Vehicle interior trim and method for manufacturing the same

Abstract

The present invention provides a vehicle interior decoration part, which makes the surface boundary of the first plate layer and the second plate layer straight, and firmly adheres the first plate layer to the second plate layer. The vehicle interior decoration part of the present invention is characterized in that it comprises: a foamed plate layer having a foamed surface opposite to the first back surface of the first plate layer; the first plate layer is joined along the foamed surface; and the second plate layer is joined to a part of the first surface of the first plate layer, and the first surface of the first plate layer has: a joining portion formed to be substantially the same as the width dimension of the second plate layer and in a straight line; and a surface treatment layer formed at a portion other than the joining portion, the second plate layer is joined along the joining portion, and is adhered by using the pressing force of using the second surface of the second plate layer and the foamed back surface of the foamed plate layer as pressure-bearing surfaces.

Description

Technical Field

[0001] The present invention relates to a vehicle interior part used in an instrument panel (dash panel) equipped with an airbag in a vehicle such as an automobile, a pillar around a door glass, a roof rail, etc., and a manufacturing method for manufacturing the vehicle interior part.

[0002] Specifically, the present invention relates to a vehicle interior part composed of a plurality of plate layers having different color tones and a method for manufacturing the same. Background Art

[0003] Conventionally, as automotive interior parts such as instrument panels, there is a laminated sheet for surface materials, in which multiple sheets of different colors are laminated in such a way that multiple sheets are exposed on at least one surface, and the exposed surfaces of the multiple sheets are formed on approximately one plane (for example, refer to Patent Document 1).

[0004] The laminated board for the surface material is made of multiple (2 kinds) of thermoplastic polymer materials such as olefin-based thermoplastic elastomers (TPO) and other laminated boards so that two board surfaces can be seen from any one side. In the case of two kinds of boards, after any one board is calendered and rolled into a roll, the other board is calendered, and the ends of the two boards are aligned with each other in a softened state and then laminated. After that, the molding is performed as follows: the exposed surfaces of the two boards of the laminated board are located on the hard roller side, and the laminated board is pressed between the hard roller and the soft roller so that the surfaces of the two boards are roughly flat. The surface of the laminated board that has become smooth is treated by coating a surface treatment agent, and the desired pattern is formed on the surface by a printing roller. When the laminated board is finally used as a surface material for a door guard plate of a car, foam plastic is laminated on the back of the laminated board by bonding.

[0005] Furthermore, there is a vehicle interior component which is a surface decorative layer of an instrument panel with an airbag cover and is composed of an elastic foam board layer made of a foamed synthetic resin, a base board layer made of a thermoplastic synthetic resin laminated on the elastic foam board layer, and an upper floor layer made of a thermoplastic synthetic resin laminated on the base board layer, wherein a fragile portion for breaking the cover is formed into a perforated shape by irradiating a laser from the elastic foam board layer side (for example, refer to Patent Document 2).

[0006] When the cover breaking fragile portion is formed by laser irradiation, the laser beam is detected by a sensor arranged on the front side of the instrument panel to control the laser beam irradiated from the back side to the front side of the instrument panel.

[0007] Patent Document 1: Japanese Patent Application Laid-Open No. 08-323899

[0008] Patent Document 2: Japanese Patent Application Publication No. 2008-110647 Summary of the invention

[0009] Technical issues

[0010] In Patent Document 1, forming is performed as follows: a stacked plate is formed by stacking only a portion of one plate (the lower side) on a portion of another plate (the upper side), and the upper plate is pressed into a portion of the lower plate by pressing with a hard roller and a soft roller in the stacking direction, so that the surfaces of the two plates become approximately one plane.

[0011] However, when the stacked sheets pass between the rollers, the sheets on the upper side of the hard roller protrude further than the sheets on the lower side (see FIG. 4 of Patent Document 1). Therefore, the pressing force (pressure between the rollers) is likely to be concentrated only on the upper sheet, and not only the stacked portion of the sheets on the lower side is pressed toward the soft roller, but also the upper sheet is compressed in the stacking direction, which may cause the sheets to expand and deform in the width direction intersecting the stacking direction.

