Surface material and interior components

Abstract

To provide a novel surface material that can suppress wear on the light-transmitting and light-blocking portions. [Solution] The surface material 10 comprises a surface layer 11 having a first surface 11a for forming a design and a second surface 11b opposite to the first surface 11a, a printed layer 12 formed on the second surface 11b, a protective layer 13 including a first protective part 131 bonded to the printed layer 12 from the side opposite to the surface layer 11, and a second protective part 132 connected to the first protective part 131 and positioned on the second surface 11b.

Description

Technical Field

[0001] The present disclosure relates to a surface material and an interior member.

Background Art

[0002] Interior members are installed in vehicles, ships, aircraft, buildings, and other interior spaces. In recent years, interior members that incorporate a light source and express a design by light have been proposed. For example, interior members that incorporate one or more switches and express a design (e.g., shape, pattern, character) indicating the type or function of each switch by light have been proposed.

[0003] Patent Document 1 discloses an interior member that expresses a design by light. This interior member includes a surface material, a cushion material disposed on the back side of the surface material to give the interior member a flexible texture, and a light source disposed on the back side of the surface material to irradiate light onto a display area corresponding to the range where the design of the surface material is displayed. The display area of the surface material is formed to transmit light in a specific shape. The light from the light source passes through the display area of the surface material and expresses a design of a specific shape on the surface of the surface material.

Prior Art Documents

Patent Documents

[0004]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0005] The surface material used for such an interior member may be provided with a light-transmitting portion provided on its surface so as to transmit light in a specific shape and a light-blocking portion other than the light-transmitting portion. It is preferable that the surface material protects the light-transmitting portion and the light-blocking portion from friction with articles other than the surface material and suppresses wear of the light-transmitting portion and the light-blocking portion.

[0006] The object of this disclosure is to provide a novel surface material that can suppress wear of the light-transmitting portion and the light-shielding portion. [Means for solving the problem]

[0007] A surface material according to one aspect of the present disclosure comprises a surface layer having a first surface for forming a design and a second surface opposite to the first surface, a printed layer formed on the second surface, a protective layer including a first protective portion bonded to the printed layer from the side opposite to the surface layer, and a second protective portion connected to the first protective portion and positioned on the second surface. [Effects of the Invention]

[0008] According to this disclosure, a novel surface material can be provided that can suppress wear of the light-transmitting portion and the light-shielding portion. [Brief explanation of the drawing]

[0009] [Figure 1] A schematic diagram showing interior components installed inside the vehicle. [Figure 2] A cross-sectional view showing the cross-section of an interior component. [Figure 3] A magnified view showing a portion of Figure 2. [Figure 4] An explanatory diagram illustrating the effects of this disclosure. [Modes for carrying out the invention]

[0010] Hereinafter, one embodiment of this disclosure will be described with reference to the drawings.

[0011] As shown in Figure 1, the interior component 1 is installed in the vehicle C. The interior component 1 is, for example, a dashboard. However, it is not limited to this, and the interior component 1 may be, for example, an armrest, door trim, seat, or other interior component within the vehicle C. Furthermore, although the interior component 1 is installed in the vehicle C in this embodiment, it is not limited to this. For example, the interior component 1 may be installed in an aircraft, ship, building, or other interior space.

[0012] Interior component 1 incorporates one or more switches for operating the electrical components of vehicle C. The surface of interior component 1 (i.e., the design surface facing the passenger compartment) is provided with switch areas 2 that represent the type or function of each switch. Switch areas 2 are areas that the user touches or presses to operate the corresponding switches.

[0013] Switch area 2 includes, for example, a pattern resembling a fan, the words "ON / OFF", and the symbols "-" and "+" to indicate that these are switches for controlling the air conditioner of vehicle C.

[0014] Furthermore, the switch area 2 includes a light-shielding portion 2a and a light-transmitting portion 2b. The light-transmitting portion 2b is the portion that transmits light from the light-emitting portion 20 (see Figure 2) located on the back side of the interior component 1, while the light-shielding portion 2a is the portion that transmits less light than the light-transmitting portion 2b, or does not transmit any light at all.

