Parts and interior components for vehicles

Abstract

The present invention provides a part formed by integrally molding a plate-shaped substrate with a foamed resin material. [Solution] The component comprises a plate-shaped substrate having through holes, a sheet material attached to the surface of the plate-shaped substrate to cover the through holes, and a foamed resin material integrally molded with the plate-shaped substrate and laminated on the surface of the plate-shaped substrate, covering the sheet material, wherein the sheet material comprises a support layer containing fibers and a non-permeable film layer, and at least a portion of the end of the sheet material is embedded in the foamed resin material.

Description

Technical Field

[0001] The present disclosure relates to a component in which a foamed resin material is integrally formed.

Background Art

[0002] Patent Document 1 discloses a lid for a console box composed of a synthetic resin inner lid, a blocking member, and a coating material made of foamed polyurethane resin. The synthetic resin inner lid has reinforcing walls integrally protruding on the upper surface so as to form a number of small chambers. The blocking member is stretched over the reinforcing walls. The reinforcing walls are integrally coated with the foamed polyurethane resin through the blocking member. In this lid of the console box, ventilation holes are formed for each small chamber at the bottom of the inner lid in order to prevent deformation in the sealed small chambers during molding.

[0003] Patent Document 2 discloses an interior material for a vehicle including a foamed resin material covering the surface of a base material, and a skin material that is wound from the front surface side to the back surface of the base material for covering. The base material of the interior material for the vehicle has a plurality of through-holes penetrating in the thickness direction formed near the edge, and the foamed resin material protruding from the through-holes is adhered to the skin material wound from the front surface side to the back surface of the base material through the edge of the base material.

[0004] Patent Document 3 discloses a console box having a fastening structure for fastening an insert member and accessory members such as a back lid.

Prior Art Documents

Patent Documents

[0005]

Patent Document 1

Patent Document 2

Patent Document 3

Summary of the Invention

Problems to be Solved by the Invention

[0006] This disclosure provides a component that is an integrally molded product of a plate-shaped substrate and a foamed resin material. The molded panel component including the plate-shaped substrate is used as an interior component for vehicles, such as a console box lid. [Means for solving the problem]

[0007] A component according to one aspect of the present disclosure comprises a plate-shaped substrate having through holes, a sheet material attached to the surface of the plate-shaped substrate to cover the through holes, and a foamed resin material integrally molded with the plate-shaped substrate and laminated on the surface of the plate-shaped substrate, the sheet material comprising a support layer containing fibers and a non-permeable film layer, and at least a portion of the end of the sheet material being embedded in the foamed resin material. [Effects of the Invention]

[0008] According to this disclosure, it is possible to provide a part that is an integrally molded product of a plate-shaped substrate and a foamed resin material. [Brief explanation of the drawing]

[0009] [Figure 1] Schematic perspective view of interior components and a console box for a vehicle. [Figure 2] A perspective view of the console box and its lid. [Figure 3] Cross-sectional view of the console box lid (A-A in Figure 2). [Figure 4] A perspective view of the plate-shaped substrate as seen from the reverse side. [Figure 5] Cross-sectional view of the through-hole portion (B-B in Figure 4) of a plate-shaped substrate having a through-hole. [Figure 6] A perspective view of the plate-shaped substrate as seen from the surface side (the side intended to come into contact with the foamed resin material). [Figure 7] A perspective view of a plate-shaped substrate (first embodiment) as seen from the surface side, with a sheet material attached around the through-hole. [Figure 8] Cross-sectional view of the sheet material. [Figure 9] Schematic diagram showing the zigzag shape of the end of the sheet material. [Figure 10] Schematic diagram (A) near the sheet material of a component integrally formed with a plate-like base material and a foamed resin material and its enlarged schematic diagram (B). [Figure 11] Plan photograph of the sheet material cut in a zigzag shape as viewed from above. [Figure 12] Cross-sectional photograph of the cut surface of the sheet material cut in a zigzag shape. [Figure 13] Cross-sectional photograph of the cut surface of the sheet material cut linearly with scissors. [Figure 14] Perspective view of a plate-like base material (other example) as viewed from the surface side with a sheet material pasted around the through hole.

