Method for manufacturing superposed composite component

Abstract

To provide a superposed composite component that can be easily manufactured and a method for manufacturing the superposed composite component.SOLUTION: A superposed composite component is formed by superposing a substrate, a skin material and an intermediate member 13. The intermediate member 13 is formed of a soft resin material and provided between the substrate and the skin material. The intermediate member 13 has: a tabular base part 20; a plurality of first protrusions 30 which are protruded from a first face 31 opposing the substrate in the base part 20; and a plurality of second protrusions 40 which are protruded from a second face 41 opposing the skin material in the base part 20. The first protrusions 30 and the second protrusions 40 are arranged such that base end portions of the first protrusions 30 in the first face 31 do not overlap base end portions of the second protrusions 40 in the second face 41 in a thickness direction of the base part 20.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The present invention relates to a laminated composite part and a method for manufacturing the laminated composite part.

Background Art

[0002] Patent Document 1 discloses a laminated composite part including a base material and a skin material having a plurality of protrusions that protrude toward the base material and are bendable. In this composite part, when the skin material is pushed into the base material, at least a part of the plurality of protrusions comes into contact with the base material and bends and deforms. Therefore, it is possible to present a feeling similar to that of a composite part in which a foaming material such as urethane foam is embedded to the user.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] As a laminated composite part, it is conceivable to adopt one in which an intermediate member having a plate-shaped base portion and a plurality of protrusions provided on both surfaces of the base portion is provided between the base material and the skin material. According to this composite part, the degree of freedom regarding the setting of the above-mentioned feeling is increased. However, in this case, the structure of the intermediate member becomes a complicated shape having a plurality of protrusions on both surfaces. Therefore, when forming the intermediate member using a molding device, problems are likely to occur during the formation of the intermediate member, such as short shots being likely to occur.

Means for Solving the Problems

[0005] The stacked composite part for solving the above problems includes a base material, a skin material covering the base material, and an intermediate member formed of a soft resin material and provided between the base material and the skin material, and is a stacked composite part in which the base material, the intermediate member, and the skin material are stacked. The intermediate member has a plate-shaped base portion, a plurality of first protrusions protruding from a first surface of the base portion facing the base material, and a plurality of second protrusions protruding from a second surface of the base portion facing the skin material. The first protrusions and the second protrusions are arranged such that the base end portions of the first protrusions on the first surface and the base end portions of the second protrusions on the second surface do not overlap in the thickness direction of the base portion.

[0006] The manufacturing method of the stacked composite part for solving the above problems includes a base material, a skin material covering the base material, and an intermediate member formed of a soft resin material and provided between the base material and the skin material. The intermediate member has a plate-shaped base portion, a plurality of first protrusions protruding from a first surface of the base portion facing the base material, and a plurality of second protrusions protruding from a second surface of the base portion facing the skin material. The first protrusions and the second protrusions are arranged such that the base end portions of the first protrusions on the first surface and the base end portions of the second protrusions on the second surface do not overlap in the thickness direction of the base portion, and is a manufacturing method of a stacked composite part in which the base material, the intermediate member, and the skin material are stacked. As the molding device for molding the intermediate member, a first processing roll having a first hole on its outer peripheral surface for molding the first protrusion and a second processing roll having a second hole on its outer peripheral surface for molding the second protrusion are rotationally driven with their outer peripheral surfaces facing each other. With the first processing roll and the second processing roll rotationally driven, the intermediate member is extrusion molded by feeding a molten resin material between the outer peripheral surface of the first processing roll and the outer peripheral surface of the second processing roll.

Brief Description of the Drawings

[0007]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Figure 6

Figure 7

Figure 8

Figure 9

Figure 10

Mode for Carrying Out the Invention

[0008] (First Embodiment) Hereinafter, with reference to FIGS. 1 to 6, a first embodiment of a superimposed composite part and a method for manufacturing the same superimposed composite part will be described.

