Vehicle deck board

Abstract

To provide a technique capable of improving an appearance of a deck board for vehicle.SOLUTION: A deck board 1 provided in the cabin SP0 of a vehicle comprises a deck board body 20 and a handle member 50. The deck board body 20 has a top surface 21 and a reverse surface 22, and comprises a recessed part 23 having a recess 24, not reaching the reverse surface 22, on the top surface 21. The handle member 50 is fitted to the deck board 20 to hide a part of the recess 24 except an opening 28 allowing a hand HA1 to be put in the recess 24. The deck board 1 has a gap CL1, which is large enough to put the hand HA1 via the opening 28, in the recess 24 between the handle member 50 and deck board body 20.SELECTED DRAWING: Figure 3

Description

[Technical field]

[0001] The present invention relates to a deck board provided in a vehicle cabin. Do Regarding. [Background technology]

[0002] A deck board that can be lifted in a tilted manner is sometimes placed on the floor of the luggage compartment of a vehicle. Such a deck board may be provided with an operating handle for facilitating lifting by an occupant. Patent Document 1 discloses a deck board in which a base portion, a grip lever, and an operating handle including a rotation mechanism for the grip lever are embedded in a through hole of the deck board body. The base portion is a member divided into a front-side base portion exposed on the front side of the deck board and a back-side base portion exposed on the back side of the deck board. The front-side base portion is substantially box-shaped and opens upward. The grip lever is rotatable between a stored position where it is stored in the front-side base portion and an upright position where it stands up substantially perpendicular to the deck board. Therefore, the front side of the deck board is in a state where the front-side base portion embedded in the through hole of the deck board is visible behind the grip lever. An occupant can lift the deck board in a tilted manner by displacing the grip lever to the upright position and gripping it. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] JP 2014-83986 A Summary of the Invention [Problem to be solved by the invention]

[0004] The front base portion of the operating handle, which includes the rotating mechanism for the grip lever, is large and has a complex shape. Since this front base portion is located behind the grip lever, it looks ungainly. The above-mentioned problems also exist in various deck boards provided inside the vehicle.

[0005] The present invention discloses a technique that can improve the appearance of a vehicle deck board. [Means for solving the problem]

[0006] The vehicle deck board of the present invention is a deck board provided in a vehicle cabin, A deck board body having a front surface and a back surface, the deck board body having a recess on the front surface that does not reach the back surface; a handle member attached to the deck board body so as to hide a part of the recess while leaving an opening through which a hand can be inserted into the recess; A gap is provided between the handle member and the deck board body in the recess, through which a hand can be inserted via the opening. death, The deck board main body includes a first fiber layer containing fibers and a binder and extending along the back surface, a second fiber layer containing fibers and a binder and extending along the front surface, and a core layer partially present between the first fiber layer and the second fiber layer, In the recess, the core layer is absent in the deepest portion of the recess, and the first fiber layer and the second fiber layer are integrated together. , has an aspect. Effect of the Invention

[0008] According to the present invention, it is possible to provide a technique that can improve the appearance of a vehicle deck board. [Brief description of the drawings]

[0009] [Figure 1] FIG. 1 is a diagram illustrating an example of an automobile equipped with a deck board. [Diagram 2] FIG. 2 is a plan view illustrating a schematic example of a deck board. [Diagram 3] 3 is a cross-sectional view of a main portion that diagrammatically illustrates an example of a cross section of the deck board taken at position A1 in FIG. 2. [Figure 4] 3 is a cross-sectional view that illustrates a schematic example of a cross section of the deck board taken at position A2 in FIG. 2. [Diagram 5] FIG. 11 is a perspective view showing a schematic example of a recess in the deck board body. [Figure 6] FIG. 13 is a perspective view showing a typical example in which a handle member is attached to a recess in a deck board body. [Figure 7] FIG. 13 is a perspective view showing a schematic example in which a support member is disposed on the underside of a deck board main body. [Figure 8] FIG. 13 is a perspective view illustrating an example of the back side of the handle member. [Figure 9] FIG. 13 is a perspective view illustrating an example of the front side of a support member. [Figure 10] 5A to 5C are diagrams illustrating an example of a method for forming a deck board body. [Figure 11] FIG. 11 is a cross-sectional view showing a schematic example of attaching a handle member and a support member to a deck board body. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0010] DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The following embodiments of the present invention will be described. Of course, the following embodiments are merely illustrative of the present invention, and not all of the features shown in the embodiments are necessarily essential to the solution of the invention.

[0011] (1) Overview of the technology included in this invention: First, the outline of the technology included in the present invention will be described with reference to the examples shown in Figures 1 to 11. The figures in the present application are diagrams showing examples in a schematic manner, and the magnification ratios in each direction shown in these figures may differ, and the figures may not be consistent with each other. Of course, each element of the present technology is not limited to the specific example shown by the symbol. In addition, in the present application, a numerical range "Min to Max" means equal to or greater than the minimum value Min and equal to or less than the maximum value Max.

[0012] [Aspect 1] A vehicle deck board 1 according to one aspect of the present technology, as exemplified in Fig. 3 etc., is a deck board 1 provided in a vehicle interior SP0, and includes a deck board main body 20 and a handle member 50. The deck board main body 20 has a front surface 21 and a back surface 22, and is provided with a recess 23 having a recess 24 in the front surface 21 that does not reach the back surface 22. The handle member 50 is attached to the deck board main body 20 so as to hide a part of the recess 24 while leaving an opening 28 within the recess 24 through which a hand HA1 can be inserted. The present deck board 1 has a gap CL1 within the recess 24 between the handle member 50 and the deck board main body 20 through which a hand HA1 can be inserted via the opening 28.

[0013] An occupant can lift the deck board 1 by inserting hand HA1 into gap CL1 between handle member 50 and deck board main body 20 inside recess 24 through opening 28 of recess 24 on the surface of the deck board and gripping handle member 50. In aspect 1 above, recess 23 of deck board main body 20 is visible behind handle member 50. Thus, aspect 1 above can provide a vehicle deck board with improved appearance.

[0014] Here, the deck board can be provided in various locations within the vehicle interior, and may be placed, for example, on a component having storage space for items, or on top of a functional component such as a battery case. The above remarks also apply to the following aspects.

