Vehicle interior parts

Abstract

To suppress deterioration of appearance and tactile sensation caused by a storage chamber.SOLUTION: A base material 11 of a vehicle interior component 10 has one side in its own thickness direction as surfaces 14, 17 and the other side as back surfaces 15, 18, and also has an outer surface 26 between the surfaces 14, 17 and the back surfaces 15, 18. A skin layer 31 covers the base material 11 from the front side to form a foam molding space 35 between itself and the base material 11. A foam layer 41 is formed by foaming a foam material in the foam molding space 35. A sealing part 36 is formed by the skin layer 31 contacting a portion of the base material 11 adjacent to the foam molding space 35, and regulates leakage of the foam material from the foam molding space 35. A surface of the portion of the skin layer 31 that covers the foam molding space 35 constitutes a design surface 33. In the base material 11, on an opposite side of the foam molding space 35 across the sealing part 36, a storage chamber 45 is formed to store the foam material that has passed through the sealing part 36.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The present invention relates to a vehicle interior having a foam layer between a base material and a skin layer.

Background Art

[0002] For example, the vehicle interior described in Patent Document 1 includes a base material, a skin layer, a foam layer, and a seal portion. The base material has one surface in its thickness direction as the front surface and the other surface as the back surface. The skin layer forms a foam molding space between itself and the base material by covering the base material from the front side. The surface of the skin layer that covers the foam molding space constitutes a design surface. The foam layer is formed by injecting a foam material into the foam molding space and allowing the foam material to foam. The foam layer imparts a soft feeling to the vehicle interior and improves the touch feeling. The seal portion is formed when the skin layer comes into contact with a portion of the base material adjacent to the foam molding space, and restricts the leakage of the foam material from the foam molding space.

[0003] Furthermore, the base material in the vehicle interior described in Patent Document 1 includes a storage chamber for the foam material. Therefore, even if the foam material passes through the seal portion, it is accommodated in the storage chamber. The foam material is suppressed from leaking to the outside of the vehicle interior.

Prior Art Documents

Patent Documents

[0004]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0005] However, in the vehicle interior parts described in Patent Document 1, the seal portion and the storage chamber are formed between adjacent foam molding spaces and on the back side of the design surface. Therefore, these seal portions and storage chambers cause uneven portions on the design surface, degrading the appearance of the vehicle interior parts. In addition, there is a risk that the occupant may touch the uneven portions on the design surface of the vehicle interior parts. The design surface is not smooth at the uneven portions. Therefore, the tactile sensation when the occupant touches the uneven portions is lower than that when there are no uneven portions.

Means for Solving the Problems

[0006] The vehicle interior part for solving the above problems has one surface in its thickness direction as the front surface and the other surface as the back surface, and further has a base material having an outer surface between the front surface and the back surface, and an epidermal layer that forms a foam molding space between itself and the base material by covering the base material from the front side, and a foam layer formed by foaming a foaming material in the foam molding space. Further, a seal portion is formed by the epidermal layer being brought into contact with a portion of the base material adjacent to the foam molding space, and the vehicle interior part is configured such that leakage of the foaming material from the foam molding space is restricted by the seal portion. Among the epidermal layer, the surface of the portion covering the foam molding space constitutes a design surface, and in the base material, on the side opposite to the foam molding space with the seal portion interposed therebetween, a storage chamber for storing the foaming material that has passed through the seal portion is formed.

[0007] According to the above configuration, when manufacturing the vehicle interior part, since the base material is covered from the front side by the epidermal layer, a foam molding space is formed between the epidermal layer and the base material. A foaming material is injected into this foam molding space. By foaming the injected foaming material, a foam layer is formed in the foam molding space.

[0008] The seal portion is formed by the epidermal layer being brought into contact with a portion of the base material adjacent to the foam molding space. The seal portion restricts leakage of the foaming material from the foam molding space. Also, even if the foaming material passes through the seal portion, the foaming material is accommodated in the storage chamber. Therefore, leakage of the foaming material to the outside of the vehicle interior parts is suppressed.

[0009] Here, since the storage chamber is formed in the base material, there are inevitably some uneven portions on the vehicle interior parts. However, the storage chamber is formed in the base material on the side opposite to the foaming space with the seal portion interposed therebetween.

