Vehicle interior material and method for manufacturing vehicle interior material

Abstract

To provide a vehicle interior material which is easy to perform a terminal treatment of a skin, the terminal treatment structure of which does not affect a design surface, and which is hardly deformed by impact shock, and to provide a method for manufacturing a vehicle interior material.SOLUTION: A vehicle interior material 10 is configured such that a vehicle cabin inside surface of a substrate 21 is coated with a skin 41. The substrate 21 is so formed that a body part 22 and a terminal part 31 located at its end part are continued via a thin wall part 28 whose plate thickness is thin. A to-be-engaged part 23 rising up from the outer surface of the vehicle cabin of the body part 22 is formed at a position adjacent to the thin wall part 28 of the body part 22. The terminal part 31 rises in a state of being perpendicular to the body part 22 or expanding to the outside of the vehicle chamber so that an angle rising from the body part 22 becomes 90 degrees or smaller with the thin wall part 28 as an original point. The rising up state is maintained by locking a locking part 32 rising from the outer surface of the vehicle chamber of the terminal part 31 to the to-be-engaged part 23.SELECTED DRAWING: Figure 2

Description

[Technical Field]

[0001] The technology disclosed in this specification relates to a vehicle interior material and a method for manufacturing a vehicle interior material. [Background technology]

[0002] Conventionally, configurations have been proposed for vehicle interior components that can reduce the labor required to process the peripheral edge of the skin. For example, Patent Document 1 (Patent Document 1) describes a vehicle interior component having a core material including a core material main body and a roll-up portion rotatably attached to the periphery of the core material main body via a hinge portion and to which the peripheral edge of the decorative skin is attached. The core material is rolled up to the back side of the core material by folding the roll-up portion back onto the core material main body so that the decorative skin faces outward. The roll-up portion has a bent tip, and when the roll-up portion is folded back onto the core material main body, the bent portion of the tip fits into a through-hole provided in the core material main body. Furthermore, a claw portion extending from the exterior surface of the core material main body engages with the outer surface of the tip of the roll-up portion, thereby maintaining the folded state of the roll-up portion. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Laid-Open No. 2013-91441 Summary of the Invention [Problem to be solved by the invention]

[0004] However, in the conventional configuration described above, variations in the dimensions of the base material and other factors could cause the tip of the bent portion to come into contact with the back surface of the skin, affecting the design. Also, because the folded state of the wrap-around portion is maintained (the engagement between the tab and the tip of the wrap-around portion) in the interior / exterior direction, there is a risk that the engagement may easily be released if an impact is applied in the interior / exterior direction due to a side collision or the like.

[0005] Furthermore, in the conventional configuration described above, after the decorative skin is attached to the core material, it is necessary to manually fold back the wrap-around portion and engage the claw portions, and further improvements in workability have been desired.

[0006] The technology disclosed in this specification was developed based on the above circumstances, and aims to provide a vehicle interior material and a method for manufacturing a vehicle interior material that allows for easy edge treatment of the skin, does not affect the design of the surface, and is resistant to deformation due to impact. [Means for solving the problem]

[0007] The technology disclosed in this specification, which was completed to solve the above-mentioned problems, is a vehicle interior material in which the interior surface of a plate-shaped base material is covered with a skin, the base material comprising a main body portion which is the main body of the base material and a terminal portion located at an end thereof, which are connected via a thin-walled portion whose plate thickness is thinner than that of the main body portion and the terminal portion, and a locking portion which rises from the exterior surface of the vehicle cabin of the main body portion at a position adjacent to the thin-walled portion, the terminal portion rises from the thin-walled portion as a starting point, perpendicular to the main body portion or in a state where it spreads out toward the exterior of the vehicle cabin so that the rise angle from the main body portion is 90 degrees or less, and this raised state is maintained by a locking portion which rises from the exterior surface of the terminal portion and locks with the locking portion.

[0008] According to the above-mentioned configuration, the locking portion and the locked portion are locked at a position separated from the exterior surface of the vehicle cabin, thereby preventing the locking structure from affecting the design. Furthermore, since the locking portion and the locked portion are locked in a direction intersecting the interior / exterior direction of the vehicle, the locked state is not easily released when an impact is applied in the interior / exterior direction due to a side collision or the like. In other words, the structure is not easily deformed.