[0015] [Aspect 2] The deck board main body 20 may be provided with a skin material 45 on the surface 21, including the recess 24. When an occupant inserts his / her hand HA1 into the gap CL1 between the handle member 50 and the deck board main body 20, the hand HA1 touches the skin material 45. Therefore, this embodiment can improve the tactile feel of the deck board. Furthermore, if the skin material 45 is provided in the recess 24 of the deck board main body 20, the appearance of the deck board is further improved.

[0016] [Aspect 3] The recess 24 in the surface 21 may include a non-exposed surface 25 that is hidden by the handle member 50, and an exposed surface 26 that is not hidden by the handle member 50. The exposed surface 26 may include an inclined surface 27 such that the recess 24 becomes deeper the closer to the non-exposed surface 25. When an occupant puts his / her hand HA1 into the recess 24, the hand HA1 is guided by the inclined surface 27 to an operating position between the handle member 50 and the deck board main body 20. Therefore, this embodiment can improve the operability of the deck board. In addition, because the hand HA1 that has entered the recess 24 touches the inclined surface 27 of the exposed surface 26, the tactile feel of the deck board is further improved.

[0017] [Aspect 4] The deck board 1 may further include a support member 70 disposed on the back surface 22 in the recess 23. The handle member 50 may have a first contact portion (e.g., rib 52) in contact with the recess 24. The support member 70 may have a second contact portion (e.g., rib 72, rear edge 73, and base portion 75) in contact with the back surface 22. One of the handle member 50 and the support member 70 (handle member 50 in FIG. 3) may have a protruding portion (e.g., boss 55) protruding toward the other member (support member 70 in FIG. 3). The recess 23 may have a through hole 29 that connects from the front surface 21 to the back surface 22 and through which the protruding portion (55) passes. The protruding portion (55) that passes through the through hole 29 may be fixed to the other member by a fastening member (e.g., screw SC1). In this embodiment, the load of the handle member 50 gripped by the occupant is transmitted to the support member 70 via the protrusion (55) and is distributed to the first contact portion (52) of the handle member 50 and the second contact portions (72, 73, 75) of the support member 70. Therefore, in this embodiment, the load generated when the deck board is operated can be distributed not only to the front surface but also to the back surface of the deck board. Here, "first", "second", ... are terms for distinguishing each component among a plurality of components having similarities, and do not indicate an order. This statement also applies to the following aspects.

[0018] [Aspect 5] The deck board main body 20 may include a first fiber layer 41 that contains fiber F1 and binder B1 and that is along the back surface 22, a second fiber layer 42 that contains fiber F2 and binder B2 and that is along the front surface 21, and a core layer 43 that is partially present between the first fiber layer 41 and the second fiber layer 42. The core layer 43 may be absent in the portion (e.g., deepest portion 23a) where the recess 24 is deepest in the recess 23, and the first fiber layer 41 and the second fiber layer 42 may be integrated. In this embodiment, the first fiber layer 41 and the second fiber layer 42 are integrated in the portion (23a) where the recess 24 is deepest in the recess 23, so that a required strength can be obtained even if the deck board is thin. In addition, since the gap CL1 between the handle member 50 and the deck board main body 20 increases by the amount corresponding to the absence of the core layer 43, it becomes easier to insert a hand HA1 into this gap CL1. Therefore, this embodiment can improve the operability of the deck board.

[0019] [Aspect 6] Meanwhile, a manufacturing method for deck board 1 according to one aspect of the present technology is a manufacturing method for deck board 1 including deck board main body 20 having front surface 21 and back surface 22, with recess 23 having recess 24 in front surface 21 that does not reach back surface 22, and handle member 50, and includes the following steps, as exemplified in FIGS. 10 and 11 . (A) A first molding step ST1 in which a skin material 45 arranged on the surface 21 is press-molded to form a general portion 121 around a portion that becomes the recess 23 in a laminate material 120 in which the main layer 140 is laminated. (B) A second molding process ST2 in which a portion of the laminate material 120 that is surrounded by the press-molded general portion 121 is press-molded to form the deck board main body 20 having the skin material 45 on the surface 21, including the recess 24. (C) An installation process ST3 of attaching the handle member 50 to the deck board main body 20 so that a part of the recess 24 is hidden except for leaving an opening 28 within the recess 24 through which a hand HA1 can be inserted, and a gap CL1 is formed between the handle member 50 and the deck board main body 20 within the recess 24 through which a hand HA1 can be inserted via the opening 28.

[0020] When the portion that will become the recess 23 is press-molded at the same time as the general portion 121, the press mold comes into contact with the skin 45 of the portion that will become the recess 23 first, and therefore the skin 45 in the general portion 121 is pulled by the press molding of the skin 45 in the portion that will become the recess 23. This makes it easy for wrinkles to occur in the skin 45 around the recess 23. In the above-mentioned aspect 6, in laminate material 120 in which skin material 45 is overlaid on main body layer 140, general portion 121 around the portion that will become recessed portion 23 of deck board main body 20 is press-molded, and then the portion surrounded by general portion 121 is press-molded, thereby suppressing the occurrence of wrinkles in skin material 45. Behind handle member 50 of the manufactured deck board 1, recessed portion 23 of deck board main body 20 is visible. Thus, the above-mentioned aspect 6 can provide a manufacturing method for a vehicle deck board with improved appearance.

[0021] (2) Examples of vehicle deck boards: FIG. 1 is a schematic diagram of an automobile 100 (an example of a vehicle) equipped with a vehicle deck board 1. In FIG. 1, the deck board 1 in the closed position P1 is indicated by a solid line, and the deck board 1 in the open position P2 is indicated by a two-dot chain line. FIG. 2 is a plan view that is a schematic diagram of the appearance of the deck board 1 in the closed position P1 as viewed from the luggage compartment SP2. FIG. 3 is a schematic diagram of a cross section of the deck board 1 taken at a position A1 in FIG. 2. FIG. 3 shows the vicinity of the recess 23 in a cross section passing through a screw SC1 (an example of a fastening member) in the deck board 1. An enlarged view of the first fiber layer 41 and the second fiber layer 42 is shown at the bottom of FIG. 3. FIG. 4 is a schematic diagram of a cross section of the deck board 1 taken at a position A2 in FIG. 2. For ease of understanding, elements visible behind the cross section are omitted in FIGS. 3 and 4. In the drawings shown in the present application, FRONT, REAR, UP, DOWN, LEFT, and RIGHT respectively indicate the front, rear, up, down, left, and right in the case where the direction seen from the automobile 100 is used as a reference. Furthermore, the symbol D1 indicates the front-rear direction of the automobile 100, the symbol D2 indicates the up-down direction of the automobile 100, and the symbol D3 indicates the vehicle width direction of the automobile 100. The front-rear direction D1, the up-down direction D2, and the vehicle width direction D3 are assumed to be perpendicular to each other, but even if they are not perpendicular due to design or the like, they are included in the present technology as long as they intersect. Note that "perpendicular" is not limited to strictly 90°, and includes deviation from strictly 90° due to error. Furthermore, the sameness of the direction, position, etc. is not limited to strictly matching, and includes deviation from strictly matching due to error. Furthermore, the explanation of the positional relationship of each part is merely an example.