[0009] As shown in FIG. 2, the laminated composite part (hereinafter, the interior part 10) is, for example, an automobile door trim or the like. The interior part 10 includes a base material 11, a thin sheet-like skin material 12 that covers the base material 11, and an intermediate member 13 provided between the base material 11 and the skin material 12. The interior part 10 is formed by laminating the base material 11, the intermediate member 13, and the skin material 12.

[0010] The base material 11 is formed of a hard resin material such as polypropylene. The skin material 12 is formed of a soft resin material such as soft polyvinyl chloride. The intermediate member 13 is formed of a soft resin material such as soft polyvinyl chloride.

[0011] As shown in FIGS. 2 and 3, the intermediate member 13 has a base portion 20, a plurality of first protrusions 30, and a plurality of second protrusions 40. These base portion 20, the plurality of first protrusions 30, and the plurality of second protrusions 40 are integrally formed.

[0012] The base portion 20 is plate-shaped. The plurality of first protrusions 30 protrude from a first surface 31 of the base portion 20 that faces the base material 11. The plurality of second protrusions 40 protrude from a second surface 41 of the base portion 20 that faces the skin material 12. Note that the base portion 20 has a certain thickness. In the base portion 20, the first surface 31 and the second surface 41 are parallel to each other.

[0013] As shown in FIG. 2, in a state where no external force is acting on the skin material 12, the tip of each first protrusion 30 is in contact with the base material 11. Also, in the above state, the tip of each second protrusion 40 is in contact with the skin material 12.

[0014] As shown in FIGS. 2 and 3, the second protrusion 40 is a quadrangular pyramid, and all corners are rounded. Although not shown, the first protrusion 30 is also a quadrangular pyramid similar to the second protrusion 40, and all corners are rounded. In the present embodiment, the first protrusion 30 and the second protrusion 40 have the same shape.

[0015] The protruding directions of the first protrusion 30 and the second protrusion 40 are inclined with respect to the base portion 20. That is, the protruding direction of the first protrusion 30 is inclined by a predetermined angle α with respect to the normal line L1 of the first surface 31. Further, the protruding direction of the second protrusion 40 is inclined by a predetermined angle α with respect to the normal line L2 of the second surface 41 of the base portion 20.

[0016] <Arrangement mode of the first protrusion 30> Next, the arrangement mode of the first protrusion 30 on the first surface 31 of the base portion 20 will be described. As shown in FIG. 4, in the present embodiment, a virtual line (hereinafter, the first virtual lattice 32) forming a polygonal lattice is set on the first surface 31 of the base portion 20. In the present embodiment, as the polygonal lattice of the first virtual lattice 32, a regular hexagonal lattice composed of a plurality of regular hexagons (hereinafter, the first hexagon 33) is adopted.

[0017] The first protrusion 30 is provided at a position corresponding to the side (hereinafter, the first side 34) of the first hexagon 33. Specifically, for one first hexagon 33, a total of six first protrusions 30 are provided, one for each of the six first sides 34. Each first protrusion 30 is provided such that the base end portion on the first surface 31 is located on the first side 34 of the first hexagon 33.

[0018] The first protrusions 30 provided on two opposing first sides 34 in the same first hexagon 33 protrude in a state of being inclined in the same direction. Further, the first protrusions 30 provided on adjacent first sides 34 protrude in a state of being inclined in different directions from each other.

[0019] <Arrangement mode of the second protrusion 40> Next, the arrangement mode of the second protrusion 40 on the second surface 41 of the base portion 20 will be described. The arrangement pattern of the second protrusion 40 on the second surface 41 of the base portion 20 is the same as the arrangement pattern of the first protrusion 30 on the first surface 31 described above.

[0020] Specifically, a virtual line forming a polygonal lattice (hereinafter referred to as the second virtual lattice 42) is set on the second surface 41 of the base portion 20. In the present embodiment, as the polygonal lattice of the second virtual lattice 42, a regular hexagonal lattice composed of a plurality of regular hexagons (hereinafter referred to as the second hexagons 43) is adopted.