[0010] On the other hand, the design surface of the vehicle interior parts is constituted by the surface of the portion of the skin layer that covers the foaming space. Therefore, by forming the storage chamber at a location that satisfies the above conditions, the storage chamber is located at a position far from the design surface. Therefore, when the vehicle occupant views the design surface of the vehicle interior parts, the uneven portions generated due to the formation of the storage chamber are located at positions out of the occupant's line of sight and are not visible or difficult to see for the occupant.

[0011] Also, as described above, since the storage chamber is located at a position far from the design surface, it is unlikely that the occupant will touch the storage chamber. Therefore, a decrease in the tactile sensation caused by touching the uneven portions is also unlikely to occur.

[0012] In the above vehicle interior parts, the base material preferably includes a general portion and a terminal portion formed at an edge portion of the general portion and having an outer surface, and the terminal portion has a protrusion protruding toward the front side from the general portion, and the seal portion is formed by bringing the skin layer into contact with at least the outer surface of the protrusion of the terminal portion.

[0013] According to the above configuration, in the base material, the general portion and the protrusion of the terminal portion are covered from the front side by the skin layer, so that a foaming space is formed between the general portion and the skin layer. A foaming material is injected into this foaming space. When the injected foaming material foams, a foaming layer is formed in the foaming space. When forming this foaming layer, the protrusion functions to receive the flow of the injected foaming material.

[0014] When the skin layer contacts at least the protrusion of the terminal part, the skin layer contacts the part of the base material adjacent to the foaming space, and a sealing part is formed. In the vehicle interior part, it is preferable that the storage chamber is constituted by a notch that opens at a position on at least the outer surface of the terminal part, which is on the opposite side of the foaming space with respect to the sealing part with the sealing part interposed therebetween.

[0015] According to the above configuration, a notch is opened at a position on at least the outer surface of the terminal part, which is on the opposite side of the foaming space with respect to the sealing part with the sealing part interposed therebetween. Therefore, when the foaming material passes through the sealing part, the foaming material is accommodated in the notch from the opening part of the terminal part.

[0016] Here, in the terminal part, the protrusion protrudes to the front side more than the general part. In the base material, due to the protrusion, the thickness of the terminal part is larger than the thickness of the general part. Therefore, it becomes easier to form the sealing part and the notch (storage chamber) with respect to the terminal part.

[0017] Further, when the base material is formed by a resin molding method such as an injection molding method, by providing the terminal part having the protrusion as described above, a difference in thickness occurs between the general part and the terminal part. The greater the difference in this thickness, the greater the difference in the degree of shrinkage after molding. A dent (depression) called "sink mark" may occur in the terminal part, which is a part with a large thickness, and the appearance of the vehicle interior part may be impaired.

[0018] In this regard, as described above, by forming a notch in the terminal part, the substantial thickness of the terminal part becomes smaller. Therefore, the difference between the thickness of the general part and the substantial thickness of the terminal part becomes smaller, and it becomes less likely for sink marks to occur after molding the terminal part.

[0019] In the vehicle interior part, it is preferable that the notch opens across the outer surface and the back surface of the terminal part. The notch is located in the region on the back surface side including the back surface in the thickness direction of the base material by being opened across the outer surface and the back surface of the terminal portion as described above. Therefore, the region on the front side of the notch becomes wider on the outer surface of the terminal portion. Accordingly, it becomes possible to form a seal portion that seals a wide region in the thickness direction of the base material.

[0020] In the vehicle interior part, it is preferable that an auxiliary seal portion is further formed to regulate leakage of the foaming material from the storage chamber by bringing the skin layer into contact with a location adjacent to the seal portion on the opposite side across the storage chamber on the outer surface of the terminal portion.

[0021] According to the above configuration, in the auxiliary seal portion, the skin layer is brought into contact with a location adjacent to the seal portion on the opposite side across the storage chamber on the outer surface of the terminal portion. In addition to the seal portion, leakage of the foaming material is also regulated by the auxiliary seal portion. Therefore, it becomes possible to further enhance the sealing performance of the foaming material.

Advantages of the Invention

[0022] According to the vehicle interior part, it is possible to suppress a decrease in appearance and touch feeling caused by the storage chamber.

Brief Description of the Drawings

[0023]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Figure 6

Figure 7

Figure 8

Figure 9

Figure 10

Mode for Carrying Out the Invention

[0024] Hereinafter, an embodiment of a vehicle interior part will be described with reference to FIGS. 1 to 6. The vehicle interior part in this embodiment is an interior part that requires a soft feeling as a tactile sensation when a passenger touches it in the vehicle interior. Examples of the vehicle interior part include interior panels for the front part of the vehicle interior such as an instrument panel and a dashboard arranged at the front part of the vehicle interior. Also, the console side can be cited as a vehicle interior part.