[0022] The automobile 100 shown in FIG. 1 is a road vehicle designed and equipped for use on roads, and the vehicle body is formed by surrounding a passenger compartment SP1 and a luggage compartment SP2 with a metal body panel made of, for example, steel plate. The passenger compartment SP1 and the luggage compartment SP2 are collectively referred to as an interior space SP0. The automobile 100 shown in FIG. 1 is a wagon-type passenger automobile with a luggage compartment SP2 at the rear connected to the passenger compartment SP1 and multiple rows of seats (for example, front seats and rear seats 101, not shown). Of course, automobiles to which the present technology can be applied include so-called station wagons, minivans, and the like, as well as sedans and the like, in which the passenger compartment and luggage compartment are separated.

[0023] The automobile 100 shown in FIG. 1 includes a rear seat 101 in front of the luggage compartment SP2, a ceiling portion 102 above the luggage compartment SP2, an openable and closable tailgate 103 behind the luggage compartment SP2, a floor portion 110 below the luggage compartment SP2, and side walls (not shown) on the left and right sides of the luggage compartment SP2. The ceiling portion 102 has a structure in which a roof trim is attached to a roof panel, which is a vehicle body panel. When the tailgate 103 is opened, an opening 104 appears at the rear of the automobile, and when the tailgate 103 is closed, the opening 104 is closed. Therefore, when the tailgate 103 is open, a user can put luggage into the luggage compartment SP2 through the opening 104 or take luggage in the luggage compartment SP2 out of the automobile 100 through the opening 104. The floor portion 110 has a placement portion 111 on which the deck board 1 is placed, and a storage recess 112 and a groove 113 recessed downward from the placement portion 111. The storage recess 112 opens upward and surrounds the storage space SP3 in which luggage is placed except for the upper part. The deck board 1 in the closed position P1 placed on the placement portion 111 closes the storage space SP3. When an occupant places the deck board 1 in the open position P2 and inserts the rear end 13a of the deck board 1 into the groove 113, the floor portion 110 holds the deck board 1 in the open position P2. This allows the user to put luggage in or take luggage out of the storage recess 112. A spare tire may be stored in the storage recess 112.

[0024] Deck board 1 is provided in interior SP0 of automobile 100, and fulfills the functions of hiding the floor portion of automobile 100, providing a luggage space, etc. Deck board 1 shown in Fig. 1 is provided in luggage compartment SP2.

[0025] Deck board 1 shown in FIGS. 1 to 4 includes front board 11, which is the foremost board in deck board 1, rear board 13, which is the rearmost board, and central board 12, which is between front board 11 and rear board 13. Front board 11 and central board 12 are connected to each other via front hinge portion 14 so as to be able to bend and fold in a direction so that their upper surfaces face each other. Central board 12 and rear board 13 are connected to each other via rear hinge portion 15 so as to be able to bend and fold in a direction so that their lower surfaces face each other. Hinge portions 14, 15 shown in FIGS. 1 to 4 are integral hinges integrally formed with boards 11 to 13, but hinge portions 14, 15 may be separate parts attached to boards 11 to 13.

[0026] As shown in FIG. 3, the deck board 1 includes a deck board main body 20, a handle member 50, and a support member 70. The deck board main body 20 includes a recess 23 having a recess 24 on the front surface 21 that does not reach the back surface 22. Here, when the deck board 1 is in the closed position P1 as shown in FIG. 1, the front surface 21 is the upper surface of the deck board main body 20, and the back surface 22 is the lower surface of the deck board main body 20. The handle member 50 is disposed on the rear side of the recess 24 so as to hide a part of the recess 24 while leaving an opening 28 on the front side through which a hand HA1 can be inserted into the recess 24. Within the recess 24, between the handle member 50 and the deck board main body 20, there is a gap CL1 through which a hand HA1 can be inserted via the opening 28. The support member 70 is disposed on the back surface 22 of the recess 23. The recess 23 of the deck board main body 20 is between the main body portion 51 of the handle member 50 and the main body portion 71 of the support member 70. In this state, handle member 50 and support member 70 are fixed together with screw SC1 (an example of a fastening member). Therefore, handle member 50 is attached to deck board main body 20 so as to hide part of recess 24, leaving opening 28 within recess 24 through which hand HA1 can be inserted.

[0027] The deck board main body 20 includes, in order from the bottom layer upward, a skin material 44, a first fiber layer 41, a partial core layer 43, a second fiber layer 42, and a skin material 45. Between adjacent layers in these layers 41 to 45, there may be an intervening layer such as an adhesive or a film, or there may be no intervening layer. In addition, two layers being in contact with each other and joining two layers together include both having an intervening layer between them and not having an intervening layer between them. In this specific example, the deck board main body 20 including the layers 41 to 45 is integrated by press molding. The first fiber layer 41 is joined to the partial core layer 43 on the back side, and the second fiber layer 42 is joined to the front side. That is, the core layer 43 is in contact with the fiber layers 41 and 42. The first fiber layer 41 and the second fiber layer 42 are joined to each other in the portion where the core layer 43 is not present. That is, the fiber layers 41 and 42 are in contact with each other in the portion where the core layer 43 is not present. A skin material 44 is joined to the back side of the first fiber layer 41. That is, the first fiber layer 41 is in contact with the skin material 44. A skin material 45 is joined to the front side of the second fiber layer 42. That is, the second fiber layer 42 is in contact with the skin material 45. The fiber layers 41, 42 and the core layer 43 are collectively referred to as the main layer 40.