[0012] However, even if the upper and lower plates are calendered, it is difficult to strictly control their overall thickness to be uniform, and there are local areas with different thicknesses. As a result, the local thickness difference increases as the upper and lower plates are stacked. Therefore, the locally thicker part is compressed more in the stacking direction than the locally thinner part due to the pressure (roller pressure) when passing between the rollers.

[0013] Therefore, due to the changing factors when passing between the rollers, the following problems arise: the upper plate expands and deforms locally in the width direction, and the surface boundaries of multiple plates with different tones are easily bent locally due to the pressure in the stacking direction (pressure between rollers), and it is difficult to become a straight line.

[0014] Furthermore, in Patent Document 1, there is no step at the surface boundary of the various plates of different tones but it is roughly a flat surface. Therefore, even if it is sensed by a sensor arranged on the surface side of the various plates, there is no target (marked) location and the position of the surfaces of the various plates cannot be accurately controlled.

[0015] That is, there is a problem that even if one wants to form a fragile portion for breaking the cover of the airbag at a desired position on the surface of a laminated plate composed of multiple plates of different tones by laser irradiation from the back side of the laminated plate, it is impossible to accurately position it and the fragile portion for breaking the cover cannot be accurately processed.

[0016] Technical Solution

[0017] In order to solve this problem, the vehicle interior part involved in the present invention is a first board layer and a second board layer of different color tones stacked on the surface side of a foamed board layer, and bonded together using a pressing force in the stacking direction, and is characterized in that it comprises: the foamed board layer has a foamed surface opposite to the first back side of the first board layer; the first board layer is joined along the foamed surface; and the second board layer is joined to a part of the first surface of the first board layer, the first surface of the first board layer having: a joining portion formed to be substantially the same as the width dimension of the second board layer and in a straight line; and a surface treatment layer formed at a portion other than the joining portion, the second board layer is joined along the joining portion, and is bonded together using the pressing force with the second surface of the second board layer and the foamed back side of the foamed board layer as pressure-bearing surfaces.

[0018] Furthermore, in order to solve this problem, the manufacturing method of the vehicle interior part involved in the present invention comprises stacking a first board layer and a second board layer of different colors on the surface side of a foamed board layer, and bonding them by using a pressing force in a stacking direction, and is characterized in that it comprises: a surface treatment step of forming a surface treatment layer on the first surface of the first board layer except for a joining portion which has a width dimension substantially the same as that of the second board layer and is in a straight line; a first stacking step of bonding the second board layer along the joining portion of the first surface; a second stacking step of bonding the foamed surface of the foamed board layer to the first back side of the first board layer; and a bonding step of bonding the second board layer, the first board layer and the foamed board layer by using the pressing force with the second surface of the second board layer and the foamed back side of the foamed board layer as pressure-bearing surfaces. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] Figure 1 It is an explanatory diagram showing the entire structure of a vehicle interior component according to an embodiment of the present invention, and is a partial longitudinal sectional front view during a manufacturing process (laser processing process).

[0020] Figure 2 It is an explanatory diagram showing a modified example of the vehicle interior component according to the embodiment of the present invention, and is a partial longitudinal sectional front view during a manufacturing process (laser processing process).

[0021] 3 is an explanatory diagram showing the overall structure of a method for manufacturing a vehicle interior component according to an embodiment of the present invention, Figure 3a This is a reduced longitudinal section view of the surface treatment process. Figure 3b This is a reduced longitudinal section view of the first lamination process. Figure 3c It is a reduced longitudinal section front view of the second lamination process and bonding process. Figure 3d It is a reduced longitudinal cross-sectional front view of the substrate lamination process.

[0022] Explanation of symbols

[0023] A-interior parts for vehicles, 1-foamed board layer, 1a-foamed surface, 1b-foamed back side, 2-first board layer, 2a-first surface, 2b-first back side, 21-joining part, 22-surface treatment layer, 3-second board layer, 3a-second surface, 3b-side, 31-step portion, 3′, 3″-second board layer of different color, Y-stacking direction, P-pressing force in the stacking direction (pressure between rollers), S-sensor for position control. DETAILED DESCRIPTION

[0024] Hereinafter, embodiments of the present invention will be described in detail with reference to the accompanying drawings.