Mode for Carrying Out the Invention

[0010] Hereinafter, an embodiment of the present disclosure will be described with reference to the drawings. Regarding the numerical range, the description using "~" includes the lower limit value and the upper limit value unless otherwise specified. For example, the description "1~5" includes both the lower limit value "1" and the upper limit value "5". That is, "1~5" has the same meaning as "1 or more and 5 or less".

[0011] As shown in FIG. 1, the interior member 1 is installed in the vehicle C. In the present embodiment, examples of the interior member 1 include those using a panel or a base material. For example, as the interior member 1 for a vehicle, the lid 5 of the console box 70 which is a storage device for a vehicle such as an automobile can be mentioned. Hereinafter, in the present embodiment, the interior member 1 is the lid 5. However, it is not limited thereto, and the interior member 1 may be, for example, an armrest, a door trim, an instrument panel (dashboard), or other interior members in the vehicle. Further, in the present embodiment, the interior member 1 is installed in an automobile which is the vehicle C, but it is not limited thereto. For example, the interior member 1 may be installed in an aircraft, a ship, a building, or other internal spaces.

[0012] The main body of the console box 70 is a hollow box shape and extends in the longitudinal direction of the vehicle body. The console box 70 is located between the driver's seat and the front passenger seat of the vehicle C. Note that the console box 70 is connected to the center console, instrument panel, etc. of the vehicle C and is used for interior decoration.

[0013] Figure 2 is a perspective view of the console box 70 to which the interior member 1 (lid 5) is attached. As shown in Figure 2, the console box 70 includes a storage portion 90 that serves as a small item storage and a lid 5 for this storage portion 90. As shown in Figure 2, there is a storage portion 90 inside the main body of the console box 70, and it can store water bottles and small items. A lid 5 is provided above the storage portion 90 and can be opened and closed. In the state where the lid 5 is closed, it can also serve as an armrest. For example, the interior member 1 (lid 5) is supported on the main body of the console box 70 so as to be rotatable or slidable. Also, the interior member ① (lid 5) is locked to the main body in a state where the opening is blocked by a locking mechanism.

[0014] When the lid 5 is opened, the inside becomes the storage portion 90. The storage portion 90 is provided inside the console box 70 and can store various small items in an organized manner. It can be efficiently organized using partition boards and trays. The storage portion 90 serves as a space for storing small items such as smartphones, wallets, and drinks during driving. In addition, convenient functions such as a USB charger, a drink holder, and a tissue tray may be incorporated. The console box 70 includes functions for making driving comfortable, such as an armrest and a drink holder.

[0015] As shown in Figure 3, the interior member 1 (lid 5) is arranged such that the plate - like base material 10, the sheet material 20, the foamed resin material 30, and the skin material 40 are overlapped with each other.

[0016] This embodiment will be described using an example in which the interior component 1 (lid 5) rotates vertically relative to the main body. In the illustrated example, the interior component 1 (lid 5) is formed as a substantially rectangular parallelepiped, but it is not limited to this and may be any shape depending on the shape of the placement position and the desired function.

[0017] As shown in Figures 2 and 3, the interior component 1 (lid 5) has a roughly rectangular shape in a plan view from above, and is a rectangle with an open bottom. In a plan view of the lid 5, the longitudinal direction of the lid 5 is the front-to-back direction, and the direction perpendicular to the longitudinal direction (short direction) is the left-to-right direction or width direction. Also, the direction perpendicular to the surface (top) and back (bottom) of the lid 5 is the up-and-down direction.

[0018] The lid 5 of this embodiment has a substantially flat, planar surface (upper surface) and a front end surface that slopes downward toward the front from the planar surface. The lid 5 of this embodiment comprises a planar surface, a front end surface, a back surface (lower surface) located on the opposite side of the planar surface, and a vertical wall portion extending substantially perpendicularly to the peripheral edge of the surface (Figure 2).