[0028] The fiber layers 41, 42 are breathable in the up-down direction D2, which is the thickness direction of the deck board main body 20. Note that, being breathable means that the air permeability according to the A method (Fragile method) specified in JIS (Japanese Industrial Standards) L1096:2010 (Fabric testing method for woven and knitted fabrics) is 0.05 cc / cm 2 / sec or more (preferably 1cc / cm 2 / sec or more, more preferably 3cc / cm 2 / sec or more). Core layer 43 may be breathable or non-breathable in the thickness direction of deck board main body 20 (vertical direction D2). Skin materials 44, 45 may be breathable or non-breathable in the thickness direction of deck board main body 20 (vertical direction D2).

[0029] The core layer 43 is partially present between the first fibrous layer 41 and the second fibrous layer 42 . The core layer 43 may be made of a resin structure containing air, a fiber structure containing fibers and a binder, or the like. The aforementioned resin structure may include a resin molded body such as a foamed resin molded body or a resin blow molded body, a combination of a plurality of resin injection molded bodies, or the like. The resin for forming the resin structure may be a synthetic resin (including an elastomer) such as a thermoplastic resin or a thermosetting resin, and may be a polyolefin resin such as a polypropylene (PP) resin or a polyethylene (PE) resin, a polystyrene (PS) resin, an acrylonitrile styrene copolymer (AS) resin, an acrylonitrile butadiene styrene copolymer (ABS) resin, a polyurethane resin, a resin modified from these resins, or a combination of these resins. The aforementioned resin may contain additives such as a colorant or a filler, as long as the effect is not impaired. The foamed resin molded body may include a foamed resin particle molded body in which a large number of foamed resin particles are fused together, a foamed resin injection molded body, or the like. For example, a bead-shaped or cylindrical thermoplastic resin is impregnated with a foaming agent to form a large number of expandable resin particles that are pre-expanded to a predetermined ratio, and the large number of expandable resin particles are filled into a mold having a shape of a core layer, and the mold is heated to expand and fuse the large number of expandable resin particles, thereby forming an expanded resin particle molded body. The particle size of the expanded resin particles can be, for example, 0.6 to 3.0 mm. In addition, an injection foam molded body can be obtained by injecting a resin material into a mold having a shape of a core layer and foaming it with a foaming agent to form it. As the foaming agent, a volatile foaming agent that generates hydrocarbons such as butane or pentane, an inorganic foaming agent that generates carbon dioxide gas such as ammonium carbonate, and the like can be used.

[0030] The apparent density of the core layer 43 is 0.02 to 0.25 g / cm3 in order to make the deck board 1 lightweight and highly rigid. 3 The thickness of the core layer 43 may be, for example, 5 to 50 mm, and more preferably 10 to 30 mm.

[0031] The first fiber layer 41 shown in Fig. 3 contains fiber F1 and binder B1, and is formed into a shape having projections and recesses along the back surface 22 of the deck board main body 20. The second fiber layer 42 shown in Fig. 3 contains fiber F2 and binder B2, and is formed into a shape having projections and recesses along the front surface 21 of the deck board main body 20.

[0032] The fibers F1 and F2 may be inorganic fibers, synthetic resin fibers such as thermoplastic resin fibers, natural fibers such as cellulosic fibers and animal fibers, or combinations thereof. The fibers F1 and F2 may contain additives such as colorants as long as the effect is not impaired. The inorganic fibers include glass fibers, carbon fibers, and the like. The synthetic resin fibers include polyester fibers such as polyethylene terephthalate (PET) fibers, polyolefin fibers such as polyamide (PA) fibers and polypropylene (PP) fibers, acrylic (PMMA) fibers, and the like. The synthetic resin fibers include elastomer fibers. The cellulosic fibers include plant fibers such as cotton and hemp, synthetic fibers such as rayon, and the like. The plant fibers are also natural fibers. The animal fibers include wool, silk, and the like. The fibers F1 and F2 may be different from each other. The cross-sectional shape of the fibers F1, F2 is not particularly limited, and may be an ellipse including a perfect circle, a triangle, a flat shape, a hollow shape, or the like.

[0033] The binders B1 and B2 may be thermoplastic binders or thermosetting binders. The thermoplastic binders may be polyester resins such as low melting point PET resins, polyolefin resins such as PP resins and PE resins, etc. The thermoplastic binders include elastomers. The binders B1 and B2 may include additives such as colorants as long as the effect is not impaired. The binders B1 and B2 may be different from each other. When the core layer 43 is thermoplastic, it is preferable that the melting points of the binders B1 and B2 are lower than the melting point of the core layer 43.

[0034] The binder for forming each fiber layer 41, 42 may be a fibrous thermoplastic binder such as a thermoplastic resin fiber. In this case, the fibers F1, F2 are preferably at least one of a thermoplastic fiber having a higher melting point than the binders B1, B2 and a fiber containing a non-melting component. Examples of the thermoplastic fiber having a higher melting point than the binders B1, B2 include polyester fibers such as high-melting PET fibers, PA fibers, etc. Examples of the fiber containing a non-melting component include inorganic fibers, cellulosic fibers, natural fibers, etc. The binder for forming each fiber layer 41, 42 may be a binder contained in the fiber itself. When the fiber has a conjugate structure such as a core-sheath structure or a side-by-side structure, the binder may be present in the portion that appears on the surface of the structure. For example, when the fiber layers 41, 42 are formed from raw fiber having a core-sheath structure, the core of the raw fiber becomes fiber F1, F2, and the sheath of the raw fiber becomes binder B1, B2.

[0035] The content of fiber F1 in the first fiber layer 41 may be, for example, 10 to 90% by weight. The content of binder B1 in the first fiber layer 41 may be, for example, 10 to 90% by weight. The content of fiber F2 in the second fiber layer 42 may be, for example, 10 to 90% by weight. The content of binder B2 in the second fiber layer 42 may be, for example, 10 to 90% by weight.

[0036] The fibrous substrate for forming each of the fiber layers 41, 42 may be a nonwoven fabric such as a short fiber nonwoven fabric or a long fiber nonwoven fabric. The short fiber nonwoven fabric includes a chemical bond nonwoven fabric, a thermal bond nonwoven fabric, a needle punch nonwoven fabric, a spun lace nonwoven fabric, etc. The long fiber nonwoven fabric includes a spun bond nonwoven fabric, a melt blown nonwoven fabric, etc.