[0025] like Figure 1 As shown in FIG. 3 , a vehicle interior material A according to an embodiment of the present invention is used to form a surface decorative layer B of an instrument panel (dash panel), a pillar around a door glass, a roof rail, etc., in a vehicle such as an automobile equipped with an airbag G.

[0026] The surface decorative layer B is composed of a vehicle interior part A in which a first board layer 2 and a second board layer 3 of different colors are laminated on the surface side of a foamed board layer 1 , and a hard synthetic resin base material 4 attached to the back side of the foamed board layer 1 .

[0027] The appearance of the first sheet layer 2 or the second sheet layer 3 on the surface side of the surface decorative layer B is formed in a color combination of two or more colors of different color systems, or two or more colors of light and dark colors of the same color system.

[0028] Specifically, the vehicle interior material A according to the embodiment of the present invention includes, as main components: a foamed board layer 1; a first board layer 2 joined along a foamed surface 1 a of the foamed board layer 1; and a second board layer 3 joined along a first surface 2 a of the first board layer 2 .

[0029] In addition, the direction of laminating the foamed board layer 1, the first board layer 2, and the second board layer 3 is hereinafter referred to as "laminating direction Y". The direction along each layer intersecting with the laminating direction Y is hereinafter referred to as "width direction W".

[0030] The foamed board layer 1 is formed of foamed polypropylene (PPF) or a similar foamed material into a flat plate shape having a predetermined thickness.

[0031] The first sheet layer 2 is a base layer formed in a flat plate shape from a thermoplastic polyolefin resin (TPO) or a similar elastically deformable material.

[0032] When used as a surface decorative layer B of an instrument panel or the like, the thickness of the first sheet layer 2 is preferably set to about 0.50 mm to 1.00 mm, specifically, 0.65 mm to 0.75 mm.

[0033] The first plate layer 2 has a first surface 2 a formed on the first surface 2 a so as to face a second back surface 3 c of a second plate layer 3 described later, and a surface treatment layer 22 formed on a portion other than the first surface 21 .

[0034] The joining portion 21 is formed to have a width dimension substantially the same as a width dimension of a second plate layer 3 described later and to have a linear shape.

[0035] The surface treatment layer 22 is laminated over the entire first surface 2 a except for the joining portion 21 , and forms a step-shaped layer wall 23 between the first surface 2 a and the joining portion 21 .

[0036] As the surface treatment layer 22, gloss adjustment treatment using a matting agent or a glazing agent or treatment for making a protective film on the surface can be cited. As a method for forming the surface treatment layer 22, printing or coating of a surface treatment agent can be cited, preferably gravure printing or printing using a printer such as an inkjet printer, coating using a spray gun-based sprayer, etc.

[0037] The second plate layer 3 , like the first plate layer 2 , is a belt-shaped upper layer made of an elastically deformable material such as TPO and is thinner and narrower in width than the first plate layer 2 .

[0038] When used as a surface decorative layer B of an instrument panel or the like, the thickness of the second sheet layer 3 is preferably set to about 0.10 mm to 0.50 mm, specifically, 0.20 mm to 0.30 mm.

[0039] Furthermore, the second plate layer 3 is arranged in a straight line along a portion of the first surface 2a of the first plate layer 2, and the second surface 3a of the second plate layer 3 is arranged to protrude further than the first surface 2a toward a position control sensor S for processing described later. A step portion 31 is formed at a corner portion extending from the side surface 3b of the second plate layer 3 to the first surface 2a or the surface treatment layer 22.

[0040] Furthermore, a surface treatment layer 32 for gloss adjustment or protective film formation is preferably formed on the second surface 3a of the second board layer 3, similarly to the first surface 2a of the first board layer 2. The surface treatment layer 32 of the second board layer 3 is different from the surface treatment layer 22 of the first board layer 2 and is formed over the entire second board layer 3.

[0041] Although not shown in the drawings, the surface treatment layer 32 may be formed on the side surface 3 b of the second plate layer 3 .

[0042] At least the first sheet layer 2 and the second sheet layer 3 have different color tones, and are set so that the appearance becomes two colors or three or more colors in the state where the first sheet layer 2 and the second sheet layer 3 are stacked.

