Vehicle interior parts with skin

Abstract

To provide an interior material with a skin in which defective demolding during injection molding of a base material can be suppressed, and adhesive failure between a skin material and the base material caused by air accumulation during vacuum molding or press molding can be suppressed.SOLUTION: An interior material with a skin for a vehicle is given in which a skin material consisting of a surface skin layer and a foam layer is stuck on a surface 10a of a base material 10 by vacuum molding or press molding. A vertical groove 11 with a Y-shaped cross section extending in parallel with a diecutting direction of the base material 10 and a lateral groove 13 with a Y-shaped cross section extending in a direction orthogonal to the diecutting direction of the base material 10 are formed on the surface 10a of the base material 10 in a lattice-like state, and a bleeding hole 17 is formed as a through hole at a prescribed interval at an intersection 15 of the vertical groove 11 and the lateral groove 13. A groove depth Dv of the vertical groove 11 is configured to be a depth in the extent that the groove is not filled with the foam layer when sticking on the skin material, and a groove depth Dh of the lateral groove 13 is configured to be a depth which is the groove depth Dv of the vertical groove 11 or less and is a depth according to the draft angle θh of the lateral groove 13.SELECTED DRAWING: Figure 5

Description

[Technical field]

[0001] The present invention relates to a vehicle interior part with a skin, and more particularly to a vehicle interior part with a skin in which a non-breathable sheet material, that is a skin material, is attached (bonded) to the surface of a base material by vacuum forming or press forming. [Background technology]

[0002] Conventionally, as vehicle interior parts such as instrument panels, there have been known interior parts with skin in which a highly tactile skin material consisting of a skin layer and a foam layer is attached by an adhesive or the like to the surface of a hard base material (core material) manufactured by injection molding.

[0003] When molding such interior parts with a skin, adhesive is applied to the back surface (the foam layer side) and then the skin material is heated and softened before being placed over the substrate. Vacuum forming is then performed to adhere the skin material to the substrate by drawing a vacuum through air vent holes formed through the substrate, or press molding is often performed to adhere the skin material to the substrate by pressing the substrate and skin material together using a substrate mold and a skin mold.

[0004] However, since a base material manufactured by injection molding has no escape route for thermal contraction during the cooling process, raised areas are likely to occur around the air vent holes. If a skin material is attached to the base material with such raised areas, the skin material will bulge locally, resulting in a poor appearance.

[0005] Therefore, for example, Patent Document 1 discloses a method for integrally molding a substrate and a sheet material in which a plurality of suction grooves with a rectangular cross section are provided approximately parallel to each other on the surface of a substrate, a sheet material (skin material) is placed on the surface of the substrate so that the sheet material covers the suction grooves while pulling both sides of the sheet material, and then a vacuum is applied to the suction grooves to attach the sheet material to the substrate.

[0006] According to Patent Document 1, by replacing suction holes (air vent holes) with multiple suction grooves, the amount of thermal shrinkage that occurs during injection molding of the base material is distributed from a point to a line, making it possible to prevent localized bulging around the suction grooves and thereby prevent the appearance from being poor due to localized bulging of the skin material. [Prior art documents] [Patent documents]

[0007] [Patent Document 1] Japanese Patent Application Publication No. 11-286050 Summary of the Invention [Problem to be solved by the invention]

[0008] However, the technique disclosed in Patent Document 1 has the following problems.

[0009] In other words, in the case of Patent Document 1, the cross-sectional shape of the suction groove is rectangular, which has a relatively small pull-out angle when demolding, so if a relatively deep groove is formed as the suction groove, there is a risk that demolding problems will occur during injection molding of the base material.

[0010] For this reason, in the case of Patent Document 1, the groove depth of the suction grooves must be shallow, but in the case of shallow suction grooves, when attaching a non-breathable covering material to a substrate, the foam layer enters the shallow suction grooves, making it difficult to ensure an air passage. As a result, air does not escape well through the air vent holes, and air accumulates between the covering material and the substrate, causing a problem of poor adhesion.