[0009] Furthermore, since the thin-walled portions of the terminal portions are configured to rise perpendicular to the main body portion or to extend outward from the vehicle cabin so that the rise angle from the main body portion is 90 degrees or less, by placing the skin on the interior side of the flat, plate-like base material and pressing it in a forming die, it is possible to attach the skin to the base material, raise (bend) the main body portion starting from the thin-walled portions of the terminal portions, and lock the locking portion to the locked portion all at once. In other words, workability is greatly improved compared to conventional manufacturing methods in which the folding process cannot be performed by press molding and these processes must be performed separately.

[0010] The engaging portion may be a hole portion provided on a main body side protrusion that protrudes from the main body portion and penetrates in a direction intersecting the interior / exterior direction of the vehicle, and the engaging portion may be a claw portion provided at the tip of the terminal side protrusion that protrudes from the terminal portion, and the claw portion may be engaged with the hole edge portion of the hole portion.

[0011] The technology disclosed in this specification is a method for manufacturing the vehicle interior material described above, in which the skin is placed on the interior side of the flat, plate-like base material and pressed with a molding die, thereby simultaneously attaching the skin to the base material, raising the thin-walled portion of the terminal portion from the main body portion, and locking the locking portion to the locked portion. [Effects of the Invention]

[0012] The technology disclosed in this specification makes it possible to provide a vehicle interior material and a method for manufacturing a vehicle interior material, in which the edge treatment of the skin is easy, the edge treatment structure does not affect the design, and the material is not easily deformed by impact. [Brief explanation of the drawings]

[0013] [Figure 1] FIG. 1 is a perspective view of a door trim according to an embodiment, viewed from the inside of a vehicle interior; [Figure 2] Cross-sectional view of ornament board corresponding to section II in Figure 1 [Figure 3]Cross-sectional view of the substrate and skin positioned between the mold [Figure 4] An explanatory diagram (cross-sectional view) explaining the process of pressing the substrate and skin with a molding die. [Figure 5] An explanatory diagram (cross-sectional view) explaining the process of pressing the substrate and skin with a molding die. [Figure 6] An explanatory diagram (perspective view) of the surface layer superimposed on a flat substrate [Figure 7] FIG. 10 is a partially enlarged cross-sectional view showing an integral hinge portion of another embodiment. [Figure 8] 10 is a cross-sectional view of an ornament board according to another embodiment of the present invention; DETAILED DESCRIPTION OF THE INVENTION

[0014] A door trim 10, which is an interior material for a vehicle according to one embodiment, will be described with reference to Figures 1 to 6. The symbols FR, RR, UP, DW, IN, and OUT shown in the figures respectively indicate the front and rear in the longitudinal direction of a vehicle as an example of a vehicle, the upper and lower in the vertical direction, and the interior and exterior sides in the interior-exterior direction of the vehicle. However, these directions are merely defined for convenience and should not be interpreted in a restrictive manner.

[0015] 1 is a perspective view of a door trim 10 as seen from inside the vehicle cabin. The door trim 10 is mainly composed of a generally plate-shaped trim board 11, and is fastened to the interior side of a door inner panel (not shown) by fastening members such as clips (not shown), thereby improving the design and livability of the vehicle cabin. The trim board 11 is made of, for example, a synthetic resin (thermoplastic resin) such as polypropylene, or a composite material such as a mixture of plant fiber (for example, kenaf) and synthetic resin.

[0016] The trim board 11 is formed by assembling a plurality of board members together. The trim board 11 of this embodiment roughly includes an upper board 12, an ornament board 20, an armrest board 13, a lower board 14, and the like. Of these, the ornament board 20 has a longitudinal shape extending in the longitudinal direction of the vehicle and constitutes a part of the upper portion of the trim board 11. The surface (surface) of the ornament board 20 facing the interior of the vehicle is covered with a skin 41 made of natural leather, synthetic leather, fabric, or the like. In addition, the ornament board 20 has a surface that bulges slightly toward the interior of the vehicle compared to the surface of the upper board 12 that is disposed so as to surround the sides and bottom of the ornament board 20.

