Foamed molded article with display part, lighting display device and method for producing foamed molded article with display part

Abstract

To provide a foamed molded article with a display part having cushioning properties, including a translucent display part, in which the presence of a translucent cushion material does not easily appear on the surface even if the thickness of the skin material varies.SOLUTION: A panel constitution member (5) has a foamed layer (20) between a base material (10) and a skin material (30) and a translucent display part is configured to be lightable by light (DL) irradiated from the back side of the base material. A base material translucent part (13) is provided at a part corresponding to the translucent display part of the base material and a translucent cushion material (25) is provided at a part corresponding to the translucent display part of the foamed layer. The skin material and the translucent cushion material face each other with a gap smaller than the thickness dimension of the translucent cushion material. The foamed layer is composed of a translucent foaming resin with a lower light transmittance than the translucent cushion material and is filled between the translucent cushion material and the skin material.SELECTED DRAWING: Figure 3

Description

[Technical field]

[0001] The present invention relates to a foam-molded article with a display portion, a lighted display device, and a method for manufacturing a foam-molded article with a display portion. [Background technology]

[0002] Conventionally, foam-molded products with display parts that light up and display characters, patterns, etc. are known. For example, Patent Document 1 discloses an interior part for a vehicle as such a foam-molded product with a display part. The interior part disclosed in Patent Document 1 includes a skin material, a base material, and a lighting part.

[0003] The skin material is obtained by slush molding a powdered TPU resin to which a pigment has been added, and has translucency. The substrate is provided on the back surface of the skin material via a filler. An opening is formed in a predetermined position of the substrate. The lighting unit is disposed in the opening on the back side of the substrate, and emits light toward the skin material. In the interior part, the light emitted from the lighting unit is irradiated onto the back surface of the skin material through the opening in the substrate, and is transmitted to the front surface side of the skin material, thereby displaying characters and figures on the surface of the skin material. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] JP 2020-196338 A Summary of the Invention [Problem to be solved by the invention]

[0005] In the interior part disclosed in Patent Document 1, the filler is not provided on the back side of the skin material in the translucent indicator portion that transmits light through the skin material. Therefore, even if cushioning is imparted by the filler, the translucent indicator portion cannot have cushioning properties. Therefore, it is difficult to realize a high-quality feel on the surface of the interior part, including the translucent indicator portion.

[0006] Here, a possible way to provide cushioning to the translucent indicator is to provide a translucent cushioning material that transmits light on the back side of the translucent indicator. However, when the skin material is in direct contact with the translucent cushioning material, if the thickness of the skin material varies, the variation is reflected on the surface of the skin material, and there is a risk that the presence of the translucent cushioning material will become apparent on the surface.

[0007] An object of the present invention is to provide a foam-molded product with an indicator portion, which has cushioning properties on the surface including the light-transmitting indicator portion, and in which the presence of the light-transmitting cushioning material is unlikely to be apparent on the surface even if the thickness of the skin material varies. [Means for solving the problem]

[0008] In order to achieve the above object, in the present invention, a light-transmitting cushioning material that transmits light is provided in a portion of the foam layer corresponding to the back side of the light-transmitting display portion of the skin material, and a foaming layer is also filled between the light-transmitting cushioning material and the surface material.

[0009] Specifically, the first invention is directed to a foam-molded product with a display unit. The foam-molded product with a display unit of the first invention includes a base material, a foam layer provided on the front side of the base material, and a skin material provided between the foam layer and the base material. The foam-molded product with a display unit is a foam-molded product in which the skin material has a light-transmitting display unit that transmits light, and the light irradiated from the back side of the base material transmits the light-transmitting display unit, thereby enabling the light-transmitting display unit to be lit. A base material light-transmitting portion that transmits light is provided at a portion of the base material corresponding to the light-transmitting display unit. A light-transmitting cushion material that transmits light is provided at a portion of the foam layer corresponding to the light-transmitting display unit. The skin material and the light-transmitting cushion material face each other with a gap smaller than the thickness dimension of the light-transmitting cushion material. The foam layer is made of a translucent foamed resin having a lower light transmittance than the light-transmitting cushion material, and is filled between the light-transmitting cushion material and the skin material.

[0010] The second invention is a foamed molded article with a display part in the foamed molded article with a display part of the first invention, wherein a plurality of the light-transmitting display parts are provided at intervals from each other. The light-transmitting cushioning material is provided individually for each of the light-transmitting display parts. The foamed layer has a light-shielding property and is filled between the adjacent light-transmitting cushioning materials. And when the distance between the skin material and the light-transmitting cushioning material is Da and the distance between the adjacent light-transmitting cushioning materials is Db, Da < Db is satisfied.

[0011] The third invention is a foamed molded article with a display part in the foamed molded article with a display part of the first or second invention, wherein the hardness of the light-transmitting cushioning material is equal to or higher than the hardness of the foamed layer.

[0012] The fourth invention is a foamed molded article with a display part in any one of the foamed molded articles with a display part of the first to third inventions, wherein the light-transmitting cushioning material is fixed to the base material light-transmitting part.

[0013] The fifth invention is a foamed molded article with a display part in the foamed molded article with a display part of the fourth invention, wherein a light-transmitting bonding material is used for fixing the light-transmitting cushioning material to the base material light-transmitting part.

[0014] The sixth invention is a foamed molded article with a display part in any one of the foamed molded articles with a display part of the first to fifth inventions, wherein the base material has a base material main body in which an opening corresponding to the light-transmitting display part is formed, and a cap member attached to the base material main body so as to close the opening. And the cap member constitutes the base material light-transmitting part.

[0015] The seventh invention is a foamed molded article with a display part in the foamed molded article with a display part of the sixth invention, wherein the light-transmitting cushioning material has a protruding part that protrudes from a part corresponding to the cap member to the periphery of the opening of the base material main body. And the protruding part covers the boundary between the base material main body and the cap member and seals the boundary.

[0016] An eighth invention is the foam-molded product with a display part according to the seventh invention, wherein the protruding part is attached to the periphery of the opening of the base body with a bonding material.

[0017] The ninth invention is directed to a light-up display device. The light-up display device of the ninth invention includes the foam-molded product with a display unit according to any one of the first to eighth inventions, and a light source disposed on the back side of the base material. Light emitted by the light source passes through the base material translucent portion and the translucent cushioning material, and lights up the translucent display unit.

[0018] The tenth invention is directed to a method for manufacturing a foam-molded product with an indication part. The method for manufacturing a foam-molded product with an indication part of the tenth invention includes the steps of preparing a base material having a base material light-transmitting part that transmits light, preparing a skin material having a light-transmitting indication part that transmits light, fixing a light-transmitting cushion material to the base material light-transmitting part, setting the base material to which the light-transmitting cushion material is fixed and the skin material in an injection foaming mold, and clamping the injection foaming mold so that the skin material and the light-transmitting cushion material face each other with a gap smaller than the thickness dimension of the light-transmitting cushion material to form a cavity between the base material and the skin material, and then injecting a translucent foaming resin raw material having a lower light transmittance than the light-transmitting cushion material into the cavity, foaming the foaming resin raw material, and curing the foaming resin raw material to integrally mold a foam layer between the base material and the skin material. Effect of the Invention

[0019] According to the first invention, a foam layer is provided between a base material and a skin material. And a translucent cushioning material is provided at a position corresponding to the translucent display portion of the foam layer. The skin material and the translucent cushioning material face each other with a gap smaller than the thickness dimension of the translucent cushioning material, and the foam layer is filled between the translucent cushioning material and the skin material. These foam layer and translucent cushioning material impart cushioning properties to the surface of the foam-molded article with a display portion. Therefore, it is possible to impart cushioning properties to the surface of the foam-molded article including the translucent display portion. Further, even if the thickness of the skin material varies, the variation is absorbed by the translucent display portion or the foam layer. As a result, the presence of the translucent cushioning material can be made difficult to appear on the surface.