[0011] The present invention has been made in view of the above-mentioned problems, and an object of the present invention is to provide an interior part with a skin that can suppress poor adhesion between the skin material and the base material due to air pockets during vacuum molding or press molding, while suppressing problems in demolding during injection molding of the base material. [Means for solving the problem]

[0012] In order to achieve the above object, in the vehicle interior part with skin according to the present invention, a relatively large draft angle can be ensured, and vertical and horizontal grooves with a V-shaped cross section that are unlikely to be filled with a foam layer when the skin material is attached to the base material are formed in a lattice pattern on the surface of the base material as air passages.

[0013] Specifically, the present invention is directed to an interior part with a skin for a vehicle in which a skin material consisting of a skin layer and a foam layer is attached to the surface of a base material by vacuum forming or press forming.

[0014] The vehicle interior part with skin has a surface of the base material formed with a lattice pattern of a plurality of vertical grooves having a V-shaped cross section and extending parallel to a mold-pulling direction when the base material is injection-molded, and a plurality of horizontal grooves having a V-shaped cross section and extending in a direction perpendicular to the mold-pulling direction when the base material is injection-molded, and air vent holes are formed at predetermined intervals through the base material at intersections of the vertical grooves and the horizontal grooves, the groove depth of the vertical grooves is set to a depth that will not be filled with a foam layer when the skin material is attached, while the groove depth of the horizontal grooves is set to be equal to or less than the groove depth of the vertical grooves. can be, and The groove depth of a lateral groove with a small draft angle is smaller than the groove depth of a lateral groove with a large draft angle. It is characterized in that it is set.

[0015] In this configuration, the longitudinal grooves extend parallel to the mold-pulling direction during injection molding of the base material, so they do not cause resistance to demolding during demolding, and the groove depth can be set relatively deep. Specifically, the groove depth of the longitudinal grooves can be set to a depth that is not filled by the foam layer when the skin material is attached, depending on the hardness of the foam layer. In addition, by forming the cross section into a V-shape, it becomes difficult for the foam layer to reach the apex of the V during vacuum molding or press molding. These factors combine to ensure that the relatively deep longitudinal grooves ensure an air passage during vacuum molding or press molding.

[0016] On the other hand, since the lateral grooves extend in a direction perpendicular to the mold-pulling direction during injection molding of the base material, they generate resistance to demolding during demolding. However, by forming the lateral grooves in a V-shaped cross section, the pull-out angle during injection molding can be made larger than that of grooves with a rectangular cross section, and the groove depth is set to a depth that is equal to or less than the groove depth of the vertical grooves and corresponds to the pull-out angle of the lateral grooves. (The groove depth of lateral grooves with a small draft angle should be set smaller than the groove depth of lateral grooves with a large draft angle.) This reduces the resistance to demolding during injection molding. In addition, although a relatively shallow groove is easily filled with the foam layer when the skin is attached, by forming the groove with a V-shaped cross section, it is difficult for the foam layer to reach the apex of the V, so a minimum air passage can be secured.

[0017] Since these vertical and horizontal grooves are formed in a lattice pattern and air vent holes are formed through the intersections of these vertical and horizontal grooves, when the skin is attached during vacuum molding or press molding, air flows into the relatively shallow horizontal grooves as the foam layer enters, and the air that flows through the horizontal grooves collects in the vertical grooves, while the air that flows through the vertical grooves, which are set to a depth so that they are not filled by the foam layer, can be reliably discharged through the air vent holes. This makes it possible to reliably prevent air pockets from forming between the non-permeable skin material and the base material during vacuum molding or press molding. Effect of the Invention

[0018] As described above, the vehicle interior part with skin according to the present invention can suppress poor adhesion between the skin material and the base material due to air pockets during vacuum molding or press molding, while also preventing demolding problems during injection molding of the base material. [Brief description of the drawings]