[0025] <Schematic Configuration of Vehicle Interior Part> As shown in FIG. 1, the vehicle interior part 10 has a three-layer structure formed by laminating a base material 11, a skin layer 31, and a foam layer 41. Next, each layer will be described.

[0026] 〈Base Material 11〉 As shown in FIGS. 1 and 2, the base material 11 is a member that constitutes the skeleton portion of the vehicle interior part 10. The base material 11 is made of a hard resin material such as PP (polypropylene) and is formed by a resin molding method such as an injection molding method.

[0027] The base material 11 includes a general part 12 and a terminal part 21. The general part 12 includes a horizontal wall part 13 arranged in a substantially horizontal state and a vertical wall part 16 hanging down from the peripheral edge of the horizontal wall part 13. The horizontal wall part 13 has, as a front surface 14, one (upper) surface in its thickness direction, and has, as a back surface 15, the other (lower) surface. The vertical wall part 16 has, as a front surface 17, one (leftward in FIG. 1) surface in its thickness direction, and has, as a back surface 18, the other (rightward in FIG. 1) surface.

[0028] The terminal part 21 is formed at the edge part of the general part 12, more specifically, at the lower edge part of the vertical wall part 16. The terminal part 21 has a protrusion 22 that protrudes to the front side from the front surface 17 of the vertical wall part 16. Here, in order to define each part of the terminal part 21, the same direction as the thickness direction of the vertical wall part 16 (the left - right direction in FIG. 1) is defined as the thickness direction of the terminal part 21. The terminal part 21 has, as a front surface 24, one (leftward in FIG. 1) surface in its thickness direction, and has, as a back surface 25, the other (rightward in FIG. 1) surface. The front surface 24 is located on the front side of the front surface 17 by the amount of the protrusion 22. In contrast, the back surface 25 is located on the same plane as the back surface 18.

[0029] The terminal part 21 has an outer surface 26 between the front surface 24 and the back surface 25. The outer surface 26 includes an inclined surface 27 and a horizontal surface 28 that are adjacent to each other in the thickness direction. The horizontal surface 28 is located in the back part of the outer surface 26 and is connected to the back surface 25. The inclined surface 27 is located on the front side of the outer surface 26 with respect to the horizontal surface 28 and is connected to the front surface 24. The inclined surface 27 is inclined with respect to the horizontal surface 28 so as to become higher as it approaches the front surface 24.

[0030] 〈Epidermal layer 31〉 As shown in FIG. 1, the epidermal layer 31 is mainly used for the purpose of improving the texture and touch of the vehicle interior part 10. The epidermal layer 31 is formed into a sheet shape with uniform thickness by synthetic leather (artificial leather) made of olefin - based thermoplastic elastomer (TPO). The epidermal layer 31 may also be formed of polyurethane, vinyl chloride, etc. in addition to TPO.

[0031] The skin layer 31 includes a main part 32 and an end part 34. The main part 32 covers the general part 12 from the front side, thereby forming a foaming space 35 between the main part 32 and the general part 12. The main part 32 is located at a position away from the surfaces 14, 17, 24 of the base material 11 toward the front side. The surface of the main part 32 constitutes the design surface 33 of the vehicle interior part 10.

[0032] The end part 34 is connected to the edge part of the main part 32 and is in contact with the outer surface 26 (the inclined surface 27 and the horizontal surface 28) of the terminal part 21. The outer surface 26 with which the end part 34 is in contact corresponds to a location on the base material 11 adjacent to the foaming space 35. A seal part 36 is formed by the end part 34 and the inclined surface 27 that are in contact with each other.

[0033] 〈Foam layer 41〉 The foam layer 41 is a layer for imparting a soft feeling to the vehicle interior part 10, and is formed by foaming a foaming material M1 (see FIG. 4) in the foaming space 35. In this embodiment, the foam layer 41 is formed of a urethane resin foam. In this case, the foaming material M1 is a mixture of two main raw materials such as polyol and isocyanate, with a catalyst, a foaming agent, a foam stabilizer, etc.