[0020] According to the second invention, the translucent cushioning material is provided individually for a plurality of translucent display portions. And the foam layer is filled between the adjacent translucent cushioning materials. The foam layer is made of a translucent foam resin having a lower light transmittance than the translucent cushioning material. For this reason, when the interval between the adjacent translucent cushioning materials is larger than the interval between the skin material and the translucent cushioning material (satisfying Da < Db), the foam layer between the translucent cushioning materials blocks the light propagating through each translucent cushioning material. Thereby, it is possible to suppress the occurrence of light leakage between the adjacent translucent display portions.

[0021] According to the third invention, the hardness of the light-transmitting cushioning material is equal to or higher than the hardness of the foam layer. If the hardness of the light-transmitting cushioning material is lower than the hardness of the foam layer, the light-transmitting cushioning material is easily compressed when the foaming resin raw material forming the foam layer between the substrate and the skin is injected and foamed in the production of the foam-molded product. Therefore, after the foam layer is formed, the light-transmitting cushioning material attempts to restore its original shape by elastic recovery, and the part of the skin material corresponding to the light-transmitting cushioning material may be deformed so as to bulge toward the front side. On the other hand, if the hardness of the light-transmitting cushioning material is equal to or higher than the hardness of the foam layer, the light-transmitting cushioning material can withstand the pressure from the foaming resin raw material when the foaming resin raw material forming the foam layer between the substrate and the skin is injected and foamed in the production of the foam-molded product. This makes it possible to suppress the part of the skin material corresponding to the light-transmitting cushioning material from being deformed so as to bulge toward the front side.

[0022] According to the fourth aspect of the present invention, the light-transmitting cushion material is fixed to the light-transmitting portion of the substrate. In the production of the foam-molded product with the display unit, the light-transmitting cushion material is fixed to the light-transmitting portion of the substrate, and in this state, a foaming resin raw material that forms a foam layer is filled between the substrate and the skin material, thereby preventing the light-transmitting cushion material from being displaced due to the flow of the foaming resin raw material. This is advantageous in improving the yield of the foam-molded product.

[0023] According to the fifth aspect of the present invention, a bonding material having translucency is used to fix the translucent cushion material to the substrate translucent part. This reduces attenuation of light used for lighting the translucent display part by the bonding material when the light passes from the substrate translucent part to the translucent cushion material. This is advantageous for realizing clear display on the translucent display part.

[0024] According to a sixth aspect of the present invention, the substrate has a substrate body and a cap member. An opening is formed in a portion of the substrate body that corresponds to the light-transmitting display portion. The cap member is attached to the substrate body so as to close the opening, thereby forming the substrate light-transmitting portion. This makes it easier to provide the substrate light-transmitting portion on the substrate compared to a case where the substrate is molded by two-color molding.

[0025] According to the seventh invention, the translucent cushion material has a protruding portion. The protruding portion protrudes from a portion corresponding to the cap member to the periphery of the opening of the base body, covering the boundary between the base body and the cap member to seal the boundary. In the manufacture of the foam-molded product with the display unit, the protruding portion of the translucent cushion material seals the boundary between the base body and the cap member, and in this state, a foam layer is integrally molded between the base body and the skin material, thereby preventing the foamed resin raw material constituting the foam layer from leaking from the boundary between the base body and the cap member to the back side of the base body.

[0026] If the foaming resin raw material leaks to the back side of the substrate, the pressure in the cavity during foaming of the foaming resin raw material decreases. This may result in poor molding of the foam layer and unevenness on the surface of the skin material. In addition, the foaming resin raw material leaked to the back side of the substrate may block and reduce the light used for lighting the translucent display unit. In contrast, if the foaming resin raw material can be prevented from leaking to the back side of the substrate, the pressure in the cavity during foaming of the foaming resin raw material can be maintained, the foam layer can be well molded, and unevenness on the surface of the skin material can be prevented. Furthermore, the light used for lighting the translucent display unit is not reduced by the foaming resin raw material on the back side of the substrate, which is advantageous for realizing a clear display on the translucent display unit.

[0027] According to the eighth invention, the protruding portion of the light-transmitting cushion material is attached to the periphery of the opening of the base body with an adhesive. In the production of the foam-molded product with a display unit, the protruding portion of the light-transmitting cushion material is attached to the periphery of the opening of the base body with an adhesive, and in this state, a foam layer is integrally molded between the base body and the skin material, thereby further preventing the foamed resin raw material constituting the foam layer from leaking from the boundary between the base body and the cap member to the back side of the base body.

[0028] According to the ninth aspect of the present invention, a foam-molded product with a display unit is provided. The surface of the foam-molded product, including the translucent display unit, has cushioning properties. Therefore, in the light-up display device, the surface of the foam-molded product, including the translucent display unit, can provide a high-quality feel to the touch.

[0029] According to the tenth invention, the light-transmitting cushioning material is fixed to the light-transmitting portion of the substrate provided on the substrate. Furthermore, the substrate and the skin material are set in an injection foaming mold, and the injection foaming mold is clamped so that the skin material and the light-transmitting cushioning material face each other with a gap smaller than the thickness dimension of the light-transmitting cushioning material, thereby forming a cavity between the substrate and the skin material. Then, a semi-transparent foaming resin material having a lower light transmittance than the light-transmitting cushioning material is injected into the cavity, and the foaming resin material is foamed and then cured, thereby integrally forming a foam layer between the substrate and the skin material. At this time, since the light-transmitting cushioning material is fixed to the light-transmitting portion of the substrate, it is unlikely to be displaced by the flow of the foaming resin material. In addition, the foaming resin material is also filled between the skin material and the light-transmitting cushioning material to form a foam layer. As a result, even if the thickness of the skin material varies, the variation is absorbed by the foaming layer even in the light-transmitting display portion. This makes it possible to make the presence of the light-transmitting cushioning material less likely to appear on the surface. [Brief description of the drawings]

[0030] [Figure 1A] FIG. 1A is a plan view illustrating a panel component of embodiment 1 and a right half portion of a lighted display device including the panel component when the display is turned off. FIG. [Figure 1B] FIG. 1B is a plan view illustrating the panel component of the first embodiment and the right half of the display device including the panel component when the display device is turned on. [Diagram 2] FIG. 2 is a cross-sectional view illustrating a main part of the light-emitting display device taken along line II-II in FIG. 1B. [Diagram 3] FIG. 3 is a cross-sectional view illustrating a main part of the light-emitting display device taken along line III-III in FIG. 1B. [Figure 4] FIG. 4 is a cross-sectional view illustrating a part of a step of preparing a base material in the manufacture of the lighted display device of the first embodiment. [Diagram 5] FIG. 5 is a cross-sectional view illustrating a part of a step of preparing a base material in the manufacture of the lighted display device of the first embodiment. [Figure 6] FIG. 6 is a cross-sectional view illustrating a step of preparing a skin material in the manufacture of the lighted display device of the first embodiment. [Figure 7] FIG. 7 is a cross-sectional view illustrating a step of attaching a light-transmitting cushion material to a base material in the manufacture of the light-emitting display device of the first embodiment. [Figure 8] FIG. 8 is a cross-sectional view illustrating a step of setting the base material and the skin material in a foam molding die in the production of the lighted display device of the first embodiment, and a state in which the foam molding die is clamped. [Figure 9] FIG. 9 is a cross-sectional view illustrating a step of forming a foam layer in the production of the lighted display device of the first embodiment. [Figure 10] FIG. 10 is a cross-sectional view illustrating a process of assembling an illumination unit and the like to a panel component in the manufacture of the lighted display device of the first embodiment. [Figure 11] FIG. 11 is a cross-sectional view of a portion corresponding to FIG. 3, illustrating a main part of the light display device of the second embodiment. [Figure 12] FIG. 12 is a cross-sectional view of a portion corresponding to FIG. 3, illustrating a main part of the light display device of the third embodiment. [Figure 13] FIG. 13 is a cross-sectional view of a portion corresponding to FIG. 3, illustrating a main part of the light display device of the fourth embodiment. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0031] Hereinafter, exemplary embodiments will be described in detail with reference to the drawings. In the following embodiments, the foam molded product with a display unit and the lighted display device according to the present invention will be described as being applied to an interior part of a vehicle, taking an instrument panel as an example. Note that the drawings are for conceptually explaining the present invention. Therefore, in the drawings, dimensions, ratios, or numbers may be exaggerated or simplified to facilitate understanding of the present invention.

