non-foamed polyurethane resin layer at a side of a surface thereof, a second non-foamed polyurethane resin layer at a side of a base member, and a foamed polyurethane resin layer between the first non-foamed polyurethane resin layer and the second non-foamed polyurethane resin layer, configured to form an integral and uniform layer over an extent from an injection point to a distant prescribed point on a surface of the base member.

4. The mold goods as claimed in claim 3, wherein the mold goods is a cover panel for an air bag apparatus, and wherein the extent to the distant prescribed point in which the integral and uniform layer is formed has formed therein a swelling opening presumptive portion configured to form an opening with a pressure of an air bag deployed in opposition to a passenger.

5. The mold goods as claimed in claim 4, wherein the cover panel is a cover of an instrument panel, and has a proximal side proximal to a passenger, and a passenger-opposite side distant from the passenger, and wherein the integral and uniform layer is formed at the proximal side.

6. The mold goods as claimed in claim 3, wherein the mold goods is a grip member having a grip portion to be gripped by a passenger and a fixing portion for the grip portion to be fixed to a vehicle body, and wherein the skin has, covering a base member grip portion and a base part of a base member fixing portion at an end of the base member grip portion, an integral and uniform grip layer formed between a point of the grip portion and another point of the grip portion distant therefrom.

7. An insert molding method comprising:

placing a base member in a mold cavity; and

performing an injection of a reaction-molding material of a non-foaming polyurethane resin and a reaction-molding material of a foaming polyurethane resin, along a surface side of the base member, under a normal pressure, to integrally from a skin,

wherein the reaction-molding material of the foaming polyurethane resin contains a first foaming agent for a start of foaming soon after the injection, and a second foaming agent for a start of foaming in retard of the start of foaming of the first foaming agent, and

wherein the skin has an integral and uniform layer formed along a surface of the base member from an injection point of the reaction-molding materials to a point distant therefrom.

8. The insert molding method as claimed in claim 7, wherein the reaction-molding material of the foaming polyurethane resin and the reaction-molding material of the non-foaming polyurethane resin having a viscosity within a range of 400 cps to 700 cps are concurrently flowed inside the mold cavity under an atmospheric pressure, whereby the reaction-molding materials are filled in the mold cavity concurrently upon a substantial completion of foaming.

9. An insert molding method comprising:

placing a base member in a mold cavity;

performing an injection of a reaction-molding material of a non-foaming polyurethane resin along a surface side of the base member under a normal pressure; and

performing an injection of a reaction-molding material of a foaming polyurethane resin immediately after the injection of the reaction-molding material of the non-foaming polyurethane resin, to integrally form a skin,

wherein the reaction-molding material of the foaming polyurethane resin comprises;

a first reaction-molding material selective from between a reaction-molding material having a dissolved non-gaseous foaming agent and a reaction-molding material containing a first foaming agent for a start of foaming immediately after injection; and

another reaction-molding material containing a second foaming agent for a start of foaming after the start of foaming of the first reaction-molding material, and

wherein the skin has an integral and uniform layer formed along a surface of the base member from an injection point of the reaction-molding materials of both the non-foaming polyurethane resin and the foaming polyurethane resin to a point distant therefrom.

10. The insert molding method as claimed in claim 9, wherein the reaction-molding material of the foaming polyurethane resin and the reaction-molding material of the non-foaming polyurethane resin having a viscosity within a range of 400 cps to 700 cps are concurrently flowed inside the mold cavity under an atmospheric pressure, whereby the reaction-molding materials are filled in the mold cavity concurrently upon a substantial completion of foaming.