[0019] [Figure 1] 1 is a cross-sectional view that illustrates a schematic view of a portion of a skin-equipped interior part of a vehicle according to an embodiment of the present invention. [Diagram 2] FIG. 2 is a diagram for explaining a typical example of vacuum forming of an interior part with a skin. [Diagram 3] FIG. 2 is a diagram for explaining a typical aspect of press molding of an interior part with a skin. [Figure 4] FIG. 2 is a plan view illustrating a surface of a substrate. [Diagram 5] FIG. 5 is a partially enlarged view of FIG. [Figure 6] 6A and 6B are cross-sectional views showing a schematic view of vertical grooves and horizontal grooves, FIG. 6A being a view taken along line VIa-VIa in FIG. 5, and FIG. 6B being a view taken along line VIb-VIb in FIG. [Figure 7] FIG. 2 is a diagram for explaining a typical manner in which air escapes during vacuum molding or press molding. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0020] Hereinafter, an embodiment of the present invention will be described with reference to the drawings.

[0021] - Overall structure of interior parts with skin - Fig. 1 is a cross-sectional view that shows a schematic view of a part of a vehicle interior part with a skin 1 according to this embodiment. In Fig. 1, in order to make the drawing easier to see, the thicknesses of a base material 10 and a skin material 20 are exaggerated, and a vertical groove 11, a horizontal groove 13, an air vent hole 17, etc., which will be described later, are omitted. In this embodiment, an instrument panel is shown as an example of the interior part with a skin 1, but the interior part with a skin 1 is not limited to this and can be applied to interior parts of various vehicles.

[0022] As shown in Fig. 1, this interior product with skin 1 has a three-layer structure and includes a base material 10 as a core material and a skin material 20 integrally attached to a surface 10a of the base material 10 by vacuum forming or press molding. The base material 10 is made of resin and is injection molded using a base material molding die (not shown). The skin material 20 is a sheet material in which a skin layer 21, which is a fabric skin, and a foam layer 23 are bonded together.

[0023] In this embodiment, the skin layer 21 is made of a fabric skin, but in order to prevent ventilation stains due to dust absorption, etc., a foam layer 23 that functions as an air stopper is attached to the back surface of the skin layer 21, so that the skin material 20 itself is a non-breathable sheet material that does not allow air to pass through.

[0024] Fig. 2 is a diagram for explaining a typical embodiment of vacuum forming of the interior part 1 with a skin, and Fig. 3 is a diagram for explaining a typical embodiment of press forming of the interior part 1 with a skin. Note that in Figs. 2 and 3, in order to make the drawings easier to see, the longitudinal grooves 11 and the lateral grooves 13 in the base material 10 are omitted, and the skin material 20 is illustrated as a single sheet material without being divided into the skin layer 21 and the foam layer 23.

[0025] When vacuum forming the interior part 1 with skin, the base material 10 is first placed on a vacuum forming mold 30 as shown in Fig. 2. A suction hole 30a is formed through the vacuum forming mold 30 so as to be concentric with the air vent hole 17 of the base material 10 when the base material 10 is set at a predetermined position.

[0026] Next, the skin material 20, whose back surface (the foam layer 23 side) is precoated with adhesive, is held by a clamp jig 31 and placed above the substrate 10 as shown by the dashed line in FIG. 2, and the skin material 20 is heated and softened by a heater (not shown).

[0027] Next, as shown by the white arrow in Fig. 2, the clamp jig 31 is lowered to cover the surface 10a of the base material 10 with the skin material 20. Then, after driving the vacuum pump 35, the valve 33 is opened to create a negative pressure inside the vacuum forming mold 30, and the air between the skin material 20 and the base material 10 is sucked (evacuated) through the air vent hole 17 and the suction hole 30a as shown by the thick arrow in Fig. 2, so that the skin material 20 is tightly attached to the surface 10a of the base material 10.

[0028] On the other hand, when press molding the interior part with skin 1, first, the base material 10 is placed on a base material mold 37 as shown in Fig. 3. A suction hole 37a is formed through the base material mold 37 so as to be concentric with the air vent hole 17 of the base material 10 when the base material 10 is set at a predetermined position.

[0029] Next, the skin material 20, the back surface (foam layer 23 side) of which has been precoated with adhesive, is held by a clamp jig 31 and placed above the substrate 10 as shown by the dashed line in Fig. 3, and the skin material 20 is heated and softened by a heater (not shown).

