Vehicle interior component

Abstract

A vehicle interior member (30) to be installed to a vehicle body panel (10) includes a core layer (40) having a vehicle exterior surface and a cover layer (41) covering the vehicle exterior surface of the core layer (40) and having a cover layer vehicle exterior surface. The cover layer (41) includes a first region (41A) and second regions (41B3, 41B4, 41B5). The first region (41A) has a first vehicle exterior surface that is flat and is a part of the cover layer vehicle exterior surface, and the second regions (41B3, 41B4, 41B5) have second vehicle exterior surfaces that are uneven surfaces and are other parts of the cover layer vehicle exterior surface. The second regions (41B3, 41B4, 41B5) include a protruding portion (41B1) to be brought into contact with the vehicle body panel (10) or a vehicle member (20).

Description

[0001] Cross-references to related applications

[0002] This application claims priority to Japanese Patent Application No. 2022-26399, filed on February 24, 2022. The entire contents of that priority application are incorporated herein by reference. Technical Field

[0003] The technology described in this article relates to a vehicle component. Background Technology

[0004] A vehicle interior trim component (automotive interior trim component) is known to be mounted on the roof panel of a vehicle body using mounting members. This vehicle interior trim component includes a base member and an infrared reflective layer, and is mounted on the roof panel such that the infrared reflective layer faces the roof panel. With this configuration, even if sunlight shines on the roof panel from above, the heat from the sunlight is blocked by the infrared reflective layer. Japanese Unexamined Patent Application Publication No. 2011-158306 discloses an example of such a vehicle interior trim component.

[0005] However, in this configuration, when the car moves and vibrates, friction may occur between the interior trim components and the vehicle body or other vehicle parts, potentially causing noise. This is particularly true in configurations where a covering layer, such as an infrared reflective layer, is placed on the back surface of the base member (opposite to the roof), flush with the covering layer. This increases friction between the covering layer and the vehicle body or other vehicle parts, easily leading to noise. To suppress this noise, a buffer member can be placed on the back surface of the noise-prone portion of the interior trim components. However, this increases workload and cost. Furthermore, when the buffer member is placed between the vehicle body and the infrared reflective layer, the heat reflected by the infrared reflective layer is blocked by the buffer member, and the infrared reflective layer cannot effectively perform its function. Summary of the Invention

[0006] The technology described herein is based on the above-mentioned circumstances. One objective is to provide vehicle interior components that suppress noise. Another objective is to provide vehicle interior components that can reduce costs through simple construction. Yet another objective is to provide vehicle interior components that can function as heat reflectors.

[0007] The present disclosure relates to a vehicle interior member to be installed to a vehicle body panel. The vehicle interior member includes a core layer having a vehicle outer side surface and a cover layer covering the vehicle outer side surface of the core layer and having a cover layer vehicle outer surface. The cover layer includes a first region and a second region. The first region has a first vehicle outer side surface that is flat and is a part of the cover layer vehicle outer surface. The second region has a second vehicle outer side surface that is a concave-convex surface and is another part of the cover layer vehicle outer side surface. The second region includes a protruding portion to be in contact with the vehicle body panel or a vehicle component.

[0008] According to such a vehicle interior member, the second region of the cover layer vehicle outer side surface of the cover layer covering the core layer includes a protruding portion to be in contact with the vehicle body panel or a vehicle component. Therefore, the second region has a concave-convex vehicle outer side surface. By providing the second region, the area of the contact surface of the cover layer in contact with the vehicle body panel or a vehicle component can be reduced. Therefore, the friction between the vehicle interior member and the vehicle body panel or a vehicle component can be reduced, and noise is hardly caused. It is not necessary to arrange a cushioning member for suppressing such noise at the contact portion. Therefore, the cost can be reduced with a simple configuration.

[0009] In the above configuration, the cover layer can include a reflection layer that reflects at least infrared light, and the second region can include in the reflection layer.

[0010] According to such a vehicle interior member, the reflection layer can reflect infrared light (heat) and suppress noise. Therefore, a comfortable in-vehicle space can be provided. It is not necessary to arrange a cushioning member for suppressing noise. Therefore, the effect of the reflection layer is not hindered by the cushioning member.

[0011] In the above configuration, the cover layer can include an air blocking layer between the reflection layer and the core layer, and the air blocking layer functions to restrict movement of air in a thickness direction of the cover layer.

[0012] According to such a vehicle interior member, air hardly moves in the thickness direction, and the reflection layer reflects infrared light and suppresses noise. Therefore, a comfortable in-vehicle space can be provided.

[0013] In the above configuration, the cover layer can include an air blocking layer that functions to restrict movement of air in a thickness direction of the cover layer, and the second region can include in the air blocking layer.

[0014] According to such a vehicle interior member, air hardly moves in the thickness direction and noise can be suppressed. Therefore, a comfortable in-vehicle space can be provided.

[0015] In the above configuration, the second region of the cover layer can include a recess between the protruding portions. According to such a vehicle interior member, friction between the vehicle interior member and a vehicle body panel or a vehicle component can be reduced, and noise can hardly be caused.