[0015] In this embodiment, the above-mentioned pattern is formed by the light-transmitting portion 2b provided within the light-shielding portion 2a. As a result, when the light-emitting portion 20 of the interior member 1 is lit, the light passing through the light-transmitting portion 2b expresses a specific design on the surface of the interior member 1. On the other hand, when the light-emitting portion 20 is turned off, the light-transmitting portion 2b may become so dark that it is indistinguishable from the light-shielding portion 2a.

[0016] In this embodiment, a design indicating the type or function of switches is displayed on the surface of the interior component 1, but this disclosure is not limited thereto. The surface of the interior component 1 may also display a design unrelated to switches, which is intended to decorate the appearance of the interior component 1.

[0017] Figure 2 is a cross-sectional view of the interior member 1 including the switch area 2. As shown in Figure 2, the interior member 1 includes a substrate portion 4 having a first opening 41, a cushion material 6 having a second opening 61, a skin material 10, a base material 14, a porous layer 16, a light-transmissive touch sensor 18, a light-emitting portion 20, and a light-shielding wall 22. The substrate portion 4, the cushion material 6, and the skin material 10 are laminated in the direction of arrow Z. In the present embodiment, the direction of arrow Z will be described as the lamination direction.

[0018] The substrate portion 4 supports the cushion material 6 and the skin material 10 and functions as a skeletal structure for maintaining the shape of the interior member 1. The substrate portion 4 of the present embodiment is plate-shaped and extends intersecting the lamination direction, but various shapes can be selected according to the shape or dimensions of the interior member 1.

[0019] The substrate portion 4 is a resin molding member having light-shielding properties. The resin molding member may be a resin whose resin itself exhibits light-shielding properties, or may exhibit light-shielding properties by containing a black pigment even if the resin itself has no light-shielding properties.

[0020] The resin forming the substrate portion 4 is, for example, ABS resin, polypropylene (PP), polyethylene (PE), acrylic resin, polycarbonate (PC) resin, polyamide, polyethylene terephthalate (PET), modified polyphenylene ether (modified-PPE).

[0021] The cushion material 6 is disposed between the substrate portion 4 and the skin material 10 in the lamination direction and functions as a cushion material that gives the interior member 1 a soft texture. The cushion material 6 has a thickness of, for example, 1 mm or more and 5 mm or less.

[0022] The cushion material 6 is, for example, a thin plate-shaped soft polyurethane foam (PUF; Polyurethane Foam) having translucency. The cushion material 6 is formed, for example, as follows. First, a raw material composition containing a polyol, a catalyst, and a foam stabilizer and a polyisocyanate are prepared. The polyol, each raw material composition, and the polyisocyanate are mixed, poured onto a release paper, passed through a heating furnace, and foamed and cured to become a block-shaped polyurethane foam. This block-shaped polyurethane foam is sliced to become a thin plate-shaped polyurethane foam.

[0023] The second opening 61 of the cushion material 6 overlaps the first opening 41 of the substrate portion 4 in the stacking direction (arrow Z direction). The cushion material 6 and the substrate portion 4 of the present embodiment include the above-described switch region 2 (see FIG. 1) in the stacked portion of the first opening 41 and the second opening 61.

[0024] The skin material 10 is laminated on the side opposite to the substrate portion 4 of the cushion material 6 in the stacking direction (arrow Z direction). The skin material 10 is adhered to the cushion material 6 by an adhesive or frame lamination. The skin material 10 gives the interior member 1 a desired appearance and texture. The skin material 10 has, for example, a thickness of 0.3 mm or more and 3 mm or less.

[0025] The skin material 10 includes a skin layer 11, a printing layer 12, and a protective layer 13.

[0026] The surface layer 11 is formed of a translucent sheet material. The sheet material is, for example, a resin sheet or fiber material to which a plasticizer has been added to give it a flexible feel. The resin sheet in this embodiment is, for example, polyvinyl chloride (PVC) with a plasticizer added. However, the resin sheet is not limited to this and may be formed of a thermoplastic elastomer such as polyurethane resin (PU), TPO (Thermoplastic Olefinic Elastomer), TPS (Thermoplastic Stylenic Elastomer), TPU (Thermoplastic polyurethane Elastomer), or synthetic leather. The fiber material includes knitted fabrics, woven fabrics, nonwoven fabrics, and other fabrics, and may include polyester, polypropylene, nylon, cotton, etc.