[0019] The lid 5 is formed with a substantially constant thickness between its flat surface (top surface) and its back surface (bottom surface). The thickness dimension of the lid 5 refers to the vertical dimension from the flat surface of the lid 5 to the bottom end of the vertical wall, and can also be referred to as the thickness of the lid 5. The surface, left and right side end surfaces, and rear end surface of the lid 5 are connected in a curved manner. In this embodiment of the present invention, the shape and size of the lid 5 are not particularly limited.

[0020] Figure 3 is a cross-sectional view of the lid 5 along line A-A in Figure 2. As shown in Figure 3, the lid 5 comprises a plate-shaped base material 10, a foamed resin material 30 disposed on the surface 11 (upper surface) of the plate-shaped base material 10, and a surface material 40 disposed on the surface (upper surface) of the foamed resin material 30. The foamed resin material 30 is formed between the plate-shaped base material 10 and the surface material 40. The plate-shaped base material 10 and the foamed resin material 30 are molded parts formed by integral foaming. The molded part, in which the plate-shaped base material 10 and the foamed resin material 30 are integrally molded, is further covered with the surface material 40 and used as an interior component 1 for a vehicle. The surface material 40 can also be integrally molded, but it may be placed over the plate-shaped base material 10 and the foamed resin material 30 in a later process. The surface material 40 covers not only the upper surface of the plate-shaped base material 10, but also the left and right sides and the front and rear end faces of the plate-shaped base material 10.

[0021] The plate-shaped substrate 10 has through holes 16. The surface 11 of the plate-shaped substrate 10 has a sheet material 20 attached to it that covers the through holes 16 in the lamination direction of the plate-shaped substrate 10 and the foamed resin material 30, and seals the foaming raw material of the foamed resin material 30. The sheet material 20 blocks the through holes 16 in the lamination direction.

[0022] The surface 11 (upper surface) of the plate-shaped substrate 10 is composed of a foamed resin material 30 and a surface covering material 40 that further covers the upper surface. The foamed resin material 30 is laminated on the surface of the plate-shaped substrate 10, covering the entire sheet material 20.

[0023] The plate-shaped base material 10 supports the foamed resin material 30 and the surface material 40, and functions as a skeletal structure to maintain the shape of the interior member 1. The plate-shaped base material 10 has a shape that can be applied, for example, as the lid 5 of a console box 70. The thickness of the plate-shaped base material 10 is, for example, about 2 to 4 mm. This plate-shaped base material 10 has a lower surface (back surface 12) that forms the back surface of the lid 5, and an upper surface (front surface 11) that is located on the opposite side of the lower surface in the thickness direction of the lid 5. The front surface 11 (upper surface) of the plate-shaped base material 10 is located opposite the surface material 40, and is covered by the surface material 40 together with the foamed resin material 30.

[0024] The plate-shaped substrate 10 is a resin molded member formed from a highly rigid synthetic resin. Examples of resins include ABS resin, polypropylene (PP), polyethylene (PE), acrylic resin, polycarbonate (PC), polyamide, polyethylene terephthalate (PET), and modified polyphenylene ether (modified PPE). The plate-shaped substrate 10 is formed by injection molding these resin materials.

[0025] The storage compartment 90 shown in Figure 2 is formed from a material such as synthetic resin. The storage compartment 90 is made from a rigid material similar to the plate-shaped base material 10. The storage compartment 90 is the main part that makes up the largest portion of the console box 70. In this embodiment, the storage compartment 90 forms a roughly rectangular space that is roughly square in shape when viewed from above. In the illustrated example, the storage compartment 90 is rectangular in shape when viewed from above, with the longer side in the front-to-back direction and the narrower side in the width direction.

[0026] Figure 4 is a perspective view of the plate-shaped base material 10 from the back surface 12. Multiple reinforcing ribs 14 are formed on the lower surface (back surface 12) of the plate-shaped base material 10 along the short side (width direction) of the lid 5 (Figure 4). In this embodiment, six reinforcing ribs 14 are formed along the short side of the plate-shaped base material 10.

