Foamed molded product with display function and manufacturing method thereof

Abstract

To provide a foamed molded product with a display function which has cushioning properties on a surface including a translucent display part and hardly generates luminance unevenness in lighting display at the translucent display part.SOLUTION: In a panel constituting member, a foam layer (20) is provided between a base material (10) and a skin material (30), and an LED (53) arranged on a rear side of the base material is included. Light (DL) emitted from the LED is transmitted through a translucent display part (31) included in the skin material to light and display the translucent display part. A translucent support member (40) is fitted in an opening (11) formed at a portion corresponding to the translucent display part of the base material, from the rear side of the base material. A translucent cushioning material (25) is provided at a portion corresponding to the translucent display part of the foam layer. The translucent cushioning material is attached to a front side edge part of the opening of the base material by using a jointing material(19), and its rear surface is supported by the translucent support member.SELECTED DRAWING: Figure 3

Description

[Technical field]

[0001] The present invention relates to an expansion-molded product with a display function and a method for producing the same. [Background technology]

[0002] Conventionally, foam-molded products with a display function that illuminates and displays characters, patterns, etc. Patent Document 1, for example, discloses an interior part for a vehicle as a foam-molded product with a display function. This interior part includes a skin material, a base material, and a lighting unit.

[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 measure for providing cushioning properties to the light-transmitting indicator is to provide a light-transmitting cushioning material on the back side of the light-transmitting indicator. A specific configuration may be to provide a light-transmitting substrate light-transmitting portion at a portion of the substrate corresponding to the light-transmitting indicator, and to attach the back side of the light-transmitting cushioning material to the substrate light-transmitting portion with a bonding material. However, when this configuration is adopted, the light related to the lighting indication in the light-transmitting indicator is attenuated by the bonding material between the light-transmitting cushioning material and the substrate light-transmitting portion, and the degree of attenuation varies, which may cause uneven brightness in the lighting indication in the light-transmitting indicator.

[0007] An object of the present invention is to provide an expansion molded article with a display function, which has a cushioning property on the surface including the light-transmitting display part and is less likely to cause uneven brightness in the lit display in the light-transmitting display part. [Means for solving the problem]

[0008] In order to achieve the above object, in the present invention, a translucent cushion material is fixed to the front edge of the opening in the base material with a bonding material, provided on the back side of the translucent display portion of the skin material, and supported by a translucent support member fitted into the opening in the base material.

[0009] Specifically, the first invention is directed to a foam-molded product with a display function. The foam-molded product with a display function of the first invention includes a base material, a foam layer provided on the front side of the base material, a skin material provided between the foam layer and the base material, and a light source arranged on the back side of the base material. The skin material has a light-transmitting display part that transmits light. The foam-molded product with a display function is a foam-molded product in which the light-transmitting display part can be turned on by the light emitted from the light source passing through the light-transmitting display part. An opening penetrating the base material is formed at a portion of the base material corresponding to the light-transmitting display part. A light-transmitting support member that transmits light is fitted into the opening from the back side of the base material. A light-transmitting cushioning material that transmits light is provided at a portion of the foam layer corresponding to the light-transmitting display part. The light-transmitting cushioning material is attached to the front edge of the opening of the base material using a bonding material, and the back side is supported by the light-transmitting support member.

[0010] The second invention is the foam-molded product with a display function of the first invention, in which a recess is formed around the opening on the surface of the base material, recessed on the back side of the base material. The recess is open to the opening side and constitutes the front edge of the opening of the base material. The translucent cushion material is fitted into the recess and fixed to the bottom surface of the recess by the bonding material.

[0011] A third invention is the foam-molded product with an indication function of the first invention, in which the light-transmitting indicator portion is provided in a plurality of positions spaced apart from each other. The light-transmitting cushion material is provided individually for each of the light-transmitting indicator portions. The foam layer has light-shielding properties and is filled between adjacent light-transmitting cushion materials.

[0012] A fourth invention is a foam-molded product with a display function of the first invention, in which a translucent capacitive touch sensor is provided on the surface of the translucent support member for detecting a touch operation on the translucent display unit.

[0013] A fifth invention is the foam-molded product with a display function of the first invention, wherein the base material has a guide wall extending from the periphery of the opening to the back side of the base material. The light-transmitting support member is fitted inside the guide wall so as to be slidable in the front-to-back direction. A press-type switch component for detecting a pressing operation on the light-transmitting display unit is disposed on the back side of the base material. The switch component is provided so as to be pressable by sliding to the back side of the light-transmitting support member when pressed from the front side of the light-transmitting display unit.

[0014] The sixth invention is directed to a method for manufacturing a foam-molded product with an indication function. The method for manufacturing a foam-molded product with an indication function of the sixth invention includes the steps of preparing a base material having an opening formed therethrough, preparing a skin material having a light-transmitting indication portion that transmits light, attaching a light-transmitting cushion material that transmits light to the base material by using a bonding material to the front edge of the opening so as to cover the front side of the opening, setting the base material to which the light-transmitting cushion material is fixed and the skin material in an injection foaming mold so that the light-transmitting cushion material and the light-transmitting indication portion correspond to each other, and supporting the back surface of the light-transmitting cushion material in the injection foaming mold, and the steps of forming a cavity between the base material and the skin material by clamping an injection foaming mold, injecting a foaming resin raw material into the cavity, and foaming and then curing the foaming resin raw material to integrally mold a foam layer between the base material and the skin material; and assembling a light-transmitting support member that transmits light by fitting it from the back side of the base material into the opening in the foam molded body consisting of the base material, the skin material, and the foam layer, causing the light-transmitting support member to support the back side of the light-transmitting cushion material, and arranging a light source on the back side of the foam molded body so as to correspond to the light-transmitting support member. Effect of the Invention

[0015] According to the first invention, a foam layer is provided between the substrate and the skin material. A translucent cushioning material is provided at a portion of the foam layer corresponding to the translucent display portion. The foam layer and the translucent cushioning material impart cushioning properties to the surface of the foam molded product. Thus, the surface of the foam molded product, including the translucent display portion, can be made to have cushioning properties. The translucent cushioning material is attached to the front edge portion of the opening of the substrate using a bonding material, and its back surface is supported by the translucent support member. In the manufacture of the foam molded product, when the foamed resin raw material forming the foam layer is filled between the substrate and the skin material, the translucent cushioning material is fixed to the substrate as described above, so that the translucent cushioning material can be prevented from being displaced by the flow of the foamed resin raw material. This is advantageous for improving the yield of the foam molded product. Furthermore, the translucent cushioning material is fixed to the substrate at the front edge portion of the opening. Therefore, it is not necessary to attach the back surface of the translucent cushioning material to the translucent support member via a bonding material. This makes it possible to prevent uneven brightness from occurring in the illuminated display in the light-transmitting display portion of the foam-molded product.