[0032] First Embodiment The light display device 1 of this embodiment 1 is incorporated into an instrument panel 3 shown in Figures 1A and 1B. The instrument panel 3 is a panel including an instrument panel on which various devices such as an engine tachometer and a speedometer are mounted, and is installed at the front of the vehicle compartment. The instrument panel 3 of this example is for a left-hand drive vehicle. One side of the instrument panel 3 in the vehicle width direction (the left side portion not shown in Figures 1A and 1B) corresponds to the driver's seat, and the other side (the right side portion exemplified in Figures 1A and 1B) corresponds to the passenger seat.

[0033] -Configuration of lighting display device- As shown in FIGS. 2 and 3, the lighted display device 1 includes a panel component 5 and an illumination unit 40. The panel component 5 and the illumination unit 40 are arranged in a row and column.

[0034] <Panel components> A panel component 5 also shown in Figures 1A and 1B is an example of a foam molded product with an indicator, and constitutes the upper panel of the instrument panel 3. The panel component 5 has a plurality of light-transmitting indicator portions 31 (two light-transmitting indicator portions 31 in this example). The light-transmitting indicator portions 31 are provided at intervals from each other in the vehicle width direction. Note that, for the sake of convenience, the edges of each light-transmitting indicator portion 31 are shown by two-dot chain lines in Figures 1A and 1B, but in reality, the edges of the light-transmitting indicator portions 31 do not appear on the outside.

[0035] Each translucent display unit 31 constitutes an indicator light. Each translucent display unit 31 lights up and displays a predetermined icon 32 (for convenience, "A" and "B" are shown in FIG. 1B). The icons 32 displayed by the multiple translucent display units 31 are different figures and indicate different in-vehicle systems. The indicator light formed by each translucent display unit 31 may indicate the operating state (operating / stopped) of the corresponding in-vehicle system depending on whether the icon 32 is lit or not.

[0036] The panel component 5 is a cushioned panel in which the light DL irradiated from the back side of the base material 10 passes through the light-transmitting display section 31, and the light-transmitting display section 31 can be turned on. When the light DL is not irradiated from the back side of the base material 10, the light-transmitting display section 31 has the same appearance as the other parts except the light-transmitting display section 31, and the icons 32 cannot be seen. The panel component 5 has a soft-touch surface over substantially the entire panel including the light-transmitting display sections 31. As shown in FIG. 2 and FIG. 3, the panel component 5 includes the base material 10, a foam layer 20, a light-transmitting cushioning material 25, and a skin material 30.

[0037] <Base material> The substrate 10 is a resin plate-like object that forms the base of the panel component 5. The substrate 10 in this example is molded, for example, by two-color molding. The thickness of the substrate 10 is, for example, about 2.0 mm to 5.0 mm. The substrate 10 has a substrate main body 11 and a substrate light-transmitting portion 13.

[0038] The substrate body 11 has light-shielding properties. In this specification, "light-shielding properties" refers to a generally opaque property that blocks visible light. The substrate body 11 is made of a hard synthetic resin. Examples of materials for the substrate body 11 include polypropylene (PP), acrylonitrile-butadiene-styrene (ABS) resin, polycarbonate (PC), and a composite of polycarbonate (PC) and acrylonitrile-butadiene-styrene (ABS) (PC-ABS).

[0039] A plurality of bosses 17 (only two are shown in FIG. 3) are integrally formed on the back surface of the base body 11. Each boss 17 is located around a corresponding one of the plurality of light-transmitting display portions 31 and protrudes to the back surface of the base body 10. In this example, the plurality of bosses 17 are provided separately on both sides of the plurality of light-transmitting display portions 31. These plurality of bosses 17 are used as fixing portions for fixing the lighting unit 40 to the base body 10. Furthermore, an injection port 12 is formed at a predetermined position of the base body 11 so as to penetrate in the thickness direction.

[0040] The substrate light-transmitting portion 13 is provided at a position of the substrate 10 corresponding to each light-transmitting display portion 31. In this example, the substrate light-transmitting portion 13 is formed integrally with the substrate main body 11. The substrate light-transmitting portion 13 is separated for each light-transmitting display portion 31 and provided individually for each light-transmitting display portion 31. The substrate light-transmitting portion 13 has light-transmitting properties. In this specification, "light-transmitting properties" refers to the property of transmitting visible light. The substrate light-transmitting portion 13 constitutes the entire substrate 10 in the thickness direction, and transmits light DL related to lighting display.

[0041] The substrate light-transmitting portion 13 is made of a hard synthetic resin. Examples of the material of the substrate light-transmitting portion 13 include polycarbonate (PC), polymethyl methacrylate resin (PMMA), polypropylene (PP), and acrylonitrile butadiene styrene (ABS).

[0042] A plurality of recesses 15 are formed on the surface of the substrate 10. Each of the plurality of recesses 15 is a portion for fixing a translucent cushion material 25. A recess 15 is provided for each translucent display portion 31. Each recess 15 is formed by recessing the substrate translucent portion 13 of the substrate 10 and the substrate main body 11 portion surrounding the recess 15 toward the back side of the substrate 10. In this manner, each recess 15 is formed to be slightly larger than the substrate translucent portion 13. The depth of the recess 15 is, for example, about 1.0 mm to 3.0 mm.

[0043] <Foam layer> The foam layer 20 is provided on the front side of the base material 10. The foam layer 20 is a layer filled between the base material 10 and the skin material 30, and has both flexibility and elasticity. The foam layer 20 is formed by injection foam molding. The foam layer 20 is also filled between the light-transmitting cushion material 25 and the skin material 30. The foam layer 20 is further filled between adjacent light-transmitting cushion materials 25. The thickness of the foam layer 20 is about 3.0 mm to 10.0 mm in the portion where the light-transmitting cushion material 25 is not present. The foam layer 20 is made of a translucent foamed resin having a lower light transmittance than the light-transmitting cushion material 25. An example of the material of the foam layer 20 is polyurethane foam (PU).

[0044] The foam layer 20 has a semi-transparent property. The light transmittance in the thickness direction of the foam layer 20 is 1% to 10% in a relatively thick portion excluding the portion corresponding to the light-transmitting display portion 13. In this specification, the "light transmittance" means the rate at which visible light is transmitted. The light transmittance of the foam layer 20 is measured using a commercially available transmittance meter in accordance with JIS K7361. As the transmittance meter, for example, a spectroradiometer SR-LEDW manufactured by Topcon Corporation is used.

[0045] The foam layer 20 has a relatively low hardness. The hardness of the foam layer 20 is measured using a commercially available hardness tester in accordance with JIS K7312. For example, an Asker rubber hardness tester C type manufactured by ASKER is used as the hardness tester. In this case, the surface hardness of the foam layer 20 is, for example, about 20 to 55.

[0046] <Translucent cushioning material> The light-transmitting cushion material 25 is provided at a portion of the foam layer 20 corresponding to each light-transmitting indicator portion 31. The light-transmitting cushion material 25 is a block-shaped member having both flexibility and elasticity. The light-transmitting cushion material 25 is separated for each light-transmitting indicator portion 31 and provided individually for each light-transmitting indicator portion 31. The light-transmitting cushion material 25 is fitted into the recess 15 of the substrate 10 and fixed to the substrate light-transmitting portion 13. The back surface of the light-transmitting cushion material 25 is attached to the bottom surface of the recess 15 using a bonding material 19.

[0047] The bonding material 19 has translucency and transmits the light DL related to the lighting display. For example, the bonding material 19 may be a double-sided tape. The bonding material 19 may be an adhesive or a pressure sensitive adhesive such as an acrylic resin or an epoxy resin. The surface of the translucent cushion material 25 is spaced from the back surface of the skin material 30. The translucent cushion material 25 and the skin material 30 face each other with a gap smaller than the thickness dimension of the translucent cushion material 25 interposed therebetween by the foam layer 20.

