Interior materials

Abstract

To provide a new interior member.SOLUTION: An interior member comprises a first layer, a second layer, projections, a third layer, wall parts, and extended spaces. The first layer has a design surface. The second layer disposed on a side opposite to the design surface of the first layer, includes a sound absorbing material and / or a damping material. The projections project from either the first layer or the second layer and come into contact with the other first layer or the second layer. The third layer disposed on a side opposite to the first layer by sandwiching the second layer, has through-holes penetrating the third layer toward the second layer. The wall parts are disposed on either of the second layer and the third layer or both of them and go along a laminated direction. The extended spaces defined by the wall parts, the second layer and the third layer, include openings of the through-holes on part of the third layer.SELECTED DRAWING: Figure 2

Description

[Technical Field]

[0001] The present disclosure relates to interior components. [Background technology]

[0002] BACKGROUND ART Interior trim members that are formed by stacking and integrating a plurality of layered members containing different materials have been known (see, for example, Patent Document 1). [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Laid-Open No. 2009-096342 Summary of the Invention [Problem to be solved by the invention]

[0004] The interior material of Patent Document 1 reduces vibration by providing a resonator between adjacent layered members. However, it is preferable for such an interior material to have a structure that can reduce noise and vibration while preventing unevenness in the feel. Patent Document 1 does not disclose this point. The object of the present disclosure is to provide a novel interior material. [Means for solving the problem]

[0005] An interior member according to one embodiment of the present disclosure comprises a first layer, a second layer, a protruding portion, a third layer, a wall portion, and an expansion space. The first layer has a design surface. The second layer is disposed on the opposite side of the design surface of the first layer and includes a sound-absorbing and / or vibration-damping material. The protruding portion protrudes from either the first layer or the second layer and contacts the other of the first layer or the second layer. The third layer is disposed on the opposite side of the second layer from the first layer and has a through-hole penetrating toward the second layer. The wall portion is provided on either or both of the second layer and the third layer and extends along the stacking direction. The expansion space is defined by the wall portion, the second layer, and the third layer, and includes an opening for the through-hole in a portion of the third layer.

[0006] According to this interior member, a protrusion is provided between the first and second layers, and an expansion space including a through-hole is provided between the second and third layers. As a result, a vibration damping structure is provided between the first and second layers, and a resonator is provided between the second and third layers. Therefore, the interior member can damp vibrations using the resonator and damping structure. Furthermore, according to this interior member, the second layer is disposed following the first layer having a design surface. This prevents unevenness in the feel of the interior member. As a result, the interior member can reduce noise and improve the feel. [Effects of the Invention]

[0007] According to the present disclosure, a novel interior member can be provided. [Brief explanation of the drawings]

[0008] [Figure 1] FIG. 2 is a perspective view of an interior member according to an embodiment of the present disclosure. [Figure 2] 2 is a cross-sectional view showing the AA cross section of the interior member according to the embodiment of the present disclosure. FIG. [Figure 3] 1 is a schematic diagram showing a portion of a substrate of an interior member according to an embodiment of the present disclosure. [Figure 4] FIG. 10 is a schematic view showing a portion of a base material of an interior member according to another embodiment of the present disclosure. [Figure 5] 5A and 5B are schematic diagrams illustrating a method for manufacturing an interior member according to an embodiment of the present disclosure. DETAILED DESCRIPTION OF THE INVENTION

[0009] Hereinafter, embodiments of the present disclosure will be described with reference to the drawings. Fig. 1 is a perspective view showing an outline of an interior member 1 according to an embodiment of the present disclosure. In Fig. 1, the up-down direction (an example of a stacking direction) H is defined as the upper side and the lower side of the paper, but does not necessarily coincide with the actual direction of gravity. Fig. 2 is a cross-sectional view showing an outline of the cross section of the interior member 1 taken along the line AA in Fig. 1.

[0010] As shown in FIGS. 1 and 2 , the interior member 1 has a predetermined length in a stacking direction H and in a width direction W and a depth direction D that intersect with the stacking direction H. The interior member 1 of this embodiment is formed in a substantially rectangular parallelepiped shape and is used as an interior design component that constitutes part of the interior design of a vehicle. Specifically, the interior member 1 is disposed between the engine compartment and the passenger compartment of the vehicle, with the surface 22 of the skin layer 2 facing the interior of the passenger compartment. However, the shape of the interior member 1 can be formed in a variety of sizes and shapes to suit the intended use.

[0011] The interior member 1 includes a skin layer (an example of a first layer) 2, an intermediate layer (an example of a second layer) 4, and a base material (an example of a third layer) 6. The skin layer 2, the intermediate layer 4, and the base material 6 are stacked and bonded together in a stacking direction H, which is the direction in which the skin layer 2, the intermediate layer 4, and the base material 6 overlap. In this embodiment, the size of the interior member 1 in the stacking direction H is approximately 40 mm to 80 mm. The size of the interior member 1 in the stacking direction H may also be approximately 10 mm to 150 mm, which can be changed depending on the intended use.

[0012] The skin layer 2 has a design surface 21. The design surface 21 is the surface 22 of the skin layer 2 and is disposed facing the vehicle interior. In this embodiment, the design surface 21 is formed including a synthetic leather material and constitutes part of the interior design of the vehicle interior. However, the design surface 21 can be made of a variety of materials in accordance with the interior design of the vehicle, and can be provided with designs such as graining or stitching.