[0016] In addition, by attaching the translucent cushion material to the front edge of the opening of the substrate using a bonding material, it is possible to suppress leakage of the foamed resin raw material forming the foamed layer to the back side of the substrate through between the front edge of the opening of the substrate and the translucent cushion material. If the foamed resin raw material leaks to the back side of the substrate, the pressure in the cavity when the foamed resin raw material is foamed decreases. This leads to a poor molding state of the foamed layer, and there is a risk of unevenness on the surface of the skin material. In addition, the foamed resin raw material leaked to the back side of the substrate may block and reduce the light used for the lighting display of the translucent display section. In contrast, if the foamed resin raw material can be suppressed from leaking to the back side of the substrate, the pressure in the cavity when the foamed resin raw material is foamed can be maintained, the foamed layer can be molded well, and unevenness on the surface of the skin material can be prevented. Furthermore, since the light used for the lighting display of the translucent display section is not reduced by the foamed resin raw material on the back side of the substrate, it is advantageous to realize a clear display on the translucent display section.

[0017] According to the second invention, a recess that constitutes the front edge of the opening is formed on the surface of the substrate. The recess is recessed on the back side of the substrate around the opening and opens to the opening side. The light-transmitting cushion material is fitted into the recess and fixed to the bottom surface of the recess with a bonding material. This allows the light-transmitting cushion material to be stably fixed to the substrate. In addition, in the manufacture of the foam-molded product, since the recess is the position where the light-transmitting cushion material is to be provided when the light-transmitting cushion material is fixed to the substrate, the position where the light-transmitting cushion material is to be attached becomes clear.

[0018] According to the third aspect of the present invention, a light-transmitting cushion material is provided for each of the plurality of light-transmitting display parts. A foam layer is filled between adjacent light-transmitting cushion materials. The foam layer has a light-blocking property, and therefore blocks light propagating through each light-transmitting cushion material. This makes it possible to prevent light leakage between adjacent light-transmitting display parts.

[0019] According to the fourth aspect of the present invention, a capacitive touch sensor having translucency is provided on the surface of the translucent support member. This allows the foam molded product to easily have a capacitive switch function that detects a touch operation on the translucent display unit. In addition, the touch sensor can be replaced by removing the translucent support member, making the touch sensor easy to maintain.

[0020] According to the fifth invention, the base material has a guide wall. The guide wall extends from the periphery of the opening to the back side of the base material. The translucent support member is fitted inside the guide wall so as to be slidable in the front-to-back direction. A press-type switch component is disposed on the back side of the base material. This switch component is provided so as to be pressable by sliding the translucent support member to the back side in response to a pressing operation from the front side of the translucent display portion. This makes it possible to easily provide the foam-molded product with a press-type switch function that detects a pressing operation on the translucent display portion.

[0021] According to the sixth invention, the light-transmitting cushion material is fixed to the front edge of the opening of the substrate. Furthermore, the substrate and the skin material are set in an injection foaming mold, the back surface of the light-transmitting cushion material is supported by the injection foaming mold, and the injection foaming mold is clamped to form a cavity between the substrate and the skin material. After that, a foaming resin raw material is injected into the cavity, and the foaming resin raw material is foamed and then cured to integrally mold a foam layer between the substrate and the skin material. At this time, since the light-transmitting cushion material is fixed to the substrate, it is unlikely to be displaced by the flow of the foaming resin raw material. Furthermore, since the back surface of the light-transmitting cushion material is supported by the injection foaming mold, it is prevented from bending into the opening of the substrate due to pressure from the foaming resin raw material injected into the cavity. This allows the light-transmitting cushion material to be provided without losing its shape. Furthermore, a light-transmitting support member is fitted from the back side of the substrate into the opening in the foamed molded body consisting of the substrate, the skin material, and the foam layer, and assembled. In this way, since the light-transmitting cushion material is fixed to the base material, it is not necessary to attach it to the light-transmitting support member via a bonding material, which makes it possible to prevent uneven brightness in the light-transmitting display of the light-transmitting display portion of the foam-molded product. [Brief description of the drawings]

[0022] [Figure 1A] FIG. 1A is a plan view illustrating the right half of the foam-molded product with a display function of embodiment 1 when the display is turned off. [Figure 1B] FIG. 1B is a plan view illustrating the right half of the foam-molded product with a display function of the first embodiment when the display is turned on. [Diagram 2] FIG. 2 is a cross-sectional view illustrating a main part of the foam-molded product with a display function taken along line II-II in FIG. 1B. [Diagram 3] FIG. 3 is a cross-sectional view illustrating a main part of the foam-molded product with a display function taken along line III-III in FIG. 1B. [Figure 4] FIG. 4 is a cross-sectional view illustrating a step of preparing a substrate in the production of the expansion-molded product with a display function of the first embodiment. [Diagram 5]FIG. 5 is a cross-sectional view illustrating a step of preparing a skin material in the production of the foam-molded product with a display function according to the first embodiment. [Figure 6] FIG. 6 is a cross-sectional view illustrating a step of fixing a translucent cushion material to a substrate in the production of the foam-molded product with a display function according to the first embodiment. [Figure 7] FIG. 7 is a cross-sectional view illustrating a step of setting the substrate and the skin in the injection foaming mold and a state in which the injection foaming mold is clamped in the production of the foam-molded product with a display function of the first embodiment. [Figure 8] FIG. 8 is an enlarged cross-sectional view showing the main parts of the upper mold of the foam molding die and the base material with a light-transmitting cushion set in the upper mold, which are enclosed by VIII in FIG. [Figure 9] FIG. 9 is a cross-sectional view illustrating a step of forming a foam layer in the production of the foam-molded product with a display function of the first embodiment. [Figure 10] FIG. 10 is a cross-sectional view illustrating a process of assembling a light-transmitting support member and an illumination unit to a panel component in the production of the foam-molded product with a display function 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 foam-molded product with a display function according to 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 foam-molded product with a display function according to 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 foam-molded product with a display function according to the fourth embodiment. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0023] Hereinafter, exemplary embodiments will be described in detail with reference to the drawings. In the following embodiments, a foam molded product with a display function 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. 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.

[0024] First Embodiment The foam molded product 1 with a display function of this embodiment 1 is incorporated in 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 in 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.