[0037] The air permeability of each of the fiber layers 41 and 42 in the thickness direction (vertical direction D2) is, for example, 1 to 200 cc / cm 2The thickness of each of the fiber layers 41, 42 may be, for example, 0.8 to 2.4 mm, more preferably 1.0 to 2.2 mm. The basis weight of the fiber layers 41, 42 may be, for example, 300 to 2000 g / m 2 , more preferably 400 to 1100 g / m 2 It can be said that:

[0038] Skin material 44 shown in Fig. 3 appears on back surface 22 of deck board main body 20, and is formed in a shape having projections and recesses. Skin material 45 shown in Fig. 3 appears on front surface 21 of deck board main body 20, and is formed in a shape having projections and recesses.

[0039] The covering materials 44, 45 may be fibrous covering materials such as carpet, woven fabric, knitted fabric, etc. The carpet may be a needle punch carpet, a tufted carpet, etc. A needle punch carpet is a carpet in which nonwoven fabric is needled to intertwine the fibers and form nap on the surface. The covering materials 44, 45 may have a backing layer made of synthetic resin (including elastomer), rubber, etc. The covering materials 44, 45 may be of different types.

[0040] The weight of the skin material 44 appearing on the back surface 22 of the deck board body 20 is, for example, 30 to 400 g / m 2 , more preferably 50 to 300 g / m 2 The weight of the skin material 44 appearing on the back surface 22 of the deck board body 20 can be, for example, 50 to 500 g / m 2 , more preferably 70 to 400 g / m 2 It can be said that:

[0041] Deck board main body 20 is provided with skin material 45 on front surface 21, including recess 24 of recess 23. Accordingly, skin material 45 is visible behind handle member 50 attached to deck board main body 20, and the appearance of deck board 1 in the vicinity of recess 23 is good.

[0042] The handle member 50 and the support member 70 may be molded products of resin material, for example, injection molded products. The aforementioned resin material may be various synthetic resins (including elastomers), and may contain additives. From the viewpoint of ease of molding, thermoplastic resin materials such as thermoplastic resins are preferable. The aforementioned thermoplastic resin may be a polyolefin resin such as a PP resin or a PE resin, a polycarbonate (PC) resin, an acrylonitrile styrene acrylate (ASA) resin, an ABS resin, an AS resin, a polyamide resin, or a combination thereof, and may contain additives such as fibers. The aforementioned fibers may be inorganic fibers such as glass fibers or carbon fibers, plant fibers such as kenaf, or a combination thereof.

[0043] The structures of the recess 23 of the deck board main body 20, the handle member 50, and the support member 70 will be described below with reference to Figures 5 to 9 as well. Figure 5 illustrates a schematic example of the recess 23 of the deck board main body 20 when the handle member 50 is not attached. Figure 6 illustrates a schematic example of the handle member 50 attached to the recess 23 of the deck board main body 20. Figure 7 illustrates a schematic example of the support member 70 disposed on the back surface 22 of the deck board main body 20. Figure 8 illustrates a schematic example of the back side of the handle member 50. The back side of the handle member 50 is the portion that faces the recess 24 of the deck board main body 20. Figure 9 illustrates a schematic example of the front side of the support member 70. The front side of the support member 70 is the portion that faces the back surface 22 of the deck board main body 20.

[0044] As described above, the recess 23 of the deck board main body 20 has a recess 24 on the front surface 21 that does not reach the back surface 22. As shown in FIGS. 3, 5, and 6, the recess 24 includes a non-exposed surface 25 hidden by the handle member 50, and an exposed surface 26 that is not hidden by the handle member 50. The vicinity of the boundary between the non-exposed surface 25 and the exposed surface 26 is a deepest part 23a where the recess 24 is deepest. In FIG. 3, the deepest part 23a is shown on the exposed surface 26, but the deepest part 23a may be present from the non-exposed surface 25 to the exposed surface 26, may be present on the boundary between the non-exposed surface 25 and the exposed surface 26, or may be present on the non-exposed surface 25. As shown in FIGS. 3 and 4, the lowest part 23b at the bottom of the recess 23 is located at a position corresponding to the deepest part 23a on the back surface 22, and is located below a portion of the deck board main body 20 where the core layer 43 is present. As a result, gap CL1 between handle member 50 and deck board main body 20 is wide, making it easy to insert hand HA1 into this gap CL1. As shown in Figure 4, back surface 12b of center board 12 has a recess that prevents interference with bottom portion 23b of rear board 13 when boards 12, 13 are folded.

[0045] As shown in Fig. 3, in a cross section taken along the front-rear direction D1, exposed surface 26 includes an inclined surface 27 in which recess 24 curves and deepens toward the rear, i.e., inclined surface 27 in which recess 24 deepens toward non-exposed surface 25. As inclined surface 27 is smooth in a cross section taken along the front-rear direction D1, recess 24 feels good to the touch, and the rear of handle member 50 looks good. As shown in Figs. 5 and 6, in the width direction (vehicle width direction D3) of deck board main body 20, exposed surface 26 is deepest at the center and deepens in a curved manner from the left and right toward the deepest part. As exposed surface 26 is smooth in the width direction (D3), recess 24 feels good to the touch, and the rear of handle member 50 looks good.

[0046] As shown in FIG. 3, in a cross section along the front-rear direction D1, the non-exposed surface 25 includes an inclined surface in which the recess 24 becomes deeper in a curved shape toward the front. Therefore, in this respect as well, the recess 24 has a good feel to the touch. As shown in FIGS. 3 and 5, the recess 23 has a plurality of through holes 29 that connect from the front surface 21 to the back surface 22 and pass through the boss 55 (an example of a protruding portion) of the handle member 50. Each through hole 29 shown in FIG. 5 is disposed near the left and right near the rear of the recess 23. In the width direction (D3) of the deck board main body 20, the non-exposed surface 25 is deepest in the center, and becomes deeper in a curved shape from the left and right toward the deepest part, except for the vicinity of each through hole 29. Since the non-exposed surface 25 is smooth in the width direction (D3), the recess 24 has a good feel to the touch.