[0048] When the distance between the skin material 30 and the translucent cushion material 25 is Da and the distance between adjacent translucent cushion materials 25 is Db, Da < Db is satisfied. In this example, the distance Da between the skin material 30 and the translucent cushion material 25 is set to 2.0 mm or less. That is, the thickness of the portion of the foam layer 20 corresponding to the translucent display portion 31 is 2.0 mm or less and varies according to the variation in the thickness of the corresponding skin material 30 portion. Specifically, in a portion where the thickness of the skin material 30 is relatively thick compared to other portions, the thickness of the corresponding foam layer 20 is relatively thin compared to other portions. On the other hand, in a portion where the thickness of the skin material 30 is relatively thin compared to other portions, the thickness of the corresponding foam layer 20 is relatively thick compared to other portions.

[0049] The translucent cushion material 25 is made of a porous material. Examples of the material of the translucent cushion material 25 include foamed silicone, non-yellowing urethane, etc. The translucent cushion material 25 may be composed of a three-dimensional structure mesh, a highly foamed polypropylene sheet, or other cushioning members.

[0050] The translucent cushion material 25 has translucency and transmits the light DL related to the lighting display. The light transmittance in the thickness direction of the translucent cushion material 25 is 4% or more. The light transmittance of the translucent cushion material 25 is measured in accordance with JIS K7312 using a commercially available transmittance meter (for example, the spectral radiometer SR-LEDW manufactured by Topcon Corporation) in the same manner as the light transmittance of the above-described foam layer 20.

[0051] The hardness of the translucent cushion material 25 is equal to or higher than the hardness of the foam layer 20. The hardness of the translucent cushion material 25 is measured in accordance with JIS K7312 using a commercially available hardness meter in the same manner as the hardness of the above-described foam layer 20. As the hardness meter, for example, the Asker rubber hardness meter type C manufactured by Asker Co., Ltd. is used. In this case, the surface hardness of the translucent cushion material 25 is, for example, about 20 to 55.

[0052] If the hardness of the light-transmitting cushion material 25 is lower than that of the foam layer 20, the light-transmitting cushion material 25 is easily compressed when the foaming resin raw material R3 that forms the foam layer 20 is injected and foamed between the base material 10 and the skin material 30 in the manufacture of the panel component 5. For this reason, after the foam layer 20 is formed, the light-transmitting cushion material 25 attempts to restore its original shape by elastic recovery, and there is a risk that the portion of the skin material 30 that corresponds to the light-transmitting cushion material 25 will be deformed so as to swell toward the front side. For this reason, the hardness of the light-transmitting cushion material 25 is set as described above.

[0053] <Skin material> The skin material 30 is provided with the foam layer 20 interposed between it and the base material 10. The skin material 30 covers the entire front side of the foam layer 20 and each of the light-transmitting cushion materials 25, and constitutes the design surface of the panel component 5. The outer peripheral edge of the skin material 30 is joined to the outer peripheral edge of the base material 10. The skin material 30 has a plurality of light-transmitting indicator parts 31. Each light-transmitting indicator part 31 is a part that transmits light DL of the skin material 30, and functions as an indicator light.

[0054] The thickness of the skin material 30 is, for example, about 0.5 mm to 2.0 mm. The skin material 30 has a light-transmitting layer 33 and a light-shielding layer 35. The light-transmitting layer 33 is a layer that forms the base of the skin material 30. The light-transmitting layer 33 is formed by, for example, slush molding, vacuum molding, vacuum-pressure molding, injection molding, mold skin molding, or spray skin molding. The light-transmitting layer 33 is made of a synthetic resin.

[0055] Examples of materials for the light-transmitting layer 33 formed by slush molding include polyvinyl chloride (PVC), thermoplastic olefin (TPO), thermoplastic urethane (TPU), etc. Examples of materials for the light-transmitting layer 33 formed by vacuum molding or vacuum-pressure molding include polyvinyl chloride (PVC), polypropylene (PP), etc.

[0056] The light-transmitting layer 33 formed by injection molding may be made of thermoplastic olefin (TPO), etc. The light-shielding layer 35 formed by mold skin molding or spray skin molding may be made of thermoplastic urethane (TPU), etc.

[0057] The light-transmitting layer 33 contains a pigment such as black, but the content is relatively small, and the light-transmitting layer 33 has light-transmitting properties. The light-transmitting layer 33 in this example has a gray-tone smoky color. The light transmittance of the light-transmitting layer 33 in the thickness direction is, for example, about 4% to 15%. The light transmittance of the light-transmitting layer 33 is measured in accordance with JIS K7312 using a commercially available transmittance meter (for example, a spectroradiometer SR-LEDW manufactured by Topcon Corporation) in the same manner as the light transmittance of the foamed layer 20 described above.

[0058] The light-transmitting layer 33 has a higher hardness than the foam layer 20 and the light-transmitting cushioning material 25. The hardness of the light-transmitting layer 33 is measured in accordance with JIS K 6253-3 using a commercially available hardness tester. As the hardness tester, for example, an ASKER rubber hardness tester type A (manufactured by ASKER Co., Ltd.) is used. In this case, the hardness of the light-transmitting layer 33 is measured by stacking five light-transmitting layers 33 with a thickness of 1 mm, and is, for example, about 30 to 90.

[0059] The light-shielding layer 35 is provided on the back surface of the light-transmitting layer 33. The light-shielding layer 35 has light-shielding properties. The light-shielding layer 35 is made of a coating film containing a black pigment. The light-shielding layer 35 is formed by, for example, spray painting. The light-shielding layer 35 may be formed by two-layer slush molding or screen printing. Alternatively, the light-shielding layer 35 may be made of a light-shielding film such as polyethylene terephthalate (PET) and provided by attaching the light-shielding film to the back surface of the light-transmitting layer 33.

[0060] The light-shielding layer 35 of this example is provided in a partial region including each light-transmitting indicator portion 31 of the skin material 30. The thickness of the light-shielding layer 35 is, for example, about 0.005 mm to 0.8 mm. Light-transmitting holes 37 are provided in each portion of the light-shielding layer 35 constituting the light-transmitting indicator portion 31. The light-transmitting holes 37 are formed in the same shape as the icons 32 by, for example, irradiation with laser light LB or end mill processing, and allow light DL to pass through. When the light-shielding layer 35 is formed by screen printing, the light-transmitting holes 37 may be provided by using masking, or may be included in the printing pattern.

[0061] -Lighting unit configuration- The lighting unit 40 is a component that illuminates each translucent display portion 31 of the panel component 5 from the back side. The lighting unit 40 is disposed on the back side of the panel component 5. The lighting unit 40 has a substrate 41, a light-shielding wall member 43, and a plurality of LEDs (Light Emitting Diodes) 45. The LEDs 45 are an example of a light source.

[0062] The substrate 41 is fixed to the bosses 17 on the substrate 10 by using tapping screws 47. The substrate 41 is positioned at an interval with respect to each substrate light-transmitting portion 13 of the substrate 10. The light-shielding wall member 43 is sandwiched and held between the substrate 41 and the substrate 10. The light-shielding wall member 43 has a first light-shielding wall 44. The first light-shielding wall 44 individually surrounds a portion of the space between the substrate 10 and the substrate 41 that corresponds to each substrate light-transmitting portion 13, and defines a light source chamber 49 for each light-transmitting display portion 31.

[0063] The LEDs 45 are mounted on the substrate 41 and disposed on the back side of the base material 10. The LEDs 45 are located in the light source chambers 49. The LEDs 45 emit light DL (more precisely, visible light) toward the translucent display portion 31. The light DL emitted by the LEDs 45 is irradiated onto the panel component 5 from the back side of the base material 10. This light DL passes through the corresponding base material translucent portion 13 and the translucent cushioning material 25, and illuminates the translucent display portion 31 from the back side. The illumination light DL passes through the skin material 30 (translucent display portion 31) through the translucent hole 37, thereby projecting the icon 32. As a result, the translucent display portion 31 lights up and displays the icon 32.