[0034] Furthermore, the vehicle interior part 10 of this embodiment includes a storage chamber 45. <Storage chamber 45> As shown in FIGS. 1 and 2, the storage chamber 45 is a space (room) that can accommodate the foaming material M1 even when the foaming material M1 passes through the seal part 36. The storage chamber 45 is constituted by a notch 46 formed in the base material 11. In this embodiment, the notch 46 opens across a location on the outer surface 26 that is on the opposite side of the foaming space 35 with the seal part 36 interposed therebetween (the horizontal surface 28) and a location on the back surface 25 adjacent to the outer surface 26. The notch 46 has a rectangular cross-sectional shape.

[0035] Here, the direction orthogonal to the thickness direction (vertical direction) of the horizontal wall portion 13 and the thickness direction (left - right direction in FIG. 1) of the vertical wall portion 16 (the direction orthogonal to the paper surface in FIG. 1) is defined as the depth direction. The notches 46 are formed at a plurality of locations spaced apart from each other in the depth direction at the terminal portion 21.

[0036] Next, the operation of the present embodiment configured as described above will be described. Also, the effects resulting from the operation will be described together. <(1) Method for forming the skin layer 31, the foam layer 41, and the seal portion 36> In implementing this method, as shown in FIG. 3, a skin material 51 larger than the skin layer 31, a base material 11 (see FIG. 2) separately formed by a resin molding method such as an injection molding method, and a mold device 60 are used.

[0037] The skin material 51 includes a main - part planned part 52 to be shaped (formed) so as to become the main part 32 of the skin layer 31, an end - part planned part 53 to be formed so as to become the end part 34, and a cut - planned part 54 to be cut off after the formation of the skin layer 31.

[0038] The mold device 60 includes a first mold 61 having a molding recess 62 and a second mold 71 having a base 72 and a molding projection 73. At least one of the first mold 61 and the second mold 71 is provided so as to be movable in the vertical direction. By this vertical movement, the first mold 61 and the second mold 71 approach and separate from each other.

[0039] The molding recess 62 has an opening 63 at its lower end and an inner horizontal wall surface 64 at its upper end. Also, the molding recess 62 has an inner vertical wall surface 65 between the opening 63 and the inner horizontal wall surface 64. An shaping surface 66 for shaping the main - part planned part 52 to form the main part 32 is constituted by the inner horizontal wall surface 64 and the upper part of the inner vertical wall surface 65 of the molding recess 62. The lower part of the inner vertical wall surface 65 constitutes an inner surplus surface 67 along which the end - part planned part 53 and the cut - planned part 54 are arranged.

[0040] The first forming die 61 is formed with a plurality of first air suction passages (not shown), and one end of each first air suction passage is opened on the shaping surface 66. Further, the first forming die 61 is formed with a plurality of air supply passages (not shown), and one end of each air supply passage is opened on the inner surplus surface 67.

[0041] On the other hand, the forming convex portion 73 protrudes upward from the base portion 72. The forming convex portion 73 has an outer lateral wall surface 74 at the upper end and an outer longitudinal wall surface 75 between the base portion 72 and the outer lateral wall surface 74. The outer lateral wall surface 74 and the upper portion of the outer longitudinal wall surface 75 constitute an adherend surface 76 on which the base material 11 is mounted. The lower portion of the outer longitudinal wall surface 75 constitutes an outer surplus surface 77 with which the planned excision portion 54 is in close contact (see FIG. 4).

[0042] The second forming die 71 is formed with a plurality of second air suction passages (not shown), and one end of each second air suction passage is opened on the outer surplus surface 77. When forming the skin layer 31, the foam layer 41, and the seal portion 36, first, the first forming die 61 and the second forming die 71 are separated, that is, the mold device 60 is opened.

[0043] The base material 11 is placed on the adherend surface 76 of the forming convex portion 73. The back surface 15 of the horizontal wall portion 13 is brought into contact with the outer lateral wall surface 74, and the back surface 18 of the vertical wall portion 16 is brought into contact with the outer longitudinal wall surface 75. The skin material 51 is disposed near the forming recess 62 of the first forming die 61. The skin material 51 is heated by a heater (not shown) to 180° C. or higher and softened.

[0044] When the heating is completed, as shown in FIG. 3, the mold device 60 is closed. During this closing process, as the first forming die 61 and the second forming die 71 approach each other, the forming convex portion 73 enters the forming recess 62 together with the base material 11.

[0045] The air between the main part planned area 52 and the shaping surface 66 is vacuum-sucked through the first air suction passage. Among the skin materials 51, the main part planned area 52 facing the shaping surface 66 is deformed (shaped) so as to follow the shape of the shaping surface 66. In this way, the main part 32 of the skin layer 31 is formed. At this time, among the skin materials 51, the end part planned area 53 and the excision planned area 54 are in a state along the inner surplus surface 67 and are separated from the terminal part 21 and the outer surplus surface 77.