[0047] 3, in the recess 23, the deepest part 23a where the recess 24 is deepest does not have the core layer 43, and the first fiber layer 41 and the second fiber layer 42 are integrated. Since the first fiber layer 41 and the second fiber layer 42 are integrated in the deepest part 23a of the recess 23, the required strength can be obtained even though it is thin. Furthermore, since the core layer 43 is absent, the gap CL1 between the handle member 50 and the deck board main body 20 increases, making it easy to insert a hand HA1 into this gap CL1.

[0048] As described above, the handle member 50 is attached to the deck board main body 20 so as to hide a part of the recess 24, leaving an opening 28 through which a hand HA1 can be inserted into the recess 24. As shown in Figs. 3 and 8, the handle member 50 includes a main body portion 51 and a plurality of cylindrical bosses 55 protruding from the main body portion 51 toward the support member 70. Thus, the handle member 50 is an example of one member, and the support member 70 is an example of the other member. The main body portion 51 has a plurality of ribs 52 (an example of a first contact portion) on the back side. Among the plurality of ribs 52, some are connected to the boss 55, and others are spaced apart from the boss 55. Some of the plurality of ribs 52 are in contact with the recess 24 of the recess 23 so as to bite into the recess 24. The rear edge 53 of the main body portion 51 bites into the deck board main body 20 around the rear edge of the recess 24. When the rear edge 53 is in contact with the recess 24, the rear edge 53 is also an example of the first contact portion. Each boss 55 has a hollow portion 56 along the protruding direction (up-down direction D2) of the boss 55. A worker at a factory can screw the screw SC1 into the hollow portion 56 to screw the screw SC1 into the boss 55.

[0049] As described above, the support member 70 is disposed on the back surface 22 of the recessed portion 23. As shown in FIGS. 3 and 9, the support member 70 includes a main body portion 71 and a plurality of pedestal portions 75 (an example of a second contact portion) that bulge from the main body portion 71 toward the deck board main body 20. The main body portion 71 has a plurality of ribs 72 (an example of a second contact portion) on the front side. The plurality of ribs 72 are connected to the pedestal portions 75, but the main body portion 71 may have a rib spaced apart from the pedestal portions 75. Some of the plurality of ribs 72 are in contact with the back surface 22 of the recessed portion 23. A rear edge 73 (an example of a second contact portion) of the main body portion 71 bites into the back surface 22 of the deck board main body 20 near the rear edge of the recessed portion 23. Each pedestal portion 75 has a screw insertion hole 76 through which a screw SC1 can be inserted along the thickness direction (up-down direction D2) of the deck board main body 20. The screw insertion hole 76 is large enough not to allow the head of the screw SC1 to pass through. As shown in FIGS. 8 and 9, there are two combinations of the boss 55 and the base portion 75.

[0050] As illustrated in FIG. 11, an operator can fix the handle member 50 and the support member 70 to each other by passing the bosses 55 of the handle member 50 through each through hole 29 of the deck board main body 20, passing the screws SC1 through the screw insertion holes 76 of the support member 70 into the hollow portions 56 of the bosses 55, and then screwing them in. As a result, the two members 50, 70 are attached to the deck board main body 20 in a state in which the deck board main body 20 is sandwiched between them. In this state, it can also be said that the two members 50, 70 sandwiching the deck board main body 20 are fastened together. As shown in FIG. 3, the deck board 1 in a state in which the handle member 50 is attached to the deck board main body 20 has a gap CL1 between the handle member 50 and the deck board main body 20 in the recess 24, into which a hand HA1 can be inserted via the opening 28. In the deck board 1 shown in FIG. 3, the bosses 55 that pass through each through hole 29 are fixed to the support member 70 with the screws SC1. As a result, the load of the handle member 50 gripped by the occupant is transmitted from the boss 55 to the support member 70 and distributed to the first contact portion (52) of the handle member 50 and the second contact portion (72, 73, 75) of the support member 70.

[0051] (3) Specific examples of manufacturing methods for vehicle deck boards: Fig. 10 illustrates a schematic example of a method for forming deck board main body 20. Fig. 11 illustrates a schematic example of a manner in which handle member 50 and support member 70 are attached to deck board main body 20. The manufacturing method shown in FIGS. 10 and 11 includes a first molding step ST1, a second molding step ST2, and an attachment step ST3.

[0052] The press molding machine 200 shown in FIG. 10 is equipped with a lower die 212 for forming the back surface 22 of the deck board main body 20, and upper dies 214, 216 for forming the front surface 21 of the deck board main body 20 as a press molding die 210. The die 214 is a master block into which an insert die 216 that is relatively movable in the thickness direction (up and down direction) of the deck board main body 20 is fitted. The insert die 216 is a partial die that is used by being fitted into the master block, and is of a movable type that is also called a slide die. The insert die 216 has a die surface shaped to fit the recess 24 of the deck board main body 20. The die 212 and the dies 214, 216 can approach and move away from each other. Furthermore, the mold 212 may be fixed and the molds 214, 216 may be movable, or the mold 212 may be movable and the mold 214 may be fixed, or both the mold 212 and the molds 214, 216 may be movable.

[0053] 3 and 5 in the deck board main body 20. This drilling structure 220 has a protrusion 222 for drilling that protrudes from the mold surface of the nesting mold 216 towards the lower mold 212, and a receiving portion 224 that is recessed from the mold surface of the lower mold 212 at a position corresponding to the protrusion 222 and away from the nesting mold 216.

[0054] The press-molded deck board body 20 is formed according to the following procedure, where the binders B1, B2 of the fiber layers 41, 42 are thermoplastic, and the core layer 43 is made of a material that has a higher melting point than the binders B1, B2 or that does not melt.

[0055] First, a preheating process is performed to preheat the laminated material 120 (see FIG. 10) in which the skin material 44 arranged on the back surface 22, the main layer 140 which will become the main layer 40, and the skin material 45 arranged on the front surface 21 are layered in this order. The main layer 140 includes, from the bottom layer upwards, a first fiber layer 41, a partial core layer 43, and a second fiber layer 42. A cavity is formed in the portion of the laminated material 120 where the core layer 43 is not present, and the first fiber layer 41 and the second fiber layer 42 are separated from each other in the cavity. In the preheating process, the laminated material 120 is heated in a preheating device to a temperature above the softening point, preferably above the melting point, of the binders B1 and B2. 10, a lamination material setting process is performed in which the preheated lamination material 120 is set in the lower mold 212. Note that the preheating process may be performed in a state in which the lamination material 120 is set in the mold 212.