[0025] -Configuration of foam molded products with display functions- 2 and 3, the display-equipped foam-molded product 1 includes a panel component 5, a light-transmitting support member 40, and an illumination unit 50. The panel component 5 is an example of a foam-molded body.

[0026] <Panel components> A panel component 5, also shown in Figures 1A and 1B, constitutes an upper panel of the instrument panel 3. The panel component 5 has a plurality of translucent indicator portions 31 (two translucent indicator portions 31 in this example). The translucent indicator portions 31 are provided at intervals from one another in the vehicle width direction. Note that, for the sake of convenience, the edges of each translucent indicator portion 31 are shown by two-dot chain lines in Figures 1A and 1B, but in reality, the edges of the translucent indicator portions 31 do not appear on the outside.

[0027] 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.

[0028] 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 portions 31, thereby allowing the light-transmitting display portions 31 to light up. When the light DL is not irradiated from the back side of the base material 10, the light-transmitting display portions 31 have the same appearance as the portions other than the light-transmitting display portions 31, and the icons 32 cannot be seen. The panel component 5 has a soft-to-the-touch surface over substantially the entire panel component 5, including the light-transmitting display portions 31.

[0029] As shown in FIGS. 2 and 3, the panel component 5 includes a base material 10, a foam layer 20, a translucent cushion material 25, and a skin material 30.

[0030] <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 embodiment is formed by injection molding. The thickness of the substrate 10 is, for example, about 2.0 mm to 5.0 mm. The substrate 10 has light-shielding properties. In this specification, "light-shielding properties" refers to a generally opaque property that blocks visible light.

[0031] The substrate 10 is made of a hard synthetic resin. Examples of materials for the substrate 10 include polypropylene (PP), acrylonitrile butadiene styrene (ABS) resin, polycarbonate (PC), and a composite of polycarbonate (PC) and acrylonitrile butadiene styrene (ABS) (PC-ABS).

[0032] An opening 11 is formed in each portion of the base material 10 corresponding to the light-transmitting display portion 31. The opening 11 is provided individually for each light-transmitting display portion 31. Each opening 11 penetrates the base material 10 in the thickness direction and passes light DL related to the light-up display. A recess 15 is formed around the opening 11 on the surface of the base material 10. The recess 15 is a depression recessed on the back side of the base material 10 and opens to the opening 11 side. The recess 15 extends all around the opening 11 and constitutes the front side edge of the opening 11 of the base material 10. The depth of the recess 15 is, for example, about 1.0 mm to 3.0 mm.

[0033] The substrate 10 has a guide wall 16. The guide wall 16 is provided for each opening 11 individually and is formed integrally with the back surface of the substrate 10. The guide wall 16 extends from the periphery of the opening 11 to the back side of the substrate 10 and is formed in a cylindrical shape extending around the entire circumference of the opening 11. Each guide wall 16 individually surrounds a portion corresponding to the opening 11 in the space between the substrate 10 and the substrate 51, and defines a light source chamber LR for each translucent display section 31. The inner peripheral surface of the guide wall 16 is continuous with the inner peripheral surface of the opening 11 without a step in the thickness direction of the substrate 10 and forms a flat surface with the inner peripheral surface of the opening 11.

[0034] The back surface of the base material 10 is further integrally formed with a plurality of bosses 17 (only two are shown in FIG. 3). Each boss 17 is located around the plurality of openings 11 and protrudes to the back surface of the base material 10. In this example, the plurality of bosses 17 are provided separately on both sides of the plurality of openings 11. These plurality of bosses 17 are used as fixing parts for the lighting unit 50 to the base material 10. Furthermore, an injection port 12 is formed at a predetermined position of the base material 10 so as to penetrate in the thickness direction.

[0035] <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 adjacent translucent cushion materials 25. The thickness of the foam layer 20 is about 3.0 mm to 10.0 mm. The foam layer 20 is made of foamed resin. Examples of materials for the foam layer 20 include foamed polyurethane (PU).

[0036] The foam layer 20 has a light-shielding property. The light transmittance of the foam layer 20 in the thickness direction is 1% or less. In this specification, the term "light transmittance" refers to 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 K 7361. As the transmittance meter, for example, a spectroradiometer SR-LEDW manufactured by Topcon Corporation is used.

[0037] 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 K 7312. For example, an Asker rubber hardness tester type C 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.

[0038] <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 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 31 and provided individually for each light-transmitting indicator 31. The light-transmitting cushion material 25 is attached to the front edge of the opening 11 of the base material 10 using a bonding material 19.

[0039] Specifically, the light-transmitting cushion material 25 is fitted into the recess 15 and covers the opening 11 on the front side. The outer peripheral edge of the back surface of the light-transmitting cushion material 25 is fixed to the bottom surface of the recess 15 by a bonding material 19. An example of the bonding material 19 is 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 front surface of the light-transmitting cushion material 25 contacts the back surface of the skin material 30. The light-transmitting cushion material 25 of this example presses the back surface of the skin material 30. The back surface of the light-transmitting cushion material 25 is supported by the light-transmitting support member 40.

[0040] In manufacturing the panel component 5, if the foaming resin raw material R2 leaks to the back side of the base material 10, the pressure in the second cavity C2 during foaming of the foaming resin raw material R2 drops. This may result in a poor molding state of the foam layer 20, and may cause unevenness on the surface of the skin material 30. In addition, the foaming resin raw material R2 leaking to the back side of the base material 10 may block and reduce the light used for lighting the light-transmitting display portion 31. Fixing the light-transmitting cushion material 25 to the base material 10 with the bonding material 19 in the above-mentioned manner is also intended to address these problems.

[0041] The light-transmitting cushion material 25 is made of a porous material that exhibits cushioning properties. Examples of materials for the light-transmitting cushion material 25 include foamed silicone and non-yellowing urethane. The light-transmitting cushion material 25 may be made of a three-dimensional mesh, a highly expanded polypropylene sheet, or other members that have cushioning properties.

[0042] The light-transmitting cushion material 25 has light-transmitting properties. In this specification, "light-transmitting properties" refers to a property of transmitting visible light. The light-transmitting cushion material 25 transmits light DL related to lighting display. The light transmittance in the thickness direction of the light-transmitting cushion material 25 is 4% or more. The light transmittance of the light-transmitting cushion material 25 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 foam layer 20 described above.

