Interior member and method for manufacturing the same

Abstract

To provide an interior member capable of suppressing leakage of light.SOLUTION: An interior member includes: a light-shielding base material having a first opening; a cushion material arranged on a surface of the base material and having a second opening overlapping the first opening; a light-transmitting skin material arranged on the surface of the cushion material and closing the second opening; and a first light-shielding layer provided on an end surface of the cushion material within the second opening.SELECTED DRAWING: Figure 2

Description

[Technical field]

[0001] The present disclosure relates to an interior component and a method for manufacturing an interior component. [Background technology]

[0002] Interior components are installed in the interior spaces of vehicles, ships, aircraft, buildings, and other structures. In recent years, interior components have been proposed that incorporate a light source and express designs through light. For example, interior components have been proposed that incorporate one or more switches and express designs (e.g., shapes, patterns, characters) that indicate the type or function of each switch through light.

[0003] Patent Documents 1 and 2 disclose interior components that use light to express designs that indicate the functions of switches. The interior components include a skin, switches arranged on the back side of the skin, and a light source arranged on the back side of the skin to irradiate light onto switch areas of the skin that correspond to the switches. The switch areas of the skin are formed to transmit light in a specific shape. Light from the light source transmits through the switch areas of the skin to express a design of a specific shape on the surface of the skin. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] JP 2020-166960 A [Patent Document 2] JP 2023-1972 A Summary of the Invention [Problem to be solved by the invention]

[0005] The present disclosure provides an interior component capable of suppressing light leakage, and is intended to provide an interior component that suppresses light leakage from the periphery of an area of ​​an interior part that expresses a design through light, thereby impairing the clarity of the design. [Means for solving the problem]

[0006] An interior member according to one embodiment of the present disclosure includes a light-shielding base material having a first opening, a cushioning material disposed on a surface of the base material and having a second opening overlapping the first opening, a light-transmitting skin material disposed on the surface of the cushioning material and covering the second opening, and a first light-shielding layer provided on an end face of the cushioning material within the second opening. Effect of the Invention

[0007] According to the present disclosure, it is possible to provide an interior member capable of suppressing leakage of light. [Brief description of the drawings]

[0008] [Figure 1] FIG. 2 is a diagram illustrating an example of an interior member installed in a vehicle interior. [Diagram 2] FIG. 2 is a cross-sectional view showing an interior member according to the first embodiment. [Diagram 3] 3A to 3C are cross-sectional views showing a manufacturing method of an interior member according to the first embodiment. [Figure 4] FIG. 11 is a cross-sectional view showing an interior member according to a second embodiment. [Diagram 5] 13A to 13C are cross-sectional views showing a method for manufacturing an interior member according to a third embodiment. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0009] As shown in FIG. 1, an interior member 1 is installed in a vehicle C. In this embodiment, the interior member 1 is a dashboard, but is not limited to this. For example, the interior member 1 may be an armrest, a door trim, a seat, or other interior member in a vehicle. Also, in this embodiment, the interior member 1 is installed in a vehicle C, but is not limited to this. For example, the interior member 1 may be installed in an interior space of an aircraft, a ship, a building, or other.

[0010] In this embodiment, the interior member 1 has one or more switches built in. The surface of the interior member 1 (i.e., the design surface facing the passenger compartment) is provided with a switch area 2 that expresses a design indicating the type or function of each switch. The switch area 2 is an area that the user touches or presses to operate the corresponding switch.

[0011] The switch area 2 includes a pattern imitating a fan, the letters "ON / OFF", and the symbols "-" and "+" to indicate that the switches are for controlling an air conditioner, for example. The switch area 2 also includes a light-shielding portion 2a and a light-transmitting portion 2b. The light-transmitting portion 2b is a portion that transmits light from a light source 20 (see FIG. 2) arranged on the back side of the interior member 1, and the light-shielding portion 2a is a portion that transmits less light than the light-transmitting portion 2b, or does not transmit light at all. In this embodiment, the above-mentioned patterns and the like are formed by the light-transmitting portion 2b provided in the light-shielding portion 2a. In the interior member 1, when the light source 20 arranged on the back side is turned on, a specific design is expressed on the surface of the interior member 1 by the light that has passed through the light-transmitting portion 2b. On the other hand, when the light source 20 is turned off, the light-transmitting portion 2b may become dark enough to be indistinguishable from the light-shielding portion 2a. In this embodiment, a design indicating the type or function of the switches is expressed on the surface of the interior member 1, but is not limited thereto. A design that decorates the exterior of the interior member 1 and is unrelated to the switches may be expressed on the surface of the interior member 1.