[0027] The epidermal layer 11 has a first region S1 that closes the second opening 61 of the cushioning material 6, a second region S2 surrounding the first region S1, and a third region S3 surrounding the second region S2.

[0028] In this embodiment, the first region S1 includes the switch region 2 (see Figure 1) described above and corresponds to the laminated portion of the first opening 41 of the substrate 4 and the second opening 61 of the cushioning material 6. The second region S2 is the periphery of the first region S1 and corresponds to the laminated portion of the surface material 10, the cushioning material 6, and the substrate 4. The third region S3 is the periphery of the second region S2 and includes the edge of the surface layer 11, and consequently the edge of the surface material 10. In this embodiment, the portion of the surface material 10 corresponding to the third region S3 is wrapped around and bonded to the back surface of the substrate 4 (the side opposite the cushioning material 6).

[0029] The surface layer 11 has a first surface 11a that forms the design of the interior member 1, and a second surface 11b opposite to the first surface 11a.

[0030] Figure 3 is a magnified view of the area surrounding the printed layer 12 and protective layer 13 in Figure 2. As shown in Figure 3, the printed layer 12 is a light-shielding printed layer printed on the second surface 11b of the surface layer 11. The printed layer 12 is provided in the central portion which is part of the first region S1, and a gap 12a is provided between the outer edge of the printed layer 12 and the edge of the first region S1.

[0031] The printed layer 12 is formed of a resin containing a pigment corresponding to the desired color or a transparent resin that does not contain a pigment. This resin is, for example, a phenolic resin, a polyester resin, an acrylic resin, or a urethane resin. In this embodiment, the printed layer 12 is formed by printing the above-mentioned resin to the second surface 11b of the surface layer 11 to a desired thickness using a gravure printing machine (gravure offset), a screen printing machine, or a PAD printing machine.

[0032] The printed layer 12 includes a transparent window 121 and a printed area 122 excluding the transparent window 121. The thickness of the transparent window 121 and the printed area 122 (in the Z direction of the arrow) is, for example, 0.02 mm or less, and may be between 5 μm and 10 μm.

[0033] The translucent window 121 corresponds to the light-transmitting portion 2b of the switch area 2 (see Figure 1). That is, light transmitted through the translucent window 121 appears on the first surface 11a of the surface layer 11, expressing a specific design on the surface of the interior member 1. The translucent window 121 in this embodiment is formed of a transparent resin that does not contain pigment. The thickness of the translucent window 121 in this embodiment (in the direction of arrow Z) is 10 μm. Note that a printed layer of transparent resin is not required for the translucent window 121. That is, the thickness of the translucent window 121 may be 0 μm, in which case the translucent window 121 has no physical layer.

[0034] The printed portion 122 corresponds to the central part of the light-shielding portion 2a of the switch area 2 (see Figure 1). In this embodiment, the printed portion 122 is formed of a resin containing, for example, carbon black, iron black, or other black pigments. The thickness of the printed portion 122 in this embodiment (arrow Z direction) is 10 μm. As a result, a printed layer of the same thickness as the printed portion 122 is formed on the transparent window 121. Therefore, it is possible to prevent a difference in tactile sensation given to the user by the first surface 11a of the surface layer 11, and consequently, by the light-shielding portion 2a and the light-transmitting portion 2b of the switch area 2 of the interior member 1.

[0035] The protective layer 13 is a thin film that is placed on the second surface 11b of the surface layer 11 and covers part or all of the printed layer 12. The protective layer 13 has a first surface 13a that faces the printed layer 12 and / or the second surface 11b of the surface layer 11, and a second surface 13b that is opposite to the first surface 13a.

[0036] The protective layer 13 is resistant to plasticity. This prevents the migration of plasticizer from the surface layer 11. The first surface 13a of the protective layer 13 is adhesive to the second surface 11b of the printed layer 12 and / or the surface layer 11. The second surface 13b of the protective layer 13 may also be adhesive to the porous layer 16. The protective layer 13 of this embodiment is a layer structure in which a resistant adhesive or tacky layer is applied or laminated to both sides of a translucent nonwoven fabric that serves as a base material, and both the first surface 13a and the second surface 13b are provided with a resistant adhesive or tacky layer, making it a double-sided tape. As a result, the protective layer 13 can be placed on the second surface 11b of the printed layer 12 and / or the surface layer 11 while maintaining adhesive strength, while preventing the migration of plasticizer added to the resin sheet forming the surface layer 11, thereby suppressing detachment from the printed layer 12 and / or the surface layer 11. Furthermore, the protective layer 13 is bonded to the porous layer 16, and the porous layer 16 can be fixed to the protective layer 13.