[0021] The second protrusion 40 is provided at a position corresponding to the side of the second hexagon 43 (hereinafter referred to as the second side 44). Specifically, for one second hexagon 43, a total of six second protrusions 40 are provided, one on each of the six second sides 44. Each second protrusion 40 is provided such that the base end portion on the second surface 41 is located on the second side 44 of the second hexagon 43.

[0022] The second protrusions 40 provided on two opposing second sides 44 in the same second hexagon 43 protrude in a state of being inclined in the same direction. Also, the second protrusions 40 provided on adjacent second sides 44 protrude in a state of being inclined in different directions from each other.

[0023] <Position relationship between the first virtual lattice 32 and the second virtual lattice 42> In the present embodiment, the first virtual lattice 32 and the second virtual lattice 42 are set in such a manner that the first side 34 of the first hexagon 33 in the first virtual lattice 32 and the second side 44 of the second hexagon 43 in the second virtual lattice 42 are displaced in the extending direction of the intermediate member 13. Specifically, the first virtual lattice 32 and the second virtual lattice 42 are set such that the size of the first hexagon 33 having a regular hexagonal shape is the same as the size of the second hexagon 43 having a regular hexagonal shape. Also, the first virtual lattice 32 and the second virtual lattice 42 are set such that the center of the first hexagon 33 and the corner of the second hexagon 43 overlap in the thickness direction H (the direction orthogonal to the paper surface of FIG. 4) of the base portion 20. And while the first protrusion 30 is provided at a position corresponding to the first side 34 of the first virtual lattice 32, the second protrusion 40 is provided at a position corresponding to the second side 44 of the second virtual lattice 42.

[0024] As a result, the first protrusion 30 and the second protrusion 40 are arranged such that the base end portion of the first protrusion 30 on the first surface 31 and the base end portion of the second protrusion 40 on the second surface 41 do not overlap in the thickness direction H.

[0025] In the present embodiment, when viewed from the thickness direction H, the base end portions of three second protrusions 40 are arranged inside the first hexagon 33. These base end portions of the three second protrusions 40 are provided corresponding to the positions of the vertices of an equilateral triangle. And these three second protrusions 40 protrude in a state of being inclined in different directions from each other.

[0026] Also, when viewed from the thickness direction H, the base end portions of three first protrusions 30 are arranged inside the second hexagon 43. These base end portions of the three first protrusions 30 are provided corresponding to the positions of the vertices of an equilateral triangle. And these three first protrusions 30 protrude in a state of being inclined in different directions from each other.

[0027] <Molding device 50> Next, the molding device 50 used for forming the intermediate member 13 will be described. As shown in FIG. 5, the molding device 50 includes a first processing roll 51, a second processing roll 52, and a supply unit 53.

[0028] Each of the processing rolls 51, 52 has a cylindrical shape. A plurality of first holes 511 for forming the first protrusions 30 are provided on the outer peripheral surface of the first processing roll 51. Also, a plurality of second holes 521 for forming the second protrusions 40 are provided on the outer peripheral surface of the second processing roll 52. The outer peripheral surfaces of the processing rolls 51, 52 are arranged to face each other. The processing rolls 51, 52 are rotationally driven in opposite directions about their respective central axes as rotation centers. The supply unit 53 feeds a molten resin material between the outer peripheral surface of the first processing roll 51 and the outer peripheral surface of the second processing roll 52.

[0029] When the intermediate member 13 is formed by the forming device 50, while the processing rolls 51 and 52 are rotationally driven, a molten resin material is fed from the supply unit 53 between the processing rolls 51 and 52. Thereby, the intermediate member 13 having the first protrusion 30 and the second protrusion 40 is extrusion-molded.

[0030] <Function and effect> According to the present embodiment, the following functions and effects can be obtained. (1-1) The interior component 10 includes a base material 11, a skin material 12 covering the base material 11, and an intermediate member 13 formed of a soft resin material and provided between the base material 11 and the skin material 12. The interior component 10 is formed by overlapping the base material 11, the intermediate member 13, and the skin material 12. The intermediate member 13 has a plate-shaped base portion 20, a plurality of first protrusions 30 protruding from the first surface 31 of the base portion 20 facing the base material 11, and a plurality of second protrusions 40 protruding from the second surface 41 of the base portion 20 facing the skin material 12. The first protrusions 30 and the second protrusions 40 are arranged such that the base end portions of the first protrusions 30 on the first surface 31 and the base end portions of the second protrusions 40 on the second surface 41 do not overlap in the thickness direction H of the base portion 20.