[0016] In the above configuration, the core layer can include a first recess corresponding to the recess of the cover layer, respectively, and the first recess can be recessed from a vehicle-outer-side surface of the core layer.

[0017] According to such a vehicle interior member, the vehicle-outer-side surface of the portion of the core layer directly below the recess (located on the vehicle-inboard side) has the first recess. The relief shape (protrusions and recesses) of the cover layer can hardly be lost due to aging changes, and durability of the relief shape can be improved.

[0018] In the above configuration, the vehicle component can be a curtain airbag extending in the vehicle front-rear direction, and the curtain airbag can include at least two curtain airbags. The second region can include at least two second regions extending in the vehicle front-rear direction, and the at least two second regions can be arranged to sandwich the first region with respect to the vehicle width direction. The at least two second regions can be opposite to the at least two curtain airbags, respectively.

[0019] In a case where the curtain airbag is installed adjacent to a vehicle interior member long in the vehicle front-rear direction, an area of a surface of the vehicle interior member in contact with the elongated vehicle component increases, and noise is likely to be caused. However, according to the vehicle interior member, an area of a contact surface of the vehicle interior member with the curtain airbag can be reduced, and noise can hardly be caused.

[0020] In the above configuration, the vehicle interior member can be configured as a ceiling of a vehicle. Even in a vehicle interior member in large-area contact with a vehicle component and having a plurality of contact portions, noise can hardly be caused in a ceiling member having a plurality of contact portions.

[0021] In the above configuration, the second region of the cover layer can include a recess between the protruding portions, and the protruding portions can have contact surfaces that are portions of the second vehicle-outer-side surface. According to such a configuration, a contact area can be reduced, and noise can hardly be caused.

[0022] In the above configuration, the recess can be in the cover layer and recessed from the second vehicle-outer-side surface toward the vehicle-inboard side. According to such a configuration, a contact area can be reduced with a simple configuration, and noise can hardly be caused.

[0023] In the above configuration, the recesses can have bottom surfaces, and the bottom surfaces can be located on the vehicle inner side with respect to the vehicle outer side surface of the core layer. According to this configuration, the relief shape (protrusions and recesses) of the cover layer is hardly lost due to aging changes, and the durability of the relief shape is improved.

[0024] In the above configuration, the recesses can have bottom surfaces, and the bottom surfaces can be located away from a contact portion of the vehicle body panel or the vehicle component that is to be in contact with the protruding portion of the second region. According to this configuration, the area of the contact surface of the vehicle interior component with the curtain airbag can be reduced, and the friction between the vehicle interior component and the vehicle body panel or the vehicle component can be certainly reduced, and noise is hardly caused.

[0025] In the above configuration, the vehicle interior component can be a panel member. The first region can be included in a middle region of the panel member, and the second region can be included in an edge region of the panel member.

[0026] According to the present disclosure, a vehicle interior component that suppresses noise can be provided. A vehicle interior component that can reduce costs with a simple configuration can be provided. In addition, a vehicle interior component that can exert a heat reflecting function can be provided. BRIEF DESCRIPTION OF DRAWINGS

[0027] Figure 1 is a side view of an automobile according to one embodiment.

[0028] Figure 2 is a cross-sectional view of a roof, a curtain airbag, and a ceiling member.

[0029] Figure 3 is a plan view of a ceiling member.

[0030] Figure 4 is a cross-sectional view showing a cross-sectional configuration of a ceiling member including a first region.

[0031] Figure 5 is a cross-sectional view showing a cross-sectional configuration of a ceiling member including a second region.

[0032] Figure 6 is a cross-sectional view showing a cross-sectional configuration of a ceiling member according to another embodiment. DETAILED DESCRIPTION

[0033] Reference will be made to Figures 1 to 5 One embodiment of the present disclosure will be described in detail. In this section, a ceiling member 30 (a vehicle interior component) installed in an automobile 1 (a vehicle) will be described. The arrow directions FR, RR, U, D, L, and R respectively represent the front, rear, upper, lower, left, and right directions. Figure 3 The ceiling member 30 is shown as viewed from above (the vehicle outer side).

[0034] AsFigure 1 As shown, the automobile 1 includes a vehicle body panel 2 made of a metal plate. The vehicle body panel 2 forms an outline of the automobile 1. The vehicle body panel 2 includes a door panel 5, a roof panel 10, and pillar panels. The door panel 5 is configured as right and left doors of the automobile 1. The roof panel 10 is configured as an upper wall of the automobile 1. The pillar panels have an elongated shape extending in a vertical direction and support the roof panel 10 from below. From a front side of the automobile 1, the pillar panels include an A-pillar panel 11, a B-pillar panel 12, a C-pillar panel 13, and a D-pillar panel 14. The D-pillar panel 14 is arranged in a rear region of the automobile 1.

[0035] The automobile 1 includes a headliner 30 and a curtain airbag 20 (vehicle components). The headliner 30 is mounted to the roof panel 10 from a vehicle inner side (from below) and is configured as a ceiling of a passenger compartment of the automobile 1. The curtain airbag 20 is arranged between the roof panel 10 and the headliner 30. As shown in Figure 3 The headliner 30 is a panel member having a rectangular shape long in a vehicle front-rear direction. A panel surface of the headliner 30 extends in the vehicle front-rear direction and left-right direction (vehicle width direction). In Figure 4 and Figure 5 In the headliner 30, a vertical direction corresponds to a thickness direction of the headliner 30. A vehicle outer side surface 30A of the headliner 30 faces the roof panel 10 and the curtain airbag 20.