[0012] 2 is a cross-sectional view of the interior member 1 in the switch region 2. As shown in FIG. 2, the interior member 1 includes a base material 11, a cushion material 12 arranged on a surface 11b of the base material 11, and a skin material 13 arranged on a surface 12b of the cushion material 12. The base material 11 has a first opening 11a. The cushion material 12 has a second opening 12a that overlaps with the first opening 11a in the stacking direction of the base material 11 and the cushion material 12. The skin material 13 closes the second opening 12a in the stacking direction. In this embodiment, the stacked portion of the first opening 11a and the second opening 12a corresponds to the switch region 2 described above.

[0013] The base material 11 supports the cushion material 12 and the skin material 13, and functions as a framework structure for maintaining the shape of the interior member 1. The base material 11 has a shape that can be used as, for example, a dashboard.

[0014] The substrate 11 is a resin molded member formed of a resin having light-shielding properties. The resin having light-shielding properties may be a resin that itself exhibits light-shielding properties, or may be a resin that exhibits light-shielding properties by containing a black pigment even if the resin itself does not have light-shielding properties. Examples of the resin include ABS resin, polypropylene (PP), polyethylene (PE), acrylic resin, polycarbonate (PC) resin, polyamide, polyethylene terephthalate (PET), and modified polyphenylene ether (modified PPE).

[0015] The cushioning material 12 is adhered to the surface 11b of the base material 11. The cushioning material 12 imparts a soft texture to the interior member 1. The cushioning material 12 has a thickness of, for example, 1 mm or more and 5 mm or less.

[0016] The cushioning material 12 is, for example, a thin plate-like flexible polyurethane foam. The cushioning material 12 is formed, for example, as follows. First, a raw material mixture containing polyol, polyisocyanate, a catalyst, and a foam stabilizer is prepared. The raw material mixture is poured onto release paper, passes through a heating furnace, and foams and hardens to become a block-like polyurethane foam. This block-like polyurethane foam is sliced ​​to become a thin plate-like polyurethane foam.

[0017] The skin material 13 is adhered to the surface 12b of the cushion material 12 by adhesive or frame lamination. The skin material 13 gives the desired appearance and texture to the interior member 1. The skin material 13 has a thickness of, for example, 0.3 mm or more and 3 mm or less.

[0018] The skin material 13 is formed from a light-transmitting sheet material. The sheet material is, for example, a resin sheet or a fiber material. The resin sheet is, for example, formed from polyvinyl chloride (PVC) or polyurethane resin (PU). The fiber material includes knitted fabric, woven fabric, nonwoven fabric, and other fabrics.

[0019] In this embodiment, the interior member 1 further includes a light-transmitting base material 17, a light-transmitting touch sensor 18, and a circuit board 19 on which a light source 20 is mounted.

[0020] The light-transmitting base material 17 is, for example, a resin-molded member formed of a light-transmitting resin, such as ABS resin, polypropylene (PP), polyethylene (PE), acrylic resin, polycarbonate (PC) resin, polyamide, or polyethylene terephthalate (PET).

[0021] The light-transmitting base material 17 is attached to the back surface 11c of the base material 11 by a mounting member 23 such as a screw. The light-transmitting base material 17 has a protrusion 17a that is inserted into the first opening 11a. The height of the protrusion 17a is equal to the thickness of the base material 11. In this embodiment, the protrusion 17a fills the first opening 11a. The protrusion 17a suppresses damage to the cover material 13, the light-transmitting touch sensor 18, and the light source 20 caused by excessive pressure on the switch area 2 by the user.

[0022] A cushion material 22 to be inserted into the second opening 12a is bonded to the outer surface 17b of the protrusion 17a. The thickness of the cushion material 22 is equal to the thickness of the cushion material 12, or is formed to be approximately 0.5 mm thinner than the cushion material 12. In this embodiment, the cushion material 22 fills the second opening 12a. The cushion material 22 provides a soft texture to the user who presses the switch area 2.

[0023] The cushioning material 22 is, for example, a thin plate of soft polyurethane foam, or may be silicone rubber or a fiber strip.