[0027] Figure 5 is a cross-sectional view of BB in Figure 4. As shown in Figure 5, the plate-shaped base material 10 is provided with a locking projection 17, a locking portion 18, and a through hole 16. The through hole 16 is located immediately next to the locking projection 17. The locking projection 17 protrudes from the opening edge of the through hole 16. The locking projection 17 is provided on the back surface 12 of the plate-shaped base material 10. The tip of the locking projection 17 is provided with a locking portion 18 that bulges out toward the opening side of the through hole 16. The locking portion 18 of the locking projection 17 engages with the locking receiving portion of another separate component facing it. The locking projection 17 and the locking receiving portion are fitted together and fastened.

[0028] The other separate component is a plate-shaped resin and is fastened and fixed to the plate-shaped base material 10. The other separate component and the plate-shaped base material 10 are fastened together by locking projections 17 and locking receiving parts. The locking projections 17 of the plate-shaped base material 10 are molded simultaneously when the plate-shaped base material 10 is injection molded. The through-hole 16 is formed when the locking projections 17 are injection molded. The through-hole 16 is provided for mold removal when forming the locking projections 17 and the locking part 18 at their tips.

[0029] The locking projection 17 is a short projection with a height of approximately 5-10 mm, a thickness of approximately 1.5-3 mm, and a width of approximately 6-12 mm, with a locking portion 18 formed at its tip. The tip of the locking projection 17 is also chamfered to facilitate insertion.

[0030] Figure 6 is a perspective view of the plate-shaped base material 10 used for the lid 5, viewed from the oblique upper side. Through holes 16 are formed near both edges in the longitudinal direction (front-to-back direction) of the plate-shaped base material 10, penetrating through its thickness. In this embodiment, the through holes 16 are opened next to the locations where the locking projections 17 are erected. In this embodiment, four through holes 16 are formed near each of the rear edges, one near the center, and two at the front.

[0031] Figure 7 is a perspective view of a plate-shaped substrate 10 in which multiple through holes 16 are covered with a sheet material 20. It is preferable that the sheet material 20 covers all of the through holes 16 of the plate-shaped substrate 10, as this prevents foaming material from leaking and overflowing from the through holes 16 during foam molding.

[0032] The foamed resin material 30 is bonded to the surface 11 (upper surface) of the plate-shaped base material 10 to which the sheet material 20 is attached so as to seal all the through holes 16. The foamed resin material 30 gives the interior component 1 a flexible texture. The foamed resin material 30 has a thickness of, for example, 1 mm to 12 mm. The foamed resin material 30 is, for example, a thin sheet of flexible polyurethane foam.

[0033] The foamed resin material 30 is molded, for example, by a conventional mold molding method. First, a raw material composition containing, for example, a polyol, a catalyst, and a foam stabilizer, and polyisocyanate are prepared as foaming raw materials. The raw material composition and polyisocyanate are mixed and extruded into a mold to form polyurethane foam. By setting the plate-shaped substrate 10 in the mold and performing foam molding, an integrally molded product of the plate-shaped substrate 10 and the foamed resin material 30 is produced. The surface material 40 may also be similarly set in the mold and manufactured simultaneously. Alternatively, the surface material 40 may be attached later to the integrally molded product of the plate-shaped substrate 10 and the foamed resin material 30.

[0034] The surface material 40 is placed on the surface (top surface) of the foamed resin material 30. The surface material 40 gives the interior member 1 a desired appearance and texture. The surface material 40 has a thickness of, for example, 0.3 mm or more and 3 mm or less.

[0035] The surface material 40 is, for example, leather, synthetic leather, resin sheet, or fiber material. Resin sheets are formed from, for example, polyvinyl chloride (PVC) or polyurethane resin (PU). Fiber materials include knitted fabrics, woven fabrics, nonwoven fabrics, and other fabrics.

[0036] The surface material 40 is a component that constitutes the design surface of the interior component 1 for a vehicle. The surface material 40 is formed in a sheet shape that is thinner than the foamed resin material 30. The surface material 40 is arranged to cover at least the entire surface of the foamed resin material 30. A resin film may be laminated between the foamed resin material 30 and the surface material 40. A slab foamed resin layer formed from a slab foamed resin sheet may be provided on the back side of the surface material 40.