[0030] Next, as shown by the hollow arrow in FIG. 3, the clamp jig 31 and the skin mold 39 are lowered to place the skin material 20 over the surface 10a of the base material 10, and the base material 10 and the skin material 20 are pressed together by the base material mold 37 and the skin mold 39. As a result, the air between the skin material 20 and the base material 10 is released to the atmosphere through the air vent hole 17 and the suction hole 37a, as shown by the dashed arrow in FIG. 3, and the skin material 20 is brought into close contact with the surface 10a of the base material 10.

[0031] Incidentally, when press-molding the interior part 1 with skin, the valve 33 and the vacuum pump 35 may be provided so that suction is performed through the air vent hole 17 and the suction hole 37a, rather than opening to the atmosphere.

[0032] -Conventional problems- However, since the base material manufactured by injection molding has no place to escape thermal contraction during the cooling process, bulges are likely to occur around the air vent holes. If a skin material is attached to the base material with such bulges, the skin material will bulge locally, resulting in a poor appearance.

[0033] Therefore, for example, a method is conceivable in which a plurality of suction grooves with a rectangular cross section are provided on the surface of the base material at a pitch of 2 to 5 (mm) in approximately parallel fashion, the skin material is placed on the surface of the base material so as to cover the suction grooves, and then the suction grooves are evacuated to attach the skin material to the base material. In this way, by replacing the air vent holes with a plurality of suction grooves, the amount of thermal contraction caused by the injection molding of the base material is dispersed from a point to a line, so that it is possible to prevent localized swelling around the suction grooves, thereby preventing the skin material from swelling locally and thus causing a poor appearance.

[0034] However, in this method, since the cross-sectional shape of the suction groove is a rectangle with a relatively small removal angle when demolding, forming a relatively deep suction groove may cause demolding problems during injection molding of the base material. For this reason, in this method, the groove depth of the suction groove must be made shallow, but in the case of a shallow suction groove, when attaching a non-breathable skin material to the base material, the foam layer enters the shallow suction groove, making it difficult to ensure an air passage. Therefore, the air cannot be properly removed from the air vent hole, and air accumulates between the skin material and the base material, causing poor adhesion.

[0035] -Vertical and horizontal grooves- Therefore, in the vehicle interior part 1 with skin of the present embodiment, a relatively large draft angle can be ensured, and the vertical grooves 11 and horizontal grooves 13, each having a V-shaped cross section and unlikely to be filled with the foam layer 23 when the skin material 20 is attached to the base material 10, are formed in a lattice pattern on the surface 10a of the base material 10 as air passages.

[0036] Fig. 4 is a plan view showing the surface 10a of the substrate 10, and Fig. 5 is a partially enlarged view of Fig. 4. Fig. 6 is a cross-sectional view showing the longitudinal grooves 11 and the transverse grooves 13, where Fig. 6(a) is a view taken along line VIa-VIa in Fig. 5, and Fig. 6(b) is a view taken along line VIb-VIb in Fig. 5. In Fig. 4, the groove widths Wv, Wh and pitches of the longitudinal grooves 11 and the transverse grooves 13 are exaggerated for ease of viewing, and air vent holes 17 are omitted. The outline arrow in Fig. 4 indicates the mold-pulling direction during injection molding of the substrate 10.

[0037] As shown in Fig. 4, a plurality of vertical grooves 11 having a V-shaped cross section extending parallel to the mold-pulling direction when the substrate 10 is injection-molded, and a plurality of horizontal grooves 13 having a V-shaped cross section extending in a lattice pattern on the surface 10a of the substrate 10, are formed. The vertical grooves 11 and the horizontal grooves 13 are each formed at a pitch of 10 mm. In this way, by forming the vertical grooves 11 and the horizontal grooves 13 at a pitch of 10 mm, which is wider than the conventional groove pitch (2 to 5 mm), it is possible to reduce the demolding resistance during injection molding compared to conventional substrates.