[0043] The color of at least the first surface 2 a of the first sheet layer 2 is preferably set to a dark color with low laser transmittance (high laser absorptivity), such as black due to the inclusion of carbon black or the like.

[0044] The color of at least the second surface 3a of the second board layer 3 is preferably set to a color system different from the color tone of the first board layer 2, for example, a color with low laser transmittance such as brown, or a light color system with high laser transmittance (low laser absorption rate) such as gray, red, orange, and yellow. In addition, as the second board layer 3, in addition to the first board layer 2, a plurality of second board layers 3' and second board layers 3" with different color tones can be arranged in parallel.

[0045] As an example of color tone, Figure 1 3 (a) to (d), the appearance of the first board layer 2 and the second board layer 3 is set to two colors. In the example shown in the figure, the first board layer 2 is set to a dark black color, and the second board layer 3 is set to a light color.

[0046] As other examples of hue, Figure 2 In the illustrated case, the appearance of the first board layer 2 and the second board layer 3 is set to three colors. In the illustrated example, as the second board layer 3, two different colors of second board layers 3' and second board layers 3" are arranged side by side.

[0047] In addition, although other modification examples of the color tone are not shown in the figure, they can also be changed, for example, to four or more colors.

[0048] Furthermore, in addition to this, the first plate layer 2 and the second plate layer 3 can also be set to have different appearance patterns or designs in the stacked state.

[0049] However, the airbag G mounted on the vehicle is stored in a folded state on the back side of the surface decorative layer B, and is inflated and deployed by breaking the airbag cover (not shown) in an emergency. On the back side of the surface decorative layer B, a fragile portion G1 for breaking the cover of the airbag G is formed by processing from the side of the substrate 4, and the substrate 4 is formed of a hard synthetic resin such as polypropylene laminated on the back side of the foamed board layer 1.

[0050] The cover-breaking fragile portion G1 of the airbag G is preferably formed into a square frame-like airbag cover by controlling the operation of a processing machine using a position control sensor S disposed opposite to the surface side of the surface decorative layer B, namely, the second sheet layer 3 .

[0051] The processing method of the cap breaking fragile portion G1 may include partial cutting by a processing machine using irradiation of a laser beam, a cutter such as a cutter, a jet of high-pressure water or the like, or a similar method.

[0052] In the case of using laser irradiation as an example of a processing machine, a pulsed laser beam L irradiated from a laser source X is detected by a processing position control sensor S, and the irradiation position or irradiation time from the laser source X is adjusted according to the step 31 generated between the first plate layer 2 (first surface 2a or surface treatment layer 22) and the second plate layer 3 (second surface 3a), so that the airbag cover is perforated into a specified depth.

[0053] The manufacturing method for producing the vehicle interior part A according to the embodiment of the present invention includes laminating the foamed sheet layer 1, the first sheet layer 2, and the second sheet layer 3. In addition, when forming the fragile portion G1 for breaking the cover of the airbag G, the processing of the airbag cover by a processing machine is included.

[0054] The bonding process as a main step includes: a surface treatment step, forming a joint portion 21 and a surface treatment layer 22 on the first board layer 2; a first stacking step, bonding the second board layer 3 along the joint portion 21; a second stacking step, bonding the foamed board layer 1 to the first board layer 2; and a bonding step, bonding the second board layer 3, the first surface 2a and the foamed board layer 1.

[0055] In addition, it is preferable to include a base material laminating step of laminating the base material 4 on the foamed plate layer 1 .

[0056] In the surface treatment process, as shown in Fig. 3(a), first, a first plate layer 2 formed into a wide width is fed out by a calender (not shown) or the like. In the example shown in the figure, a black first plate layer 2 having a thickness of 0.70 mm is used, and a surface treatment layer 22 is formed on the first surface 2a of the first plate layer 2 except for a joint portion 21 facing the second plate layer 3 by a printing machine (not shown) or the like.

[0057] In the next first lamination step, as shown in FIG3(b), a second plate layer 3 cut into a narrow strip of a predetermined size is joined (overlapped) along a portion of the first surface 2a of the first plate layer 2, i.e., a joining portion 21, using a slit machine (not shown) or the like. In the example shown in the figure, a gray second plate layer 3 having a thickness of 0.25 mm is used, and a surface treatment layer 32 is formed on at least the second surface 3a of the second plate layer 3.

