Vehicle interior material and manufacturing method for vehicle interior material

Abstract

To provide a vehicle interior material capable of reducing the number of through-holes formed in a base material.SOLUTION: A vehicle interior material includes a plate-shaped base material 21 and a skin material 30 attached to a cabin-side surface 21A of the base material 21. A plurality of through-holes 25 are formed in the base material 21, and a groove portion 26 connecting the plurality of through-holes 25 is formed in the cabin-side surface 21A.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] A conventionally known vehicle interior material is described in Patent Document 1. The vehicle interior material described in Patent Document 1 includes a base material and a skin material attached to the surface of the base material. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Laid-Open No. 2000-313293 Summary of the Invention [Problem to be solved by the invention]

[0004] In the manufacturing process of the vehicle interior material having the above-described configuration, when attaching a skin material to a substrate, it is necessary to adhere the skin material to the surface of the substrate. One known method for adhering the skin material to the surface of the substrate is to apply negative pressure to multiple through-holes formed in the substrate, thereby sucking the skin material toward the surface of the substrate. When the substrate is made of a synthetic resin, suction through-holes are formed during molding of the substrate. Specifically, pins can be erected on the molding surface of a mold used to injection-molde the substrate, thereby forming through-holes with shapes corresponding to the pins. To ensure that the skin material is sucked across the entire surface of the substrate, a larger number of suction through-holes is preferable. However, increasing the number of through-holes also increases the number of pins required to form them, thereby increasing the cost of manufacturing the mold. Furthermore, if the diameter of the suction through-holes is large, there is a concern that the skin material may be dented at the through-hole formation location, resulting in a deterioration in design. To prevent this from happening, the diameter of the through-holes must be reduced, and the diameter of the pins used to form the through-holes must be reduced. As a result, the strength of the pins is reduced, and there is a possibility that the pins will break due to the pressure acting on them during molding of the substrate. As the number of through holes and therefore the number of pins increases, there is a problem in that the possibility of the pins breaking increases even more.

[0005] The technology disclosed in this specification was completed based on the above circumstances, and aims to provide a vehicle interior material and a method for manufacturing a vehicle interior material that can reduce the number of through holes formed in a substrate. [Means for solving the problem]

[0006] As a means for solving the above-mentioned problems, the vehicle interior material disclosed in this specification comprises a plate-shaped substrate and a skin material attached to one side of the substrate, wherein a plurality of through holes are formed in the substrate, and a groove portion connecting the plurality of through holes is formed in the one side.

[0007] According to the above configuration, during the manufacturing process of a vehicle interior material, by applying negative pressure to the multiple through holes from the back side of the substrate (the side opposite the skin material), the skin material can be sucked toward one side of the substrate. Here, the substrate has grooves connecting the multiple through holes. Therefore, by applying negative pressure to the multiple through holes, negative pressure can be applied to the grooves through each through hole, and the skin material can be sucked along the entire length of the grooves. As a result, the grooves can be used to suck in the portions of the skin material corresponding to the spaces between adjacent through holes, eliminating the need to form additional through holes between adjacent through holes. As a result, the number of through holes can be reduced compared to a configuration in which the skin material is sucked in using only through holes.

[0008] The substrate may have a recess that opens toward the skin material, and the groove may be formed on the inner surface of the recess. Because it is more difficult to suck the skin material onto the inner surface of the recess than when sucking the skin material onto a flat surface, the density of the through holes must be increased. In this configuration, the groove may be formed on the inner surface of the recess, thereby reducing the number of through holes to be formed in the recess.

[0009] Furthermore, as a means for solving the above-mentioned problems, the method for manufacturing a vehicle interior material disclosed in this specification includes a skin attachment step of attaching a skin to one surface of a plate-shaped substrate, the substrate having a plurality of through holes and grooves formed on the one surface and connecting the plurality of through holes, and the skin attachment step is characterized in that negative pressure is applied to the plurality of through holes and the grooves, thereby sucking the skin to the one surface.