[0017] 2 is a cross-sectional view of the ornament board 20 alone before assembly, corresponding to cross section II in FIG. 1. As shown in the figure, the ornament board 20 has a shape in which its end is bent toward the outside of the vehicle cabin. In detail, the base material 21 constituting the ornament board 20 has a main body portion 22 that forms the main body and a terminal portion 31 that forms the end, which are connected via an integral hinge portion 28 (an example of a thin portion) that has a relatively thin plate thickness, and the terminal portion 31 is bent at the integral hinge portion 28 so that it rises perpendicularly from the main body portion 22 toward the outside of the vehicle cabin. Note that a skin 41 entirely covers one surface side of the base material 21 (the surface side disposed inside the vehicle cabin).

[0018] A locking portion 23 is provided on the main body portion 22 of the base material 21 at a position adjacent to the integral hinge portion 28, and rises from the outer surface of the vehicle cabin. The locking portion 23 is configured by providing a rectangular locking hole (an example of a hole) 25 penetrating the plate surface of a standing wall (an example of a main body portion-side protrusion) 24 extending along the extension direction of the integral hinge portion 28 (a direction perpendicular to the paper surface of FIG. 2) (see FIG. 6). The inner circumferential surface of the locking hole 25, which faces away from the main body portion 22, forms a guide surface 26 that slopes away from the main body portion 22 as it approaches the terminal portion 31 (see FIG. 2). In addition, a reinforcing rib 27 for supporting the standing state of the standing wall 24 is provided on the surface of the standing wall 24 facing away from the terminal portion 31, so as to bridge the surface between the main body portion 22 and the wall.

[0019] Meanwhile, in the state where the terminal portion 31 is bent so as to rise perpendicularly to the main body portion 22 (the state in FIG. 2 ), a locking portion 32 is provided in a position facing the above-mentioned locking hole 25. The locking portion 32 has a protruding piece (an example of a terminal-side protrusion) 33 that rises from the outer surface of the vehicle interior of the terminal portion 31, and a claw portion 34 provided at the tip of the protruding piece 33. The protruding piece 33 extends parallel to the main body portion 22 in the state where the terminal portion 31 is bent so as to rise perpendicularly to the main body portion 22, and the claw portion 34 protrudes from the tip of the protruding piece 33 toward the outside of the vehicle interior (the opposite side of the main body portion 22, downward in FIG. 2 ) and is locked to the hole edge of the locking hole 25 in the fore-and-aft direction of the vehicle (a direction intersecting the vehicle interior-exterior direction).

[0020] In addition, when the terminal portion 31 is bent so as to stand perpendicular to the main body portion 22 (as shown in Figure 2), the boundary between the main body portion 22 and the terminal portion 31 has a shape in which the right-angled corner formed between the main body portion 22 and the terminal portion 31 is cut out diagonally, i.e., an inclined surface 29 that is inclined diagonally in the direction of expanding toward the main body portion 22.

[0021] Next, a method for manufacturing the ornament board 20 will be described. First, a flat base material 21 having a predetermined shape is prepared. Specifically, as shown in FIG. 3, a base material 21 is prepared in which a main body portion 22 and a terminal portion 31 are connected in a flat state via an integral hinge portion 28 formed by providing a V-groove on one surface side (the upper surface in FIG. 3), and the above-mentioned locked portion 23 is provided upright on the other surface side (the lower surface in FIG. 3) of the main body portion 22, and the above-mentioned locking portion 32 is provided upright on the other surface side of the terminal portion 31. In this embodiment, the angle of the V-groove provided in the base material 21 in a flat state is set to 45 degrees with respect to the plate surfaces of the main body portion 22 and the terminal portion 31.

[0022] Next, an adhesive layer 42 is formed on one surface (the surface on which the V-groove is provided) of the substrate 21. The adhesive layer 42 may be formed by applying or spraying a liquid adhesive, or by applying a solid adhesive such as a film or tape.

[0023] Next, the substrate 21 with the adhesive layer 42 facing upward and the skin 41 arranged above the substrate 21 so as to face the adhesive layer 42 are set between a pair of molding dies 50 (upper die 51 and lower die 55) of a predetermined shape (see Figure 3), and the upper die 51 and lower die 55 of the molding die 50 are closed.