[0056] 10, in a first molding process ST1, a first molding process is performed to press-mold a general portion 121 around a portion that will become the recess 23 in the laminate material 120. The press molding machine 200 moves the lower mold 212 and the upper molds 214, 216 close to each other while retracting the nested mold 216 away from the lower mold 212, and press-molds the general portion 121. As a result, in the general portion 121, the skin material 44, the first fiber layer 41, the core layer 43, the second fiber layer 42, and the skin material 45 are firmly fused together by any one of the binders B1, B2, an adhesive (not shown), and a thermoplastic film (not shown). When the portion that will become the recess 23 is press-molded at the same time as the general portion 121, the upper mold comes into contact with the skin 45 of the portion that will become the recess 23 first, so that the skin 45 in the general portion 121 is pulled by the press-molding of the skin 45 in the portion that will become the recess 23. This may cause wrinkles to form in the skin 45 around the recess 23. In particular, wrinkles are likely to form in the skin 45 in the general portion 121 near the four corners 24c (see FIG. 5) of the recess 24. In the first molding step ST1 described above, the skin 45 in the portion that will become the recess 23 is not press-molded, so that the skin 45 in the general portion 121 is prevented from being wrinkled.

[0057] In the second molding step ST2 after the first molding step ST1, as shown in the middle to lower part of FIG. 10, a second molding process is performed to press-mold the portion surrounded by the press-molded general portion 121 in the laminate material 120. The press molding machine 200 brings the nested die 216 close to the lower die 212, press-molds the portion surrounded by the press-molded general portion 121, and forms the through holes 29 by penetrating the convex portion 222 of the perforated structure 220 into the concave portion 23. As a result, the first fiber layer 41 and the second fiber layer 42 are firmly fused to each other by at least one of the binder B1, an adhesive (not shown), and a thermoplastic film (not shown) in the portion of the laminate material 120 where the core layer 43 is not present. Also, the skin material 44 and the first fiber layer 41 are firmly fused to each other by at least one of the binder B1, an adhesive (not shown), and a thermoplastic film (not shown) in the portion of the laminate material 120 including the concave portion 23. Furthermore, in the portion of the laminate material 120 including the recesses 23, the skin material 45 and the second fiber layer 42 are firmly fused together by at least one of the binder B2, an adhesive (not shown), and a thermoplastic film (not shown).

[0058] In this manner, deck board main body 20 is formed, with skin material 45 on surface 21, including recesses 24. If press molding die 210 does not have drilling structure 220, a drilling process can be performed to form through holes 29 in recesses 23 after second molding step ST2.

[0059] As described above, in laminate material 120 in which at least skin material 45 is layered on main body layer 140, general portion 121 surrounding the portion that will become recess 23 of deck board main body 20 is press-molded, and then the portion including recess 23 is press-molded, thereby suppressing the occurrence of wrinkles in skin material 45. Therefore, the manufacturing method of this specific example makes it possible to manufacture a vehicle deck board with improved appearance.

[0060] After the deck board main body 20 is formed, in an attachment step ST3 shown in FIG. 11, an attachment process is performed to attach the handle member 50 and the support member 70 to the deck board main body 20. The worker simply passes the boss 55 of the handle member 50 through each through hole 29 of the deck board main body 20, passes the screw SC1 through the screw insertion hole 76 of the support member 70 into the hollow portion 56 of each boss 55, and then screws it in. As a result, the boss 55 that passed through the through hole 29 is fixed to the support member 70 by the screw SC1, the handle member 50 and the support member 70 are fixed to each other, and both members 50, 70 are attached to the deck board main body 20. As shown in FIG. 3, the handle member 50 attached to the deck board main body 20 hides a part of the recess 24, leaving an opening 28 within the recess 24 through which a hand HA1 can be inserted. A gap CL1 is formed between the handle member 50 and the deck board main body 20 within the recess 24, through which a hand HA1 can be inserted via the opening 28.

[0061] (4) Functions and Effects of the Vehicle Deck Board According to the Specific Example: An occupant can lift the rear board 13 (deck board 1) in a tilted manner by inserting hand HA1 into gap CL1 between handle member 50 and deck board main body 20 within recess 24 through opening 28 of recess 24 on the deck board surface and gripping handle member 50. In the automobile 100 shown in FIG. 1 , when the deck board 1 is in the closed position P1, the occupant grips handle member 50 with hand HA1 and lifts the front side of the rear board 13, causing the deck board 1 to bend. When the occupant inserts rear end 13a of the rear board 13 into groove 113, the deck board 1 is held by the floor portion 110 in the open position P2. When the deck board 1 is in the open position P2, the occupant grips handle member 50 with hand HA1 and slightly lifts the rear board 13, causing the rear end 13a of the rear board 13 to come out of groove 113. When the passenger pulls rear board 13 rearward from this state to unfold deck board 1 substantially horizontally, deck board 1 assumes a state in which it is placed on mounting portion 111 of floor portion 110 in closed position P1.

[0062] When an occupant places hand HA1 in recess 24 to operate deck board 1, hand HA1 is guided by inclined surface 27 to an operating position between handle member 50 and deck board main body 20, and therefore operability of the deck board is good. Since core layer 43 is not present in deepest part 23a where recess 24 of recess 23 is the deepest, gap CL1 into which hand HA1 can be inserted between handle member 50 and deck board main body 20 is wide, and in this respect as well, operability of the deck board 1 is good. Furthermore, since bottom part 23b, which is the lowest part in recess 23, protrudes below the part of deck board main body 20 where core layer 43 is present, gap CL1 into which hand HA1 can be inserted is wide, and in this respect as well, operability of the deck board 1 is good. Furthermore, since handle member 50 does not have a complicated mechanism, this specific example reduces the weight of deck board 1, thereby improving the operability of deck board 1 and enabling the cost of deck board 1 to be reduced.

[0063] When a passenger grasps handle member 50 with hand HA1 and lifts deck board 1, the load of handle member 50 grasped by the passenger is distributed not only to front surface 21 of deck board main body 20, but also to back surface 22 via boss 55. Handle member 50 grasped by hand HA1 is also supported at trailing edge 53, with boss 55 as a fulcrum. Therefore, deck board 1 of this example provides a stable feel when operated.