[0031] As shown in FIG. 6, when the intermediate member 13 is formed by the forming device 50, between the first processing roll 51 and the second processing roll 52, two branched flows of the molten resin material (indicated by arrows F1 and F2 in FIG. 6) occur. One of the two flows (hereinafter, the first flow F1) is a flow of the molten resin material that branches from the portion forming the base portion 20 and heads toward the portion forming the first protrusion 30, that is, the first hole 511 of the first processing roll 51. The other of the two flows (hereinafter, the second flow F2) is a flow of the molten resin material that branches from the portion forming the base portion 20 and heads toward the portion forming the second protrusion 40, that is, the second hole 521 of the second processing roll 52.

[0032] According to this embodiment, when the intermediate member 13 is molded by the molding device 50, between the first processing roll 51 and the second processing roll 52, the first flow F1 directed toward the first hole 511 and the second flow F2 directed toward the second hole 521 branch at different positions. Thereby, the structure of the molding device 50 can be made into a structure that is less likely to cause a pressure drop of the molten resin material at the branching portion of the flow of the molten resin material as compared with the molding device of the comparative example in which the two flows F1 and F2 branch at the same position. Therefore, when the intermediate member 13 is molded using the molding device 50, the intermediate member 13 having the first protrusion 30 and the second protrusion 40 can be easily molded while suppressing the occurrence of short shots. Thereby, the interior component 10 formed by overlapping such an intermediate member 13, the base material 11, and the skin material 12 can be easily formed.

[0033] (1-2) When a virtual line that is set on the first surface 31 and forms a regular hexagonal lattice is defined as the first virtual lattice 32, and a virtual line that is set on the second surface 41 and forms a regular hexagonal lattice is defined as the second virtual lattice 42. The first virtual lattice 32 and the second virtual lattice 42 are set in a manner such that the first side 34 of the first hexagon 33 that constitutes the regular hexagonal lattice of the first virtual lattice 32 and the second side 44 of the second hexagon 43 that constitutes the regular hexagonal lattice of the second virtual lattice 42 are displaced in the extending direction of the intermediate member 13. The first protrusion 30 is provided at a position corresponding to the first side 34 of the first hexagon 33. The second protrusion 40 is provided at a position corresponding to the second side 44 of the second hexagon 43.

[0034] According to such a configuration, based on the first virtual lattice 32 set on the first surface 31 of the base portion 20, the first protrusion 30 can be arranged on the first surface 31 in a well-balanced manner. Also, based on the second virtual lattice 42 set on the second surface 41 of the base portion 20, the second protrusion 40 can be arranged on the second surface 41 in a well-balanced manner.

[0035] Moreover, in the above configuration, the first virtual lattice 32 and the second virtual lattice 42 are displaced in the extending direction of the base portion 20. As a result, the first protrusion 30 and the second protrusion 40 are arranged such that the base end portion of the first protrusion 30 on the first surface 31 and the base end portion of the second protrusion 40 on the second surface 41 do not overlap in the thickness direction H. According to the above configuration, since the first protrusion 30 and the second protrusion 40 are arranged in this way, the first protrusion 30 and the second protrusion 40 can be arranged in a well-balanced manner with respect to the entire base portion 20 having the first surface 31 and the second surface 41. Therefore, variations in each part of the interior component 10 regarding the feeling when the skin material 12 is pushed toward the base material 11 can be suppressed.

[0036] (1-3) The first virtual lattice 32 and the second virtual lattice 42 are virtual lines each forming a regular hexagonal lattice. The size of the first hexagon 33 in the first virtual lattice 32 is the same as the size of the second hexagon 43 in the second virtual lattice 42. The first virtual lattice 32 and the second virtual lattice 42 are set such that the center of the first hexagon 33 and the corner of the second hexagon 43 overlap in the thickness direction H.