[0064] -Manufacturing method for lighting display device- The manufacturing method of the lighted display device 1 includes a panel component manufacturing process and an assembly process.

[0065] <Panel component manufacturing process> The panel component manufacturing process is a process for manufacturing the panel component 5. The panel component manufacturing process includes a base material preparation process, a skin material preparation process, a translucent cushion material fixing process, a setting process, and a foam layer molding process.

[0066] <Base material preparation process> The substrate preparation step is a step of preparing a substrate 10 having a substrate light-transmitting portion 13. In the substrate preparation step, the substrate 10 is molded, for example, by two-color molding. As shown in FIGS. 4 and 5, a two-color molding machine that molds the substrate 10 includes a common core mold 101, a first cavity mold 103, and a second cavity mold 105. The common core mold 101 and the first cavity mold 103 constitute a primary molding die 111. The common core mold 101 and the second cavity mold 105 constitute a secondary molding die 113.

[0067] In the substrate preparation step, as shown in the left diagram of FIG. 4, first, the common core mold 101 is combined with the first cavity mold 103, and the primary molding die 111 is clamped. Thereby, a first cavity C1 for molding the substrate body 11 is formed between the common core mold 101 and the first cavity mold 103. Next, as shown in the right diagram of FIG. 4, a first resin raw material R1, which is the material of the substrate body 11, is injected into the first cavity C1 from a gate (not shown) provided in the primary molding die 111 to fill it. Furthermore, the first resin raw material R1 in the first cavity C1 is cooled and hardened.

[0068] In this manner, the substrate body 11 is molded as a primary molded product. The substrate body 11 molded in this manner has an injection port 12 formed therein. The injection port 12 is an opening for injecting the foaming resin raw material R3 when molding the foam layer 20. Thereafter, the primary molding die 111 is opened so that the substrate body 11 is held by the common core die 101.

[0069] Next, the common core mold 101 holding the substrate body 11 is moved to a position corresponding to the second cavity mold 105. Then, as shown in the left diagram of FIG. 5, the common core mold 101 is combined with the second cavity mold 105, and the secondary molding die 113 is clamped. Thereby, a second cavity C2 for molding the substrate light-transmitting portion 13 is formed between the common core mold 101 and the second cavity mold 105. Next, as shown in the right diagram of FIG. 5, the second cavity C2 is filled by injecting the second resin raw material R2, which is the material of the substrate light-transmitting portion 13, from a gate (not shown) provided in the secondary molding die 113. Furthermore, the second resin raw material R2 in the second cavity C2 is cooled and hardened.

[0070] In this way, the substrate 10 is molded as a secondary molded product in which the substrate light-transmitting portion 13 is integrally provided with the substrate main body 11. Thereafter, the secondary molding die 113 is opened so that the substrate 10 is held by the common core mold 101. Then, the substrate 10 is removed from the secondary molding die 113. Thereafter, post-processing is performed to remove excess parts remaining on the substrate 10, such as gate residues and burrs.

[0071] <Skin material preparation process> The skin preparation process is a process of preparing a skin 30 having a light-transmitting display portion 31. In the skin preparation process, first, a light-transmitting layer 33 is formed by slush molding. Next, as shown in the upper diagram of FIG. 6, spray painting is performed on the back surface of the light-transmitting layer 33. For the spray painting, a setting jig 120 having a mounting surface 121 that conforms to the surface shape of the skin 30 is used. Specifically, the light-transmitting layer 33 is placed and set on the mounting surface 121 of the setting jig 120, and paint 34, which is the material of the light-shielding layer 35, is sprayed from a painting nozzle 130 onto a predetermined area on the back surface of the light-transmitting layer 33. In this way, the light-shielding layer 35 is formed.

[0072] Next, as shown in the lower diagram of FIG. 6, a light transmitting hole 37 is formed by removing a portion of the light shielding layer 35. The light transmitting hole 37 is formed while the light shielding layer 35 is still set in the setting jig 120. The portion of the light shielding layer 35 to be removed is positioned based on the three-dimensional shape of the light shielding layer 33 or the position of the setting jig 120. In this example, the laser beam LB is irradiated from the laser irradiation tool 140 to the positioned portion of the light shielding layer 35 to be removed. This removes the light shielding layer 35 in the shape of the icon 32. In this way, the light transmitting hole 37 having a shape corresponding to the icon 32 is formed in the light shielding layer 35.

[0073] <Translucent cushioning material fixing process> The light-transmitting cushion material fixing step is a step of fixing the light-transmitting cushion material 25 to the substrate light-transmitting portion 13 of the substrate 10. Here, in addition to the substrate 10 prepared in the substrate preparation step, a number of light-transmitting cushion materials 25 corresponding to the substrate light-transmitting portions 13 are prepared in advance.

[0074] 7, in the light-transmitting cushion material fixing step, first, a bonding material 19 is provided on the back surface of each light-transmitting cushion material 25 prepared in advance. Next, each light-transmitting cushion material 25 is fitted into the recess 15 of the substrate 10 and attached to the bottom surface of the recess 15, i.e., the surface of the substrate light-transmitting portion 13 and the surface of the substrate main body 11 around it, via the bonding material 19. In this way, the light-transmitting cushion material 25 is fixed in the recess 15 of the substrate 10.

[0075] <Setting process> The setting step is a step of setting the base material 10 to which the light-transmitting cushion material 25 is fixed and the skin material 30 in an injection foaming mold 150, as shown in the upper diagram of Fig. 8. The injection foaming mold 150 includes an upper mold 151 and a lower mold 161. The lower mold 161 is a fixed mold that does not basically move. The upper mold 151 is a movable mold that is arranged so as to be able to approach and move away from the lower mold 161.

[0076] The upper die 151 has a first set surface 153 on which the substrate 10 is set. A resin injection path 155 such as a direct gate is formed in the upper die 151. One end of the resin injection path 155 opens to the first set surface 153, and the other end of the resin injection path 155 opens to the outer surface of the upper die 151. A resin injector 157 (part of which is shown in FIG. 9) is detachably connected to the outer surface opening of the resin injection path 155. On the other hand, the lower die 161 is disposed below the upper die 151. The lower die 161 has a second set surface 163 on which the skin material 30 is set.

[0077] In the setting step, the base material 10 with the light-transmitting cushion material 25 is set on the first setting surface 153 of the upper mold 151. Specifically, the base material 10 is attached to the upper mold 151 so that the light-transmitting cushion material 25 is located on the opposite side to the first setting surface 153, that is, so that the front side of the base material 10 faces the same direction as the first setting surface 153. At this time, the opening of the resin injection path 155 on the first setting surface 153 corresponds to the injection port 12 formed in the base material main body 11.

[0078] The skin 30 is set on the second set surface 163 of the lower die 161. Specifically, the skin 30 is attached to the lower die 161 so that the light-shielding layer 35 is located on the opposite side to the second set surface 163, that is, so that the back surface of the skin 30 faces the same direction as the second set surface 163. The upper die 151 and the lower die 161 are then oriented so that the first set surface 153 and the second set surface 163 face each other. At this time, the light-transmitting cushion material 25 fixed to the base material 10 and the light-transmitting display portion 31 of the skin 30 are positioned so as to correspond to each other in the up-down direction.

[0079] <Foam layer molding process> The foam layer molding step is a step of integrally molding the foam layer 20 between the base material 10 and the skin material 30. In the foam layer molding step, the lower die 161 is moved so as to approach the upper die 151, and the injection foaming mold 150 is clamped as shown in the lower diagram of FIG. 8. This forms a third cavity C3 between the base material 10 and the skin material 30 in the clamped injection foaming mold 150. At this time, the skin material 30 and the light-transmitting cushion material 25 are opposed to each other with a gap smaller than the thickness dimension of the light-transmitting cushion material 25. Therefore, the third cavity C3 also extends between the light-transmitting cushion material 25 and the skin material 30.