[0024] 3, the lower die 55 of the molding die 50 has a horizontally extending die surface that can support from below the portion of the main body 22 of the base material 21 that does not interfere with the portion that protrudes to the exterior surface of the vehicle cabin (the engaged portion 23 and the reinforcing rib 27). The upper die 51 of the molding die 50 includes a first press unit 52 having a horizontally extending die surface that presses the main body 22 between itself and the lower die 55, a third press unit 54 having a vertically extending die surface that protrudes downward from the end of the first press unit 52 and presses the terminal portion 31 downward during the mold closing process and supports the terminal portion 31 from the exterior of the vehicle cabin so that it stands perpendicular to the main body 22 in the mold closed state, and a second press unit 53 having a die surface inclined 45 degrees from the horizontal so as to bridge the corner formed between the first press unit 52 and the second press unit 53.

[0025] 4 and 5 are explanatory diagrams illustrating the deformation process of the base material 21 and the skin 41 during mold closing. For convenience, the molding die 50 is omitted from FIGS. 4 and 5. In the process of closing the molding die 50, first, the third press section 54 abuts against the skin 41 and presses (adheres) the skin 41 against the terminal portion 31 of the base material 21, and then the integrated skin 41 and terminal portion 31 are bent downward relative to the main body portion 22, starting from the integral hinge portion 28 (see the dashed line in FIG. 4). Then, the tip of the locking portion 32 reaches the locking hole 25, and the tip of the locking portion 32 is displaced toward the back (to the left in FIG. 4) while being guided by the guide surface 26 of the locking hole 25.

[0026] As the mold closing progresses further, the tip of locking portion 32 passes over the edge of locking hole 25, and then claw portion 34 climbs over the edge of the hole and locks onto the edge of the hole (see FIG. 5). In this state, terminal portion 31 of substrate 21 is in a state of standing vertically relative to main body portion 22. Furthermore, integral hinge portion 28 is in an open state such that opposing groove walls of the V-groove are flush with each other, and the space between main body portion 22 and terminal portion 31 is in the form of an inclined surface (inclined surface 29) cut out at an angle of 45 degrees relative to main body portion 22 (or terminal portion 31). In this state, the first press section 52 of the upper mold 51 presses the skin 41 against the main body 22 of the substrate 21, the second press section 53 presses the skin 41 against the inclined surface 29 (the V-groove in the open state) of the substrate 21, and the third press section 54 presses the skin 41 against the terminal portion 31.

[0027] In this way, the engaging portion 32 and the engaged portion 23 of the base material 21 are engaged, the terminal portion 31 is held perpendicular to the main body portion 22, and the skin 41 is integrally adhered to the base material 21. Then, the molding die 50 is opened and demolded to obtain an ornament board 20 of the desired shape.

[0028] Next, the operation and effect of this embodiment will be described. This embodiment is an ornament board 20 in which the interior surface of a plate-shaped base material 21 is covered with a skin 41. The base material 21 comprises a main body portion 22, which is the main body of the base material 21, and a terminal portion 31 located at an end thereof, which are connected via an integral hinge portion 28, the thickness of which is thinner than that of the main body portion 22 and the terminal portion 31. A locking portion 23 rising from the exterior surface of the main body portion 22 is provided at a position of the main body portion 22 adjacent to the integral hinge portion 28. The terminal portion 31 rises perpendicular to the main body portion 22, starting from the integral hinge portion 28, at an angle of 90 degrees from the main body portion 22. This rising state is maintained by locking the locking portion 32 rising from the exterior surface of the terminal portion 31 with the locking portion 23.

[0029] According to the above configuration, the engagement between the locking portion 32 and the locked portion 23 is performed at a position separated from the exterior surface of the vehicle interior of the base material 21, thereby preventing the locked state from affecting the design. Furthermore, since the locking portion 32 and the locked portion 23 are engaged with each other in a direction intersecting the interior / exterior direction of the vehicle interior (a direction along the plate surface of the main body portion 22), the locked state is not easily released when an impact is applied in the interior / exterior direction due to a side collision or the like.

[0030] Furthermore, because terminal portion 31 is configured to rise perpendicularly to main body portion 22 at integral hinge portion 28 so that the rise angle from main body portion 22 is 90 degrees, by pressing using a mold with skin 41 placed on the interior side of flat, plate-like base material 21, it is possible to simultaneously attach skin 41 to base material 21, raise (bend) terminal portion 31 from main body portion 22 starting from integral hinge portion 28, and lock locking portion 32 to locked portion 23. In other words, workability is greatly improved compared to conventional manufacturing methods in which the folding work cannot be performed by press molding and these work steps must be performed separately.