[0058] In the subsequent second lamination step, as shown in FIG. 3( c ), the foamed surface 1 a of the foamed board layer 1 is joined (overlapped) to the first back surface 2 b of the first board layer 2 .

[0059] In the subsequent bonding process, the second board layer 3, the first board layer 2 and the foamed board layer 1 of the three-layer structure are bonded in an overlapping state by a printing machine, etc., using the pressing force P in the stacking direction Y with the second surface 3a of the second board layer 3 and the foamed back side 1b of the foamed board layer 1 as the pressure-bearing surfaces, thereby forming an interior part A for a vehicle.

[0060] As a specific example of the pressing force P in the stacking direction Y, in the case of the example shown in the figure, the second board layer 3, the first board layer 2 and the foamed board layer 1 of the three-layer structure are passed between a pair of pressure rollers R1 and R2. As a result, the entire second surface 3a and the first surface 2a (surface treatment layer 22) of the first board layer 2 and the entire foamed back surface 1b become pressure-bearing surfaces, and are subjected to a substantially uniform pressure between the rollers.

[0061] As the first pressure roller R1 facing the second surface 3a and the first surface 2a (surface treatment layer 22), a hard roller or a soft roller having a recessed portion R1a can be used, and the recessed portion R1a is engaged with the second board layer 3 protruding from the first surface 2a of the first board layer 2. On the pressing surface of the first pressure roller R1, an embossing (not shown) for imparting a predetermined concave and convex pattern such as a leather pattern is formed on the second surface 3a or the first surface 2a (surface treatment layer 22).

[0062] In the next substrate lamination step, as shown in FIG3(d), a coating machine (not shown) or the like is used to apply an adhesive such as a pre-coating material to the foamed back surface 1b of the foamed board layer 1, and the substrate 4 is bonded and laminated to form a surface decorative layer B. Finally, a cutting tool (not shown) such as a cutter is used to cut the integrated surface decorative layer B into a predetermined shape.

[0063] Afterwards, in the case of a processing process for an airbag cover using a processing machine, a position control sensor S is used for processing, and based on the step 31 generated between the first plate layer 2 (first surface 2a or surface treatment layer 22) and the second plate layer 3 (second surface 3a), a fragile portion G1 for breaking the cover is drilled to a specified depth on the back side of the surface decorative layer B from the side of the substrate 4 using laser irradiation or a cutting machine.

[0064] As a processing process using a processing machine, Figure 1 or Figure 2 In the example shown, the case of the above-mentioned laser irradiation is shown.

[0065] As another example, although not shown, instead of laser irradiation, a processing machine such as a cutter may be used to bore the cover-breaking fragile portion G1 to a predetermined depth from the substrate 4 side to the back side of the surface decorative layer B.

[0066] According to the vehicle interior part A and the manufacturing method thereof according to the embodiment of the present invention, the second board layer 3 is joined to the first surface 2a of the first board layer 2 along the linear joining portion 21 except the surface treatment layer 22, and the foamed surface 1a of the foamed board layer 1 is joined to the first back surface 2b of the first board layer 2 to form a three-layer stack. The stack is clamped from both sides of the second surface 3a and the foamed back surface 1b by a pressing force (pressure between rollers) P in the stacking direction Y.

[0067] As a result, the foamed board layer 1 is compressed and deformed in the stacking direction Y before the second board layer 3, so that only the pressing force P on the second board layer 3 is reduced. Even if the second board layer 3 is compressed in the stacking direction Y due to the pressing force P in the stacking direction Y, the side surface 3b of the second board layer 3 abuts against the layer wall 23 of the surface treatment layer 22, so the expansion deformation of the second board layer 3 in the width direction W is suppressed.

[0068] Furthermore, when the second board layer 3 is attached to the first surface 2a, the second board layer 3 (back surface 3c) and the joint portion 21 are bonded without sandwiching the surface treatment layer 22. Therefore, the first board layer 2 and the second board layer 3 can be attached without affecting the material of the surface treatment layer 22.