[0036] As shown in Figure 3 The headliner 30 includes recessed portions 31, 32 at right and left edge portions 30C, 30D and auxiliary handle holes 33, 34. The recessed portions 31, 32 are recessed inward (toward a middle region) from right and left edges of the headliner 30. The auxiliary handle holes 33, 34 penetrate the headliner 30 in the thickness direction. Auxiliary handles to be held by an occupant seated in the automobile 1 are to be installed in the auxiliary handle holes 33, 34. The recessed portion 31 is recessed in such a manner that a peripheral edge of the recessed portion 31 extends along an outline of the B-pillar panel 12, and the B-pillar panel is received in the recessed portion 31. The recessed portion 32 is recessed in such a manner that a peripheral edge of the recessed portion 32 extends along an outline of the C-pillar panel 13, and the C-pillar panel is received in the recessed portion 32.

[0037] As shown in Figure 3 The headliner 30 includes holes in a front end portion 30E. The holes penetrate the headliner 30 in the thickness direction. The holes include clamp holes 35, sun visor holes 37, and lighting device holes 38. Clamps 25 (see Figure 1 ) are respectively inserted through the clamp holes 35 to fix the front end portion 30E of the headliner 30 to the roof panel 10. Sun visors are respectively fixed to the headliner 30 via the sun visor holes 37. Via the lighting device holes 38, lighting devices for illuminating the passenger compartment are installed in the headliner 30. The headliner 30 includes a clamp hole 36 in a rear end portion 30F. The clamps 25 (seeFigure 1 ) are inserted through the clamp holes 36, respectively, to fix the rear end portion 30F to the head cover 10. The clamp holes 36 penetrate the roof member 30 in the thickness direction. When the roof member 30 is fixed to the head cover 10, the hole edge portions of the clamp holes 35, 36 and the hole edge portion of the sun visor hole 37 come into contact with the vehicle inner side surface of the head cover 10. The hole edge portions of the clamp holes 35, 36 and the sun visor hole 37 correspond to the panel side contact portions (second regions 41B4, 41B5).

[0038] As shown in Figure 1 and Figure 2 , the curtain airbag 20 extends in the vehicle front-rear direction. Two curtain airbags 20 are arranged in the right side portion and the left side portion of the roof member 30 and between the head cover 10 and the roof member 30, respectively. The curtain airbag 20 includes a resin case 21 having a box shape extending in the vehicle front-rear direction and a bag 22 housed in the resin case 21. The inflatable bag 22 is rolled up and housed in the resin case 21 (normal state). In a state where the bag 22 is housed in the resin case 21, the curtain airbag 20 is fixed to the head cover 10 or the roof member 30. When the curtain airbag 20 is deployed, gas flows from an inflator into the bag 22, the bag 22 is inflated and comes out of the resin case 21. Then, the bag 22 pushes down the right side edge portion 30C and the left side edge portion 30D of the roof member 30 (see Figure 3 ), and is deployed in the vehicle inner room below the right side edge portion 30C and the left side edge portion 30D. As shown in Figure 2 and Figure 5 , the curtain airbag 20 includes a support portion 20A (rib) to be in contact with some portions of the right side edge portion 30C and the left side edge portion 30D of the roof member 30. In Figure 3 , the portions of the right side edge portion 30C and the left side edge portion 30D to be in contact with the support portion 20A are shown by a plurality of pairs of short solid lines and are defined as a curtain airbag contact portion P. The curtain airbag contact portion P includes a contact portion 41B1 (protruding portion) to be described later. The curtain airbag contact portion P includes in a second region 41B3 to be described later. The curtain airbag contact portion P is disposed in the vehicle front-rear direction along the edge of the right side edge portion 30C and the edge of the left side edge portion 30D of the roof member 30. Some of the curtain airbag contact portion P are disposed in an inwardly curved shape around the auxiliary handle holes 33, 34.

[0039] As shown in Figure 4 and Figure 5As shown, the ceiling member 30 includes a core layer 40 and a cover layer 41 covering a vehicle outer side surface 40A of the core layer 40. The cover layer 41 includes a reflection layer 43 and an air barrier layer 42. The reflection layer 43 reflects at least infrared light. The air barrier layer 42 is arranged between the reflection layer 43 and the core layer 40, and prevents air movement at least in a thickness direction (up-down direction) of the cover layer 41. A vehicle inner side surface 40B of the core layer 40 can be exposed to a passenger compartment, or can be covered with a skin that provides some design.