[0043] The hardness of the light-transmitting cushioning material 25 is equal to or lower than the hardness of the foamed layer 20. The hardness of the light-transmitting cushioning material 25 is measured in accordance with JIS K 7312 using a commercially available hardness tester, similar to the hardness of the foamed layer 20 described above. As the hardness tester, for example, an Asker rubber hardness tester type C manufactured by ASKER Corporation is used. In this case, the surface hardness of the light-transmitting cushioning material 25 is, for example, about 20 to 55.

[0044] If the hardness of the light-transmitting cushion material 25 is higher than the hardness of the foam layer 20, the force with which the light-transmitting cushion material 25 presses the skin material 30 from the back side due to its elasticity will be relatively large. Therefore, there is a risk that the portion of the skin material 30 corresponding to the light-transmitting cushion material 25 will deform so as to bulge toward the front side. For this reason, the hardness of the light-transmitting cushion material 25 is set as described above.

[0045] <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.

[0046] 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.

[0047] 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.

[0048] 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.

[0049] 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 K 7312 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.

[0050] 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.

[0051] 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.

[0052] 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.

[0053] -Configuration of the light-transmitting support member- The light-transmitting support member 40 is a member that supports the light-transmitting cushion material 25 on the back side. The light-transmitting support member 40 is formed in a bottomed cylindrical shape that corresponds to the inner peripheral shape of the guide wall 16. The light-transmitting support member 40 is fitted into the inside of the guide wall 16 and the opening 11 from the back side of the base material 10. The light-transmitting support member 40 is sandwiched and held between the light-transmitting cushion material 25 and the substrate 51 of the lighting unit 50.

[0054] The light-transmitting support member 40 has a support plate portion 41 and a peripheral wall portion 43. The support plate portion 41 is located within the opening 11 of the base material 10, and supports the light-transmitting cushion material 25 by contacting its back surface. The peripheral wall portion 43 extends in a cylindrical shape from the peripheral edge portion of the support plate portion 41 to the back surface. The outer peripheral surface of the peripheral wall portion 43 faces the inner peripheral surface of the guide wall 16. No bonding material such as an adhesive, a pressure-sensitive adhesive, or a double-sided tape is provided between the support plate portion 41 of the light-transmitting support member 40 and the light-transmitting cushion material 25.

[0055] The light-transmitting support member 40 has light-transmitting properties and transmits light DL related to lighting display. The light-transmitting support member 40 is formed by injection molding. The light-transmitting support member 40 is made of a hard synthetic resin. Examples of materials for the light-transmitting support member 40 include polycarbonate (PC), polymethyl methacrylate resin (PMMA), polypropylene (PP), and acrylonitrile butadiene styrene (ABS).

[0056] -Lighting unit configuration- The lighting unit 50 is a component that illuminates each translucent display portion 31 of the panel component 5 from the back side. The lighting unit 50 is disposed on the back side of the panel component 5. The lighting unit 50 has a substrate 51 and a plurality of LEDs (Light Emitting Diodes) 53. The LEDs 53 are an example of a light source.

[0057] The substrate 51 is fixed to the bosses 17 on the base material 10 by using tapping screws 57. The substrate 51 is positioned at an interval relative to the base material 10. The LEDs 53 are mounted on the substrate 51 and disposed on the rear side of the base material 10. The LEDs 53 are positioned inside the light-transmitting support member 40 (areas surrounded by the peripheral wall portion 43) in each light source chamber LR, and emit light DL (strictly speaking, visible light) toward the light-transmitting display portion 31.

[0058] The light DL emitted by the LEDs 53 is irradiated onto the panel component 5 from the back side of the base material 10. This light DL passes through the corresponding light-transmitting support member 40 and light-transmitting cushion material 25, and illuminates the light-transmitting display portion 31 from the back side. The illumination light DL passes through the cover material 30 (light-transmitting display portion 31) through the light-transmitting hole 37, thereby projecting the icon 32. As a result, the light-transmitting display portion 31 lights up and displays the icon 32.

[0059] -Method of manufacturing foam molded products with display function- The method for producing the foam-molded product 1 with a display function includes a panel component manufacturing step and an assembly step.

[0060] <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.

[0061] <Base material preparation process> The substrate preparation step is a step of preparing a substrate 10 having an opening 11 formed therethrough. In the substrate preparation step, the substrate 10 is molded by injection molding. As shown in FIG. 4, an injection molding die 111 used to mold the substrate 10 includes a core die 101 and a cavity die 103.

[0062] In the substrate preparation step, as shown in the left diagram of Fig. 4, first, the core mold 101 and the cavity mold 103 are brought relatively close to each other to clamp the injection molding die 111. Thereby, a first cavity C1 for molding the substrate 10 is formed between the core mold 101 and the cavity mold 103. Next, as shown in the right diagram of Fig. 4, a resin raw material R1, which is the material of the substrate 10, is injected and filled into the first cavity C1 from a gate (not shown) provided in the injection molding die 111. Furthermore, the resin raw material R1 in the first cavity C1 is cooled and hardened.

[0063] In this manner, the substrate 10 is molded in the first cavity C1. Thereafter, the injection molding die 111 is opened so that the core die 101 holds the substrate 10. The substrate 10 is then removed from the injection molding die 111. Furthermore, a post-processing step is performed to remove excess portions remaining on the substrate 10, such as gate residues and burrs.

[0064] <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. 5, 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 a material for 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.

[0065] Next, as shown in the lower diagram of FIG. 5, 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.

[0066] <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 base material 10 using a bonding material 19. Here, in addition to the base material 10 prepared in the base material preparation step, a number of light-transmitting cushion materials 25 corresponding to the number of openings 11 of the base material 10 are prepared in advance.

[0067] 6, in the light-transmitting cushion material fixing step, first, a bonding material 19 is provided on the outer peripheral edge of 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 base material 10 to close the opening 11, and is attached to the bottom surface of the recess 15, i.e., the front edge of the opening 11 of the base material 10, via the bonding material 19. In this way, the light-transmitting cushion material 25 is fixed within the recess 15 of the base material 10.

[0068] <Setting process> 7, 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 used for molding the foam layer 20. 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.

[0069] The upper mold 151 has a first setting surface 153 on which the base material 10 is set. A groove 153a is formed in the first setting surface 153, into which the guide wall 16 of the base material 10 is fitted. A portion of the first setting surface 153 surrounded by the groove 153a constitutes a cushioning material supporting surface 153b. In addition, the upper mold 151 is formed with a resin injection path 155 such as a direct gate.

[0070] 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 mold 151. A resin injector 157 (part of which is shown in FIG. 8) is detachably connected to the outer surface opening of the resin injection path 155. On the other hand, the lower mold 161 is disposed below the upper mold 151. The lower mold 161 has a second set surface 163 on which the skin material 30 is set.

