Lighting structure for vehicle interior material and method for manufacturing vehicle interior material

Abstract

To provide a lighting structure for a vehicle interior material that allows light to be seen with the same brightness even when seen from any direction and a method for manufacturing a vehicle interior material.SOLUTION: A lighting structure 1 in a vehicle interior material 10 includes a board member 12 that constitutes an interior design surface 12A, and a plurality of light sources 23 arranged on the vehicle cabin exterior side of the board member 12. The board member 12 includes a base material 13, a translucent resin layer 15 laminated on the vehicle cabin interior side of the base material 13 and having translucency, and a cover material 18 that covers the vehicle cabin interior side of the translucent resin layer 15. The base material 13 includes base material side through holes 14 at positions facing the respective light sources 23. The cover material 18 includes cover material side through holes 19 at positions overlapping the base material side through holes 14. A portion of the translucent resin layer 15 that overlaps the cover material through holes 19 constitutes a lens portion 16 that fills at least a portion of the cover material side through holes 19.SELECTED DRAWING: Figure 2

Description

[Technical Field]

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

[0002] In recent years, various lighting structures have been proposed for improving the interior design of vehicles such as automobiles. For example, Patent Document 1 below discloses a lighting structure that is installed on the ceiling of a vehicle, in which light from multiple light sources installed in the ceiling space is irradiated into the vehicle interior through multiple holes provided in an interior ceiling material, thereby creating a starry sky-like design. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] German Patent Application Publication No. 102012016399 Summary of the Invention [Problem to be solved by the invention]

[0004] In the lighting structure disclosed in the above document, the decorative surface of the ceiling material is covered with a skin, and light from the light source is irradiated into the vehicle cabin through the skin with the holes covered, i.e., lighting that irradiates soft light.

[0005] On the other hand, there is a demand for emitting light with higher brightness than the illumination of the lighting structure disclosed in the above document. To address this, drilling holes in the epidermis is considered, but simply drilling holes results in brightness varying depending on the direction of the line of sight when looking at the hole. Specifically, there is a problem in that the light appears bright when viewed from a direction where the light source is visible, but appears dark when viewed from a direction where the light source is not visible.

[0006] The technology disclosed in this specification was completed in consideration of the above circumstances, and aims to provide a lighting structure for vehicle interior materials and a method for manufacturing vehicle interior materials that produce light with the same brightness regardless of the direction from which it is viewed. [Means for solving the problem]

[0007] The technology disclosed in this specification, which was completed to solve the above-mentioned problems, is a lighting structure for vehicle interior materials, comprising a board member that forms a vehicle interior design surface, and a plurality of light sources arranged on the exterior side of the board member, wherein the board member is configured to include a base material, a light-transmitting resin layer that is laminated on the interior side of the base material, and a skin that covers the interior side of the light-transmitting resin layer to form the design surface, wherein the base material has base material-side through holes that pass through to the exterior of the vehicle interior at positions opposite each of the plurality of light sources, and the skin has skin-side through holes that pass through to the exterior of the vehicle interior at positions overlapping the base material-side through holes, and portions of the light-transmitting resin layer that overlap the skin-side through holes form lens portions that fill at least a portion of the skin-side through holes.

[0008] According to the above lighting structure, light emitted from the light source can be irradiated into the vehicle interior through the lens portion, so that the light irradiated from the vehicle interior material appears to have the same brightness no matter what direction the vehicle interior material is viewed from.

[0009] The lens portion may fill the skin-side through-hole with the opposing surface facing the light source recessed in the shape of a concave lens and the surface opposite the opposing surface being flush with the design surface.

[0010] According to the above configuration, light emitted from the light source is condensed by the concave lens-shaped opposing surface, allowing brighter light to be irradiated into the vehicle cabin. Furthermore, by making the opposing surface flush with the design surface, the entire opposing surface of the lens portion (the irradiated surface) can be seen from any direction, making the light appear more uniformly bright, compared to when the opposing surface is recessed from the design surface. Furthermore, compared to when the opposing surface is bulged from the design surface, the design surface is flat, resulting in a more attractive appearance.

[0011] The light source may be an LED mounted on an LED substrate, the LED substrate may be laminated on the exterior surface of the board member, and the LED may be housed in the base-side through-hole. With this configuration, it is possible to eliminate the space that the light source would occupy on the exterior surface of the board member.