[0040] The core layer 40 is a base member that is a plate member extending in the vehicle front-rear direction and the left-right direction. A material of the core layer 40 can include one, two or more of a porous fiber material, a hard foam material, and a composite material of a hard foam material and a nonwoven fabric. Examples of the porous fiber material can be hard fibers such as glass fibers, PET fibers, and plant fibers including a thermoplastic resin as a binder resin. Examples of the hard foam material can be polyurethane including hard polyurethane and semi-hard polyurethane, polyolefin, and other foaming resins. Among the above materials, polyurethane foam material is preferred, and semi-hard polyurethane foam material is more preferred. An example of the composite material of the hard foam material and the nonwoven fabric can be a composite material obtained by bonding a nonwoven fabric made of hard fibers such as glass fibers to at least one of a front surface and a rear surface of the hard foam material.

[0041] The air barrier layer 42 is configured to prevent air movement at least in the thickness direction of the cover layer 41, and also configured as a base film for holding the reflection layer 43 on the core layer 40. The thickness of the air barrier layer 42 is smaller than the thickness of the core layer 40 and larger than the thickness of the reflection layer 43. Specifically, the thickness of the air barrier layer 42 can be in a range from any one of 5 μm or more, 10 μm or more, 15 μm or more to any one of 60 μm or less, 40 μm or less, 25 μm or less. The thickness of the air barrier layer 42 is preferably 20 μm. Examples of a material for the air barrier layer 42 can be thermoplastic resins. Specifically, the air barrier layer 42 can use one or two or more of thermoplastic resins including polyester resins, polyamide resins, polyolefin resins, cyclic polyolefin resins, polyvinyl alcohol resins, and ethylene-vinyl alcohol copolymers. As for molding, polyester resins and polyamide resins are preferred, and polyamide resins are more preferred. An example of such polyamide resins is an unstretched nylon film. In a configuration in which a thermoplastic resin such as polypropylene is used as a material of the core layer 40, it is preferable to use a resin having a melting point of 200 degrees or more as a material of the air barrier layer 42. In a configuration in which a thermosetting resin such as polyurethane is used as a material of the core layer 40, a polypropylene resin having a melting point of 160 degrees can be used as a material of the air barrier layer 42.

[0042] The air barrier layer 42 is adhered to the core layer 40 with an adhesive. The adhesive can be impregnated into the core layer 40, or a small amount of solidified adhesive can be left between the air barrier layer 42 and the core layer 40 as an adhesive layer. In a configuration in which a thermoplastic resin is used as the material of the core layer 40, a thermoplastic resin having a melting point lower than that of the core layer 40 can be used as the adhesive (adhesive layer). For example, a polypropylene resin, an acid-modified polypropylene resin, or an ethylene resin such as polyethylene and a polyethylene copolymer can be used as the adhesive. In a configuration in which a thermosetting resin is used as the material of the core layer 40, diphenylmethane diisocyanate (MDI) can be used as the adhesive.

[0043] The reflective layer 43 is configured to reflect light (infrared light) having a wavelength range from 0.7 μm to 1000 μm inclusive. The wavelength range of the light can be in a range from any one of 2 μm or more, 4 μm or more, to 20 μm or less. The reflective layer 43 can be configured to reflect light (infrared light) having a wavelength range from 4 μm to 1000 μm inclusive. The reflective layer 43 can reflect light having a wavelength range from 4 μm to 1000 μm inclusive and light having a wavelength range outside the above wavelength range. The infrared reflectance of light having a wavelength range from 2 μm to 20 μm inclusive can be 55% or more and can be 60% or more in view of the reflectance of light. The thickness of the reflective layer 43 can be in a range from any one of 0.1 μm or more, 0.5 μm or more, 1 μm or more, to any one of 10 μm or less, 5 μm or less, 2 μm or less, 1.5 μm or less in view of improving the reflection function of infrared light and reducing cost.

[0044] The reflective layer 43 is manufactured by disposing a scale-like metal sheet containing a coating material (gravure printing) on the air barrier layer 42. The scale-like metal sheet containing a coating material includes a resin and a scale-like metal sheet pigment made of a metal such as aluminum, gold, indium, and copper. A preferred example of the scale-like metal sheet pigment is a leaf-like aluminum sheet pigment. The leaf-like aluminum sheet pigment is obtained by coating the surface of scale-like aluminum powder having a long diameter of 1 μm to 150 μm with a treating agent such as stearic acid. In a case where the back surface of the air barrier layer 42 (a thermoplastic resin film such as an unstretched nylon film) is coated with a coating material containing such a pigment, the scale-like aluminum powder moves to the surface of the coating layer and arranges in parallel with each other. Thus, the reflective layer 43 including the scale-like metal sheet arranged at intervals and the resin for preventing contact between the scale-like metal sheets is formed.

[0045] Examples of the resin included in the flaky metal sheet containing the coating material (resin for preventing contact between the flaky metal sheets in the coating layer) include alkyd resins, acrylic resins, epoxy resins, olefin resins, polyamide resins, polyurethane resins, polyester resins, polybutadiene resins, and modified resins thereof. Among the examples of the resin, the polyurethane resin is preferable. With this reflective layer 43, the surface resistivity of the reflective layer 43 can be improved. For example, even if a metal wire as an internal electric wire arranged between the roof cover 10 and the ceiling member 30 is exposed due to some reason, short-circuiting is hardly caused between the exposed metal wire and the reflective layer 43.