[0038] 5, air vent holes 17 are formed at predetermined intervals (30 (mm)) at intersections 15 between the vertical grooves 11 and the horizontal grooves 13 in the base material 10. In other words, air vent holes 17 are formed at every two intersections 15 vertically and horizontally so as to penetrate the base material 10 in the thickness direction.

[0039] Here, the longitudinal grooves 11 extend parallel to the demolding direction during injection molding of the base material 10, and therefore do not cause resistance to demolding during demolding, so the groove depth Dv can be made relatively deep. Specifically, the groove depth Dv of the longitudinal grooves 11 is set according to the hardness of the foam layer 23 to a depth that will not be filled by the foam layer 23 when the skin material 20 is attached.

[0040] For example, as shown in Fig. 6(b), the longitudinal grooves 11 of this embodiment are formed in a V-shaped cross section with a groove depth Dv = 500 (μ) and a groove width Wv: groove depth Dv = 1:1 (draft angle θv = 53 (°)), and have a relatively deep groove depth Dv and a relatively large draft angle θv. In addition, by forming the longitudinal grooves 11 in a V-shaped cross section, it becomes difficult for the foam layer 23 to reach the apex of the V shape during vacuum molding or press molding. In combination, the relatively deep longitudinal grooves 11 can reliably secure an air passage during vacuum molding or press molding.

[0041] On the other hand, since the lateral grooves 13 extend in a direction perpendicular to the demolding direction during injection molding of the base material 10, demolding resistance occurs during demolding. However, by forming the cross section into a V-shape, the demolding angle during injection molding is made larger than that of a groove with a rectangular cross section, and the groove depth Dh of the lateral grooves 13 is set to a depth equal to or less than the groove depth Dv of the longitudinal grooves 11 and according to the demolding angle θh of the lateral grooves 13, specifically, to 200 to 500 (μ), thereby reducing the demolding resistance during injection molding.

[0042] More specifically, (1) in areas where demolding resistance is particularly likely to occur (for example, areas where the draft angle θh is 20° or less), the groove depth Dh of the lateral grooves 13 is set to 200 (μ) (in this case, groove width Wh≦71 (μ)), and the relatively shallow groove depth Dh is used to reduce demolding resistance during injection molding.

[0043] In addition, (2) in typical areas (for example, areas where the draft angle θh is 21° or more and less than 42°), the groove depth Dh of the lateral grooves 13 is set to 300μ (in this case, 111μ≦groove width Wh<230μ) so that the relatively deep groove depth Dh achieves both a reduction in demolding resistance during injection molding and an assurance of an air passage during vacuum molding or press molding.

[0044] Furthermore, (3) in areas where demolding resistance is unlikely to occur (for example, areas where the demolding angle θh is 42 (°) or more), the groove depth Dh of the lateral grooves 13 is set to 500 (μ) (in this case, 384 (μ)≦groove width Wh), similar to the vertical grooves 11, so that the relatively deep groove depth Dh ensures an air passage during vacuum molding or press molding.

[0045] Furthermore, although the relatively shallow lateral grooves 13 are easily filled with the foam layer 23 when the covering material 20 is applied, by forming the cross section in a V-shape, it is difficult for the foam layer 23 to reach the apex of the V, so that a minimum air passage can be secured.

[0046] The vertical grooves 11 and horizontal grooves 13 having a V-shaped cross section and groove widths Wv, Wh and groove depths Dv, Dh can be easily realized by forming a V-groove on the surface 10a of a substrate molding mold used for injection molding the substrate 10 by NC processing or special etching processing.

[0047] Fig. 7 is a diagram for explaining the mode of air escape during vacuum molding or press molding. The vertical grooves 11 and horizontal grooves 13 configured as described above are formed in a lattice shape, and air escape holes 17 are formed at the intersections 15 between the vertical grooves 11 and horizontal grooves 13. Therefore, when the skin material 20 is attached during vacuum molding or press molding, the foam layer 23 enters the relatively shallow horizontal grooves 13, and air flows as shown by the dashed arrows in Fig. 7. The air that flows through the horizontal grooves 13 gathers in the vertical grooves 11, and the air that flows through the vertical grooves 11, which are set to a depth such that they are not filled by the foam layer 23, can be reliably discharged from the air escape holes 17 as shown by the thick arrows in Fig. 7. This reliably prevents air from pooling between the non-permeable skin material 20 and the substrate 10 during vacuum molding or press molding.