[0010] According to the above method, the skin material can be sucked along the entire length of the groove. This allows the groove to suck the skin material in the areas between adjacent through holes, eliminating the need to form additional through holes between adjacent through holes. This reduces the number of through holes compared to a configuration in which the skin material is sucked only through through holes. [Effects of the Invention]

[0011] According to the present invention, it is possible to provide a vehicle interior material and a method for manufacturing a vehicle interior material that can reduce the number of through holes formed in a base material. [Brief explanation of the drawings]

[0012] [Figure 1] FIG. 1 is a front view showing a door trim according to an embodiment of the present invention; [Figure 2] Cross-sectional view showing the recessed area of ​​the door trim (corresponding to the cross-sectional view taken along line II-II in Figure 1) [Figure 3] FIG. 1 is a perspective view showing the vicinity of a recess in a substrate; [Figure 4] A cross-sectional view showing a state in which a through hole is formed by a pin in a substrate molding process. [Figure 5] FIG. 10 is a cross-sectional view showing a state in which grooves are formed by protrusions in a substrate molding process. [Figure 6] FIG. 10 is a cross-sectional view showing a state in which the substrate and the skin material are placed on the mounting surface of the vacuum forming mold in the skin material attaching step. [Figure 7] FIG. 10 is a cross-sectional view showing a state in which the skin material is sucked onto the interior-facing surface of the base material in the skin material attaching step. [Figure 8] A cross-sectional view showing the state in which the skin material is sucked onto the interior side of the substrate during the skin material attachment process (corresponding to the cross-sectional view taken along line VIII-VIII in Figure 7). [Figure 9] Cross-sectional view showing the location where the grooves are formed in the skin attachment process [Figure 10] FIG. 10 is a perspective view showing the vicinity of a recess in a substrate of a comparative example. DETAILED DESCRIPTION OF THE INVENTION

[0013] An embodiment of the present invention will be described with reference to Figs. 1 to 10. In this embodiment, a door trim 10 (vehicle door trim) disposed on the side of an occupant in a vehicle is exemplified as a vehicle interior material. The door trim 10 is attached to the interior side of a door inner panel (not shown) constituting a vehicle door, and constitutes the interior surface of the vehicle door. As shown in Fig. 1, the door trim 10 includes a trim board 11 (main body of the interior material) that covers the door inner panel from the interior side of the vehicle, and an ornament 13 that is attached to close an opening 12 formed in the trim board 11. Note that Fig. 1 shows a state in which the ornament 13 has been removed from the trim board 11. The door trim 10 also includes an inside handle 14, a speaker grill 15, and a door pocket 16 that are used when opening and closing the vehicle door.

[0014] As shown in FIG. 2, the trim board 20 includes a plate-shaped base material 21 and a skin material 30 attached to a surface 21A (one surface) of the base material 21 facing the interior of the vehicle. As shown in FIG. 1, an armrest 17 that bulges toward the interior of the vehicle is formed in the vertical center of the trim board 20. The ornaments 13 are attached to mounting pieces 18 formed on the edge of an opening 12 disposed above the armrest 17. The mounting pieces 18 extend in the fore-and-aft direction of the vehicle (the left-and-right direction in FIG. 1), and each mounting piece 18 has a plurality of mounting holes 18A formed in the extending direction. As shown in FIG. 2, a mounting boss 13A provided on the back surface of the ornament 13 is inserted into the mounting hole 18A from the interior side of the vehicle (the left side in FIG. 2), and a tip end 13B of the mounting boss 13A is fastened to the mounting piece 18 by a fastening means such as thermal caulking.

[0015] The base material 21 is made of a synthetic resin material such as polypropylene, and as shown in Fig. 2, includes a main wall portion 22 having a main surface facing the inside of the vehicle cabin, and a side wall portion 23 that defines the opening 12. The side wall portion 23 extends from the main wall portion 22 toward the outside of the vehicle cabin, and the mounting piece 18 is provided at the end of the side wall portion 23 facing the outside of the vehicle cabin. In other words, the mounting piece 18 forms a step with respect to the main wall portion 22 and is disposed on the outside of the vehicle cabin. Therefore, in the base material 21, the boundary between the side wall portion 23 and the mounting piece 18 forms a recess 27 that opens toward the inside of the vehicle cabin (the skin material 30 side), and the boundary between the main wall portion 22 and the side wall portion 23 forms a protrusion 28 that bulges toward the inside of the vehicle cabin.

[0016] As shown in Fig. 3, a plurality of through holes 25 are formed in the base material 21. The plurality of through holes 25 are arranged over the entire surface of the base material 21. The plurality of through holes 25 are formed in a recess 27 of the base material 21 so as to be aligned along the extension direction of the recess 27. On the surface 21A of the base material 21 facing the interior of the vehicle, a groove portion 26 connecting the plurality of through holes 25 is formed in a portion corresponding to the recess 27 (the inner surface of the recess 27). Furthermore, on the surface 21A of the base material 21 facing the interior of the vehicle, a groove portion 26 connecting the plurality of through holes 25 is formed in a portion corresponding to the protrusion 28.