[0080] Thereafter, the resin injector 157 is connected to the upper mold 151 and operated to inject a foaming resin raw material R3, such as a semi-transparent foamed urethane raw material having a lower light transmittance than the light-transmitting cushion material 25, into the third cavity C3 through the resin injection path 155 and the injection port 12 of the base material 10, as shown in Fig. 9, and the foaming resin raw material R3 is foamed while being spread throughout the entire third cavity C3. At this time, the foaming resin raw material R3 also enters and fills the gap between the light-transmitting cushion material 25 and the skin material 30.

[0081] Then, the foaming resin raw material R3 filled in the third cavity C3 is cured. As a result, the foam layer 20 is integrally formed between the base material 10 and the skin material 30. In this way, the panel component 5 is formed in the injection foaming mold 150. Thereafter, the injection foaming mold 150 is opened so that the panel component 5 is held by the lower mold 161. The panel component 5 is then removed from the injection foaming mold 150. Thereafter, post-processing is performed to remove excess parts such as gate residues and burrs remaining on the panel component 5.

[0082] In this manner, the panel component 5 can be manufactured.

[0083] <Assembly process> The assembly process is a process for assembling the lighted display device 1, as shown in Fig. 10. Here, in addition to the panel component 5 manufactured in the panel component manufacturing process, the components that constitute the lighting unit 40, that is, the LED-mounted board 41 on which the LEDs 45 are mounted and the light-shielding wall member 43, are prepared in advance.

[0084] In the assembly process, the light-shielding wall member 43 is placed against the rear surface of the panel component 5 (the rear surface of the base material 10) so that the portions corresponding to the base material light-transmitting portions 13 are individually surrounded by the first light-shielding walls 44, and the board 41 on which the LEDs are mounted is disposed so that the light-shielding wall member 43 is sandwiched between the board 41 and the panel component member 5. Then, the board 41 is fixed to each boss 17 of the base material 10 using tapping screws 47.

[0085] In this manner, the lighted display device 1 can be manufactured.

[0086] -Features of the first embodiment- In the panel component 5 of the first embodiment, a foam layer 20 is provided between the base material 10 and the skin material 30. A light-transmitting cushioning material 25 is provided at a portion of the foam layer 20 corresponding to the light-transmitting indicator 31. The skin material 30 and the light-transmitting cushioning material 25 face each other with a gap smaller than the thickness dimension of the light-transmitting cushioning material 25, and the foam layer 20 is filled between the light-transmitting cushioning material 25 and the skin material 30. The foam layer 20 and the light-transmitting cushioning material 25 impart cushioning properties to the surface of the panel component 5. Thus, the surface of the panel component 5, including the light-transmitting indicator 31, can have cushioning properties. Furthermore, even if the thickness of the skin material 30 varies, the variation is absorbed by the foam layer 20 even in the light-transmitting indicator 31. This makes it difficult for the light-transmitting cushioning material 25 to be visible on the surface.

[0087] In the panel constituent member 5 of this Embodiment 1, the translucent cushioning materials 25 are provided individually for a plurality of translucent display parts 31. And, a foamed layer 20 is filled between the mutually adjacent translucent cushioning materials 25. The foamed layer 20 is made of a translucent foamed resin having a lower light transmittance than the translucent cushioning materials 25. For this reason, when the interval between the mutually adjacent translucent cushioning materials 25 is larger than the interval between the skin material 30 and the translucent cushioning materials 25 (satisfying Da < Db), the foamed layer 20 between the translucent cushioning materials 25 blocks the light DL propagating through each translucent cushioning material 25. Thereby, it is possible to prevent light leakage from occurring between the mutually adjacent translucent display parts 31.

[0088] In the panel constituent member 5 of this Embodiment 1, the hardness of the translucent cushioning material 25 is equal to or higher than the hardness of the foamed layer 20. According to this, in the manufacture of the panel constituent member 5, when the foamed resin raw material R3 forming the foamed layer 20 is injection-molded between the base material 10 and the skin material 30, the translucent cushioning material 25 can withstand the pressure from the foamed resin raw material R3. Thereby, it is possible to suppress the portion of the skin material 30 corresponding to the translucent cushioning material 25 from being deformed so as to bulge to the front side.

[0089] In the panel constituent member 5 of this Embodiment 1, the translucent cushioning material 25 is fixed to the base material translucent part 13. According to this, in the manufacture of the panel constituent member 5, by fixing the translucent cushioning material 25 to the base material translucent part 13 and filling the foamed resin raw material R3 forming the foamed layer 20 between the base material 10 and the skin material 30 in that state, it is possible to suppress the translucent cushioning material 25 from being displaced by receiving the flow of the foamed resin raw material R3. This is advantageous for improving the yield of the panel constituent member 5.

[0090] In the panel constituent member 5 of this Embodiment 1, a translucent bonding material 19 is used for fixing the translucent cushioning material 25 to the base material translucent part 13. Thereby, when the light DL used for the lighting display of the translucent display part 31 is transmitted from the base material translucent part 13 to the translucent cushioning material 25, it is possible to reduce the attenuation by the bonding material 19. This is advantageous for realizing a clear display on the translucent display part 31.

[0091] The lighted display device 1 of the first embodiment includes a panel component 5. The surface of the panel component 5 has cushioning properties, including the translucent display section 13. Therefore, in the lighted display device 1, the surface of the panel component 5, including the translucent display section 13, can achieve a high-quality feel.

[0092] In the manufacturing method of the panel component 5 of the first embodiment, the light-transmitting cushion material 25 is fixed to the substrate light-transmitting portion 13 provided on the substrate 10. Furthermore, the substrate 10 and the skin material 30 are set in an injection foaming mold 150, and the injection foaming mold 150 is clamped so that the skin material 30 and the light-transmitting cushion material 25 face each other with a gap smaller than the thickness dimension of the light-transmitting cushion material 25, thereby forming a third cavity C3 between the substrate 10 and the skin material 30. Then, a translucent foaming resin raw material R3 having a lower light transmittance than the light-transmitting cushion material 25 is injected into the third cavity C3, and the foaming resin raw material R3 is foamed and then cured, thereby integrally forming a foam layer 20 between the substrate 10 and the skin material 30.

[0093] At this time, the light-transmitting cushion material 25 is fixed to the base material light-transmitting portion 13, so it is unlikely to be displaced by the flow of the foamed resin raw material R3. The foamed resin raw material R3 is also filled between the skin material 30 and the light-transmitting cushion material 25 to form the foamed layer 20. As a result, even if the thickness of the skin material 30 varies, the variation is absorbed by the foamed layer 20 even in the light-transmitting display portion 31. This makes it possible to make the presence of the light-transmitting cushion material 25 less likely to be visible on the surface.

[0094] Second Embodiment The light display device 1 of this embodiment 2 differs from the above embodiment 1 in the configuration of the panel component 5 and in that the light-shielding wall member 43 of the lighting unit 40 is not provided separately from the base material 10. In the following embodiments, only the configuration of the light display device 1 that differs from the above embodiment 1 will be described, and the matters related to the same components as the above embodiment 1 will be left to the description of the above embodiment 1, and detailed description thereof will be omitted.

[0095] 11 , in the panel component 5 of the second embodiment, the second light-shielding wall 50 is provided integrally with the base material 10. That is, the second light-shielding wall 50 is provided to protrude from the back surface of the base material 10. The second light-shielding wall 50 individually surrounds the portions corresponding to the base material light-transmitting portions 13 to define the light source chamber 49. The protruding end face of the second light-shielding wall 50 contacts the surface of the substrate 41 or is close to the surface of the substrate 41.

[0096] The second light-shielding wall 50 has a hooked portion 51 in the middle in the height direction. A hooked portion 51 is provided for each light source chamber 49. The hooked portion 51 protrudes toward the light source chamber 49 and is formed in a stepped shape having a surface facing the back side of the base material 10. The hooked portion 51 is used to fix the cap member 60. It is to be noted that the lighting unit 40 of this example does not have a light-shielding wall member 43.