[0012] Another technique disclosed in this specification is a method for manufacturing a vehicle interior material having the above-mentioned lighting structure for a vehicle interior material, the method including a substrate-side through-hole forming step of forming a plurality of substrate-side through-holes penetrating a plate surface at predetermined positions of the substrate, a skin-side through-hole forming step of forming skin-side through-holes penetrating the front and rear of portions of the skin that overlap the substrate-side through-holes, a heating step of heating a light-transmitting resin film made of a thermoplastic resin having light-transmitting properties, and heating the light-transmitting resin film heated by the heating step on a surface of the skin in which the skin-side through-holes are formed that is disposed on the outside of the vehicle cabin. a lens portion forming step of applying pressure from the light-transmitting resin layer side toward the surface of the skin to a portion where the light-transmitting resin layer is formed while the laminate is sandwiched between press dies, thereby drawing the light-transmitting resin layer into the light-transmitting resin layer, thereby forming the lens portion; and a second lamination step of laminating the laminate with the lens portion formed on the surface of the substrate where the substrate-side through hole is formed, with the light-transmitting resin layer side overlapping.

[0013] Another method for manufacturing a vehicle interior material disclosed in this specification includes a substrate-side through hole forming step of forming a plurality of substrate-side through holes that penetrate a plate surface at predetermined positions of the substrate; a skin-side through hole forming step of forming skin-side through holes that penetrate from the front to the back of portions of the skin that overlap the substrate-side through holes; a resin layer and lens portion forming step of applying a light-transmitting liquid resin to a surface of the skin in which the skin-side through holes have been formed, the surface being located on the exterior side of the vehicle cabin, and filling the skin-side through holes with the liquid resin, and then curing the liquid resin, thereby forming the light-transmitting resin layer and the lens portions on the skin; and a lamination step of laminating the skin in which the light-transmitting resin layer and lens portions have been formed, with the light-transmitting resin layer side overlapping, on a surface of the substrate in which the substrate-side through holes have been formed, the surface being located on the interior side of the vehicle cabin.

[0014] The method may also include a polishing process in which the portion of the lens portion that extends beyond the design surface of the skin is polished so that the surface opposite the opposing surface of the lens portion that faces the light source is flush with the design surface. [Effects of the Invention]

[0015] The technology disclosed in this specification makes it possible to provide a lighting structure for vehicle interior materials and a method for manufacturing vehicle interior materials that produce light with the same brightness regardless of the direction from which it is viewed. [Brief explanation of the drawings]

[0016] [Figure 1] FIG. 1 is an explanatory diagram showing a ceiling of a vehicle having an illumination structure according to a first embodiment. [Figure 2] Enlarged cross-section of a portion of the ceiling [Figure 3] Partially enlarged cross-sectional view showing the substrate-side through-hole forming step [Figure 4] Partially enlarged cross-sectional view showing the skin-side through-hole forming step [Figure 5] An explanatory diagram showing the heating process [Figure 6] Partially enlarged cross-sectional view showing the first lamination process (mold open state) [Figure 7]Partially enlarged cross-sectional view showing the first lamination process (mold closed state) [Figure 8] Partially enlarged cross-sectional view showing the lens portion forming process [Figure 9] Partially enlarged cross-sectional view showing the laminate removed from the mold. [Figure 10] Partially enlarged cross-sectional view showing the polishing process [Figure 11] Partially enlarged cross-sectional view showing the laminate after polishing [Figure 12] Partially enlarged cross-sectional view showing the second lamination step [Figure 13] Partially enlarged cross-sectional view showing the light source unit installation process [Figure 14] Partially enlarged cross-sectional view of the ceiling of embodiment 2 [Figure 15] Partially enlarged cross-sectional view of a ceiling according to another embodiment. [Figure 16] Partially enlarged cross-sectional view of a ceiling according to another embodiment. DETAILED DESCRIPTION OF THE INVENTION

[0017] <Embodiment 1> A first embodiment will be described with reference to Fig. 1 to Fig. 13. In this embodiment, a lighting structure 1 (lighting structure for vehicle interior material) provided on a ceiling 10 of a vehicle and a manufacturing method for the ceiling 10 provided with the lighting structure 1 (manufacturing method for vehicle interior material) will be illustrated.