[0024] The light-transmitting touch sensor 18 is, for example, a light-transmitting flexible circuit board on which a capacitive touch sensor is mounted. The light-transmitting touch sensor 18 is attached to the inner surface 17c of the protrusion 17a. The light-transmitting touch sensor 18 detects that the user has touched the switch area 2, generates a signal, and transmits the generated signal to an external controller.

[0025] The light source 20 is an LED, a laser, an incandescent light bulb, a fluorescent lamp, or another light source. The circuit board 19 is attached to the back surface 17d of the light-transmitting base material 17 with an attachment member 24 such as a screw, with the light source 20 disposed inside the protrusion 17a.

[0026] In this embodiment, the interior member 1 further has a first light-shielding layer 14 provided on an end surface 12d of the cushion material 12 within the second opening 12a. The end surface 12d of the cushion material 12 is an inner peripheral surface surrounding the second opening 12a.

[0027] In this embodiment, the interior member 1 does not have a light-shielding layer between the cushion material 12 and the skin material 13. If the cushion material 12 receives light from the light source 20 at its end surface 12d, the light may leak from the periphery of the switch region 2 to the outside of the interior member 1 through the cushion material 12 and the skin material 13. The first light-shielding layer 14 prevents the cushion material 12 from receiving light at its end surface 12d, and as a result, prevents light from leaking from the periphery of the switch region 2.

[0028] The first light-shielding layer 14 has a thickness of, for example, 0.02 mm or less, and preferably has a thickness of 5 μm or more and 10 μm or less. The first light-shielding layer 14 may be formed continuously or discontinuously over the entire end face 12d from the front surface 12b of the cushion material 12 to the back surface 12c of the cushion material 12. In this embodiment, the first light-shielding layer 14 is formed continuously over the entire end face 12d from the front surface 12b of the cushion material 12 to the back surface 12c of the cushion material 12.

[0029] The first light-shielding layer 14 is made of a resin containing, for example, carbon black, iron black, or other black pigments. The resin is, for example, a phenol resin, a polyester resin, an acrylic resin, or a urethane resin.

[0030] In this embodiment, the interior member 1 further has a second light-shielding layer 15 provided on the back surface 13c of the skin material 13 corresponding to the second opening 12a of the cushion material 12. The second light-shielding layer 15 has a light-transmitting window 15a that transmits light. In the above-mentioned switch region 2, the light-transmitting window 15a corresponds to the light-transmitting portion 2b, and the second light-shielding layer 15 corresponds to the light-shielding portion 2a. The light-transmitting window 15a may simply be a hole formed in the second light-shielding layer 15, or the hole formed in the second light-shielding layer 15 may be filled with a light-transmitting material.

[0031] The second light-shielding layer 15 is made of a resin containing, for example, carbon black, iron black, or other black pigments. The resin is, for example, a phenol resin, a polyester resin, an acrylic resin, or a urethane resin.

[0032] The second light-shielding layer 15 may be formed of the same material as the first light-shielding layer 14, or may be formed of a different material. In this embodiment, the second light-shielding layer 15 is formed of the same material as the first light-shielding layer 14. Since the second light-shielding layer 15 is formed of the same material as the first light-shielding layer 14, it can exhibit the same light-shielding performance as the first light-shielding layer 14.

[0033] The second light-shielding layer 15 has a thickness of, for example, 0.02 mm or less, and preferably has a thickness of 5 μm or more and 10 μm or less. The second light-shielding layer 15 may have the same thickness as the first light-shielding layer 14, or may have a different thickness. In this embodiment, the second light-shielding layer 15 has the same thickness as the first light-shielding layer 14. Since the second light-shielding layer 15 has the same thickness as the first light-shielding layer 14, it can exhibit the same light-shielding performance as the first light-shielding layer 14.

[0034] The second light-shielding layer 15 may be connected to the first light-shielding layer 14 or may be separated from the first light-shielding layer 14. In this embodiment, the second light-shielding layer 15 is connected to the first light-shielding layer 14 over the entire circumference of the second opening 12a. Since the second light-shielding layer 15 is connected to the first light-shielding layer 14 over the entire circumference of the second opening 12a, leakage of light from the boundary between the second light-shielding layer 15 and the first light-shielding layer 14 can be prevented.

[0035] The second opening 12a may be the same size as the first opening 11a, or may be smaller than the first opening 11a. In this embodiment, the second opening 12a is smaller than 11a. In this embodiment, the interior member 1 further includes a third light-shielding layer 16 provided on the back surface 12c of the cushion material 12 corresponding to the first opening 11a.