[0097] In addition, the substrate light-transmitting portion 13 constituting the substrate 10 is separate from the substrate main body 11. Specifically, the substrate 10 has the substrate main body 11 and a plurality of cap members 60. An opening 53 is formed in each portion of the substrate main body 11 corresponding to the light-transmitting display portion 31. The opening 53 is formed to be slightly larger in the portion on the front surface side of the substrate 10. As a result, a seat portion 55 having a surface facing the front side is provided on the inner peripheral surface of the opening 53.

[0098] The cap member 60 is a member that constitutes the base material light-transmitting portion 13 and has light-transmitting properties. The cap member 60 is formed by injection molding. The cap member 60 is made of a hard synthetic resin. Examples of materials for the cap member 60 include polycarbonate (PC), polymethyl methacrylate resin (PMMA), polypropylene (PP), and acrylonitrile butadiene styrene (ABS).

[0099] The cap member 60 has a closing plate portion 61 and a plurality of claw pieces 63. The closing plate portion 61 is a main body portion that closes the opening 53 of the cap member 60, and has a shape corresponding to the opening 53 of the base body 11. A protrusion 65 is provided on the outer edge of the front side of the closing plate portion 61. The protrusion 65 protrudes from the outer periphery of the closing plate portion 61. When the cap member 60 of this example is attached to the inside of the opening 53 of the base body 10, the surface of the closing plate portion 61 is approximately flush with the surface of the base body 11, and the protrusion 65 abuts against the seat portion 55 to function as a stopper.

[0100] Each of the claw pieces 63 protrudes from the peripheral portion of the back surface of the closing plate portion 61 to the back side of the cap member 60, and is formed in a relatively flexible state. A claw portion that protrudes toward the outer periphery of the cap member 60 is provided at the tip portion of each of the claw pieces 63. The cap member 60 is attached to the base material 10 by inserting the claw pieces 63 from the front side into the opening 53 of the base material 10 and inserting the opening 53 into the rear position where the protruding piece 65 of the closing plate portion 61 abuts against the seat portion 55.

[0101] The claw piece 63 bends as it is inserted into the opening 53 and the second light-shielding wall 50, and when the cap member 60 reaches the rear position, it elastically returns to its original position and is hooked onto the latched portion 51 of the second light-shielding wall 50. As a result, the cap member 60 is fixed to the base body 11 within the opening 53 with a part of the base body 11 sandwiched between the protrusion 65 and the claw piece 63. In this manner, the cap member 60 is attached to the base body 11 so as to close the opening 53. The light-transmitting cushion material 25 of this example is provided only in a region corresponding to the surface of the cap member 60.

[0102] -Features of the second embodiment- In the panel component 5 of the second embodiment, the substrate 10 has a substrate main body 11 and a cap member 60. An opening 53 is formed in a portion of the substrate main body 11 that corresponds to the substrate light-transmitting portion 13. The cap member 60 is attached to the substrate main body 11 so as to close the opening 53, and constitutes the substrate light-transmitting portion 13. This makes it easier to provide the substrate light-transmitting portion 13 on the substrate 10 compared to, for example, a case in which the substrate 10 is molded by two-color molding.

[0103] Third Embodiment 12, in the lighted display device 1 of the third embodiment, a second light-shielding wall 50 is provided to protrude from the back surface of the substrate 10, similar to the second embodiment. Also, the substrate light-transmitting portion 13 constituting the substrate 10 is configured by a cap member 60 separate from the substrate main body 11, similar to the second embodiment. And the light-transmitting cushion material 25 is provided not only on the surface of the cap member 60 but also in the area surrounding it, and has a protruding portion 27.

[0104] The protruding portion 27 of the light-transmitting cushion material 25 is a portion that protrudes from the portion corresponding to the cap member 60 to the periphery of the opening 53 of the base material body 11. The protruding portion 27 covers the boundary between the base material body 11 and the cap member 60. This seals the boundary between the base material body 11 and the cap member 60 on the front side. The light-transmitting cushion material 25 of this example is attached only to the surface of the cap member 60 with the bonding material 19, and is fixed to the base material light-transmitting portion 13. In other words, the light-transmitting cushion material 25 is not attached to the surface around the opening 53 of the base material body 11 with the bonding material 19.

[0105] In the manufacture of the panel component 5, if the foaming resin raw material R3 leaks to the back side of the base material 10 in the foam layer forming step, the pressure in the third cavity C3 during foaming of the foaming resin raw material R3 drops. This can lead to poor molding of the foam layer 20 and the surface of the skin material 30 can become uneven. In addition, the foaming resin raw material R3 leaking to the back side of the base material 10 can block and reduce the light DL related to the lighting display of the light-transmitting indicator 31. Providing the protruding portion 27 in the light-transmitting cushion material 25 is a measure to address these problems.

[0106] -Features of the third embodiment- In the panel component 5 of the third embodiment, the light-transmitting cushion material 25 has a protruding portion 27. The protruding portion 27 protrudes from a portion corresponding to the cap member 60 to the periphery of the opening 53 of the base material main body 11, covering the boundary between the base material main body 11 and the cap member 60 to seal the boundary. According to this, in the manufacture of the panel component 5, the protruding portion 27 of the light-transmitting cushion material 25 seals the boundary between the base material main body 11 and the cap member 60, and in this state, the foam layer 20 is integrally molded between the base material 10 and the skin material 30, thereby preventing the foamed resin raw material R3 constituting the foam layer 20 from leaking from the boundary between the base material main body 11 and the cap member 60 to the back side of the base material 10.

[0107] If the foaming resin raw material R3 can be prevented from leaking to the back side of the base material 10, the pressure in the third cavity C3 during foaming of the foaming resin raw material R3 can be maintained. This allows the foam layer 20 to be well molded and prevents the surface of the skin material 30 from becoming uneven. Furthermore, the light DL used for lighting the translucent display portion 31 is not reduced by the foaming resin raw material R3 on the back side of the base material 10. This is advantageous for realizing a clear display on the translucent display portion 31.

[0108] Fourth Embodiment 13, in the lighted display device 1 of the fourth embodiment, a second light-shielding wall 50 is provided to protrude from the back surface of the substrate 10, similar to the second embodiment. Also, the substrate light-transmitting portion 13 constituting the substrate 10 is configured by a cap member 60 separate from the substrate main body 11, similar to the second embodiment. Also, the light-transmitting cushion material 25 is provided not only on the surface of the cap member 60 but also in the area surrounding it, similar to the third embodiment, and has a protruding portion 27.

[0109] The light-transmitting cushion material 25 is attached to the surface of the cap member 60 as well as to its periphery using the bonding material 19. The bonding material 19 is provided over the entire back surface of the light-transmitting cushion material 25, and is bonded continuously from the surface of the cap member 60 to the surface of the surrounding base material body 11. That is, the protruding portion 27 of this example is attached to the periphery of the opening 53 of the base material body 11 by the bonding material 19.

[0110] -Features of the fourth embodiment- In the panel component 5 of the fourth embodiment, the protruding portion 27 of the light-transmitting cushion material 25 is attached to the periphery of the opening 53 of the base material main body 11 by the bonding material 19. According to this, in manufacturing the panel component 5, by attaching the protruding portion 27 of the light-transmitting cushion material 25 to the periphery of the opening 53 of the base material main body 11 and integrally molding the foam layer 20 between the base material 10 and the skin material 30 in this state, it is possible to further prevent the foaming resin raw material R3 constituting the foam layer 20 from leaking from the boundary between the base material main body 11 and the cap member 60 to the back side of the base material 10.

[0111] Other Embodiments In the above-mentioned embodiments 1 to 4, the light-shielding layer 35 is provided in a part of the region including each light-transmitting display portion 31 of the skin material 30, but this is not limited thereto. The light-shielding layer 35 may be provided over the entire back surface of the skin material 30. In addition, the light-transmitting layer 33 has a gray-tone smoky color, but the gray-tone smoky color is merely an example, and any color can be adopted for the light-transmitting layer 33 as long as the light-transmitting layer 33 transmits the light DL.