[0018] 1, a ceiling (an example of a vehicle interior material) 10 of this embodiment is provided with a plurality of lighting units 11 above the rear seats of the vehicle. The plurality of lighting units 11 are randomly arranged over the entire ceiling 10. This ceiling 10 is configured with a ceiling material (an example of a board member) 12 that forms the interior design surface 12A of the vehicle, and a plurality of light source units 21 that are provided between the ceiling material 12 and the roof panel on the outside of the passenger compartment.

[0019] The ceiling material 12 is a plate-like member, and is shaped as a gentle arch or a generally flat plate overall. Figure 2 is an enlarged cross-sectional view of a portion of the ceiling 10, and the ceiling material 12 is composed of a base material 13, a light-transmitting resin layer 15 laminated on the interior surface of the base material 13, and a flexible skin 18 covering the interior surface of the light-transmitting resin layer 15.

[0020] The base material 13 is made of a thermoplastic resin such as polypropylene or a mixture of a thermoplastic resin and glass fiber or wood fiber, and has a plurality of base material-side through holes 14 that penetrate from the interior to the exterior of the vehicle. The plurality of base material-side through holes 14 are randomly arranged throughout the entire ceiling material 12.

[0021] On the other hand, the skin 18 also has a plurality of skin-side through holes 19 that penetrate from the interior to the exterior of the vehicle. The skin-side through holes 19 are arranged at positions that overlap the substrate-side through holes 14 and so that their axes coincide with those of the substrate-side through holes 14. The inner diameter of the skin-side through holes 19 is smaller than the inner diameter of the substrate-side through holes 14.

[0022] The light-transmitting resin layer 15 disposed between the substrate 13 and the skin 18 is made of, for example, a thermoplastic resin material (such as acrylic, polyethylene, or polypropylene) that has a refractive index sufficiently higher than that of air and is nearly transparent (excellent light-transmitting). In this embodiment, it is made of polypropylene or a polypropylene mixed resin.

[0023] An LED (an example of a light source) 23 of a light source unit 21 is housed inside each of the base-side through holes 14. The light source unit 21 includes an LED substrate 22 and a plurality of LEDs 23 mounted on the lower surface of the LED substrate 22.

[0024] The LED substrate 22 is configured by a flexible sheet-like FPC (flexible printed circuit board) made of an insulating material, and is arranged along the cabin exterior surface 12B (upper surface) of the ceiling material 12 (base material 13). The LED substrate 22 is sized to be able to collectively cover a plurality of base material-side through holes 14.

[0025] The LEDs 23 are mounted on the LED substrate 22 at positions (overlapping positions) that correspond to the base-side through-holes 14 of the ceiling material 12 when the LED substrate 22 is installed on the ceiling material 12. The LED substrate 22 is provided with a wiring pattern (not shown) that serves as a conductive path, and is electrically connected to a power supply device (not shown), so that power can be supplied to each of the LEDs 23 from the power supply device.

[0026] The LEDs 23 mounted on the LED substrate 22 are top-illuminated LEDs that emit light from the end face (top face) opposite to the LED substrate 22 when the LEDs 23 are mounted on the LED substrate 22. The beam angle of these LEDs 23 is set within a range of 120 degrees centered on an axis perpendicular to the top face.

[0027] 2, a lens portion 16 is formed inside the skin-side through-hole 19 in the ceiling material 12 of this embodiment. The lens portion 16 is formed by drawing a portion of the light-transmitting resin layer 15 that overlaps the skin-side through-hole 19 into the skin-side through-hole 19, and fills the skin-side through-hole 19 in a state where the outer surface (an example of the opposing surface) of the vehicle interior facing the LED 23 forms a recess 17 recessed in the shape of a concave lens, and the inner surface (an example of the opposite surface) 16A of the vehicle interior is flush with the design surface 12A of the skin 18.

[0028] With this configuration, light emitted from each of the LEDs 23 housed in the plurality of substrate-side through-holes 14 is irradiated toward the interior of the vehicle cabin (vertically downward) through the lens portion 16 (see FIG. 2). At this time, the light emitted from each of the LEDs 23 is condensed by the concave lens-shaped recess 17 of the lens portion 16 and emitted from the interior surface 16A that is flush with the design surface 12A of the skin 18. In other words, bright light is irradiated into the vehicle cabin in a state where the brightness appears to be the same when viewed from any direction within the vehicle cabin.

[0029] Next, a description will be given of a method for manufacturing the ceiling 10 having the lighting structure 1 of the present embodiment described above. The method for manufacturing the ceiling 10 of the present embodiment involves sequentially performing a base material-side through-hole forming process, a skin-side through-hole forming process, a heating process, a first lamination process, a lens portion forming process, a polishing process, a second lamination process, and a light source unit mounting process.