[0071] 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, as shown in FIG. 8, the guide wall 16 of the base material 10 is fitted into the groove 153a, and the back surface of the light-transmitting cushion material 25 is supported on the cushion material support surface 153b. In addition, the opening of the first setting surface 153 of the resin injection path 155 corresponds to the injection port 12 formed in the base material 10.

[0072] 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.

[0073] <Foam layer molding process> The foam layer molding step is a step of integrally molding the foam layer 20 between the substrate 10 and the skin material 30. In the foam layer molding step, the upper die 151 is moved so as to approach the lower die 161, thereby clamping the injection foaming mold 150 as shown in the lower diagram of FIG. 7. This forms a second cavity C2 between the substrate 10 and the skin material 30 in the clamped injection foaming mold 150. At this time, the translucent cushion material 25 is pressed against and in contact with a part of the skin material 30 including the translucent display portion 31. Therefore, the translucent cushion material 25 and the skin material 30 are in close contact with each other, and the gap between them is sealed.

[0074] Thereafter, the resin injector 157 is connected to the upper mold 151 and operated, and as shown in FIG. 9, a foaming resin raw material R2 such as a urethane foam raw material is injected into the second cavity C2 through the resin injection passage 155 and the injection port 12 of the base material 10, and the foaming resin raw material R2 is foamed while being spread throughout the entire second cavity C2. At this time, since the space between the light-transmitting cushion material 25 and the skin material 30 is sealed, the foaming resin raw material R2 is unlikely to enter between the light-transmitting cushion material 25 and the skin material 30. In addition, the light-transmitting cushion material 25 is also pressed against the bottom surface of the recess 15 via the bonding material 19. As a result, the foaming resin raw material R2 is unlikely to enter between the light-transmitting cushion material 25 and the base material 10.

[0075] Then, the foaming resin raw material R2 filled in the second cavity C2 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. Furthermore, post-processing is performed to remove excess parts such as gate residues and burrs remaining on the panel component 5.

[0076] In this manner, the panel component 5 can be manufactured.

[0077] <Assembly process> The assembly process is a process for assembling the foam-molded product 1 with a display function, as shown in Fig. 10. Here, in addition to the panel component 5 manufactured in the panel component manufacturing process, the lighting unit 50 (i.e., the board 51 on which the LEDs 53 are already mounted) and the number of translucent support members 40 corresponding to the number of translucent display units 31 are prepared in advance.

[0078] In the assembly process, each light-transmitting support member 40 is inserted into the corresponding guide wall 16 from the back side of the base material 10 in the panel constituent member 5 and fitted into the opening 11. At this time, each light-transmitting support member 40 is guided by the guide wall 16. Then, the height of each light-transmitting support member 40 is adjusted so that the support plate portion 41 abuts against the back surface of the light-transmitting cushion material 25, and each light-transmitting support member 40 supports the back surface of the light-transmitting cushion material 25. In this manner, the light-transmitting support member 40 is assembled to the panel constituent member 5.

[0079] Furthermore, the substrate 51 of the lighting unit 50 is disposed so that each of the light-transmitting support members 40 is sandwiched between the substrate 51 and the panel constituent member 5. Here, the substrate 51 is oriented so that the LEDs 53 face the panel constituent member 5, and each of the LEDs 53 is positioned inside the light-transmitting support member 40 in the light source chamber LR, and disposed on the back side of the panel constituent member 5 so as to correspond to the light-transmitting support member 40. Then, the substrate 51 is fixed to each of the bosses 17 of the base material 10 using tapping screws 57.

[0080] In this manner, the foam-molded product 1 with a display function can be manufactured.

[0081] -Features of the first embodiment- In the display-function-equipped foam-molded product 1 of the first embodiment, a foam layer 20 is provided between a substrate 10 and a skin material 30. A light-transmitting cushioning material 25 is provided in a portion of the foam layer 20 corresponding to the light-transmitting indicator 31. The foam layer 20 and the light-transmitting cushioning material 25 impart cushioning properties to the surface of the foam-molded product 1. Thus, the surface of the foam-molded product 1, including the light-transmitting indicator 31, can be provided with cushioning properties. The light-transmitting cushioning material 25 is attached to the front edge of the opening 11 of the substrate 10 using a bonding material 19, and its back surface is supported by a light-transmitting support member 40.

[0082] In the manufacture of the foam-molded product 1, when the foamed resin raw material R2 forming the foam layer 20 is filled between the substrate 10 and the skin material 30, the light-transmitting cushion material 25 is fixed to the substrate 10 as described above, so that the light-transmitting cushion material 25 can be prevented from being displaced by the flow of the foamed resin raw material R2. This is advantageous for improving the yield of the foam-molded product 1. Furthermore, the light-transmitting cushion material 25 is fixed to the substrate 10 at the front edge of the opening 11. Therefore, it is not necessary to attach the back surface of the light-transmitting cushion material 25 to the light-transmitting support member 40 via the bonding material 19. This makes it possible to prevent the light-up display in the light-transmitting display section 31 in the foam-molded product 1 from having uneven brightness.

[0083] Furthermore, by attaching the translucent cushion material 25 to the front edge of the opening 11 of the base material 10 using the bonding material 19, it is possible to prevent the foaming resin raw material R2 forming the foam layer 20 from leaking to the back side of the base material 10 through a gap between the front edge of the opening 11 of the base material 10 and the translucent cushion material 25. This makes it possible to maintain the pressure in the second cavity C2 during foaming of the foaming resin raw material R2, to favorably mold the foam layer 20, and to prevent unevenness from being formed on the surface of the skin material 30. Furthermore, since the light DL used for lighting the translucent display portion 31 is not reduced by the foaming resin raw material R2 on the back side of the base material 10, it is advantageous to realize a clear display on the translucent display portion 31.

[0084] In the foam-molded product 1 with a display function of the first embodiment, a recess 15 constituting the front edge of the opening 11 is formed on the surface of the substrate 10. The recess 15 is recessed on the back side of the substrate 10 around the opening 11 and opens to the opening 11 side. The light-transmitting cushion material 25 is fitted into the recess 15 and fixed to the bottom surface of the recess 15 by a bonding material 19. This allows the light-transmitting cushion material 25 to be stably fixed to the substrate 10. In addition, in manufacturing the foam-molded product 1, since the recess 15 is the position where the light-transmitting cushion material 25 is provided when the light-transmitting cushion material 25 is fixed to the substrate 10, the position where the light-transmitting cushion material 25 is attached becomes clear.