[0112] In the above-mentioned first embodiment, the setting jig 120 is used for spray painting in the skin material preparation step in the manufacture of the panel component 5, but this is not limited to this. For the spray painting, the lower die 161 of the injection foaming mold 150 may be used instead of the setting jig 120, the skin material 30 may be set on the second setting surface 163 of the lower die 161, and the paint 34, which is the material of the light-shielding layer 35, may be sprayed onto a predetermined area on the back surface of the light-transmitting layer 33.

[0113] In the above-mentioned embodiments 1 to 4, the substrate light-transmitting portion 13 is provided individually for each of the light-transmitting display portions 31, but this is not limited thereto. Only one substrate light-transmitting portion 13 may be provided in common for the plurality of light-transmitting display portions 31. That is, the substrate light-transmitting portion 13 may be continuous with the portions of the substrate 10 corresponding to the plurality of light-transmitting display portions 31, and may also be provided in portions of the substrate 10 corresponding to the spaces between the adjacent light-transmitting display portions 31. Moreover, the entire substrate 10 may be made of a light-transmitting material.

[0114] In the above-mentioned embodiments 1 to 4, the case where a plurality of light-transmitting display units 31 are provided on the panel component 5 has been described as an example, but the present invention is not limited to this, and the number of light-transmitting display units 31 provided on the panel component 5 may be one. In addition, the case where the icon 32 is lit up and displayed on the panel component 5 according to the shape of the light-transmitting hole 37 has been described as an example, but the present invention is not limited to this. The object lit up and displayed on the panel component 5 may be a figure, design, character, symbol, etc. other than the icon 32, and any sign may be adopted, and may also be a decorative pattern, etc.

[0115] In the above-mentioned first to fourth embodiments, each translucent display section 31 of the panel component 5 functions as an indicator light, but this is not limited thereto. For example, the panel component 5 may be configured to include a touch sensor sheet provided on the rear surface of the skin material 30 or on the front surface of the substrate 10, and to detect a touch operation on the translucent display section 31 by a user by the function of the touch sensor sheet. Moreover, the panel component 5 may realize a switch function by incorporating a switch component that is operated by a user pressing the translucent display section 31, instead of the touch sensor sheet.

[0116] In the above-mentioned first to fourth embodiments, the foam molded product with a display unit and the light display device according to the present invention have been described as being applied to the instrument panel 3, but the present invention is not limited thereto. The foam molded product with a display unit and the light display device according to the present invention can also be applied to other vehicle interior parts, such as a console box lid, door trim, pillar trim, and sun visor. In addition, the foam molded product with a display unit and the light display device according to the present invention can also be widely applied to products other than vehicle interior parts, such as home appliances and furniture.

[0117] As described above, a preferred embodiment has been described as an example of the present invention. However, the present invention is not limited to this, and can be applied to embodiments in which appropriate changes, substitutions, additions, omissions, etc. are made. It will be understood by those skilled in the art that various further modifications of the above embodiment are possible without departing from the spirit of the present invention, and that such modifications also fall within the scope of the present invention.

[0118] Note that the descriptions "first," "second," etc., mentioned above are merely used to distinguish the words to which these descriptions are attached, and do not limit the number or order of the words. Also, the description "~" in the numerical ranges mentioned above means a range that includes the numerical values ​​before and after it. In other words, when X and Y are substituted for numerical values, the description "X~Y" indicates a range of "greater than or equal to X and less than or equal to Y." [Industrial Applicability]

[0119] INDUSTRIAL APPLICABILITY As described above, the present invention is useful for a foam-molded article with a display portion, a lighted display device, and a method for manufacturing a foam-molded article with a display portion. [Explanation of symbols]

[0120] 1 Lighting display device 5 Panel components (foam molded product with display section) 10 Base material 11 Base material body 13 Base transparent part 19 Bonding material 20 Foam layer 25 Translucent cushioning material 27 Protruding part 30 Skin material 31 Translucent display section 53 Aperture 60 Cap member 150 Injection foam mold C3 3rd cavity (cavity) DL Hikari R3 Foam resin raw material

Claims

1. A substrate (10); a foam layer (20) provided on a front side of the substrate (10); a skin material (30) provided between the foam layer (20) and the base material (10), the skin material (30) has a light-transmitting indicator portion (31) that transmits light (DL), and the light (DL) irradiated from the back side of the base material (10) transmits through the light-transmitting indicator portion (31), thereby causing the light-transmitting indicator portion (31) to light up; a substrate light-transmitting portion (13) that transmits light (DL) is provided at a portion of the substrate (10) corresponding to the light-transmitting display portion (31); a light-transmitting cushion material (25) that transmits light (DL) is provided at a portion of the foam layer (20) corresponding to the light-transmitting indicator (31); the surface material (30) and the light-transmitting cushion material (25) face each other with a gap therebetween that is smaller than the thickness dimension of the light-transmitting cushion material (25); The foam layer (20) is made of a semi-transparent foamed resin having a lower light transmittance than the translucent cushion material (25), and is filled between the skin material (30) and the translucent cushion material (25). A foam-molded product with a display unit.

2. The foam-molded product with a display unit according to claim 1, The light-transmitting indicator (13) is provided in plurality at intervals, The translucent cushion material (25) is provided individually for each of the translucent display portions (13), The foam layer (20) is filled between adjacent pieces of the light-transmitting cushion material (25), When the distance between the surface material (30) and the light-transmitting cushion material (25) is Da and the distance between adjacent light-transmitting cushion materials (25) is Db, Da<Db is satisfied. A foam-molded product with a display unit.

3. The foam-molded product with a display unit according to claim 1, The hardness of the light-transmitting cushion material (25) is equal to or higher than the hardness of the foam layer (20). A foam-molded product with a display unit.

4. The foam-molded product with a display unit according to claim 1, The light-transmitting cushion material (25) is fixed to the base light-transmitting portion (13). A foam-molded product with a display unit.

5. The foam-molded product with a display unit according to claim 5, A light-transmitting bonding material (19) is used to fix the light-transmitting cushion material (25) to the base material light-transmitting portion (13). A foam-molded product with a display unit.

6. The foam-molded product with a display unit according to claim 1 or 5, The substrate (10) includes a substrate body (11) having an opening (53) corresponding to the light-transmitting display portion (31) formed therein, and a cap member (60) attached to the substrate body (11) so as to cover the opening (53), The cap member (60) constitutes the substrate light-transmitting portion (13). A foam-molded product with a display unit.

7. The foam-molded product with a display unit according to claim 6, the light-transmitting cushion material (25) has a protruding portion (27) that protrudes from a portion corresponding to the cap member (60) to a periphery of the opening (53) of the base body (11); The protruding portion (27) covers the boundary between the base body (11) and the cap member (60) and seals the boundary. A foam-molded product with a display unit.

8. The foam-molded product with a display unit according to claim 7, The protruding portion (27) is attached to the periphery of the opening (53) of the base body (11) by a bonding material (19). A foam-molded product with a display unit.

9. A foam-molded product (5) with a display unit according to claim 1; a light source (45) disposed on the rear side of the substrate (10); The light (DL) emitted by the light source (45) passes through the base material light-transmitting portion (13) and the light-transmitting cushion material (25) and lights up the light-transmitting indicator (31). A lighting display device characterized by the above.

10. A step of preparing a substrate (10) having a substrate light-transmitting portion (13) that transmits light (DL); A step of preparing a cover material (30) having a light-transmitting display portion (31) that transmits light (DL); a step of fixing a light-transmitting cushion material (25) that transmits light (DL) to the base material light-transmitting portion (13); a step of setting the base material (10) to which the light-transmitting cushion material (25) is fixed and the skin material (30) in an injection foaming mold (150); and forming a cavity (C3) between the base material (10) and the skin material (30) by clamping the injection foaming mold (150) so that the skin material (30) and the light-transmitting cushion material (25) face each other with a gap smaller than a thickness dimension of the light-transmitting cushion material (25) therebetween, and then injecting a translucent foaming resin raw material (R3) having a lower light transmittance than the light-transmitting cushion material (25) into the cavity (C3), foaming the foaming resin raw material (R3) and then curing it, thereby integrally forming a foam layer (20) between the base material (10) and the skin material (30). A method for producing a foam-molded product with a display portion, comprising:

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