[0046] (1-1) Here, in the present embodiment, the protrusion 22 protrudes to the front side with respect to the vertical wall part 16. Therefore, the general part 12 and the protrusion 22 can be covered from the front side by the main part planned area 52, and the foam molding space 35 can be formed.

[0047] (1-2) Further, in the present embodiment, the inner surplus surface 67 is formed at the lower part of the molding recess 62, and the outer surplus surface 77 is formed at the lower part of the molding protrusion 73. Therefore, a deformation space 78 for deforming the end part planned area 53 and the excision planned area 54 can be formed between the inner vertical wall surface 65 and the outer vertical wall surface 75 and between the base part 72 and the terminal part 21.

[0048] Next, the vacuum suction through the first air suction passage is stopped. At substantially the same timing as this stop, as shown in FIGS. 3 to 5, the injection of the foam material M1 into the foam molding space 35 is started.

[0049] (1-3) As shown in FIG. 4, when the foam material M1 is injected into the foam molding space 35 to a certain extent, the air in the deformation space 78 is vacuum-sucked as shown by the arrow B. The vacuum suction is performed by sucking the air between the end part planned area 53 and the excision planned area 54 and the outer surplus surface 77 in the deformation space 78 through the second air suction passage. A suction force acts on the end part planned area 53 and the excision planned area 54 from the outer surplus surface 77 side. Since the skin material 51 is softened by heating as described above, it can be easily deformed. Therefore, due to the above suction force, the end part planned area 53 is deformed so as to follow the outer surface 26, and the excision planned area 54 is deformed so as to follow the shape of the outer surplus surface 77.

[0050] Also, substantially simultaneously with the above-described vacuum suction, air is blown from the opening portion of the air supply passage on the inner surplus surface 67 onto the planned end portion 53 and the planned cutting portion 54 as indicated by the arrow C. By this air, a pressing force acts on the planned end portion 53 and the planned cutting portion 54. Therefore, the planned end portion 53 deforms so as to further follow the outer surface 26. Further, the planned cutting portion 54 deforms so as to further follow the outer surplus surface 77.

[0051] Due to the vacuum suction and the blowing of air performed in the deformation space 78, the planned end portion 53 is brought into contact with the inclined surface 27 in a close contact state to form the seal portion 36. Further, the planned cutting portion 54 is brought into contact with the outer surplus surface 77 in a close contact state.

[0052] The foaming material M1 injected into the foaming space 35 attempts to expand to the terminal portion 21 located at the end of the foaming space 35 while undergoing a foaming reaction and a resinification reaction. (1-4) At the terminal portion 21, the inner surface 23 of the protrusion 22 protruding to the front side from the general portion 12 is located at the end of the foaming space 35. The inner surface 23 is substantially orthogonal to the flow direction of the foaming material M1. Therefore, the protrusion 22 can exhibit the function of receiving the flow of the foaming material M1.

[0053] (1-5) The foaming material M1 that has reached the terminal portion 21 attempts to pass between the base material 11 and the skin layer 31 (skin material 51) below the surface 24 of the terminal portion 21. The foaming material M1 here includes, in addition to the foaming material M1 itself, gas generated by the foaming of the foaming material M1, a foam-like fluid (an uncured foam such as viscous urethane), and the like.

[0054] In this regard, in the present embodiment in which the seal portion 36 is formed below the surface 24 of the terminal portion 21, the planned end portion 53 is in close contact with the inclined surface 27. Therefore, leakage of the foaming material M1 through between the inclined surface 27 and the planned end portion 53 is regulated by the seal portion 36.

[0055] (1-6) Further, in the present embodiment, a notch 46 is formed in a portion of the outer surface 26 on the side opposite to the foaming space 35 with the seal portion 36 interposed therebetween. Therefore, even if the foaming material M1 passes through the seal portion 36, the foaming material M1 can be accommodated in the notch 46 (storage chamber 45) from the opening portion on the outer surface 26 (horizontal plane 28).

[0056] Accordingly, it is possible to suppress the foaming material M1 from leaking to the outside of the vehicle interior part 10. Further, it is possible to suppress the foaming material M1 from entering and clogging the second air suction passage.