[0046] As shown in FIG. 1, the ceiling member 30 includes a core layer 40 and a cover layer 41. The core layer 40 is a resin layer. The cover layer 41 is a resin layer. The cover layer 41 covers the core layer 40. The cover layer 41 includes a first region 41A and second regions 41B3, 41B4, 41B5. The first region 41A corresponds to a majority of the ceiling member 30. The first region 41A corresponds to a middle region of the ceiling member 30. The second region 41B3 is included in the right side edge portion 30C and the left side edge portion 30D. The second regions 41B4, 41B5 are included in the front end portion 30E and the rear end portion 30F. The cover layer 41 has a vehicle outer side surface 43A (cover layer vehicle outer side surface) corresponding to the vehicle outer side surface 30A of the ceiling member 30. The vehicle outer side surface 43A (first vehicle outer side surface) of the first region 41A is flat. The vehicle outer side surfaces 43A (second vehicle outer side surfaces) of the second regions 41B3, 41B4, 41B5 are uneven and include contact portions 41B1 (protruding portions) and recessed portions 41B2 (recesses). Figures 3 to 5 As shown in FIG. 1, the ceiling member 30 includes a core layer 40 and a cover layer 41. The core layer 40 is a resin layer. The cover layer 41 is a resin layer. The cover layer 41 covers the core layer 40. The cover layer 41 includes a first region 41A and second regions 41B3, 41B4, 41B5. The first region 41A corresponds to a majority of the ceiling member 30. The first region 41A corresponds to a middle region of the ceiling member 30. The second region 41B3 is included in the right side edge portion 30C and the left side edge portion 30D. The second regions 41B4, 41B5 are included in the front end portion 30E and the rear end portion 30F. The cover layer 41 has a vehicle outer side surface 43A (cover layer vehicle outer side surface) corresponding to the vehicle outer side surface 30A of the ceiling member 30. The vehicle outer side surface 43A (first vehicle outer side surface) of the first region 41A is flat. The vehicle outer side surfaces 43A (second vehicle outer side surfaces) of the second regions 41B3, 41B4, 41B5 are uneven and include contact portions 41B1 (protruding portions) and recessed portions 41B2 (recesses).

[0047] Figure 4 A cross-sectional configuration of the ceiling member 30 including the first region 41A of the cover layer 41 is shown. The first region 41A corresponds to a portion of the ceiling member 30 other than an adjacent portion thereof to the contact portion 41B1 in contact with the roof cover 10 or the curtain airbag 20. As shown in FIG. 2, the vehicle outer side surface 40A of the core layer 40 corresponding to the first region 41A is a flat surface. The vehicle outer side surface (first vehicle outer side surface) of the first region 41A of the cover layer 41 is a flat surface. That is, the vehicle outer side surface 30A of the ceiling member 30 including the first region 41A is a flat surface. Figure 4 A cross-sectional configuration of the ceiling member 30 including the first region 41A of the cover layer 41 is shown. The first region 41A corresponds to a portion of the ceiling member 30 other than an adjacent portion thereof to the contact portion 41B1 in contact with the roof cover 10 or the curtain airbag 20. As shown in FIG. 2, the vehicle outer side surface 40A of the core layer 40 corresponding to the first region 41A is a flat surface. The vehicle outer side surface (first vehicle outer side surface) of the first region 41A of the cover layer 41 is a flat surface. That is, the vehicle outer side surface 30A of the ceiling member 30 including the first region 41A is a flat surface. Figure 5 A cross-sectional configuration of the ceiling member 30 including the second region 41B3 of the cover layer 41 is shown. The second regions 41B3, 41B4, 41B5 have the same configuration and will be described with reference to FIG. 3. Figure 5 A cross-sectional configuration of the ceiling member 30 including the second region 41B3 of the cover layer 41 is shown. The second regions 41B3, 41B4, 41B5 have the same configuration and will be described with reference to FIG. 3. Figure 5 As shown in FIG. 3, the second region 41B3 includes the contact portion 41B1 and the recessed portion 41B2. The contact portion 41B1 is to be in contact with the support portion 20A of the roof cover 10 or the curtain airbag 20. In the second region 41B3, the contact portion 41B1 is in contact with the support portion 20A of the roof cover 10 or the curtain airbag 20. Figure 3In the drawing, the second regions 41B3, 41B4, 41B5 of the roof member 30 are shown with small dots, and the first region 41A corresponds to a portion of the roof member 30 other than the second regions 41B3, 41B4, 41B5.

[0048] The second region 41B3 is included in the right side edge portion 30C and the left side edge portion 30D and opposes the curtain airbag 20. The second region 41B3 is located on the vehicle outer side of the first region 41A with respect to the vehicle width direction, and has a band shape extending in the vehicle front-rear direction. The second regions 41B4, 41B5 are located at and around the hole edges (plate side contact portions) of the clamp holes 35, 36 and the sun visor hole 37, and have a ring shape (circular shape). The band-shaped second region 41B3 is partially bent in a manner projecting inward (toward the middle region of the roof member 30) along the auxiliary handle holes 33, 34. The band-shaped second region 41B3 includes a curtain airbag contact portion P. As shown in Figure 5 the drawing, the contact portion 41B1 of the band-shaped second region 41B3 contacts the support portion 20A of the curtain airbag 20 at the curtain airbag contact portion P. As shown in Figure 1 the drawing, in the case where the roof member 30 is installed to the roof header 10 with the clamp 25, the contact portion 41B1 of the ring-shaped second regions 41B4, 41B5 contacts a portion of the roof header 10 adjacent to the clamp holes 35, 36 and the sun visor hole 37. The band-shaped second region 41B3 and the ring-shaped second regions 41B4, 41B5 have the same configuration including the contact portion 41B1 and the recessed portion 41B2.