[0030] <Substrate-side through-hole forming process and skin-side through-hole forming process> First, in the plate-shaped base material 13, a plurality of base material-side through holes 14 are formed, for example by drilling, in portions (an example of predetermined positions) that will overlap the LEDs 23 when the completed ceiling 10 is formed (see FIG. 3). Then, in the skin 18, skin-side through holes 19 are formed, for example by punching, in portions that will overlap the base material-side through holes 14 when the completed ceiling material 12 is formed (see FIG. 4). The inner diameter of the skin-side through holes 19 is set to be smaller than the inner diameter of the base material-side through holes 14.

[0031] <Heating process> Next, the light-transmitting resin film 15F, which is made of polypropylene or a polypropylene mixed resin material and has light-transmitting properties, is heated to 120 to 130 degrees by the heater 30 (see FIG. 5). This softens the light-transmitting resin film 15F. In this embodiment, the thickness of the light-transmitting resin film 15F is approximately the same as the thickness of the skin 18 to twice the thickness of the skin.

[0032] <First lamination process> Next, as shown in Fig. 6, the skin 18 with the skin-side through-holes 19 formed therein and the light-transmitting resin film 15F softened by the heating process are placed at predetermined positions between the press mold 31 (upper mold 32 and lower mold 34) so ​​that the skin 18 is on the bottom and the light-transmitting resin film 15F is on the top, and the mold is closed. As a result, a first laminate (an example of a laminate) 20A is formed in which the light-transmitting resin layer 15 is laminated on the top surface of the skin 18 (the surface that will face the outside of the vehicle cabin when the completed ceiling material 12 is formed) (see Fig. 7).

[0033] <Lens forming process> Next, with the press die 31 kept closed, pressure is applied to the portion where the skin-side through-hole 19 is formed, from the light-transmitting resin layer 15 side toward the skin 18 side (from the upper die 32 toward the lower die 34) (see FIG. 8). Note that air vents 33, 35 are formed in advance in the press die 31 at positions overlapping the skin-side through-hole 19, and the press die 31 is configured to be capable of vacuum pressure molding, in which compressed air is sent through the air vent 33 of the upper die 32 and a vacuum is drawn through the air vent 35 of the lower die 34. As a result, part of the light-transmitting resin layer 15, which has been softened by heating, is drawn into the skin-side through-hole 19, forming a lens portion 16L in which the skin-side through-hole 19 is filled with light-transmitting resin, and forming a second laminate 20B in which the light-transmitting resin layer 15 is integrated with the skin 18 by the anchor effect. The lens portion 16L has an upper surface (surface facing the outside of the vehicle cabin) that is a recess 17 recessed in the shape of a concave lens, and a lower surface (the design surface 12A side) that is a convex shape that bulges from the skin-side through-hole 19.

[0034] The second laminate 20B having the lens portion 16L formed in this manner is demolded by opening the upper mold 32 and the lower mold 34 after the thermoplastic resin constituting the translucent resin layer 15 and the lens portion 16L has cooled and solidified (see Figure 9).

[0035] <Polishing process> Next, of the lens portion 16L formed by the lens portion forming process, the portion that bulges out from the skin 18 is polished with a polishing roller 36 to make the interior surface of the lens portion 16 flush with the design surface 12A (third laminate 20C, see Figures 10 and 11).

[0036] <Second lamination process> Next, the surface of the third laminate 20C obtained by the polishing step on the side of the light-transmitting resin layer 15 is aligned and laminated so as to overlap the surface of the base material 13 on the interior side of the vehicle, on which the base material-side through-hole 14 is formed, and the two are bonded together. This completes the ceiling material 12 in which the axes of the base material-side through-hole 14 and the skin-side through-hole 19 are aligned and the lens portion 16 is formed in the skin-side through-hole 19 (see FIG. 12).

[0037] <Light source unit installation process> Finally, the light source unit 21, in which the LED 23 is mounted at a predetermined position (a position that overlaps with the substrate-side through-hole 14 when the LED substrate 22 is arranged on the outer surface of the cabin of the ceiling material 12), is placed at a predetermined position on the outer surface 12B of the cabin of the ceiling material 12 (see Figure 13). As a result, the LED 23 is housed within the substrate-side through-hole 14. The LED 23 and the recess 17 of the lens portion 16 are also arranged opposite each other (see Figure 2). In this way, the ceiling 10 having the lighting structure 1 of this embodiment is completed.