[0037] As shown in Figure 8, the sheet material 20 comprises at least a support layer 23 containing fibers and a non-permeable film layer 24. The sheet material 20 may also have the non-permeable film layer 24 on the upper surface of the support layer 23 containing fibers. The sheet material 20 is a laminate comprising the support layer 23 containing fibers and the non-permeable film layer 24, and is preferably equipped with an adhesive layer 25 or bonding agent on the bottom surface for ease of handling. Separately, an adhesive or bonding agent may be applied to the surface 11 (upper surface) of the plate-shaped substrate 10 or the bottom surface of the sheet material 20. The non-permeable film layer 24 may be a resin film laminated to the support layer 23.

[0038] The top surface of the sheet material 20, which is a laminate containing a fiber-containing support layer 23 and a non-permeable film layer 24, may have a release layer coated with a release agent (back treatment agent). The release agent (back treatment agent) is used to prevent the adhesive layer 25 on the bottom surface of the sheet material 20 from remaining on the back surface of the top surface of the sheet material 20 laminated below when the sheet materials 20 are stacked. Examples of such sheet materials 20 include kraft tape.

[0039] If the top surface of the sheet material 20 is not provided with a release layer, the sheet material 20 exhibits excellent adhesion to the foamed resin material 30. However, when the foaming raw material (urethane raw material composition) is foamed and molded in a mold, molding defects may occur. From the viewpoint of the foaming moldability of the foamed resin material 30, it is preferable to provide a release layer on the top surface of the sheet material 20. However, if a release layer is provided on the top surface of the sheet material 20, the adhesion between the foamed resin material 30 and the sheet material 20 may decrease, causing them to peel off.

[0040] The sheet material 20 can have any shape; for example, when viewed from above, the shape of the periphery may be approximately rectangular, approximately circular, or elliptical. A roughly rectangular shape for the sheet material 20 is preferable from the viewpoint of ease of use during the manufacture of the lid 5. The size of the sheet material 20 is preferably smaller than the plate-shaped base material 10.

[0041] The edges of the sheet material 20 are cut, and the end portion 28, which is part of the edge, has a zigzag shape when viewed from above (Figure 7). For example, if the shape of the sheet material 20 is roughly rectangular, then one or more of the four sides, or part of the end portion 28, has a zigzag shape. For example, if the shape of the edge of the sheet material 20 is roughly rectangular, it is preferable that one or more of the four sides have a zigzag shape.

[0042] When the sheet material 20 is roughly rectangular in shape, two adjacent sides, or two opposing sides, are zigzag in shape. In this case, a sheet material with two opposing sides being zigzag is preferable from the standpoint of ease of use during the manufacturing of the lid 5.

[0043] From the viewpoint of adhesion between the foamed resin material 30 and the sheet material 20, it is preferable that the number of zigzag-shaped sides be two rather than one, and more preferable that there be three sides. Furthermore, it is even more preferable that the entire circumference is zigzag-shaped, for example, in the case of a rectangle, all four sides are zigzag-shaped. Also, from the viewpoint of adhesion, it is preferable that the ratio of the circumference of the zigzag-shaped end 28 to the entire circumference of the sheet material 20 be 20% or more, more preferably 40% or more, even more preferably 60% or more, and particularly preferable that it be 100%. By making the sheet material 20 zigzag-shaped, the distance of the peripheral edge, which is the cut surface of the sheet material 20, can be increased, making it easier to bond the sheet material 20 and the foamed resin material 30.

[0044] Here, "zigzag" refers to a shape or form in which a line is repeatedly bent in a Z-shape, as shown in Figure 9. This includes shapes such as saw teeth, broken lines, lightning bolts, and wavy lines. The angles in this zigzag shape can be acute angles α (Figure 9(A)), right angles β (Figure 9(B)), or obtuse angles γ (Figure 9(C)). The bent lines are not limited to straight lines; even slightly curved lines are included in the zigzag shape.