[0057] (1-7) In particular, in the present embodiment, the notches 46 are formed at a plurality of positions spaced apart from each other in the depth direction. Therefore, the foaming material M1 that has flowed in the thickness direction of the seal portion 36 can be accommodated in the storage chamber 45 closest to the location where the foaming material M1 has passed among the plurality of storage chambers 45.

[0058] (1-8) In the present embodiment, the seal portion 36 is formed by deforming the end portion planned portion 53 by vacuum suction and air blowing and bringing it into close contact with the inclined surface 27. Therefore, the following various effects can be obtained.

[0059] 〈1-8A〉The degree of freedom of the shape of the terminal portion 21 where the end portion planned portion 53 can be brought into close contact, particularly the degree of freedom of the shape of the outer surface 26, and thus the degree of freedom of the shape of the seal portion 36 that can seal the foaming material M1 can be increased.

[0060] In this regard, the present embodiment is superior to the case where the skin material is pressed against the base material by a mold, a jig, or the like. In a conventional method of forming a seal portion by pressing a part of a skin material against a base material by clamping a mold device, depending on the shape of the seal portion, there may be strong interference between the skin material and the mold device. Due to this strong interference, there is a possibility that a wrinkled seal portion may be formed. In this case, problems such as a decrease in the appearance of the skin layer at the seal portion and unstable sealing performance may occur.

[0061] On the other hand, in the present embodiment where the seal portion 36 is formed by vacuum suction and air blowing, there is no strong interference between the skin material 51 and the mold device 60, and it is difficult for the seal portion 36 to wrinkle. It is possible to suppress the appearance of the seal portion 36 from deteriorating and the sealing performance from becoming unstable due to wrinkles.

[0062] (1-8C) Compared with the case where the planned end portion 53 is deformed by only one of vacuum suction and air blowing and brought into contact with the outer surface 26, the same planned end portion 53 can be brought into strong contact with the outer surface 26. The adhesion to the inclined surface 27 of the planned end portion 53 can be enhanced, and a seal portion 36 with higher sealing performance can be formed.

[0063] (1-8D) At the end of the vehicle interior part, if the foam layer is exposed, it is necessary to cover and hide the exposed part with another part. On the other hand, in the present embodiment, the terminal portion 21 of the base material 11 is located at the end of the vehicle interior part 10. And the planned end portion 53 of the skin material 51 covers the terminal portion 21. Therefore, at the end of the vehicle interior part 10, the foam layer 41 is not exposed. It is not necessary to cover and hide the exposed part with another part.

[0064] As a case where the foam layer is exposed, for example, there is a case where a seal portion is created in a state connected to the vehicle interior part outside the vehicle interior part, and after forming the foam layer, the seal portion is cut. In this case, the foam layer is exposed at the cut portion.

[0065] Incidentally, when the foaming material M1 injected into the foaming space 35 hardens, as shown in FIG. 6, an intermediate product 81 in which the base material 11 and the skin layer 31 are integrated by a soft foaming layer 41 is obtained.

[0066] Subsequently, the injection of the foaming material M1, the vacuum suction, and the air blowing are stopped. The mold device 60 is opened, and the intermediate product 81 is taken out. When the planned excision portion 54 of the skin material 51 is excised from the intermediate product 81 at a location D shown by, for example, a one-dot chain line in FIG. 6, the target vehicle interior 10 shown in FIG. 1 is obtained.

[0067] <(2) Regarding the Appearance and Tactility of the Vehicle Interior 10> As shown in FIG. 1, since the storage chamber 45 is formed in the base material 11, there are quite a few uneven portions on the vehicle interior 10.

[0068] (2-1) However, in the present embodiment, the storage chamber 45 is formed on the opposite side of the foaming space 35 with the seal portion 36 interposed therebetween in the base material 11 (terminal portion 21). On the other hand, the design surface 33 of the vehicle interior 10 is constituted by the surface of the portion of the skin layer 31 that covers the foaming space 35.

[0069] Therefore, the storage chamber 45 is located at a position far from the design surface 33. Therefore, when the occupant views the design surface 33 of the vehicle interior 10, the uneven portions generated due to the formation of the storage chamber 45 are located at positions out of the occupant's line of sight and are not visible or are difficult to see for the occupant.

[0070] Also, as described above, since the storage chamber 45 is located at a position far from the design surface 33, it is unlikely that the occupant will touch the uneven portions. Therefore, a decrease in tactile sensation caused by touching the uneven portions is also unlikely to occur.