[0017] As shown in Fig. 3, the through-hole 25 has a circular shape in a plan view (as viewed from inside the vehicle cabin). Furthermore, as shown in Fig. 2, the through-hole 25 is designed so that the hole diameter increases toward the outside of the vehicle cabin. The grooves 26 formed in the recesses 27 extend along the extension direction of the recesses 27. Furthermore, the grooves 26 formed in the protrusions 28 extend along the extension direction of the protrusions 28. Furthermore, the grooves 26 are designed so that the groove width increases toward the inside of the vehicle cabin.

[0018] The skin material 30 is made of synthetic resin (for example, olefin-based thermoplastic elastomer) and has flexibility. As shown in FIG. 2, the skin material 30 is disposed in close contact with the surface 21A of the base material 21 facing the interior of the vehicle. If the diameter of the through-hole 25 is large, the skin material 30 may enter the through-hole 25 at the location where the through-hole 25 is formed, causing a concern that the skin material 30 may be partially recessed. For this reason, the diameter of the through-hole 25 is preferably small, and is set to, for example, 1 mm or less, but is not limited to this. The groove width of the groove portion 26 is set to, for example, half or less the diameter of the through-hole 25, but is not limited to this.

[0019] Next, a description will be given of a manufacturing method of the door trim 10. The manufacturing method of the door trim 10 includes a base material molding step of molding the base material 21 by injection molding using a pair of molding dies 50, 60 (see FIG. 4), and a skin material attachment step of attaching the skin material 30 to the interior-facing surface 21A of the base material 21 by vacuuming using a vacuum forming die 70 (see FIG. 6).

[0020] As shown in FIG. 4, one mold 50 of the pair of molds 50, 60 has a molding surface 51 for molding the surface 21A of the substrate 21 facing the interior of the vehicle. The other mold 60 has a molding surface 61 for molding the surface 21B of the substrate 21 facing the exterior of the vehicle. One of the pair of molds 50, 60 (e.g., mold 50) is connected to a drive device (e.g., an electric motor, an air cylinder, a hydraulic cylinder, etc.) not shown, and can be moved toward or away from the other mold 60. This allows the pair of molds 50, 60 to be closed and opened. In the mold closed state shown in FIG. 4, a molding space S1 for molding the substrate 21 is formed between the molding surface 51 and the molding surface 61.

[0021] The molding surface 61 is provided with cylindrical pins 62 for forming the through holes 25. The pins 62 are set so that their diameter decreases toward the molding surface 51. The pins 62 can be formed, for example, by cutting portions of the molding die 60 other than the pins 62 when forming the molding surface 61 by cutting. The molding die 60 also has a flow path (not shown) formed therein through which cooling water flows to cool the molding die 60 (and thus the molten resin that forms the substrate 21) during injection molding.

[0022] 5, the molding surface 51 is provided with protrusions 52 for forming the grooves 26. The width of the protrusions 52 is set to decrease toward the molding surface 61. The protrusions 52 can be formed, for example, by cutting the areas other than the protrusions 52 when forming the molding surface 51 by cutting in the molding die 50.

[0023] As shown in FIG. 6 , the vacuum forming mold 70 has a mounting surface 71 on which the substrate 21 is placed. The mounting surface 71 has a shape that follows the surface 21B of the substrate 21 facing the cabin exterior. Recesses 72 are formed on the mounting surface 71 at locations corresponding to the through holes 25. When the substrate 21 is placed on the mounting surface 71, the plurality of through holes 25 are configured to communicate with the recesses 72. The vacuum forming mold 70 also has suction holes 73 formed in communication with the recesses 72. A vacuum pump (not shown) is connected to the suction holes 73. As a result, when the vacuum pump is driven, negative pressure acts on the recesses 72, the through holes 25, and the grooves 26 via the suction holes 73.

[0024] In the substrate molding process, as shown in Fig. 4, molten resin (for example, polypropylene) is injected into molding space S1 from an injection device (not shown). The molten resin is then cooled and solidified to form substrate 21. Here, as shown in Fig. 4, the portions corresponding to pins 62 become through holes 25, and as shown in Fig. 5, the portions corresponding to protrusions 52 become grooves 26.

[0025] In the skin attachment process, which is performed after the base material molding process, the base material 21 is placed on the placement surface 71 of the vacuum forming mold 70, and then the skin material 30 is placed to cover the surface 21A facing the interior of the vehicle, as shown in Fig. 6. Note that before being placed on the placement surface 71, an adhesive is applied in advance to the surface 21A facing the interior of the vehicle of the base material 21. In addition, the skin material 30 is softened by being heated in advance by a heater.