[0037] The protective layer 13 includes a first protective portion 131 and a second protective portion 132. The first protective portion 131 is bonded to the printed layer 12 from the side opposite to the surface layer 11. The first protective portion 131 covers the entire printed layer 12. In this embodiment, the first protective portion 131 is positioned between the second surface 11b of the surface layer 11 and the porous layer 16 in the lamination direction (arrow Z direction) to protect the printed layer 12 from friction with the porous layer 16. The second protective portion 132 is connected to the first protective portion 131 and positioned on the second surface 11b of the surface layer 11. The edge of the second protective portion 132 opposite to the first protective portion 131 is positioned in the gap 12a between the outer edge of the printed layer 12 and the end of the first region S1. In this embodiment, the second protective portion 132 covers a part of the surface layer 11 corresponding to the gap 12a, but is not limited to this; the second protective portion 132 may be positioned to cover the entire surface layer 11 corresponding to the gap 12a, completely sealing the gap 12a. As a result, the second protective portion 132 is bonded to the second surface 11b of the surface layer 11, and the printed layer 12 can be fixed to the surface layer 11. In addition, the second protective portion 132 protects the printed layer 12 from friction with the porous layer 16 by covering its edges.

[0038] The second protective section 132 includes a light-shielding section 132a. The light-shielding section 132a is a light-shielding printed layer printed on the second protective section 132. The light-shielding section 132a may be provided over the entire second protective section 132 or in part. If the light-shielding section 132a is provided in part of the second protective section 132, it is arranged to include at least the end on the first protective section 131 side. As a result, when viewed in the stacking direction (arrow Z direction), the light-shielding section 132a is arranged to overlap with or be continuous with the printed portion 122 of the printed layer 12, thereby suppressing unintended light leakage from between the printed layer 12 and the light-shielding section 132a. Furthermore, from the viewpoint of suppressing light leakage from between the light-shielding section 132a and the printed portion 122 of the printed layer 12, the light-shielding section 132a may extend from the second protective section 132 towards the first protective section 131 side. In this case, when viewed in the stacking direction, it is preferable that the light-shielding portion 132a overlaps with the printed portion 122 of the printed layer 12 and does not overlap with the transparent window 121.

[0039] The light-shielding portion 132a is formed of a resin containing a pigment corresponding to a desired color, similar to that of the printed layer 12, or a transparent resin that does not contain a pigment. In this embodiment, the light-shielding portion 132a is formed by applying or printing a light-shielding resin to the nonwoven fabric that serves as the base material in the layer structure constituting the protective layer 13. However, it is not limited to this, and may also be formed by adding a pigment to the material that forms the adhesive layer or tack layer. In this case, as shown in Figure 3, the light-shielding portion 132a may be formed by adding a light-shielding pigment to the material that forms the adhesive layer or tack layer on the first surface 13a of the protective layer 13. Furthermore, if the adhesive layer or tack layer is provided only on the first surface 13a side of the protective layer 13, it may be formed by printing a light-shielding pigment on the second surface 13b.

[0040] Returning to Figure 2, the base material 14 is, for example, a resin molded member formed from a translucent resin. Examples of resins include ABS resin, polypropylene (PP), polyethylene (PE), acrylic resin, polycarbonate (PC), polyamide, and polyethylene terephthalate (PET).

[0041] The base material 14 is attached to the substrate portion 4 by mounting members 141 such as screws. The base material 14 has a protrusion 14a that is inserted into the first opening 41 of the substrate portion 4, and an insertion hole 14d. The protrusion 14a (base material 14) is inserted into the first opening 41 and laminated onto the surface material 10 from the protective layer 13 side. The height of the protrusion 14a is equal to the thickness of the substrate portion 4 (in the direction of arrow Z). In this embodiment, the protrusion 14a fills the first opening 41. The protrusion 14a prevents damage to the surface material 10, damage to the translucent touch sensor 18 (described later), and damage to the light-emitting portion 20 due to excessive pressure on the switch area 2 (see Figure 1) by the user.