[0038] Next, the effects will be described. The lighting structure 1 for the vehicle ceiling 10 of this embodiment is a lighting structure 1 for the vehicle ceiling 10, and includes a ceiling material 12 that forms an interior design surface 12A of the vehicle and a plurality of LEDs 23 arranged on the exterior side of the ceiling material 12, the ceiling material 12 including a base material 13, a translucent resin layer 15 having translucency laminated on the interior side of the base material 13, and a skin 18 that covers the interior side of the translucent resin layer 15 and forms the design surface 12A, the base material 13 has base material-side through holes 14 that penetrate from the interior to the exterior of the vehicle at positions opposite to the plurality of LEDs 23, the skin 18 has skin-side through holes 19 that penetrate from the interior to the exterior of the vehicle at positions overlapping the base material-side through holes 14, and the portion of the translucent resin layer 15 that overlaps the skin-side through holes 19 forms a lens portion 16 in a state where the interior of the skin-side through holes 19 are filled.

[0039] According to the above lighting structure 1, the light emitted from the LED 23 can be irradiated into the vehicle interior through the lens portion 16, so that the light irradiated from the ceiling 10 appears to have the same brightness no matter what direction the ceiling 10 is viewed from.

[0040] The lens portion 16 has a recess 17 recessed in the shape of a concave lens on the outer surface of the vehicle interior facing the LED 23, and fills the skin-side through-hole 19 with the interior surface 16A of the vehicle interior being flush with the design surface 12A.

[0041] According to the above configuration, the light emitted from the LED 23 is condensed by the concave lens-shaped recess 17, so that brighter light can be irradiated into the vehicle interior. Furthermore, by making the interior surface 16A of the lens unit 16 flush with the design surface 12A, the entire interior surface 16A (illumination surface) of the lens unit 16 can be seen from any direction, and the light appears with a similar brightness, compared to when the interior surface 16A is recessed from the design surface 12A. Furthermore, compared to when the interior surface 16A is protruding from the design surface 12A, the entire design surface 12A is flat, so the appearance is better.

[0042] The light source is an LED 23 mounted on an LED substrate 22, which is laminated on the exterior surface 12B of the ceiling material 12, and the LED 23 is housed in the base material-side through-hole 14. With this configuration, it is possible to eliminate the space that the light source occupies on the exterior side of the ceiling material 12.

[0043] The present embodiment is also a method for manufacturing a ceiling 10 of a vehicle equipped with the above-described lighting structure 1, and includes a substrate-side through-hole forming step of forming a plurality of substrate-side through-holes 14 penetrating a plate surface at predetermined positions of the substrate 13, a skin-side through-hole forming step of forming skin-side through-holes 19 penetrating the front and rear of a skin 18 in portions overlapping the substrate-side through-holes 14, a heating step of heating a light-transmitting resin film 15F made of a thermoplastic resin having light transmission properties, and laminating the light-transmitting resin film 15F heated in the heating step on a surface of the skin 18 in which the skin-side through-holes 19 have been formed, the surface being disposed on the outside of the vehicle compartment, thereby forming the light-transmitting resin film 15F of the skin 18. the first laminate 20A is sandwiched between a press mold 31 and pressure is applied from the light-transmitting resin layer 15 side toward the skin 18 side to the portion where the skin-side through-hole 19 is formed, thereby drawing the light-transmitting resin layer 15 into the skin-side through-hole 19 to form the lens portion 16; and the second laminate step is stacked such that the light-transmitting resin layer 15 side of the third laminate 20C on the surface of the base material 13 on which the base material-side through-hole 14 is formed is overlapped with the third laminate 20C on which the lens portion 16 is formed, on the surface of the base material 13 on which the base material-side through-hole 14 is formed, facing the interior of the vehicle.

[0044] The method also includes a polishing step of polishing the portion of the lens portion 16 that protrudes from the design surface 12A of the skin 18 so that the interior surface 16A of the lens portion 16 is flush with the design surface 12A.

[0045] <Embodiment 2> Next, a second embodiment will be described with reference to Fig. 14. Note that only the configurations different from the first embodiment will be described below, and the same configurations as those in the first embodiment will be given the same reference numerals, and redundant description will be omitted.