[0026] Next, as shown in Fig. 7, a vacuum pump (not shown) connected to the suction hole 73 is driven to apply negative pressure to the through-holes 25 and the grooves 26 via the suction hole 73, thereby sucking the skin material 30 onto the interior-facing surface 21A. At the locations where the grooves 26 are formed, the skin material 30 is sucked along the entire length of the grooves 26, as shown in Figs. 8 and 9. This allows the skin material 30 to be tightly attached to the interior-facing surface 21A, and the skin material 30 is attached to the base material 21 by the adhesive present between the base material 21 and the skin material 30.

[0027] Next, the effects of this embodiment will be described. According to this embodiment, during the manufacturing process of the door trim 10, negative pressure is applied to the plurality of through holes 25 from the back side (the side opposite to the upholstery material 30) of the base material 21, thereby sucking the upholstery material 30 toward the interior-facing surface 21A of the base material 21. Here, the base material 21 has grooves 26 connecting the plurality of through holes 25. Therefore, by applying negative pressure to the plurality of through holes 25, negative pressure can be applied to the grooves 26 through each of the through holes 25, and the upholstery material 30 can be sucked along the entire length of the grooves 26. As a result, the grooves 26 can suck the portions of the upholstery material 30 corresponding to the spaces between adjacent through holes 25, eliminating the need to form additional through holes between adjacent through holes 25. As a result, the number of through holes 25 can be reduced compared to a configuration in which the upholstery material 30 is sucked using only the through holes 25.

[0028] As shown in FIG. 10, the substrate 1 of the comparative example does not have the groove portion 26, and therefore, in order to reliably suck the skin material 30 over the entire length of the recess 27, it is necessary to arrange more through holes 25 along the extension direction of the recess 27. However, in this embodiment, the number of through holes 25 can be reduced compared to such a configuration.

[0029] Furthermore, the substrate 21 has a recess 27 that opens to the skin material 30 side, and the grooves 26 are formed on the inner surface of the recess 27. When sucking the skin material 30 onto the inner surface of the recess 27, it is more difficult to suck the skin material 30 than when sucking the skin material 30 onto a flat surface, so it is necessary to increase the arrangement density of the through holes 25. In the above configuration, by forming the grooves 26 on the inner surface of the recess 27, the number of through holes 25 formed in the recess 27 can be reduced.

[0030] Furthermore, when the base material 21 is molded by injection molding as in this embodiment (see FIG. 4), the injected resin is cooled, for example, by circulating cooling water through the molding die 60. Therefore, during the cooling process of the injected resin, the molding die 60 side is cooled more easily than the molding die 50 side. As a result, a temperature difference occurs between the front and back sides of the base material 21, and thermal contraction caused by this temperature difference generates relatively high stress, particularly in the side wall portion 23. As a result, stress acts on the pins 62 arranged near the side wall portion 23, in other words, in the recesses 27, and there is a concern that the pins 62 may be damaged. In this embodiment, the number of through holes 25 and therefore the number of pins 62 can be reduced, thereby reducing the possibility of the pins 62 being damaged.

[0031] <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. (1) In the above embodiment, the grooves 26 are formed in the convex portions 28 of the substrate 21, but the grooves 26 may be formed only in the locations corresponding to the concave portions 27 of the substrate 21. Furthermore, the locations where the grooves 26 are formed are not limited to the concave portions 27 and the convex portions 28 and can be changed as appropriate. (2) In the above embodiment, the groove width of the groove portion 26 may be set larger than the diameter of the through-hole 25 . (3) In the above embodiment, the vehicle interior material is exemplified as a door trim for a vehicle, but is not limited thereto. For example, the vehicle interior material may be a vehicle interior material other than a door trim (instrument panel, pillar garnish, roof lining, etc.), an interior material for an airplane, a ship, etc., or an interior part constituting furniture such as a sofa or a chair. (4) The materials of the base material 21 and the skin material 30 are not limited to those exemplified in the above embodiment and can be changed as appropriate. [Explanation of symbols]

[0032] 10...door trim (vehicle interior material), 21...base material, 21A...surface facing the interior of the vehicle (one surface of the base material), 25...through hole, 26...groove portion, 27...recess, 30...surface material

Claims

1. A plate-shaped substrate; a skin material attached to one surface of the base material, A plurality of through holes are formed in the substrate, A groove portion connecting the plurality of through holes is formed on the one surface.

2. the substrate has a recess that opens to the skin side, The vehicle interior material according to claim 1 , wherein the groove is formed on an inner surface of the recess.

3. a skin attaching step of attaching a skin to one surface of the plate-shaped substrate, the base material has a plurality of through holes and a groove portion formed on the one surface and connecting the plurality of through holes, In the skin attaching step, negative pressure is applied to the plurality of through holes and the grooves to suck the skin onto the one surface.

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