[0071] As a result, it is possible to suppress a decrease in the appearance and tactile sensation of the vehicle interior 10 caused by the provision of the storage chamber 45. <(3) Regarding the Resin Molding of the Base Material 11> When the base material 11 is formed by a resin molding method such as an injection molding method, by providing the terminal portion 21 having the protrusion 22 as described above, a difference in thickness occurs between the general portion 12 and the terminal portion 21. The greater this thickness difference, the greater the difference in the degree of shrinkage after molding. In the terminal portion 21, which is the portion with a large thickness, a dent (depression) called "sink mark" may occur, which may impair the appearance of the vehicle interior part 10.

[0072] In this regard, as described above, by forming the notch 46 in the terminal portion 21, the substantial thickness of the terminal portion 21 is reduced. The difference between the thickness of the general portion 12 and the substantial thickness of the terminal portion 21 is reduced, and it becomes less likely for sink marks to occur after the terminal portion 21 is molded.

[0073] <(4) Other matters> (4-1) In the terminal portion 21, due to the protrusion 22 protruding to the front side more than the general portion 12 (vertical wall portion 16), the thickness is greater than that of the general portion 12.

[0074] Therefore, it becomes easier to form the seal portion 36 and the notch 46 (storage chamber 45) in the terminal portion 21. (4-2) Since the notch 46 is opened across the outer surface 26 and the back surface 25 of the terminal portion 21, the notch 46 is located in the region on the back surface side including the back surface 25 in the thickness direction of the terminal portion 21. Among the outer surface 26 of the terminal portion 21, the region on the front side of the notch 46 becomes wider. Therefore, a seal portion 36 that seals a wide region in the thickness direction of the terminal portion 21 can be formed, and higher sealing performance can be obtained.

[0075] (4-3) In the present embodiment, the shaping of the skin layer 31, the formation of the foam layer 41, and the formation of the seal portion 36 can be performed with a small number of molding dies such as the first molding die 61 and the second molding die 71, and moreover, in a short time.

[0076] Note that the above embodiment can also be implemented as a modified example in which it is modified as follows. The above embodiment and the following modified examples can be implemented in combination with each other within a technically non - conflicting range.

[0077] <Regarding the shape of the vehicle interior part 10> · On the condition that it has a three-layer structure formed by laminating the base material 11, the skin layer 31, and the foam layer 41, the shape of the vehicle interior part 10 may be changed to a shape different from that of the above embodiment.

[0078] <Regarding the position of the notch 46 (storage chamber 45) in the terminal part 21> · As shown in FIGS. 7 to 10, the notch 46 is opened only on the outer surface 26 of the back surface 25 and the outer surface 26. And a part of the end portion planned part 53 is brought into contact with a portion adjacent to the opposite side of the seal part 36 across the storage chamber 45 on the outer surface 26, so that an auxiliary seal part 37 (see FIG. 8) may be formed.

[0079] With this auxiliary seal part 37, it is possible to regulate the leakage of the foam material M1 from the storage chamber 45. As the leakage regulation of the foam material M1 by the auxiliary seal part 37 is added, it becomes possible to further enhance the sealing performance of the foam material M1.

[0080] <Regarding the resin material forming the foam layer 41> · The foam layer 41 may be constituted by a foam of a resin of a type different from the urethane resin.

[0081] <Regarding the seal part 36> · The seal part 36 may be formed by the skin layer 31 being in contact with only the outer surface 26 of the protrusion 22 in the terminal part 21. Also, the seal part 36 may be formed by the skin layer 31 being in contact across the protrusion 22 and a portion on the back side thereof.

[0082] <Regarding the form of the notch 46 (storage chamber 45)> · As shown in FIGS. 7 and 10, the notch 46 may be formed in a groove shape extending in the above depth direction.

[0083] According to this modification example, it is possible to cope even when a large storage chamber 45 is required. Also, from any position in the depth direction, the foaming material M1 that has passed through the seal portion 36 can be stored in the storage chamber 45.

[0084] · As shown in FIG. 9, the notches 46 may be formed at a plurality of positions spaced apart from each other in the depth direction. <Regarding the cross-sectional shape of the notch 46 (storage chamber 45)> · As shown in FIGS. 7 to 10, the cross-sectional shape of the notch 46 (storage chamber 45) may be changed to a shape different from the cross-sectional shape of the above-described embodiment.