[0037] According to such a configuration, since a regular hexagonal lattice is adopted as the polygonal lattice of the first virtual lattice 32, the first polygon (in this embodiment, the first hexagon 33) constituting the polygonal lattice can be arranged more efficiently compared to the case where a regular triangular lattice or a square lattice is adopted. Therefore, based on the regular hexagonal lattice of the first virtual lattice 32, the first protrusion 30 can be arranged efficiently on the first surface 31.

[0038] Also, since a regular hexagonal lattice is adopted as the polygonal lattice of the second virtual lattice 42, the second polygon (in this embodiment, the second hexagon 43) constituting the polygonal lattice can be arranged more efficiently compared to the case where a regular triangular lattice or a square lattice is adopted. Therefore, based on the regular hexagonal lattice of the second virtual lattice 42, the second protrusion 40 can be arranged efficiently on the second surface 41.

[0039] Moreover, in the above configuration, the first virtual lattice 32 and the second virtual lattice 42 are set such that the center of the first hexagon 33 and the corner of the second hexagon 43 overlap in the thickness direction H. As a result, as is clear from FIG. 1, the first virtual lattice 32 and the second virtual lattice 42 are set at positions where they are maximally displaced without any bias in the displacement direction. Therefore, according to the above configuration, the first protrusion 30 and the second protrusion 40 can be arranged in a well-balanced manner with respect to the entire base portion 20 having the first surface 31 and the second surface 41 while suppressing bias. Thereby, the feeling when pushing the skin material 12 toward the base material 11 can be made equivalent in each part of the interior component 10.

[0040] (Second Embodiment) Hereinafter, with reference to FIG. 7, differences between the second embodiment and the first embodiment will be mainly described. For the same or corresponding configurations as those in the first embodiment, the same reference numerals will be given and redundant descriptions will be omitted.

[0041] <Virtual Lattice> In the first embodiment, two virtual lattices (the first virtual lattice 32 and the second virtual lattice 42) are set, whereas in this embodiment, only one virtual lattice is set.

[0042] As shown in FIG. 7, the virtual lattice 60 of this embodiment is a virtual line that extends in the extending direction of the base portion 20 and forms a regular hexagonal lattice. In this embodiment, based on this virtual lattice 60, the first protrusion 30 is arranged on the first surface 31 of the base portion 20, and the second protrusion 40 is arranged on the second surface 41 of the base portion 20.

[0043] <Arrangement Modes of the First Protrusion 30 and the Second Protrusion 40> The first protrusion 30 and the second protrusion 40 are arranged so as to sandwich the side 64 of the hexagon 63 that constitutes the regular hexagonal lattice of the virtual lattice 60 between the base end portion of the first protrusion 30 on the first surface 31 and the base end portion of the second protrusion 40 on the second surface 41 when viewed from the thickness direction H. Specifically, one first protrusion 30 and one second protrusion 40 are provided so as to be paired with the side 64 of the hexagon 63 interposed therebetween.

[0044] Also, the first protrusion 30 and the second protrusion 40 are provided at positions along the side 64 of the hexagon 63. Inside the hexagon 63, the first protrusion 30 is provided on one of the adjacent sides 64 and the second protrusion 40 is provided on the other, such that the first protrusion 30 and the second protrusion 40 are arranged alternately on the adjacent sides 64.

[0045] In the present embodiment, the first protrusion 30 and the second protrusion 40 are arranged such that the base end portion of the first protrusion 30 on the first surface 31 and the base end portion of the second protrusion 40 on the second surface 41 do not overlap in the thickness direction H.

[0046] The base end portions of the three first protrusions 30 arranged inside the same hexagon 63 are provided corresponding to the positions of the vertices of an equilateral triangle. These three first protrusions 30 protrude in a state of being inclined in different directions. Also, the base end portions of the three second protrusions 40 arranged inside the same hexagon 63 are provided corresponding to the positions of the vertices of an equilateral triangle. These three second protrusions 40 protrude in a state of being inclined in different directions.