[0046] The lighting structure 2 of this embodiment differs from the above-described embodiment 1 in the shape of the lens portion 116 and the manufacturing method of the ceiling material 112. The lens portion 116 of this embodiment does not have a recess 17, and the exterior surface is flat.

[0047] The manufacturing method of the ceiling 110 of this embodiment involves sequentially performing a base material-side through-hole forming process, a skin-side through-hole forming process, a resin layer and lens portion forming process, a polishing process, a lamination process, and a light source unit attaching process. Of these, the base material-side through-hole forming process, the skin-side through-hole forming process, the polishing process, and the light source unit attaching process are the same as those in embodiment 1, so only the resin layer and lens portion forming process and the lamination process will be described.

[0048] <Resin layer and lens portion forming process> In this process, a light-transmitting liquid resin is applied to the surface of the skin 18, in which the skin-side through-holes 19 are formed, that faces the exterior of the vehicle cabin, and the liquid resin is filled into the skin-side through-holes 19. As the liquid resin, for example, a transparent epoxy resin can be used. The liquid resin also includes a resin having a viscosity that allows it to be spread over the sheet surface of the skin 18. The liquid resin applied to and filled into the skin 18 is then cured to form a resin-coated skin 20D in which the light-transmitting resin layer 115 and the lens portions 116 are formed in the skin 18.

[0049] <Lamination process> The lens portion 116 bulging from the design surface 112A of the resin-coated skin 20D obtained by the resin layer and lens portion forming process described above is polished in a polishing process, and then the resin-coated skin 20D is laminated with the translucent resin layer 115 side overlapping on the surface of the base material 13 on the interior side of the vehicle, where the base material-side through-hole 14 is formed, thereby forming the ceiling material 112.

[0050] Thereafter, the ceiling 110 of this embodiment is obtained by going through the light source unit attachment process in the same manner as in embodiment 1. In this way, the ceiling 110 having the lens portion 116 can also be manufactured according to this embodiment.

[0051] <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.

[0052] (1) In the above-described embodiment 1, the thickness of the translucent resin film 15F is approximately equal to or twice the thickness of the skin 18. However, as shown in FIG. 14, the thickness of the translucent resin film 215 may be thinner than the thickness of the skin 18.

[0053] (2) In the above embodiment, the skin-side through-hole 19 is filled with the interior surface 16A, 116A of the lens portion 16, 116 flush with the design surface 12A, 112A, but as shown in Fig. 15, the interior surface 216A of the lens portion 216 may not reach the design surface 12A, or as shown in Fig. 16, part of the lens portion 316 may reach the design surface 12A but only part of the skin-side through-hole 19 may be filled. Also, when the lens portion bulges out from the design surface of the skin, the polishing step may be omitted and the lens portion may remain bulging.

[0054] (3) In the above embodiment, the epidermis-side through hole 19 has an inner diameter smaller than the inner diameter of the substrate-side through hole 14, but the epidermis-side through hole may have an inner diameter equal to or larger than the substrate-side through hole.

[0055] (4) In the above embodiment 1, the first lamination process and the lens portion forming process are performed consecutively using one press mold 31, but the first lamination process may be performed separately without using a press mold.

[0056] (5) In the first embodiment, the press mold 31 is exemplified as performing vacuum pressure molding in which compressed air is fed through the air vent 33 of the upper mold 32 and a vacuum is drawn through the air vent 35 of the lower mold 34 in the lens portion forming step. However, the press mold may be one that presses the entire upper surface of the translucent resin layer 15 with air pressure, or one that simply draws a vacuum from the lower mold. In short, any configuration may be used as long as it is possible to draw a part of the translucent resin layer 15 into the skin-side through-hole 19.

[0057] (6) In the above embodiment, the manufacturing method is described in which the lens portions 16, 116 are filled into the skin-side through-holes 19, a polishing step is performed, and then the substrate 13 and the laminate 20 are bonded together. However, the polishing step may be performed after the skin and the laminate are bonded together.