[0031] The engaging portion 23 is an engaging hole 25 that is provided in a vertical wall 24 that protrudes from the main body portion 22 and penetrates in a direction that intersects with the interior and exterior of the vehicle (a direction along the plate surface of the main body portion 22), and the engaging portion 32 is a claw portion 34 that is provided at the tip of a protruding piece 33 that protrudes from the terminal portion 31, and the claw portion 34 engages with the hole edge portion of the engaging hole 25.

[0032] The technology disclosed in this specification is a manufacturing method for the ornament board 20 described above, in which the skin 41 is placed on the interior side of the flat, plate-like base material 21 and pressed with a forming die 50, thereby simultaneously attaching the skin 41 to the base material 21, raising the end portion 31 from the main body portion 22 starting from the integral hinge portion 28, and locking the locking portion 32 to the locked portion 23. This manufacturing method can significantly improve workability.

[0033] <Other embodiments> The technology disclosed in this specification is not limited to the embodiments described above and illustrated in the drawings, and the following embodiments, for example, are also included in the technical scope.

[0034] (1) In the above embodiment, integral hinge portion 28 is formed by providing a V-groove on one side of base material 21. However, integral hinge portion 129 is not limited to a V-groove and may be formed by providing a trapezoidal groove, for example, as shown in FIG. 7.

[0035] (2) In the above embodiment, the terminal portion 31 is shown standing perpendicular to the main body portion 22, but as shown in Fig. 8, the terminal portion 131 may be shown standing in a state where it extends outward from the vehicle cabin so that its angle of rise is 90 degrees or less relative to the main body portion 122. In short, any form may be used as long as it is possible to simultaneously perform the following by pressing with a molding die: attaching the skin to the base material; raising (bending) the terminal portion from the main body portion starting from the integral hinge portion; and locking the locking portion to the locked portion.

[0036] (3) In the above embodiment, a vehicle door trim 10 is used as an example of a vehicle interior material. However, the technology disclosed in this specification is not limited to vehicle door trim, and can be modified and applied to other vehicle interior materials such as ceilings, pillar garnishes, console boxes, dashboards, various instrument panels, deck trims, etc., as well as vehicle interior materials for trains, airplanes, ships, etc., and for uses other than vehicle interior materials. [Explanation of symbols]

[0037] 10: Door trim (vehicle interior material) 11: Trim board (vehicle interior material) 20, 120: Ornament board (vehicle interior material) 21: Base material 22, 122: Main body portion 23: Locked portion 24: Standing wall (main body portion side protrusion) 25: Locking hole (hole portion) 28: Integral hinge portion (thin portion) 31, 131: Terminal portion 32: Locking portion 33: Protruding piece (terminal portion side protrusion) 34: Claw portion 41: Skin 42: Adhesive layer 50: Molding mold 51: Upper mold 55: Lower mold

Claims

1. A vehicle interior material in which an interior surface of a plate-shaped substrate is covered with a skin, The substrate is formed by a main body portion that is the main body of the substrate and a terminal portion located at an end portion, the main body portion and the terminal portion being connected via a thin-walled portion that is thinner than the main body portion and the terminal portion, a locking portion that rises from an exterior surface of the vehicle cabin of the main body portion is provided at a position adjacent to the thin-walled portion of the main body portion, The terminal portion rises from the thin-walled portion as a starting point, perpendicular to the main body portion or extending outward from the vehicle cabin so that the rising angle from the main body portion is 90 degrees or less, and this rising state is maintained by a locking portion rising from the outer surface of the vehicle cabin of the terminal portion locking onto the locked portion.

2. 2. The vehicle interior material according to claim 1, wherein the engaging portion is a hole portion provided in a main body-side protrusion that protrudes from the main body portion and penetrates in a direction intersecting the interior / exterior direction of the vehicle, and the engaging portion is a claw portion provided at the tip of the terminal-side protrusion that protrudes from the terminal portion, and the claw portion engages with the hole edge portion of the hole portion.

3. A method for producing the vehicle interior material according to claim 1 or 2, A method for manufacturing a vehicle interior material, in which the skin is placed on the interior side of the flat, plate-shaped base material and pressed using a forming die, thereby simultaneously attaching the skin to the base material, raising the terminal portion from the main body portion starting from the thin-walled portion, and engaging the engaging portion with the engaged portion.

Images