[0036] The third light-shielding layer 16 is made of a resin containing, for example, carbon black, iron black, or other black pigments. The resin is, for example, a phenol resin, a polyester resin, an acrylic resin, or a urethane resin.

[0037] The third light-shielding layer 16 may be formed of the same material as the first light-shielding layer 14, or may be formed of a different material. In this embodiment, the third light-shielding layer 16 is formed of the same material as the first light-shielding layer 14. Since the third light-shielding layer 16 is formed of the same material as the first light-shielding layer 14, it can exhibit the same light-shielding performance as the first light-shielding layer 14.

[0038] The third light-shielding layer 16 has a thickness of, for example, 0.02 mm or less, and preferably has a thickness of 5 μm or more and 10 μm or less. The third light-shielding layer 16 may have the same thickness as the first light-shielding layer 14, or may have a different thickness. In this embodiment, the third light-shielding layer 16 has the same thickness as the first light-shielding layer 14. Since the third light-shielding layer 16 has the same thickness as the first light-shielding layer 14, it can exhibit the same light-shielding performance as the first light-shielding layer 14.

[0039] The third light-shielding layer 16 may be connected to the first light-shielding layer 14, or may be separated from the first opening 11a. In this embodiment, the third light-shielding layer 16 is connected to the first light-shielding layer 14 over the entire periphery of the first opening 11a. Since the third light-shielding layer 16 is connected to the first light-shielding layer 14 and the entire periphery of the first opening 11a, leakage of light from the boundary between the third light-shielding layer 16 and the first light-shielding layer 14 can be prevented.

[0040] The third light-shielding layer 16 may be provided on the entire area of ​​the back surface 12c of the cushion material 12 corresponding to the first opening 11a, or may be provided on a partial area. In this embodiment, the third light-shielding layer 16 is provided on a partial area of ​​the back surface 12c of the cushion material 12 corresponding to the first opening 11a. Specifically, as shown in FIG. 2, the third light-shielding layer 16 has a gap between itself and the end surface 11d of the base material 11. When the light source 20 has directional light distribution characteristics, the amount of light that reaches this gap is small, so that the adverse effects of light leaking from the gap can be ignored.

[0041] Next, moving to FIG. 3, a method for manufacturing the interior member 1 will be described.

[0042] As shown in (a) of Fig. 3, a base material 11 and a laminated material 21 are prepared. A first opening 11a is formed in the base material 11. The laminated material 21 includes a cushioning material 12 and a skin material 13 disposed on the surface of the cushioning material 12. At this point, a second opening 12a is not formed in the cushioning material 12.

[0043] Next, as shown in FIG. 3B, the laminate 21 is fixed to the surface 11b of the base material 11 so as to cover the first opening 11a and the cushion material 12 faces the base material 11. The laminate 21 is fixed to the base material 11 by, for example, an adhesive. As a result, a part of the cushion material 12 is exposed from the first opening 11a of the base material 11. The part of the cushion material 12 exposed from the first opening 11a is removed. In this embodiment, the cushion material 12 is removed by a mill 32. Specifically, the mill 32 is inserted into the first opening 11a from the back surface 11c side of the base material 11. The mill 32 is moved using the first opening 11a of the base material 11 as a guide, and partially removes the cushion material 12. However, the cushion material 12 may be removed by other mechanical or chemical methods without being limited thereto. As a result, a second opening 12a overlapping the first opening 11a is formed in the cushion material 12.

[0044] In this manner, an intermediate product 25 is prepared as shown in Fig. 3(c). The intermediate product 25 includes a base material 11, a cushion material 12 disposed on a surface 11b of the base material 11, and a skin material 13 disposed on a surface 12b of the cushion material 12. The base material 11 has a first opening 11a. The cushion material 12 has a second opening 12a overlapping the first opening 11a. The skin material 13 closes the second opening 12a.

[0045] Next, as shown in (d) of FIG. 3, a light-shielding material is printed on the intermediate product 25 through the first opening 11a to form the first light-shielding layer 14, the second light-shielding layer 15, and the third light-shielding layer 16. In this embodiment, the first light-shielding layer 14, the second light-shielding layer 15, and the third light-shielding layer 16 are simultaneously formed of the same material. The printing method is, for example, pad printing, silk screen printing, or inkjet printing. The light-shielding material may be an ink containing a black pigment, a resin, a solvent, or other suitable liquid. In this manner, the interior member 1 is formed.