[0085] In the display-function-equipped foam molded product 1 of the first embodiment, the light-transmitting cushion materials 25 are provided individually for the plurality of light-transmitting display parts 31. Then, the foam layer 20 is filled between the adjacent light-transmitting cushion materials 25. Since the foam layer 20 has a light-shielding property, the light DL propagating through each light-transmitting cushion material 25 is blocked. This makes it possible to prevent light leakage between the adjacent light-transmitting display parts 31.

[0086] In the foam-molded product 1 with a display function of the first embodiment, the translucent cushion material 25 presses the back surface of the skin material 30. In this manner, in the manufacture of the panel component 5, the translucent cushion material 25 presses the back surface of the skin material 30, 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 R2 constituting the foam layer 20 from penetrating to the back side of the translucent display portion 31. This is advantageous in realizing a clear display on the translucent display portion 31.

[0087] In the foam molded product 1 with a display function of this embodiment 1, the hardness of the light-transmitting cushion material 25 is equal to or lower than the hardness of the foam layer 20. This makes it possible to relatively reduce the pressing force that the light-transmitting cushion material 25 exerts on the skin material 30 due to its elasticity. This makes it possible to suppress deformation of the portion of the skin material 30 that corresponds to the light-transmitting cushion material 25 so as to bulge outward.

[0088] In the display-function-equipped foam molded product 1 of the first embodiment, the light-transmitting cushion material 25 is fixed to the base material 10. In this manner, in the manufacture of the panel component 5, the light-transmitting cushion material 25 is fixed to the base material 10, and in this state, the foamed resin raw material R2 forming the foamed layer 20 is filled between the base material 10 and the skin material 30, thereby preventing the light-transmitting cushion material 25 from being displaced due to the flow of the foamed resin raw material R2. This is advantageous in improving the yield of the panel component 5.

[0089] In the manufacturing method of the foam-molded product 1 with a display function of the first embodiment, a light-transmitting cushion material 25 is fixed to the front edge of the opening 11 of the substrate 10. The substrate 10 and the skin material 30 are then set in an injection foaming mold 150, the back surface of the light-transmitting cushion material 25 is supported by the injection foaming mold 150, and the injection foaming mold 150 is clamped to form a second cavity C2 between the substrate 10 and the skin material 30. Thereafter, a foaming resin raw material R2 is injected into the second cavity C2, and the foaming resin raw material R2 is foamed and then cured to integrally mold a foam layer 20 between the substrate 10 and the skin material 30.

[0090] At this time, the light-transmitting cushion material 25 is fixed to the base material 10 by the bonding material 19, so that it is difficult for the light-transmitting cushion material 25 to be displaced by the flow of the foaming resin raw material R2. In addition, it is possible to prevent the foaming resin raw material R2 from leaking to the back side of the base material 10 from between the peripheral edge of the opening 11 of the base material 10 and the light-transmitting cushion material 25. This makes it possible to form the foam layer 20 well and prevent the surface of the skin material 30 from becoming uneven. Furthermore, since the back side of the light-transmitting cushion material 25 is supported by the injection foaming mold 150, it is possible to prevent the light-transmitting cushion material 25 from bending into the opening 11 of the base material 10 due to pressure from the foaming resin raw material R2 injected into the second cavity C2. This allows the light-transmitting cushion material 25 to be provided without losing its shape.

[0091] In the manufacturing method of the foam molded product 1 with a display function of the first embodiment, the light-transmitting support member 40 is further fitted into the opening 11 in the panel component 5 consisting of the base material 10, the skin material 30, and the foam layer 20 from the back side of the base material 10 to be assembled. In this manner, the light-transmitting cushion material 25 is fixed to the base material 10, and therefore does not need to be attached to the light-transmitting support member 40 via the bonding material 19. This makes it possible to prevent uneven brightness in the illuminated display in the light-transmitting display section 31 in the panel component 5.

[0092] In the manufacturing method of the foam-molded product 1 with a display function of the first embodiment, the injection foaming mold 150 is clamped so that the light-transmitting cushion material 25 is pressed against and in contact with a part of the skin material 30 including the light-transmitting indicator portion 31. This makes it possible to prevent the foaming resin raw material R2 from penetrating the back side of the light-transmitting indicator portion 31 when the foaming resin raw material R2 is injected and foamed into the second cavity C2. This is advantageous for realizing a clear display on the light-transmitting indicator portion 31.

[0093] In addition, the repulsive force of the light-transmitting cushion material 25, which is generated when the injection foaming mold 150 is closed and pressed against the skin material 30, is released by the light-transmitting cushion material 25 expanding toward the opening 11 after the panel component 5 is removed from the injection foaming mold 150, so that the front side of the skin material 30 is less likely to expand due to the repulsive force.

[0094] Second Embodiment The foam-molded product 1 with a display function of this embodiment 2 differs from the above-mentioned embodiment 1 in that it has a capacitance-type switch function. Note that in the following embodiments, only the configuration of the foam-molded product 1 with a display function that is different from the above-mentioned embodiment 1 will be described, and the details of the matters related to the same configuration parts as the above-mentioned embodiment 1 will be left to the description of the above-mentioned embodiment 1, and the detailed description thereof will be omitted.

[0095] 11, the foam-molded product 1 with a display function of this embodiment 2 includes a light-transmitting support member 40 that is not attached by a bonding material 19, as in the above-mentioned embodiment 1. Since this light-transmitting support member 40 is attached to the panel component 5 later as described above during the production of the foam-molded product 1, the use of the light-transmitting support member 40 makes it easy to add functions such as a switch.

[0096] The foam-molded product 1 with a display function of the second embodiment is obtained by adding a configuration for realizing a capacitance type switch function to the foam-molded product 1 with a display function of the first embodiment.

[0097] Specifically, the foam molded product 1 with a display function of the second embodiment includes a capacitive touch sensor 60. The touch sensor 60 is a sheet-like component for detecting a user's touch operation on the light-transmitting display portion 31, and is provided individually for each light-transmitting display portion 31. The touch sensor 60 is provided on the surface of the support plate portion 41 of the light-transmitting support member 40, and is sandwiched between the support plate portion 41 and the light-transmitting cushion material 25. The touch sensor 60 is light-transmitting and transmits light DL related to lighting display.