[0047] <Function and Effect> According to the present embodiment, in addition to the function and effect described in the previous (1-1), the function and effect described in the following (2-1) can be obtained.

[0048] (2-1) A virtual line extending in the extending direction of the base portion 20 and forming a regular hexagonal lattice is defined as a virtual lattice 60. The first protrusion 30 and the second protrusion 40 are arranged so as to sandwich the side 64 of the hexagon 63 that constitutes the virtual lattice 60 between the base end portion of the first protrusion 30 on the first surface 31 and the base end portion of the second protrusion 40 on the second surface 41 when viewed from the thickness direction H of the base portion 20.

[0049] According to such a configuration, based on the common virtual lattice 60 of the first surface 31 and the second surface 41, the first protrusions 30 can be arranged on the first surface 31 and the second protrusions 40 can be arranged on the second surface 41 in the same arrangement pattern in a well-balanced manner.

[0050] Moreover, in the above configuration, the first protrusion 30 and the second protrusion 40 are arranged such that the base end portion of the first protrusion 30 on the first surface 31 and the base end portion of the second protrusion 40 on the second surface 41 do not overlap in the thickness direction H. Therefore, the first protrusion 30 and the second protrusion 40 can be arranged in a well-balanced manner with respect to the entire base portion 20 having the first surface 31 and the second surface 41. Accordingly, variations in each part of the interior component 10 regarding the feeling when the skin material 12 is pushed into the base material 11 can be suppressed.

[0051] (Modification example) Note that each of the above embodiments can be modified and implemented as follows. Each of the above embodiments and the following modification examples can be implemented in combination with each other within a technically non - conflicting range.

[0052] · In the first embodiment, the first virtual lattice 32 and the second virtual lattice 42 can be set such that the center of the first hexagon 33 and the corner of the second hexagon 43 do not overlap in the thickness direction H. In this case, the first virtual lattice 32 and the second virtual lattice 42 may be set such that at least a part of the first side 34 of the first hexagon 33 and at least a part of the second side 44 of the second hexagon 43 do not overlap in the thickness direction H.

[0053] · In the first embodiment, as the polygonal lattice of the first virtual lattice 32 and the second virtual lattice 42, in addition to adopting a regular hexagonal lattice, a square lattice or a regular triangular lattice can be adopted.

[0054] When the first virtual lattice 32 and the second virtual lattice 42 are square lattices, for example, the intermediate member 13 can be configured as follows. As shown in FIG. 8, on the first surface 31 of the base portion 20, a virtual line forming a square lattice (hereinafter, the first virtual lattice 32) is set. Further, on the second surface 41 of the base portion 20, a virtual line forming a square lattice (hereinafter, the second virtual lattice 42) is set. In this example, when viewed from the thickness direction H, the second squares forming the square lattice of the second virtual lattice 42 are in a state rotated by 45 degrees with respect to the first squares forming the square lattice of the first virtual lattice 32. Also, if a square formed by four first squares is defined as a "large square", the four corners of the second square are in contact with the four sides of the "large square". And the first protrusion 30 is provided at a position corresponding to the side of the first square. Also, the second protrusion 40 is provided at a position corresponding to the side of the second square.

[0055] When the first virtual lattice 32 and the second virtual lattice 42 are equilateral triangular lattices, the intermediate member 13 can be configured as follows, for example. As shown in FIG. 9, on the first surface 31 of the base portion 20, a virtual line forming an equilateral triangular lattice (hereinafter, the first virtual lattice 32) is set. Further, on the second surface 41 of the base portion 20, a virtual line forming a triangular lattice (hereinafter, the second virtual lattice 42) is set.

[0056] In this example, the first virtual lattice 32 and the second virtual lattice 42 are set such that the first triangles forming the equilateral triangular lattice of the first virtual lattice 32 and the second triangles forming the equilateral triangular lattice of the second virtual lattice 42 have the following relationship. That is, the first virtual lattice 32 and the second virtual lattice 42 are set such that an equilateral triangle formed by four second triangles becomes the first triangle. And the first protrusion 30 is provided at a position corresponding to the side of the first triangle. Also, the second protrusion 40 is provided at a position corresponding to the side of the second triangle.