[0069] Therefore, the surface boundary portion between the first plate layer 2 and the second plate layer 3 can be made linear, and the first plate layer 2 and the second plate layer 3 can be firmly bonded together.

[0070] As a result, compared with the previous technology in which the surface boundaries of multiple plates with different color tones are easily locally bent due to pressing in the stacking direction (pressure between rollers), the molding accuracy of the surface boundaries is excellent, which can improve the product value when developing into automotive interior products such as instrument panels.

[0071] In particular, as the second board layer 3, it is preferable to arrange a plurality of second board layers 3' and second board layers 3" having different colors in parallel.

[0072] In this case, it is possible to produce the skin (the first sheet layer 2 and the second sheet layer 3 ) having three or more colors including the color difference with the first sheet layer 2 .

[0073] Therefore, it is possible to provide a vehicle interior part A having a multi-color surface.

[0074] As a result, the design flexibility increases, and the product value can be improved.

[0075] Furthermore, the second plate layer 3 preferably has a second surface 3 a disposed to protrude further than the first surface 2 a toward the processing position control sensor S, and a step portion 31 formed from the side surface 3 b of the second plate layer 3 to the first surface 2 a .

[0076] In this case, the position of the linear step portion 31 is sensed by the position control sensor S, and the position of the foamed board layer 1, the first board layer 2 and the second board layer 3 as a whole can be controlled by laser irradiation or a processing machine such as a cutter based on the position sensing.

[0077] Therefore, the formation position of the lid-breaking fragile portion G1 can be accurately aligned with respect to the entire foamed sheet layer 1 , the first sheet layer 2 , and the second sheet layer 3 .

[0078] As a result, compared with the conventional technology in which the surface boundary of multiple plates with different color tones has no step but is substantially flat, the cover-breaking fragile portion G1 of the airbag G can be accurately positioned and the cover-breaking fragile portion G1 can be manufactured with high precision, thereby achieving excellent workability.

[0079] Although one embodiment of the present invention has been described above, the present invention is not limited thereto and the structure of the detailed parts may be modified as appropriate within the scope of the gist of the present invention.

[0080] In the above embodiment, the method of forming the cover-breaking fragile portion G1 of the airbag G by a processing machine such as laser irradiation or a cutter is described, but the present invention is not limited thereto. The cover-breaking fragile portion G1 may be bored to a predetermined depth from the substrate 4 side to the back side of the surface decorative layer B by a method other than laser irradiation or a cutter.

[0081] Furthermore, the position control sensor S can use a color detection sensor capable of distinguishing colors to sense the step portion 31. In this case, the surface boundary portion of the first plate layer 2 and the second plate layer 3 is formed into a straight line by the manufacturing method of the present invention, so that the step portion 31 can be accurately sensed by the color detection sensor, and the cover rupture fragile portion G1 of the airbag G can be accurately positioned.

[0082] In the above embodiment, the vehicle interior part A is described as being used to form the surface decorative layer B of a pillar or roof rail around an instrument panel or door glass equipped with an airbag G, but the invention is not limited thereto and may be used in vehicles other than automobiles.

[0083] In this case as well, the same effects and advantages as those of the above-described embodiment can be obtained.

Claims

1. A method for manufacturing a vehicle interior part, wherein a first plate layer and a second plate layer having different color tones are stacked on the surface side of a foamed plate layer and bonded together by a pressing force in a stacking direction, It is characterized in that include: A surface treatment step of forming a surface treatment layer on the first surface of the first plate layer, except for a linear joint portion having a width substantially the same as that of the second plate layer, over the entire first surface; a first lamination step of joining the second board layer along the joining portion of the first surface in such a manner that a portion of a side surface of the second board layer abuts against a layer wall of the surface treatment layer; a second lamination step of bonding the foamed surface of the foamed board layer to the first back surface of the first board layer; and a laminating step of laminating the second board layer, the first board layer and the foamed board layer by using the pressing force with the second surface of the second board layer and the foamed back surface of the foamed board layer as pressure receiving surfaces, The second plate layer has: the second surface configured to protrude more than the first surface in the stacking direction; and a step portion formed from the side surface of the second plate layer to the first surface, The first plate layer and the second plate layer are made of elastically deformable materials.

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