[0058] (7) In the above embodiment, the vehicle ceilings 10, 110 are used as examples of vehicle interior materials. However, the technology disclosed in this specification is not limited to the vehicle ceilings 10, 110, and can be modified and applied to other vehicle interior materials such as door trim, pillar garnish, console box, dashboard, various instrument panels, deck trim, etc., as well as vehicle interior materials for trains, airplanes, ships, etc., and for uses other than vehicle interior materials. [Explanation of symbols]

[0059] 1, 2: lighting structure 10, 110: ceiling (vehicle interior material) 12, 112: ceiling material (board component) 12A, 112A: design surface 12B, 112B: vehicle interior exterior surface 13: substrate 14: substrate-side through-hole 15, 115, 215, 315: light-transmitting resin layer 15F: light-transmitting resin film 16, 116, 216, 316: lens portion 16A, 116A, 216A: vehicle interior surface (opposite surface) 16L: lens portion 17: recess 18: skin 19: skin-side through-hole 20: light source unit 21: LED substrate 22: LED (light source) 31: press mold 32: upper mold 34: lower mold

Claims

1. A lighting structure for a vehicle interior material, The vehicle interior design panel includes a board member that constitutes an interior design surface of the vehicle, and a plurality of light sources that are arranged on the exterior side of the board member, The board member is configured to include a base material, a light-transmitting resin layer laminated on the interior side of the base material, and a skin covering the interior side of the light-transmitting resin layer to form the design surface, the substrate has substrate-side through holes penetrating through to the interior and exterior of the vehicle at positions facing each of the plurality of light sources, and the skin has skin-side through holes penetrating through to the interior and exterior of the vehicle at positions overlapping the substrate-side through holes, a light emitting element for illuminating an interior surface of a vehicle, the light emitting element being a light source for illuminating an interior surface of the ...

2. 2. The lighting structure for a vehicle interior material according to claim 1, wherein the lens portion has a surface facing the light source that is recessed in the shape of a concave lens, and the surface opposite the surface facing the light source is flush with the design surface, and the lens portion fills the skin-side through hole.

3. the light source is an LED mounted on an LED substrate, 3. The lighting structure for a vehicle interior material according to claim 1, wherein the LED substrate is laminated on an outer surface of the board member, and the LED is accommodated in the base-side through-hole.

4. A method for manufacturing a vehicle interior material having the lighting structure for a vehicle interior material according to claim 1 or 2, comprising: a substrate-side through-hole forming step of forming a plurality of the substrate-side through-holes penetrating a plate surface at predetermined positions of the substrate; a skin-side through-hole forming step of forming the skin-side through-hole that penetrates from the front to the back of the skin in a portion of the skin that overlaps the substrate-side through-hole; a heating step of heating a light-transmitting resin film made of a light-transmitting thermoplastic resin; a first lamination step of laminating the light-transmitting resin film heated in the heating step onto a surface of the skin on which the skin-side through-hole is formed, the surface being disposed on the exterior side of the vehicle cabin, to form a laminate in which the skin and the light-transmitting resin layer are laminated; a lens portion forming step of applying pressure from the light-transmitting resin layer side toward the surface side to a portion where the surface-skin-side through hole is formed while the laminate is sandwiched between press dies, thereby drawing the light-transmitting resin layer into the surface-skin-side through hole to form the lens portion; a second lamination step of laminating the laminate having the lens portion formed thereon in such a manner that the light-transmitting resin layer side is overlapped on a surface of the base material having the base material-side through-hole formed thereon, the surface being disposed on the interior side of the vehicle; A method for manufacturing a vehicle interior material, comprising:

5. A method for manufacturing a vehicle interior material having the lighting structure for a vehicle interior material according to claim 1 or 2, comprising: a substrate-side through-hole forming step of forming a plurality of the substrate-side through-holes penetrating a plate surface at predetermined positions of the substrate; a skin-side through-hole forming step of forming the skin-side through-hole that penetrates from the front to the back of the skin in a portion of the skin that overlaps the substrate-side through-hole; a resin layer and lens portion forming step of applying a light-transmitting liquid resin to a surface of the skin in which the skin-side through-hole is formed, the surface being disposed on the exterior side of the vehicle cabin, filling the skin-side through-hole with the liquid resin, and then hardening the liquid resin to form the light-transmitting resin layer and the lens portion on the skin; and laminating the skin, on which the light-transmitting resin layer and the lens portion are formed, in a manner that the light-transmitting resin layer side is overlapped on a surface of the base material, on which the base material-side through hole is formed, that is to be disposed inside the vehicle cabin.

6. 5. The method for manufacturing a vehicle interior material according to claim 4, further comprising a polishing step of polishing a portion of the lens portion that extends beyond the design surface of the skin, so that the surface of the lens portion opposite the opposing surface that faces the light source is flush with the design surface.

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