[0048] As described above, with the vehicle interior part with skin 1 of this embodiment, it is possible to ensure relatively large draft angles θv, θh, and when the skin material 20 is attached to the base material 10, the vertical grooves 11 and horizontal grooves 13 having a V-shaped cross section that is unlikely to be filled up to the apex of the V with the foam layer 23 are formed in a lattice pattern on the surface 10a of the base material 10 as air passages. This simple configuration makes it possible to prevent poor demolding during injection molding of the base material 10 while also preventing poor adhesion between the skin material 20 and the base material 10 due to air traps during vacuum molding or press molding.

[0049] (Other embodiments) The present invention is not limited to the embodiments, and can be embodied in various other forms without departing from the spirit or main characteristics thereof.

[0050] In the above embodiment, the skin layer 21 is made of a fabric skin, but this is not limited to the above and the skin layer 21 may be made of a skin other than a fabric skin as long as the skin material 20 itself is a non-breathable sheet material that does not allow air to pass through.

[0051] In addition, in the above embodiment, the vertical grooves 11 and the horizontal grooves 13 are each formed at a pitch of 10 mm, but this is not limited to the above. In order to further reduce the demolding resistance during injection molding, for example, the vertical grooves 11 and the horizontal grooves 13 may each be formed at a pitch of more than 10 mm.

[0052] Furthermore, in the above embodiment, the air vent holes 17 are formed at the intersections 15 at intervals of 30 mm, but this is not limiting. In order to further improve the ability to discharge air from the air vent holes 17 during vacuum forming or press forming, the air vent holes 17 may be formed at the intersections 15 at intervals of less than 30 mm, for example.

[0053] In addition, in the above embodiment, the groove depth Dv of the vertical groove 11 is set to 500 (μ), but this is not limited thereto. In cases where the foam layer 23 is soft, the groove depth Dv of the vertical groove 11 may be set to a depth exceeding 500 (μ), and conversely, in cases where the foam layer 23 is hard, the groove depth Dv of the vertical groove 11 may be set to a depth less than 500 (μ).

[0054] As such, the above-described embodiment is merely illustrative in all respects and should not be construed as limiting. Furthermore, all modifications and variations within the scope of the claims are within the scope of the present invention. [Industrial Applicability]

[0055] According to the present invention, it is possible to suppress poor adhesion between the skin material and the substrate due to air pockets formed during vacuum forming or press forming while preventing problems in demolding during injection molding of the substrate, and therefore the present invention is extremely useful when applied to vehicle interior parts with skin in which the skin material, which is a non-breathable sheet material, is attached to the surface of the substrate by vacuum forming or press forming. [Explanation of symbols]

[0056] 1 Interior parts with skin 10 Base material 10a surface 11 Vertical groove 13 Yokomizo 15 intersection 17 Air vent hole 20 Skin material 21 Epidermal layer 23 Foam Layer Dh Depth of lateral groove Dv Depth of longitudinal groove θh Draft angle of lateral groove

Claims

[Claim 1] A skin-attached interior part for a vehicle, in which a skin material consisting of a skin layer and a foam layer is attached to a surface of a base material by vacuum forming or press forming, a surface of the substrate is formed with a lattice pattern of a plurality of vertical grooves having a V-shaped cross section and extending parallel to a mold-pulling direction during injection molding of the substrate, and a plurality of horizontal grooves having a V-shaped cross section and extending in a direction perpendicular to the mold-pulling direction during injection molding of the substrate, and air vent holes are formed at predetermined intervals at intersections of the vertical grooves and the horizontal grooves in the substrate; The depth of the longitudinal grooves is set so that they will not be filled by the foam layer when the skin is attached. The groove depth of the lateral groove is equal to or less than the groove depth of the longitudinal groove, and the groove depth of the lateral groove having a smaller draft angle is set smaller than the groove depth of the lateral groove having a larger draft angle.

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