[0098] The touch sensor 60 has an electrode. The touch sensor 60 is drawn out to the back side of the base material 10 along the outer peripheral surface of the peripheral wall portion 43 of the translucent support member 40, and is connected to the substrate 51. The substrate 51 is provided with an operation detection circuit (not shown). When a user performs a touch operation on the translucent display unit 31, the operation detection circuit detects a capacitance formed between a contact object such as a finger that touches the translucent display unit 31 and the electrode of the touch sensor 60, and detects the touch operation based on the capacitance. The operation detection circuit is basically composed of an IC (Integrated Circuit).

[0099] With this configuration, each translucent display part 31 functions as a touch switch in the display-function-equipped foam molded product 1. The function of the touch switch may be to switch the operation state (e.g., ON / OFF) of the in-vehicle system indicated by the indicator light displayed by the translucent display part 31, or to cause the in-vehicle system to perform any other operation.

[0100] -Features of the second embodiment- According to the foam-molded product 1 with a display function of the second embodiment, a capacitive touch sensor 60 having translucency is provided on the surface of the translucent support member 40. This makes it possible to easily provide the foam-molded product 1 with a capacitive switch function for detecting a touch operation on the translucent display unit 31. In addition, since the touch sensor 60 can be replaced by removing the translucent support member 40, the touch sensor 60 is easy to maintain.

[0101] Third Embodiment The foam-molded product 1 with a display function of this embodiment 3 differs from the foam-molded product 1 with a display function of this embodiment 3 in that it has a push-type switch function. That is, the foam-molded product 1 with a display function of this embodiment 3 is obtained by adding a configuration for realizing a push-type switch function to the foam-molded product 1 with a display function of the embodiment 1.

[0102] Specifically, as shown in Fig. 12, the foam-molded product 1 with a display function of the third embodiment includes a press-type switch component 70. The switch component 70 is a component for detecting a pressing operation on the translucent display portion 31, and is provided individually for each of the translucent display portions 31. The switch component 70 is mounted on the same surface of the substrate 51 as the LED 53, and is disposed on the rear side of the base material 10. The switch component 70 is a tact switch, and has a pressing surface that receives a pressing operation. Also, the translucent support member 40 is fitted inside the guide wall 16 so as to be slidable in the front-to-back direction.

[0103] A switch contact portion 45 is provided integrally on the rear end surface of the peripheral wall portion 43 of the light-transmitting support member 40. The switch contact portion 45 protrudes from the rear side of the light-transmitting support member 40 and faces the pressing surface of the switch component 70. The rear end surface of the switch contact portion 45 contacts the pressing surface of the switch component 70 or is adjacent to the pressing surface with a small gap therebetween. The switch component 70 is disposed in the vicinity of the LED 53 at a position where the pressing surface faces the switch contact portion 45 of the light-transmitting support member 40.

[0104] A spring insertion portion 47 is further provided integrally with the rear end surface of the peripheral wall portion 43 of the light-transmitting support member 40. The spring insertion portion 47 protrudes from the rear side of the light-transmitting support member 40, and when the light-transmitting display portion 31 is not pressed, a gap is provided between the spring insertion portion 47 and the substrate 51 that is greater than the pressing depth (stroke) of the switch component 70 when it is operated. A compression coil spring 75 is inserted into the spring insertion portion 47. The compression coil spring 75 is interposed between the peripheral wall portion 43 of the light-transmitting support member 40 and the substrate 51. The compression coil spring 75 constantly exerts a biasing force on the light-transmitting support member 40, pressing it toward the light-transmitting cushion material 25.

[0105] When the user presses the translucent display section 31, the skin material 30 is bent backward and concaves, the translucent cushion material 25 is compressed, and a pressing force is applied to the translucent support member 40. As a result, the translucent support member 40 slides backward of the substrate 10 against the biasing force of the compression coil spring 75, and the pressing surface of the switch component 70 is pressed by the switch contact portion 45. When the user releases the pressure on the translucent display section 31, the translucent support member 40 is pushed up toward the translucent cushion material 25 by the biasing force of the compression coil spring 75, and the translucent cushion material 25 elastically returns to its original position, eliminating the concave portion of the translucent display section 31.

[0106] The function of constantly applying a biasing force to the light-transmitting support member 40 toward the light-transmitting cushion material 25 may be provided by the switch component 70 in addition to the compression coil spring 75 or without using the compression coil spring 75 .

[0107] With this configuration, each translucent display part 31 functions as a push button switch in the foam molded product with a display function 1. The function of the push button switch may be to switch the operation state (e.g., ON / OFF) of the in-vehicle system indicated by the indicator light displayed by the translucent display part 31, or to cause the in-vehicle system to perform any other operation.

[0108] -Features of the third embodiment- In the foam-molded product 1 with a display function of the third embodiment, the substrate 10 has a guide wall 16. The guide wall 16 extends from the periphery of the opening 11 to the rear side of the substrate 10. The translucent support member 40 is fitted inside the guide wall 16 so as to be slidable in the front-to-rear direction. A press-type switch component 70 is disposed on the rear side of the substrate 10. The switch component 70 is provided so as to be pressable by sliding the translucent support member 40 to the rear side in response to a pressing operation from the front side of the translucent display portion 31. This makes it possible to easily provide the foam-molded product 1 with a press-type switch function that detects a pressing operation on the translucent display portion 31.

[0109] Fourth Embodiment In the foamed molded article 1 with a display function according to this Embodiment 4, the configuration of the panel constituent member 5 is different from that of the above-described Embodiment 1. When the skin material 30 directly contacts the translucent cushioning material 25 as in the above-described Embodiment 1, if the thickness of the skin material 30 varies, the variation is reflected on the surface of the skin material 30. For this reason, the presence of the translucent cushioning material 25 may appear on the surface of the skin material 30. Therefore, as shown in FIG. 13, in the panel constituent member 5 of this example, a configuration is adopted in which the translucent cushioning material 25 and the skin material 30 have a foam layer 20 interposed therebetween and face each other with a space therebetween.

[0110] The distance between the translucent cushioning material 25 and the skin material 30 is smaller than the thickness dimension of the translucent cushioning material 25. Further, when the distance between the skin material 30 and the translucent cushioning material 25 is Da and the distance between adjacent translucent cushioning materials 25 is Db, Da < Db is satisfied. In this example, the distance Da between the skin material 30 and the translucent cushioning material 25 is set to 2.0 mm or less.

[0111] 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 changes 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.

[0112] The hardness of the translucent cushioning material 25 in this example is equal to or higher than the hardness of the foam layer 20. If the hardness of the translucent cushioning material 25 is lower than the hardness of the foam layer 20, when injecting and foaming the foam resin raw material R2 that forms the foam layer 20 between the base material 10 and the skin material 30 in the manufacture of the panel constituent member 5, the translucent cushioning material 25 is easily compressed. For this reason, after forming the foam layer 20, there is a possibility that the portion of the skin material 30 corresponding to the translucent cushioning material 25 is deformed so as to bulge toward the front side as the translucent cushioning material 25 attempts to recover by elastic recovery. Therefore, the hardness of the translucent cushioning material 25 is set as described above.