[0057] ·In the second embodiment, as the polygonal lattice of the virtual lattice 60, in addition to adopting an equilateral hexagonal lattice, a square lattice or an equilateral triangular lattice can be adopted. When the virtual lattice 60 is a square lattice, the intermediate member 13 can be configured as follows, for example.

[0058] In the example shown in FIG. 10, a virtual line (hereinafter referred to as virtual lattice 60) that extends in the extending direction of the base portion 20 and forms a square lattice is set. When viewed from the thickness direction H, the first protrusion 30 and the second protrusion 40 are arranged so as to sandwich the side of the square that constitutes the above square lattice between the proximal end portion of the first protrusion 30 and the proximal end portion of the second protrusion 40. Specifically, one first protrusion 30 and one second protrusion 40 are provided so as to form a pair with the side of the square therebetween.

[0059] When the virtual lattice 60 is a regular triangular lattice, for example, the intermediate member 13 can be configured as follows. That is, a virtual line (hereinafter referred to as virtual lattice 60) that extends in the extending direction of the base portion 20 and forms a square lattice is set in the intermediate member 13. Then, when viewed from the thickness direction H, the first protrusion 30 and the second protrusion 40 are arranged so as to sandwich the side of the equilateral triangle that constitutes the above regular triangular lattice between the proximal end portion of the first protrusion 30 on the first surface 31 and the proximal end portion of the second protrusion 40 on the second surface 41. Specifically, one first protrusion 30 and one second protrusion 40 are provided so as to form a pair with the side of the equilateral triangle therebetween.

[0060] · In each embodiment, as the molding device 50 used for molding the intermediate member 13, any molding device can be adopted, such as adopting an injection molding machine. Also in this case, similar to the above embodiments, when molding the intermediate member 13 using the molding device, the intermediate member 13 having the first protrusion 30 and the second protrusion 40 can be easily molded while suppressing the occurrence of short shots.

[0061] · In each embodiment, the virtual lattices 32, 42, 60 are not limited to regular polygon lattices constituted by regular polygons, and can be polygon lattices constituted by polygons with different angles at each corner.

[0062] · The material of the skin material 12 can also be changed to a soft resin material other than soft polyvinyl chloride such as an elastomer (shore hardness of about 30D to 40D), or a woven fabric. ·The material of the intermediate member 13 can also be changed to a soft resin material other than soft polyvinyl chloride such as a polyester-based elastomer.

[0063] ·The shapes and sizes of the first protrusion 30 and the second protrusion 40 can be appropriately changed. For example, the shape of the first protrusion 30 and the shape of the second protrusion 40 can be made different from each other, or the size of the first protrusion 30 and the size of the second protrusion 40 can be made different from each other.

[0064] ·The intermediate member 13 is not limited to being integrally formed as a whole. For example, the intermediate member 13 can be divided into a portion on the first protrusion 30 side in the base portion 20 and a first divided portion constituted by the first protrusion 30, and a portion on the second protrusion 40 side in the base portion 20 and a second divided portion constituted by the second protrusion 40.

[0065] ·The inclination angle of the protruding direction of the first protrusion 30 with respect to the normal line L1 and the inclination angle of the protruding direction of the second protrusion 40 with respect to the normal line L2 can be made different from each other. ·The first protrusion 30 and the second protrusion 40 are not limited to being inclined with respect to the normal lines L1 and L2. For example, the protruding directions of both the first protrusion 30 and the second protrusion 40 may be orthogonal to the base portion 20. Alternatively, either the first protrusion 30 or the second protrusion 40 may be orthogonal to the base portion 20.

[0066] ·In each of the above embodiments, the configuration in which the tip of each first protrusion 30 contacts the base material 11 and the tip of each second protrusion 40 contacts the skin material 12 has been described. The configuration is not limited to this, and a configuration in which some or all of the tips of the plurality of first protrusions 30 do not contact the base material 11, or a configuration in which some or all of the tips of the plurality of second protrusions 40 do not contact the skin material 12 may also be acceptable.