[0049] Figure 5A cross-sectional configuration of the roof member 30 including the second zone 41B3 in a band shape is shown. The second zone 41B3 is included on the vehicle outer side surface 30A of the roof member 30. The second zone 41B3 is included in the reflective layer 43. The second zone 41B3 includes the contact portion 41B1 and the recessed portion 41B2. The contact portion 41B1 is a protruding portion between the recessed portions 41B2. The contact portion 41B1 is to be in contact with the roof head 10 or the support portion 20A of the curtain airbag 20. The vehicle outer side surface 43A of the contact portion 41B1 is a portion of the vehicle outer side surface 30A of the roof member 30. That is, the upper surface of the contact portion 41B1 is a contact surface, and is a portion of the vehicle outer side surface 43A of the cover layer 41 (a cover layer vehicle outer side surface). The recessed portion 41B2 is recessed toward the vehicle inner side as compared to the contact portion 41B1. The recessed portion 41B2 is recessed from the vehicle outer side surface 30A of the roof member 30. That is, the recessed portion 41B2 is recessed from the vehicle outer side surface 43A of the cover layer 41. In a case where the curtain airbag 20 is installed to the roof member 30, the contact portion 41B1 is in contact with the curtain airbag 20, but the recessed portion 41B2 is not in contact with the curtain airbag 20. In a case where the curtain airbag 20 is installed to the roof member 30, there is a space between the bottom surface of the recessed portion 41B2 and the support portion 20A. That is, the bottom surface of the recessed portion 41B2 is away from the support portion 20A. Directly below the recessed portion 41B2, a portion of the air barrier layer 42 and the core layer 40 included in a layer lower than the reflective layer 43 is recessed toward the vehicle inner side. The bottom surface of the recessed portion 41B2 (a vehicle inner side surface of the recessed portion 41B2) is lower than (on the vehicle inner side) a portion of the vehicle outer side surface 40A of the core layer 40 directly below the contact portion 41B1.

[0050] The depth of the recessed portion 41B2 (a distance between the vehicle outer side surface 43A of the contact portion 41B1 and the bottom surface of the recessed portion 41B2) can be in a range between any one of 0.005 mm or more, 0.01 mm or more, and 0.02 mm or more and any one of 2 mm or less, 1 mm or less, and 0.1 mm or less. The depth of the recessed portion 41B2 can preferably be between 0.02 mm and 1 mm inclusive. The depth of the recessed portion 41B2 can be greater than the total thickness of the air barrier layer 42 and the reflective layer 43. In a case where the depth of the recessed portion 41B2 is in such a range, a recess (a first recess) is formed in the vehicle outer side surface 40A of the core layer 40. This improves the durability of the uneven shape of the vehicle outer side surface 30A of the roof member 30. In addition, the design deterioration of the vehicle inner side surface 40B of the core layer 40 is suppressed.

[0051] The distance between the contact portions 41B1 adjacent to each other (the size of the recessed portions 41B2) can be in a range from any one of 0.05 mm or more and 0.1 mm or more to any one of 10 mm or less and 5 mm or less. The distance between the adjacent contact portions 41B1 is preferably between 0.1 mm and 5 mm inclusive. The ratio of the area of the contact portions 41B1 in contact with the support portion 20A to the area of the second regions 41B3 is preferably between 30% and 70% inclusive. Similarly, the ratio of the area of the contact portions 41B1 in contact with the roof 10 to the area of the second regions 41B4, 41B5 is preferably between 30% and 70% inclusive. With the ratio in this range, friction can be effectively reduced. This suppresses stress concentration from the support portion 20A on the roof 10 or the reflective layer 43, and the reflective layer 43 and the air barrier layer 42 are hardly broken.

[0052] In the case where a thermoplastic resin is used as the material of the core layer 40, a preboard is obtained by arranging the air barrier layer 42 and the reflective layer 43 on the core layer 40, the preboard is exposed to hot air inside a furnace and heated by a far infrared heater. Then, cold pressing is performed on the heated preboard, and the ceiling member 30 is obtained. In the case where a thermosetting resin is used as the material of the core layer 40, a preboard is obtained by arranging the air barrier layer 42 and the reflective layer 43 on the core layer 40, and hot pressing is performed on the preboard at about 130 degrees. Thereby, the ceiling member 30 is obtained. In the pressing process, the rear surface of the preboard is pressed with a molding die partially having an embossed form, and the rear surface of the ceiling member 30 is embossed to form the second regions 41B3, 41B4, 41B5. Such an embossed form is provided to a nest die removably attached to the molding die. The nest die can be made of the same material (metal) as the molding die, or can be made of a resin (thermosetting resin such as an epoxy resin and a phenol resin) having good heat resistance and durability.