[0042] A porous layer 16, which is inserted into the second opening 61 of the cushioning material 6, is adhered to the outer surface 14b of the protrusion 14a. In this embodiment, the thickness of the porous layer 16 is equal to the thickness of the cushioning material 6, or is formed to be about 0.5 mm thinner than the cushioning material 6. In this embodiment, the porous layer 16 fills the second opening 61. The porous layer 16 provides a flexible texture to the user who presses the switch area 2.

[0043] The insertion hole 14d penetrates the base material 14 along the stacking direction (arrow Z direction). In this embodiment, two insertion holes 14d are provided and are spaced apart from each other in the X direction intersecting the stacking direction.

[0044] The porous layer 16 is positioned between the protrusions 14a (base material 14) and the surface material 10 in the lamination direction (arrow Z direction) and is translucent. The porous layer 16 may be made of the same material as the cushioning material 6 or a different material. In this embodiment, the porous layer 16 is made of a different material from the cushioning material 6, for example, a so-called 3D mesh made of resin fibers formed into a three-dimensional structure. Alternatively, the porous layer 16 may be made of the same material as the cushioning material 6, and may be a thin sheet of soft polyurethane foam, silicone rubber, or fibrous material.

[0045] The translucent touch sensor 18 is, for example, a translucent flexible circuit board on which a capacitive touch sensor is mounted. The translucent touch sensor 18 is attached to the inner surface 14c of the protrusion 14a. The translucent touch sensor 18 senses when the user touches the switch area 2, generates a signal, and transmits the generated signal to an external controller.

[0046] The light-emitting unit 20 is an LED, laser, incandescent bulb, fluorescent lamp, or other light source. The light-emitting unit 20 is positioned on the opposite side of the substrate 14 from the surface material 10 (opposite direction of arrow Z) and irradiates light onto the surface material 10. The circuit board 19, which is electrically connected to the light-emitting unit 20 and the translucent touch sensor 18, is attached to the substrate 14 by mounting members 141 such as screws, with the light-emitting unit 20 positioned inside the protrusion 14a.

[0047] The light-shielding wall 22 has light-shielding properties and controls the irradiation range of light from the light-emitting part 20 on the surface material 10 by blocking a portion of the light irradiated from the light-emitting part 20. The light-shielding wall 22 is provided between the second protective part 132 of the protective layer 13 and the light-emitting part 20. Specifically, the light-shielding wall 22 is provided so as to block the path of light irradiated from the light-emitting part 20 to the second protective part 132. As a result, the light-shielding wall 22 can suppress unintended light leakage in the second protective part 132 and, consequently, in the first region S1. The light-shielding wall 22 in this embodiment is plate-shaped extending in the lamination direction (arrow Z direction) and is held in the base material 14 by being inserted into the insertion hole 14d of the base material 14. The end of the light-shielding wall 22 on the surface material 10 side extends to the outer surface 14b of the base material 14, but may also protrude from the outer surface 14b and extend into the interior of the porous layer 6. Furthermore, the shape and dimensions of the light-shielding wall 22 can be changed in various ways depending on the distance or positional relationship between the light-emitting part 20 and the second protective part 132 of the protective layer 13. For example, it may be cylindrical in shape so as to surround the light-emitting part 20. In this case, the insertion hole 14d of the base material 14 may be appropriately changed according to the shape of the light-shielding wall 22.

[0048] Next, using Figure 4, the path through which light emitted from the light-emitting unit 20 passes and the effect of the light-shielding wall 22 will be explained. Figure 4 is a schematic diagram showing how light emitted from the light-emitting unit 20 passes through the substrate 14, the porous layer 16, and the surface material 10. As shown by the dotted lines in Figure 4, the light emitted from the light-emitting unit 20 is blocked by the light-shielding wall 22 and reaches the surface material 10 via the porous layer 16 without diffusing in a direction intersecting the lamination direction (arrow Z direction). The light that reaches the surface material 10 passes through the first protective part 131 of the protective layer 13, while being blocked by the light-shielding part 132a provided in the second protective part 132. As a result, the light-shielding part 132a can suppress unintended light leakage from the edge of the printed layer 12. Furthermore, light that reaches the printing layer 12 via the first protective portion 131 of the protective layer 13 passes through the translucent window 121 of the printing layer 12 and is exposed on the surface of the interior member 1 (the first surface 11a of the surface layer 11). On the other hand, light is blocked in the printing portion 122, and as a result, the design corresponding to the light-transmitting portion 2b appears on the interior member 1. In this way, the interior member 1 can display the desired design while suppressing unintended light leakage.