[0045] The shape of the corner at the bend, for example, the corner at the tip of a saw blade, may in reality be somewhat rounded (Figure 9(D)). For example, in a zigzag shape, the angle between two adjacent lines usually corresponds to the interior angle of a triangle or polygon. However, the angle between two adjacent lines in a zigzag shape is not necessarily the point where the two lines intersect; the angle may be rounded.

[0046] Specifically, in the case of a zigzag shape as shown in Figures 9(A), (B), and (C), the corner formed by two adjacent straight lines is sharp. In contrast, when two adjacent lines are slightly curved (Figure 9(D)), for example, the curve at that corner can be locally considered as an arc of a circle. In this embodiment, if the radius of curvature (R), which is the radius of the circle, is 1 / 2 or less of the length (L) of the adjacent sides, it is included in the zigzag shape (see Figures 9(D) and (C)).

[0047] In this zigzag shape, the corners are preferably as follows, from the viewpoint of cutting the sheet material 20 and integral molding of the foamed resin material 30 and the plate-shaped base material 10. In this zigzag shape, it is preferable that the corners formed by adjacent straight lines are sharp. Alternatively, the radius of curvature (R) of the corners in the zigzag shape is preferably 1 / 3 or less of the length of the adjacent side (L), more preferably 1 / 4 or less, and even more preferably 1 / 5 or less (see Figures 9(D) and 9(C)).

[0048] The zigzag shape in this embodiment is formed, for example, by cutting the periphery of the sheet material 20 as follows. The sheet material 20 is cut by pulling it in the width direction while a cutter with a zigzag-shaped cutting edge is applied to the surface of the sheet material 20. The cutting edge of the zigzag blade is fixed and applied to the surface of the sheet material 20, and the sheet material 20 is pulled in a direction that intersects the longitudinal direction. Small holes and small cuts are made in the sheet material 20, and the sheet material 20 is cut by continuing to pull it.

[0049] In this embodiment, the sheet material 20 is cut by tearing it in a zigzag pattern as described above. Due to this zigzag cut, multiple fibers are raised from the cut surface of the sheet material 20 toward the sides and upwards of the support layer 23 of the sheet material 20. The fuzzed fibers 29 protrude from the end surface, which is the cut surface of the sheet material 20. Fuzzing is generated on the cut surface of the end 28 of the sheet material 20, and the fuzzed fibers 29 are provided on the end 28, which is the periphery of the sheet material 20. Figure 11 is a 500x magnified photograph of the zigzag-shaped sheet material 20. The zigzag-shaped end 28 has fuzzing, and the fuzzed fibers 29 protrude from the end surface. Also, the shape of the corner at the bent end is somewhat rounded. Here, "fuzzing" refers to the state in which the surface becomes napped due to friction or other causes, as defined in JIS P0001(1998)7020, for example, and in which fibers protrude from the surface (the end face in this embodiment).

[0050] In the sheet material 20 of this embodiment, at the cross-section of the zigzag-cut end 28, multiple fibers of the support layer 23 are frayed, and the frayed fibers 29 protrude. Also, at the cross-section of the zigzag-cut end 28 of the sheet material 20, the spacing between multiple fibers is widened, and the thickness of the cross-section is wider than the thickness of the sheet material 20 (Figures 12 and 13). The zigzag-cut end 28 of the sheet material 20 is an end 28 that is wider than the thickness of the sheet material 20. Figure 12 is a 150x magnification photograph of the cross-section. Figure 13 is a 150x magnification photograph of the cross-section of the sheet material 20 cut in a straight line with scissors. Comparing the cross-section (end face) cut in a straight line with scissors with the cross-section (end face) cut in the zigzag shape described above, the cross-section (end face) cut in a zigzag shape is formed to be thicker. Fluffy fibers 29 protrude from the edge of the sheet material 20, and multiple fibers are raised from the surface (top surface) of the sheet material 20 upwards.