[0053] Next, the effects of the present embodiment will be described. The ceiling member 30 (vehicle interior member) according to the present embodiment is to be installed in the roof 10 of the automobile 1 from the inside of the vehicle, and includes the core layer 40 and the cover layer 41 covering the vehicle outer side surface 40A of the core layer 40. The cover layer 41 includes the first region 41A and the second regions 41B3, 41B4, 41B5. The first region 41A has a flat vehicle outer side surface. The second regions 41B3, 41B4, 41B5 have a concave-convex vehicle outer side surface. The second regions 41B3, 41B4, 41B5 include the contact portions 41B1 on the vehicle outer side surface 43A. The contact portions 41B1 are to be in contact with a vehicle component such as a curtain airbag 20 or the roof 10 arranged between the roof 10 and the ceiling member 30.

[0054] According to this ceiling member 30 (vehicle interior member), the second regions 41B3, 41B4, 41B5 of the cover layer 41 covering the vehicle outer side surface 40A of the core layer 40 include contact portions 41B1 to be contacted with the curtain airbag 20 (vehicle component) or the roof 10 (vehicle body panel). Therefore, the second regions 41B3, 41B4, 41B5 have a concave-convex vehicle outer side surface. The second regions 41B3, 41B4, 41B5 include recessed portions 41B2 between the adjacent contact portions 41B1. The recessed portions 41B2 are not contacted with the curtain airbag 20 or the roof 10. With the second regions 41B3, 41B4, 41B5 provided, the area of the contact surface of the cover layer 41 contacted with the curtain airbag 20 or the roof 10 can be reduced. That is, the area of the contact surface of the ceiling member 30 contacted with the curtain airbag 20 or the roof 10 can be reduced. Therefore, the friction between the ceiling member 30 and the curtain airbag 20 or the roof 10 can be reduced, and noise is hardly caused. It is not necessary to arrange a cushion member for suppressing such noise at the contact portion. Therefore, the cost can be reduced with a simple configuration.

[0055] The cover layer 41 includes a reflection layer 43 that reflects at least infrared light and includes the second regions 41B3, 41B4, 41B5 in the reflection layer 43. According to this ceiling member 30 (vehicle interior member), the reflection layer 43 can reflect infrared light (heat) and suppress noise. Therefore, a comfortable in-vehicle space can be provided. It is not necessary to arrange a cushion member for suppressing noise. Therefore, the effect of the reflection layer 43 is not hindered by the cushion member.

[0056] The cover layer 41 includes an air barrier layer 42 between the reflection layer 43 and the core layer 40. The air barrier layer 42 functions to prevent air from moving in the thickness direction. According to this ceiling member 30 (vehicle interior member), air hardly moves in the thickness direction, and the reflection layer 43 reflects infrared light and suppresses noise. Therefore, a comfortable in-vehicle space can be provided.

[0057] The recessed portions 41B2 of the second regions 41B3, 41B4, 41B5 are further recessed in the core layer 40. The vehicle outer side surface 40A of the portion of the core layer 40 directly below (on the vehicle inner side of) the recessed portions 41B2 has a recessed portion. The concave-convex shape (protrusions and recesses) of the cover layer 41 hardly loses due to aging change, and the durability of the concave-convex shape can be improved.

[0058] The curtain airbag 20 (vehicle component) extends in the vehicle front-rear direction. The second regions 41B3 extend in the vehicle front-rear direction. The cover layer 41 includes the second regions 41B3 located on the outer side in the vehicle width direction with respect to the first regions 41A. The second regions 41B3 respectively oppose the curtain airbag 20.

[0059] In a case where the curtain airbag 20 is installed adjacent to the roof member 30 (a vehicle interior member) that is long in the vehicle front-rear direction, the area of the surface of the roof member 30 that contacts the elongated curtain airbag 20 increases and can be prone to causing noise. However, according to the roof member 30 of the present embodiment, the area of the contact surface of the roof member 30 and the curtain airbag 20 can be reduced and noise is hardly caused.

[0060] The roof member 30 is configured as a roof of a vehicle. The roof member 30 is in large-area contact with the roof cover 10 and has a plurality of contact portions. However, according to the present embodiment, noise is hardly caused in the roof member 30 having a plurality of contact portions.

[0061] <Second Embodiment>

[0062] Next, a second embodiment will be described with reference to Figure 6 A door trim 230 that is installed to a door panel 5 (see Figure 1 ) from the inside of a vehicle as a vehicle interior member according to the second embodiment will be described. The same components of the present embodiment as those of the first embodiment are designated by the same reference numerals, and the configuration, operation, and effects of the same components will not be described. In the drawings, arrows IN and OUT point to the inside and outside of the vehicle, respectively. In a case where the door trim 230 is installed to the left door panel 5 as shown in Figure 1 , the inside and outside of the vehicle correspond to the right and left sides, respectively.