[0046] Although the embodiment of the present disclosure has been described above, the present disclosure is not limited to the above embodiment, and various modifications are possible without departing from the gist of the invention. In particular, the multiple modifications described in this specification can be arbitrarily combined as necessary.

[0047] In the above embodiment, the interior member 1 includes the first light-shielding layer 14, the second light-shielding layer 15, and the third light-shielding layer 16, but is not limited thereto. For example, as shown in FIG. 4, the interior member 1 may include the first light-shielding layer 14 but not the second light-shielding layer 15. For example, if the shape of the second opening 12a itself matches the shape of the design expressed by light, the second light-shielding layer 15 is unnecessary. Also, as shown in FIG. 4, the interior member 1 may include the first light-shielding layer 14 but not the third light-shielding layer 16. For example, if the second opening 12a is the same size as the first opening 11a and is aligned with the first opening 11a, the third light-shielding layer 16 is unnecessary.

[0048] In the above embodiment, the light from the light source 20 passes directly through the light-transmitting window 15a of the second light-shielding layer 15, but this is not limited thereto. For example, the interior member 1 may further include a color filter layer laminated on the second light-shielding layer 15. The light from the light source 20 is filtered by the color filter layer to become light of a desired color and passes through the light-transmitting window 15a.

[0049] In the above embodiment, the second opening 12a of the cushion material 12 is formed after the cushion material 12 is fixed to the base material 11, but this is not limited thereto. The second opening 12a may be formed before the cushion material 12 is fixed to the base material 11. For example, as shown in FIG. 5(a), the base material 11, the cushion material 12, and the skin material 13 are each prepared. At this point, the cushion material 12 has the second opening 12a. The second opening 12a is formed, for example, by die cutting. Next, as shown in FIG. 5(b), the cushion material 12 is fixed to the surface 11b of the base material 11 so that the second opening 12a overlaps the first opening 11a. Next, as shown in FIG. 5(c), the skin material 13 is fixed to the surface 12b of the cushion material 12 so as to close the second opening 12a. In this way, an intermediate product 25 is obtained. [Explanation of symbols]

[0050] 11 Base material 12 Cushioning material 13 Skin material 14 1st light shielding layer 15 Second light shielding layer 16 Third light shielding layer

Claims

1. a light-shielding substrate having a first opening; a cushioning material disposed on a surface of the base material and having a second opening overlapping the first opening; a translucent skin material disposed on a surface of the cushion material and covering the second opening; a first light-shielding layer provided on an end surface of the cushion material within the second opening; An interior component comprising:

2. a second light-shielding layer provided on a back surface of the skin material corresponding to the second opening and having a light-transmitting window through which light passes; The first light-shielding layer is formed of the same material as the second light-shielding layer. The interior member according to claim 1 .

3. The second opening is smaller than the first opening, The interior member according to claim 1 , further comprising a third light-shielding layer provided on a rear surface of the cushion material corresponding to the first opening.

4. A step of preparing an intermediate product including a light-shielding base material having a first opening, a cushioning material disposed on a surface of the base material and having a second opening overlapping the first opening, and a light-transmitting skin material disposed on the surface of the cushioning material and closing the second opening; a step of printing a light-shielding material through the first opening of the intermediate product to form a first light-shielding layer on an end face of the cushion material within the second opening, and forming a second light-shielding layer having a light-transmitting window that transmits light on a back surface of the skin material corresponding to the second opening; A method for manufacturing an interior component comprising the steps of:

5. In the step of preparing the intermediate product, preparing a laminated material including the cushioning material and the skin material disposed on a surface of the cushioning material; The laminated material is fixed to a surface of the base material so as to cover the first opening and so that the cushioning material faces the base material; forming the second opening in the cushion material overlapping the first opening by removing a portion of the cushion material exposed by the first opening; The method for manufacturing an interior component according to claim 4, further comprising:

6. In the step of preparing the intermediate product, The cushion material and the cover material having the second opening formed therein are prepared in advance, The cushioning material is fixed to a surface of the base material such that the second opening overlaps the first opening; fixing the cover material to a surface of the cushion material so as to close the second opening; The method for manufacturing an interior component according to claim 4, further comprising:

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