[0051] The sheet material 20 is attached to the plate-shaped base material 10 so as to cover the through holes 16, and the foamed resin material 30 is placed on the surface 11 of the plate-shaped base material 10. The foamed resin material 30 is, for example, a polyurethane foam that has been foamed and molded from a foaming raw material.

[0052] The foamed resin material 30 is, for example, a polyurethane resin, which is a polymer obtained by the reaction of a polyol component and a polyisocyanate component of a foaming raw material. It can be manufactured by conventional mold molding using a plate-shaped substrate 10 as an insert. This makes it possible to obtain a part 8 in which the plate-shaped substrate 10 and the foamed resin material 30 are integrally molded.

[0053] A plate-shaped base material 10 is created by attaching a sheet material 20 to the plate-shaped base material 10 so as to cover the through holes 16. The plate-shaped base material 10 is set in the upper mold. A release agent is applied to the lower mold, and then polyurethane foaming material is poured into the mold. Both molds are closed by aligning the upper mold with the lower mold. When the mold is heated for a predetermined time, the foaming material foams and hardens to become polyurethane foam. As a result, the plate-shaped base material 10 and the foamed resin material 30 are integrally molded.

[0054] When the foaming raw material described above foams and hardens, at least a portion of the fuzzy fibers 29 at the end 28 of the sheet material 20 attached to the plate-shaped substrate 10 are embedded in the foamed resin material 30 (Figure 10). The fuzzy fibers 29 from the cut surface of the sheet material 20 are embedded in the foamed resin material 30, allowing the sheet material 20 and the foamed resin material 30 to be bonded (joined).

[0055] Furthermore, at the cut surface of the end 28 of the sheet material 20, the spacing between multiple fibers widens, making it easier for the foaming material to penetrate from the periphery of the sheet material 20, and allowing the fibers at the cut surface to be embedded in the foamed resin material 30. This increases the adhesive strength (bonding strength) between the foamed resin material 30 and the sheet material 20. Even if the top surface of the sheet material 20 is equipped with a release layer, the fuzzy fibers 29 are embedded in the foamed resin material 30, thereby maintaining adhesion between the foamed resin material 30 and the sheet material 20.

[0056] Typically, olefin-based resins such as polypropylene and polyethylene have poor adhesion. Therefore, even if an olefin-based resin is used for a plate-shaped substrate 10 and a foamed resin material 30 (polyurethane foam) is integrally molded onto it, the integrally molded plate-shaped substrate 10 and the foamed resin material 30 tend to peel off. Furthermore, if a release layer is provided on the top surface of the sheet material 20, the adhesion between the sheet material 20 and the foamed resin material 30 decreases, making them more prone to peeling apart. However, the fibers 29 that are frayed from the cut surface of the sheet material 20 are embedded in the foamed resin material 30, which increases the adhesion between the sheet material 20 and the foamed resin material 30. Furthermore, since the sheet material 20 and the plate-shaped substrate 10 are adhered together by the adhesive layer 25 of the sheet material 20, the foamed resin material 30 becomes less likely to peel off from the plate-shaped substrate 10 via the sheet material 20.

[0057] After integral foam molding, the foamed resin material 30 laminated on the plate-shaped base material 10 is covered with a surface material 40 to create the lid 5. The surface material 40 may be pre-set in the lower mold into which the foaming raw material is injected. The foamed resin material 30 is formed as a foamed layer with a thickness of, for example, 5 to 12 mm.

[0058] Next, the zigzag shape of the sheet material 20 to be attached to the plate-shaped substrate 10 according to this embodiment will be described (Figure 7).

[0059] <Example of attaching sheet material 20> As an example of how the sheet material 20 is attached in this embodiment, as shown in Figure 7, sheet materials 20 of various shapes can be attached to the plate-shaped substrate 10 through the through holes 16. The sheet material 20 has a non-permeable film layer 24 on the upper surface of a fiber-containing support layer 23, and the uppermost surface of the film layer 24 has a release layer coated with a release agent (back treatment agent). Furthermore, an adhesive layer 25 is provided on the bottom surface. At the zigzag-shaped cut ends 28, multiple fibers of the support layer 23 are frayed.