[0067] · The lamination composite part and the method for manufacturing the lamination composite part according to each of the above embodiments are not limited to being applied to the interior part 10 constituting the door trim, and can also be applied to other interior parts such as the instrument panel and glove box of the vehicle. Further, not limited to being applied to the interior parts of the vehicle, the lamination composite part and the method for manufacturing the lamination composite part according to each of the above embodiments are applicable to panel parts other than those for vehicles as well.

Explanation of Reference Numerals

[0068] 10… Interior part 11… Base material 12… Skin material 13… Intermediate member 20… Base part 30… First protrusion 31… First surface 32… First virtual grid 33… First hexagon 34… First side 40… Second protrusion 41… Second surface 42… Second virtual grid 43… Second hexagon 44… Second side 50… Molding device 51… First processing roll 511… First hole 52… Second processing roll 521… Second hole 53… Feeding part 60… Virtual grid 63… Hexagon 64… Side

Claims

1. A laminated composite part comprising a base material, a skin material covering the base material, and an intermediate member made of a soft resin material and provided between the base material and the skin material, the base material, the intermediate member, and the skin material being laminated together, the intermediate member has a plate-shaped base portion, a plurality of first projections protruding from a first surface of the base portion facing the substrate, and a plurality of second projections protruding from a second surface of the base portion facing the skin material, the first protrusion and the second protrusion are arranged such that a base end portion of the first protrusion on the first surface and a base end portion of the second protrusion on the second surface do not overlap with each other in a thickness direction of the base portion. Superimposed composite parts.

2. When a virtual line that is set on the first surface and forms a polygonal lattice is defined as a first virtual lattice, and a virtual line that is set on the second surface and forms a polygonal lattice is defined as a second virtual lattice, the first virtual lattice and the second virtual lattice are set in such a manner that at least a part of a side of a first polygon constituting a polygonal lattice of the first virtual lattice and at least a part of a side of a second polygon constituting a polygonal lattice of the second virtual lattice are shifted in an extending direction of the intermediate member, The first protrusion is provided at a position corresponding to a side of the first polygon, The second protrusion is provided at a position corresponding to a side of the second polygon. The laminated composite part according to claim 1 .

3. the first virtual lattice and the second virtual lattice are virtual lines each forming a regular hexagonal lattice, and are set so that a size of the first polygon forming a regular hexagon is the same as a size of the second polygon forming a regular hexagon, and a center of the first polygon and a corner of the second polygon overlap in the thickness direction. The laminated composite part according to claim 2 .

4. When imaginary lines extending in the extending direction of the base portion and forming a polygonal lattice are defined as a virtual lattice, the first protrusion and the second protrusion are disposed such that, when viewed from the thickness direction, a side of a polygon constituting the virtual lattice is sandwiched between a base end portion of the first protrusion and a base end portion of the second protrusion. The laminated composite part according to claim 1 .

5. a base material, a skin material covering the base material, and an intermediate member made of a soft resin material and provided between the base material and the skin material; the intermediate member has a plate-shaped base portion, a plurality of first projections protruding from a first surface of the base portion facing the substrate, and a plurality of second projections protruding from a second surface of the base portion facing the skin material, the first projection and the second projection are arranged such that a base end portion of the first projection on the first surface and a base end portion of the second projection on the second surface do not overlap with each other in a thickness direction of the base portion, A method for producing a laminated composite part formed by laminating the base material, the intermediate member, and the skin material, comprising the steps of: As a molding device for molding the intermediate part, a first processing roll having a first hole on an outer circumferential surface for molding the first protrusion and a second processing roll having a second hole on an outer circumferential surface for molding the second protrusion are used, the first processing roll being rotated while the outer circumferential surfaces are disposed opposite to each other, The intermediate member is extruded by feeding a molten resin material between the outer circumferential surface of the first processing roll and the outer circumferential surface of the second processing roll while rotating the first processing roll and the second processing roll. A method for manufacturing overlapping composite parts.

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