[0085] The notches 46 in FIGS. 7 and 8 have a triangular cross-sectional shape, the notch 46 in FIG. 9 has a trapezoidal cross-sectional shape, and the notch 46 in FIG. 10 has a rectangular (oblong) cross-sectional shape. In the modification example of FIG. 9, the inner surface 46a on the front side of the notch 46 is formed horizontally. In the modification examples of FIGS. 7 and 8, the inner surface 46a on the front side of the notch 46 is inclined so as to become lower as it approaches the surface 24. As the inclination of the inner surface 46a becomes steeper, the cross-sectional shape of the notch 46 becomes smaller. Therefore, it is desirable to set the inclination of the inner surface 46a according to the required size of the notch 46.

[0086] In addition, the technical ideas that can be grasped from the above-described embodiments are described together with their effects. (A) A base material including a general portion and a terminal portion formed at an edge portion of the general portion, An epidermal layer including a main portion that covers the general portion from the front side and an end portion that forms a seal portion by contacting an outer surface of the terminal portion, A foaming layer formed between the general portion and the main portion A method for forming the main portion, the foaming layer, and the seal portion, which is applied to a vehicle interior component including, and uses a mold device including a first mold having a molding recess and a second mold having a molding protrusion, and a skin material having a main portion planned portion and an end portion planned portion. Attach the base material to the forming convex portion, soften the skin material disposed in the first mold by heating, and then clamp the mold device to form a foaming space between the planned main portion and the general portion, and form a deformation space adjacent to the foaming space. Subsequently, deform the planned main portion to follow the shape of the forming concave portion by vacuum suction to form the main portion. While injecting a foaming material into the foaming space to form the foaming layer, suck the planned end portion of the deformation space to the outer surplus surface side of the forming convex portion, and blow air from the inner surplus surface of the forming concave portion toward the planned end portion to bring the planned end portion into contact with the outer surface of the terminal portion to form the seal portion.

[0087] According to the above method, by clamping the mold device, a foaming space and a deformation space are formed. The planned main portion of the softened skin material is shaped by vacuum suction to form the main portion. A foaming material is injected into the foaming space to form the foaming layer. The planned end portion disposed in the deformation space is sucked to the outer surplus surface side of the forming convex portion. Air is blown from the inner surplus surface of the forming concave portion toward the planned end portion. The planned end portion is brought into contact with the outer surface of the terminal portion to form the seal portion.

[0088] In this way, by performing vacuum suction and air blowing in the deformation space, the planned end portion is deformed in the deformation space to form the seal portion. Therefore, it is possible to increase the degree of freedom of the shape of the terminal portion that can bring the planned end portion of the skin material into close contact, particularly the shape of the outer surface, and thus the degree of freedom of the shape of the seal portion.

Explanation of Reference Numerals

[0089] 10... Interior trim for vehicle 11... Base material 12... General portion 14, 17... Surface 15, 18... Back surface 21... Terminal portion 22... Protrusion 26... Outer surface 31... Skin layer 33…Design surface 35…Foaming forming space 36…Sealing part 37…Auxiliary sealing part 41…Foaming layer 45…Reservoir chamber 46…Notch M1…Foaming material

Claims

1. A vehicle interior part comprising a base material having one surface in its thickness direction as a front surface, the other surface as a back surface, and further having an outer surface between the front surface and the back surface; An epidermal layer covering the base material from the front side; A foam layer formed between the base material and the epidermal layer; wherein the epidermal layer forms a seal portion by being brought into contact with a portion of the base material adjacent to the foam layer, and the surface of the portion of the epidermal layer covering the foam layer constitutes a design surface, and in the base material, a storage chamber opening at least to the outer surface is formed on the side opposite to the foam layer with the seal portion interposed therebetween.

2. The base material includes a general portion and a terminal portion formed at an edge of the general portion and having the outer surface, the terminal portion has a protrusion protruding to the front side more than the general portion, and the seal portion is formed by the epidermal layer being brought into contact with at least the outer surface of the protrusion of the terminal portion. The vehicle interior part according to Claim 1.

3. The storage chamber is constituted by a notch opening at a portion of at least the outer surface of the terminal portion on the side opposite to the foam layer with the seal portion interposed therebetween. The vehicle interior part according to Claim 2.

4. The notch opens across the outer surface and the back surface of the terminal portion. The vehicle interior part according to Claim 3.

5. An auxiliary seal portion is further formed by the epidermal layer being brought into contact with a portion adjacent to the seal portion on the side opposite to the storage chamber on the outer surface of the terminal portion. The vehicle interior part according to Claim 2 or 3.

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