[0063] Figure 6 A cross-sectional configuration of a portion of the door trim 230 that contacts the door panel 5 from the inside of the vehicle is shown. The door trim 230 includes a core layer 240 and an air barrier layer 241 that is configured as a cover layer and covers a vehicle-outer-side surface 240A of the core layer 240. The air barrier layer 241 functions to prevent movement of air in the thickness direction (vehicle inside-outside direction). In the present embodiment, the door trim 230 does not include the reflection layer 43.

[0064] The door trim 230 is plate-shaped. The air barrier layer 241 configured as a cover layer includes a first region in the middle region of the door trim 230 and a second region 241B in the outer edge portion of the door trim 230. The second region 241B includes a contact portion 241B1 and a recessed portion 241B2. The contact portion 241B1 is to be in contact with the door panel 5 when the door trim 230 is installed to the door panel 5. The recessed portion 241B2 is arranged between the contact portions 241B1. The second region 241B has a vehicle outer side surface 241A as an uneven surface. The recessed portion 241B2 is recessed toward the vehicle inner side as compared with the contact portion 241B1. The vehicle outer side surface 241A of the second region 241B is a contact surface to be in contact with the door panel 5.

[0065] According to this door trim 230, noise is hardly caused, and air hardly moves in the thickness direction of the air barrier layer 241. Therefore, a comfortable in-vehicle space can be provided.

[0066] <Other Embodiments>

[0067] The present disclosure is not limited to the embodiments described above and shown in the drawings. The following embodiments can be included within the technical scope of the technology described herein. The technology described herein can be modified within the technical scope.

[0068] (1) Vehicle interior components other than the ceiling member and the door trim can also be used as the vehicle interior component. The vehicle interior component to be in contact with the vehicle component or the vehicle body panel can be a pillar trim, an instrument panel, and a scuff plate.

[0069] (2) The ceiling member can include a second region having an uneven surface adjacent to a hole edge of the jig hole in the middle region of the ceiling member or adjacent to a hole edge of the illumination device hole in the front middle region of the ceiling member.

[0070] (3) The curtain airbag can not include a resin case, and the bag can be held by a belt. In this configuration, the belt can be in contact with the contact portion of the second region having an uneven surface.

[0071] (4) The vehicle interior component can be used for ground vehicles such as trains and recreational vehicles, flight vehicles such as airplanes and helicopters, marine vehicles such as ships, and underwater vehicles such as submarines.

Claims

1. A vehicle interior member to be installed to a vehicle body panel, the vehicle interior member comprising: a core layer having a vehicle outer side surface; and a cover layer covering the vehicle outer side surface of the core layer and having a cover layer vehicle outer side surface, the cover layer including: a first region having a first vehicle outer side surface, the first vehicle outer side surface being flat and being a part of the cover layer vehicle outer side surface, and a second region having a second vehicle outer side surface, the second vehicle outer side surface being a concavo-convex surface and being another part of the cover layer vehicle outer side surface, the second region including a protruding portion to be in contact with the vehicle body panel or a vehicle member, wherein the second region of the cover layer includes recesses between the protruding portions, the core layer includes first recesses corresponding to the recesses of the cover layer, respectively, and the first recesses are recessed from the vehicle outer side surface of the core layer.

2. The vehicle interior member according to claim 1, wherein the cover layer includes a reflective layer that reflects at least infrared light, and the second region is included in the reflective layer.

3. The vehicle interior component of Claim 2, wherein, the cover layer includes an air blocking layer between the reflective layer and the core layer, the air blocking layer serving to restrict movement of air in a thickness direction of the cover layer.

4. The vehicle interior member according to claim 1 or 2, wherein the cover layer includes an air blocking layer serving to restrict movement of air in a thickness direction of the cover layer, and the second region is included in the air blocking layer.

5. The vehicle interior member according to any one of claims 1 to 3, wherein the vehicle member is a curtain airbag extending in a vehicle front-rear direction, and the curtain airbag includes at least two curtain airbags, the second region includes at least two second regions extending in the vehicle front-rear direction, the at least two second regions being arranged to sandwich the first region with respect to a vehicle width direction, and the at least two second regions are respectively opposite to the at least two curtain airbags.

6. The vehicle interior component of any one of claims 1-3, wherein the vehicle interior member is configured as a roof of a vehicle.

7. The vehicle interior member according to any one of claims 1 to 3, wherein the protruding portions have contact surfaces that are parts of the second vehicle outer side surface.

8. The vehicle interior component of any one of claims 1-3, wherein, the recesses are recessed in the cover layer from the second vehicle outer side surface toward a vehicle inner side.

9. The vehicle interior component of any one of claims 1-3, wherein, the recesses have bottom surfaces, and the bottom surfaces are located on a vehicle inner side with respect to the vehicle outer side surface of the core layer.

10. The vehicle interior component of any one of claims 1-3, wherein the recesses have bottom surfaces that are distanced from contact portions of the vehicle body panel or the vehicle member to be in contact with the protruding portions of the second region.

11. The vehicle interior member according to any one of claims 1 to 3, wherein the vehicle interior member is a panel member, the first region is included in a middle region of the panel member, and the second region is included in an edge region of the panel member.

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