[0049] As shown in Figure 3, the interior member 1 may further include a side light-shielding portion 24. The side light-shielding portion 24 is a light-shielding layer provided across the end face of the substrate portion 4 defining the first opening 41 and the end face of the cushioning material 6 defining the second opening 61. In this embodiment, the side light-shielding portion 24 is formed by applying or printing a resin containing a pigment corresponding to a desired color, similar to the printed portion 122 of the printed layer 12. As a result, the side light-shielding portion 24 can suppress leakage of light from areas other than the light-transmitting window 121 (light-transmitting portion 2b) of light irradiated from the light-emitting portion 20 and reflected inside the porous layer 16 and the surface layer 11 of the surface material 10. As a result, the aesthetic appearance of the design displayed on the interior member 1 can be improved.

[0050] As described above, the surface material 10 according to this embodiment can achieve the following effects.

[0051] The surface material 10 comprises a surface layer 11 having a first surface 11a for forming a design and a second surface 11b opposite to the first surface 11a, a printed layer 12 formed on the second surface 11b, a protective layer 13 including a first protective part 131 bonded to the printed layer 12 from the side opposite to the surface layer 11, and a second protective part 132 connected to the first protective part 131 and positioned on the second surface 11b.

[0052] As a result, the protective layer 13 covers the printed layer 12 from the opposite side of the surface layer 11 in the lamination direction (arrow Z direction). This allows the protective layer 13 to move in sync with the printed layer 12 when the surface material 10 is deformed or displaced due to contact with an object other than the surface material 10. Therefore, the protective layer 13 can suppress wear of the printed layer 12 due to contact with an object other than the surface material 10. As a result, the surface material 10 can suppress unintended light leakage due to wear or peeling of the printed layer 12 and maintain the aesthetic appearance of the design appearing in the switch area 2.

[0053] Furthermore, the first protective portion 131 may cover the entire printed layer 12. This allows the protective layer 13 to protect the entire printed layer 12 from external stimuli such as friction.

[0054] Furthermore, the protective layer 13 may contain a plasticizer-resistant agent. This allows the protective layer 13 to inhibit the migration of plasticizers from the surface layer 11 to the protective layer 13 when the surface layer 11 contains plasticizers, thereby suppressing any alteration in the tactile feel of the surface material 10.

[0055] Furthermore, the interior member 1 may include a surface material 10, a light-transmitting base material 14 laminated on the surface material 10 from the side of the protective layer 13, a light-emitting part 20 positioned on the opposite side of the base material 14 from the surface material 10 and irradiating the surface material 10 with light, and a light-shielding wall 22 provided between the second protective part 132 and the light-emitting part 20.

[0056] As a result, the interior component 1 reduces light leakage from the second protective part 132 by the light-shielding wall 22, suppressing unintended light leakage from the surface layer 11, and the printing layer 12 controls the transmission of light from the light-emitting part 20, allowing the desired design to be displayed on the surface material 10.

[0057] Furthermore, the interior component 1 is disposed between the base material 14 and the surface material 10 and further comprises a light-transmitting porous layer 16, and the second protective part 132 may also include a light-shielding part 132a. As a result, the porous layer 16 functions as a cushioning material between the base material 14 and the surface material 10, improving the tactile feel provided by the surface material 10. In addition, the light-shielding part 132a can suppress unintended light leakage from the second protective part 132 and thus from the surface material 10, even when light from the light-emitting part 20 is diffused by the light-transmitting porous layer 16.

[0058] Although embodiments have been described above, this disclosure is not limited to the embodiments described above, and various modifications are possible without departing from the spirit of the invention. In particular, the various modifications described herein can be combined as needed. [Explanation of Symbols]

[0059] 1: Interior component 10: Surface material 14: Base material 16: Porous layer 11: Surface layer 11a: First side 11b: Second side 12: Printed layer 13: Protective layer 131: First protective section; 132: Second protective section; 132a: Light-shielding section

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