[0113] The foam layer 20 in this embodiment is made of a translucent foamed resin having a lower light transmittance than the light-transmitting cushioning material 25. Examples of materials for the foam layer 20 include foamed polyurethane (PU). The foam layer 20 has translucent properties. The light transmittance in the thickness direction of the foam layer 20 is 1% to 10% in relatively thick portions excluding the portions corresponding to the light-transmitting display portions 31.

[0114] -Features of the fourth embodiment- In the foam molded product 1 with a display function of the fourth embodiment, 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, and the foam layer 20 is filled between the light-transmitting cushion material 25 and the skin material 30. With this, even if the thickness of the skin material 30 varies, the variation is absorbed by the foam 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 noticeable on the surface of the skin material 30.

[0115] 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.

[0116] 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.

[0117] In the above-mentioned first to fourth embodiments, the openings 11 of the base material 10 are provided individually for each of the translucent display portions 31, but this is not limited thereto. Only one opening 11 may be provided in common for the plurality of translucent display portions 31. In other words, the opening 11 may be continuous with the portions of the base material 10 corresponding to the plurality of translucent display portions 31, and may include portions of the base material 10 corresponding to the portions between the adjacent translucent display portions 31.

[0118] 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.

[0119] In the above-mentioned fourth embodiment, the foam-molded product 1 with a display function that does not have a switch function has been described as an example, but this is not limiting. The configuration of the foam-molded product 1 with a display function of the fourth embodiment can also be adopted in the foam-molded product 1 with a switch function as shown in the second and third embodiments.

[0120] In the above-mentioned first to fourth embodiments, the foam-molded product with a display function according to the present invention has 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 function according to the present invention can be applied to other vehicle interior parts such as a console box lid, door trim, pillar trim, sun visor, etc. In addition, the foam-molded product with a display function according to the present invention can be widely applied to products other than vehicle interior parts such as home appliances and furniture.

[0121] 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.

[0122] 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]

[0123] INDUSTRIAL APPLICABILITY As described above, the present invention is useful for an expansion-molded product with a display function and a method for producing the same. [Explanation of symbols]

[0124] 1. Foam molded products with display function 5 Panel components (foam molded body) 10 Base material 11 Aperture 15 Recess 19 Bonding material 20 Foam layer 25 Translucent cushioning material 30 Skin material 31 Translucent display section 40 Translucent support member 53 LED (light source) 60 Touch Sensor 70 Switch parts 150 Injection foam mold C2 2nd cavity (cavity) DL Hikari R2 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); a light source (53) disposed on the rear side of the substrate (10); the skin material (30) has a light-transmitting indicator portion (31) that transmits light (DL), and the light (DL) emitted from the light source (53) transmits through the light-transmitting indicator portion (31), thereby enabling the light-transmitting indicator portion (31) to be lit up; an opening (11) penetrating the base material (10) is formed at a portion of the base material (10) corresponding to the light-transmitting display portion (31); A light-transmitting support member (40) that transmits light (DL) is fitted into the opening (11) from the back side of the base material (10), 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 light-transmitting cushion material (25) is attached to the front edge of the opening (11) of the base material (10) using a bonding material (19), and its back surface is supported by the light-transmitting support member (40). A foam-molded product with a display function.

2. The display-function-equipped foam-molded product according to claim 1, a recess (15) recessed toward the back side of the substrate (10) is formed around the opening (11) on the surface of the substrate (10); the recess (15) is open to the opening (11) side and constitutes a front edge portion of the opening (11) of the base material (10); The translucent cushion material (25) is fitted into the recess (15) and fixed to the bottom surface of the recess (15) by the bonding material (19). A foam-molded product with a display function.

3. The display-function-equipped foam-molded product according to claim 1, The light-transmitting indicator (31) is provided in plurality at intervals, The translucent cushion material (25) is provided individually for each of the translucent display portions (31), The foam layer (20) has a light-shielding property and is filled between the adjacent light-transmitting cushion materials (25). A foam-molded product with a display function.

4. The display-function-equipped foam-molded product according to claim 1, A capacitive touch sensor (60) having translucency is provided on a surface of the translucent support member (40) for detecting a touch operation on the translucent display unit (31). A foam-molded product with a display function.

5. The display-function-equipped foam-molded product according to claim 1, The base material (10) has a guide wall (16) extending from the periphery of the opening (11) to the back side of the base material (10), The light-transmitting support member (40) is fitted inside the guide wall (16) so as to be slidable in the front-to-back direction, A push-type switch component (70) for detecting a push operation on the light-transmitting indicator (31) is disposed on the back side of the base material (10), The switch part (70) is provided so as to be depressible by sliding the light-transmitting support member (40) to the rear side in response to pressing of the light-transmitting indicator (31) from the front side. A foam-molded product with a display function.

6. Providing a substrate (10) having an opening (11) formed therethrough; A step of preparing a cover material (30) having a light-transmitting display portion (31) that transmits light (DL); a step of attaching and fixing a light-transmitting cushion material (25) that transmits light (DL) to the base material (10) by using a bonding material (19) to a front edge portion of the opening (11) so as to cover the front side of the opening (11); a step of setting the base material (10) to which the light-transmitting cushion material (25) is fixed and the surface material (30) in an injection foaming mold (150) such that the light-transmitting cushion material (25) and the light-transmitting display portion (31) correspond to each other, and supporting a back surface of the light-transmitting cushion material (25) on the injection foaming mold (150); a step of forming a cavity (C2) between the base material (10) and the skin material (30) by clamping the injection foaming mold (150), injecting a foaming resin raw material (R2) into the cavity (C2), foaming the foaming resin raw material (R2) and then curing the foamed resin raw material (R2), thereby integrally forming a foam layer (20) between the base material (10) and the skin material (30); and fitting a light-transmitting support member (40) that transmits light (DL) into the opening (11) in the foam molded body (5) composed of the base material (10), the skin material (30), and the foam layer (20) from the back side of the base material (10), causing the back side of the light-transmitting cushion material (25) to be supported by the light-transmitting support member (40), and arranging a light source (53) on the back side of the foam molded body (5) so as to correspond to the light-transmitting support member (40). A method for producing a foam-molded product with a display function, comprising:

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