[0060] At the back (upper) left side of the plate-shaped base material 10 and at the position of the second through hole 16, a sheet material 20 is attached, which, when viewed from above, is roughly rectangular, with one edge (end 28) of the periphery having a zigzag shape (Figure 7). Below (front of) that, two more roughly rectangular sheet materials 20, each with a zigzag shape all around, are attached.

[0061] On the far right side (upper part), a sheet material 20 with a roughly rectangular shape has two or three sides of its peripheral edge 28 that are zigzag-shaped attached to it. Below and in front of the sheet material 20 with three zigzag sides, a sheet material 20 with two adjacent zigzag sides is attached. Further in and below that position, two sheet materials 20 with two opposing zigzag sides are attached.

[0062] A roughly rectangular sheet material 20 with a zigzag pattern all around is attached to the center of the plate-shaped base material 10. At two locations on the lower front, a roughly rectangular sheet material 20 with one edge (end 28) of the periphery is attached with a zigzag pattern.

[0063] <Other examples of attaching sheet material 20> Next, other examples of how the sheet material 20 is attached in this embodiment will be described with reference to Figure 14. In principle, the description of components common to the first example will be omitted, and the focus will be on the differences.

[0064] Another example of how the sheet material 20 is attached in this embodiment is that a sheet material 20 that is roughly rectangular in shape has two opposing sides of its peripheral edge 28 that are zigzag-shaped, and this sheet material 20 is attached to the plate-shaped base material 10. As shown in Figure 14, in the plate-shaped base material 10, all 11 through holes 16 are covered by the sheet material 20 with two opposing sides that are zigzag-shaped.

[0065] According to the application method of the sheet material 20 in the other examples described above, a zigzag-shaped end 28 can be formed on the sheet material 20 using a cutter (tape cutter) having a zigzag-shaped blade. When manufacturing the zigzag-shaped sheet material 20, in addition to a flat sheet material 20, a rolled tape material with an adhesive layer 25 on its bottom surface can be used. Therefore, a single-piece molded part 8 can be efficiently provided.

[0066] Although the present disclosure has described the embodiments described above, it is not limited to these embodiments, and various modifications are possible without departing from the spirit of the invention. In particular, the configurations described herein can be combined as needed. [Explanation of symbols]

[0067] 1: Interior components 5: Lid 8: Parts (Panel parts) 10: Plate-shaped substrate 11: Surface of the plate-shaped substrate 12: Back surface of the plate-shaped substrate 14: Reinforcement Ribs 16: Through hole 17: Locking protrusion 18: Locking part 20: Sheet material 23: Support layer 24; Film layer 25: Adhesive layer 28: End 29: Fuzzy fibers (fuzziness of fibers) 30: Foamed resin material 40:Skin material 70: Console Box 90: Storage compartment C: Vehicles

Claims

1. A plate-shaped substrate having through holes, A sheet material covering the through hole, which is attached to the surface of the plate-shaped substrate, A part comprising: a foamed resin material integrally molded with the plate-shaped substrate and laminated on the surface of the plate-shaped substrate, covering the sheet material, The aforementioned sheet material comprises a support layer containing fibers and a non-permeable film layer. A component in which at least a portion of the end of the sheet material is embedded in the foamed resin material.

2. The edges of the sheet material embedded in the foamed resin material are provided with the fuzzy fibers. The component according to claim 1.

3. The end of the sheet material embedded in the foamed resin material has an end face having a thickness greater than the thickness of the sheet material. The component according to claim 1.

4. The edges of the sheet material are zigzag in shape. The component according to claim 1.

5. The aforementioned sheet material is An adhesive layer is provided on the lower surface of the support layer containing the aforementioned fibers, The upper surface of the support layer containing the aforementioned fibers is provided with a non-breathable film layer. The component according to claim 1.

6. On the surface of the foamed resin material of the part according to any one of claims 1 to 5, Interior components for vehicles, consisting of laminated surface materials.

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