[0064] Because recess 23 of deck board main body 20 is visible behind handle member 50, the rear of handle member 50 on deck board 1 looks good. Because handle member 50 does not have a complicated mechanism, deck board 1 does not look ostentatious. Also, because skin material 45 is present in recess 24 of deck board main body 20, hand HA1 placed in gap CL1 between handle member 50 and deck board main body 20 touches skin material 45, giving deck board 1 a good feel to the touch. Furthermore, hand HA1 that enters recess 24 touches inclined surface 27 of exposed surface 26, also in this respect giving the deck board a good feel to the touch.

[0065] In addition, when the front-side base member and the back-side base member are embedded in a relatively large through hole in the deck board main body, the back of the handle for operating the deck board is not the deck board main body but the embedded front-side base member. In addition, when the deck board is formed so that a handle member having a recess and a handle as a member separate from the deck board main body is embedded in the deck board main body, the back of the handle is a handle member separate from the deck board main body. In these cases, the appearance behind the handle is monotonous. In addition, the front-side base member and the handle member embedded in the deck board main body are prone to positional deviation, and are also prone to deviation in the rotational direction along the surface of the deck board main body, which makes them prone to rattling. Compared to these cases, the handle member 50 of the deck board 1 of this specific example is less likely to be misaligned, is less likely to be misaligned in the rotational direction along the surface 21 of the deck board main body 20, and is less likely to rattle.

[0066] (5) Variation: The present invention contemplates various modifications. For example, a vehicle deck board to which the present technology can be applied is not limited to a foldable deck board 1 having a board divided into multiple pieces, and may be a single non-foldable deck board. The location of the handle member 50 relative to the recess 24 is not limited to the rear side of the recess 24, and may be the front side of the recess 24, the left side of the recess 24, the right side of the recess 24, etc. In other words, the location of the opening 28 relative to the recess 24 is not limited to the front side of the recess 24, and may be the rear side of the recess 24, the right side of the recess 24, the left side of the recess 24, etc. For example, the handle member in a single non-foldable deck board may be located on the front side of the recess so as to hide part of the recess while leaving an opening on the rear side through which a hand can be inserted into the recess. Deck board 1 may be provided with a separate locking mechanism for releasably fixing deck board 1 to another portion of automobile 100.

[0067] The protrusion that is passed through the through hole 29 of the deck board main body 20 is not limited to being provided on the handle member 50 like the boss 55 described above, but may be provided on the support member 70. In this case, the support member 70 as one member has a protrusion that protrudes toward the handle member 50 as the other member.

[0068] Furthermore, the basic effect of improving the appearance of the dual-use deck board can be obtained even when core layer 43 is present in deepest portion 23a of recess 23, when the protruding portion of handle member 50 is welded to support member 70, when deck board 1 does not have support member 70, etc.

[0069] (6) Conclusion: As described above, the present invention provides a technique that can improve the appearance of a vehicle deck board through various aspects. Of course, the basic functions and effects described above can be obtained even with a technique that is composed only of the constituent elements of the independent claims. In addition, configurations in which the configurations disclosed in the above examples are substituted with each other or the combination is changed, configurations in which the configurations disclosed in the publicly known techniques and the above examples are substituted with each other or the combination is changed, etc. The present invention also includes these configurations. [Explanation of symbols]

[0070] 1...Deck board, 11...front board, 12...center board, 12b...back side, 13...rear board, 13a...rear end, 20: Deck board body, 21: front surface, 22: back surface, 23...recess, 23a...deepest part, 23b...lower part, 24...dent, 25...non-exposed surface, 26...exposed surface, 27...slanted surface, 28...opening, 29...through hole, 40...main body layer, 41...first fiber layer, 42...second fiber layer, 43...core layer, 44,45…Skin material, 50: handle member; 51: main body; 52: rib (example of first contact portion); 53: rear edge; 55...Boss (example of protruding part), 56...Hollow part, 70...support member, 71...main body portion, 72...rib (example of second contact portion), 73...rear edge (example of second contact portion), 75...base portion (example of second contact portion), 76...screw insertion hole, 100...car, 101...back seat, 102...ceiling, 103...back door, 104...opening, 110: floor portion, 111: placement portion, 112: storage recess, 113: groove, 120... laminated material, 121... general part, 140... main body layer, 200...press molding machine, 210...press molding die, 212, 214...die, 216...nested die, 220 ... perforation structure, 222 ... protrusion, 224 ... receiving portion, B1, B2…binder, CL1: gap, D1: Front-rear direction, D2: Up-down direction, D3: Vehicle width direction, F1, F2: Fiber, HA1: Hands, SC1: Screws (an example of fastening material), SP0: Interior, SP1: Car compartment, SP2: Luggage compartment, SP3: Storage space, ST1...first molding process, ST2...second molding process, ST3...installation process.

Claims

1. A deck board provided in a vehicle interior, A deck board body having a front surface and a back surface, the deck board body having a recess on the front surface that does not reach the back surface; a handle member attached to the deck board body so as to hide a part of the recess while leaving an opening through which a hand can be inserted into the recess; a gap is provided between the handle member and the deck board main body within the recess, through which a hand can be inserted via the opening, The deck board main body includes a first fiber layer containing fibers and a binder and extending along the back surface, a second fiber layer containing fibers and a binder and extending along the front surface, and a core layer partially present between the first fiber layer and the second fiber layer, a portion of the recess where the recess is deepest is absent of the core layer, and the first fiber layer and the second fiber layer are integrated together.

2. The deck board according to claim 1 , wherein the deck board body is provided with a skin material on the surface including the recess.

3. the recess in the surface includes a non-exposed surface that is hidden by the handle member and an exposed surface that is not hidden by the handle member, 3. The deck board according to claim 1 or 2, wherein the exposed surface includes an inclined surface in which the recess becomes deeper toward the non-exposed surface.

4. A support member is further provided on the back surface of the recess, the handle member has a first contact portion in contact with the recess; The support member has a second contact portion in contact with the back surface, One of the handle member and the support member has a protrusion protruding toward the other member, the recess has a through hole that connects from the front surface to the back surface and through which the protrusion passes, The deck board according to any one of claims 1 to 3, wherein the protrusion passing through the through hole is fixed to the other member with a fastening member.

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