Patent ID: 9731439
Date: 2017-08-15
CPC Classifications: B29C,B32B,B60R

Claim:
1. A method for manufacturing a vehicle interior board having a first board joined to a second board in plane and in a substantially band form, the method comprising the steps of: arranging a pair of opposing thin plates to have a main surface of one of the thin plates opposing a main surface of the other of the thin plates with a predetermined distance therebetween; forming the second board of a plate-shaped porous structure having two plates spaced from one another at least at an edge of the second board, a main surface of one of the two plates opposing a main surface of the other of the two plates at the edge, and a plurality of sheared injection holes penetrating through each of the two plates of the second board at the edge; inserting the edge of plate-shaped porous structure of the second board, where the injection holes are formed, within a cavity defined by the predetermined distance between a predetermined width part of the pair of thin plates so that gaps are formed between the pair of thin plates and the edge of the plate-shaped porous structure; and injecting liquid raw material of hard polyurethane foam into a space disposed between the pair of thin plates, whereby a chemical reaction causes the injected material to form a hard polyurethane foam, wherein the step of injecting includes supplying the liquid raw material between the spaced plates of the second board, through the injection holes of each of the two plates, and into the gaps formed between the pair of thin plates and the plate-shaped porous structure, and wherein said forming of the hard polyurethane foam simultaneously forms the first board while joining and integrating the first and second boards together at the gaps formed between the pair of thin plates and the plate-shaped porous structure, the first board comprised of the pair of thin plates with at least some of the hard foam sandwiched therebetween.