[0013] The intermediate layer 4 is disposed on the opposite side of the design surface 21 of the skin layer 2 and contains a sound-absorbing and / or vibration-damping material. In this embodiment, the intermediate layer 4 has substantially the same shape as the skin layer 2 in the width direction W and depth direction D. The size of the intermediate layer 4 in the stacking direction H is approximately 2 mm to 10 mm. The size of the intermediate layer 4 in the stacking direction H may also be approximately 1 mm to 100 mm. The intermediate layer 4 contains a porous material including a foam, such as urethane, felt, nonwoven fabric, or rubber sponge, and acts as at least one or both of a sound-absorbing material and a vibration-damping material that attenuates noise and vibration.

[0014] The base material 6 is disposed on the opposite side of the skin layer 2 with the intermediate layer 4 in between. In this embodiment, the base material 6 has substantially the same shape as the skin layer 2 and the intermediate layer 4 in the width direction W and the depth direction D. The size of the base material 6 in the stacking direction H is approximately 1 mm to 5 mm. The base material 6 contains resin and is a hard material with greater rigidity than the skin layer 2 and the intermediate layer 4. The base material 6 may be configured to include curved surfaces to match the design of the location where the interior member 1 is to be installed. This allows the entire interior member 1 to be shaped to suit a variety of designs.

[0015] FIG. 3 is a perspective view showing an enlarged outline of a portion of the substrate 6 according to an embodiment of the present disclosure. As shown in FIGS. 2 and 3 , the substrate 6 has a through hole 61. The through hole 61 penetrates the substrate 6 from the back surface 62 to the front surface 63 toward the intermediate layer 4 along the stacking direction H. In this embodiment, the through hole 61 has a diameter of approximately 1 mm to 3 mm. Furthermore, the diameter of the through hole 61 may be approximately 0.5 mm to 10 mm. At least one through hole 61 is provided in the substrate 6. In this embodiment, a plurality of through holes 61 are provided in the substrate 6, and are regularly and evenly arranged at predetermined intervals in the width direction W and the depth direction D. Furthermore, in this embodiment, the through holes 61 are regularly arranged so that the intervals between them are approximately 10 mm to 30 mm in the width direction W and the depth direction D. Furthermore, the intervals between the through holes 61 may be approximately 5 mm to 50 mm. The distance between the through holes 61 can be changed in various ways in accordance with the size of the plate-like member 81 including the wall portion 8, which will be described later.

[0016] As shown in FIGS. 2 and 3, the interior member 1 further includes a wall portion 8, an expansion space 10, and a protrusion 12.

[0017] The wall portion 8 is provided on either or both of the intermediate layer 4 and the substrate 6, and is a surface extending along the stacking direction H. In this embodiment, the wall portion 8 is provided integrally with the substrate 6 and is a part of a plate-like member 81 extending from the surface 63 of the substrate 6 toward the intermediate layer 4. Alternatively, the wall portion 8 may be part of a recessed shape formed by carving the substrate 6 from the surface 63 along the stacking direction H.

[0018] As shown in FIGS. 2 and 3 , the plate-like member 81 including the wall portion 8 extends from the surface 63 of the substrate 6 toward the intermediate layer 4 along the stacking direction H and has a substantially rectangular cross-sectional shape with a predetermined thickness. In this embodiment, the plate-like member 81 is formed into a substantially square shape with sides measuring approximately 10 mm to 40 mm in the width direction W and the depth direction D. Furthermore, the plate-like member 81 may be formed into a substantially square shape with sides measuring approximately 5 mm to 50 mm. As a result, the wall portion 8 forms a substantially square partitioned space with sides measuring approximately 10 mm to 30 mm in the width direction W and the depth direction D. Furthermore, the wall portion 8 may form a substantially square partitioned space with sides measuring approximately 4 mm to 40 mm. The size and shape of the plate-like member 81 and the wall portion 8 can be varied in various ways depending on the volume of the through-hole 61 and the expansion space 10 described below.

[0019] A plurality of plate-like members 81 are provided on the surface 63 of the base material 6, and are evenly arranged at predetermined intervals in the width direction W and the depth direction D. In this embodiment, the plate-like members 81 are regularly arranged in the width direction W and the depth direction D at intervals of about 1 mm to 10 mm. The intervals at which the plate-like members 81 are arranged can be changed in various ways in accordance with the through-holes 61 and the volume of the expansion space 10, which will be described later. However, the plate-like members 81 may be arranged on the surface 63 of the base material 6 at different intervals.

[0020] The tip of the plate-like member 81 is pressed against and comes into contact with the back surface 42 of the intermediate layer 4. That is, the tip of the wall portion 8 comes into contact with the back surface 42 of the intermediate layer 4. As a result, the wall portion 8 can divide the space between the intermediate layer 4 and the base material 6 in the width direction W and the depth direction D into an inside and an outside, including the wall portion 8, with the plate-like member 81 sandwiched therebetween.

[0021] The expansion space 10 is a space between the intermediate layer 4 and the base material 6, partitioned by the wall portion 8, the intermediate layer 4, and the base material 6. The expansion space 10 is tightly fitted between the tip of the plate-like member 81 including the wall portion 8 and the back surface 42 of the intermediate layer 4, with no gap between them. Meanwhile, the expansion space 10 includes the opening of one through hole 61 in a part of the base material 6. That is, one expansion space 10 includes the opening of one through hole 61. In this embodiment, the through hole 61 is located approximately at the center of the expansion space 10 in a plan view along the stacking direction H. The expansion space 10 is a substantially closed space between the intermediate layer 4 and the base material 6, and communicates with the outside of the interior member 1 through the opening of the through hole 61. As described above, in this embodiment, the interior member 1 is located between the engine compartment and the passenger compartment, and the skin layer 2 is located facing the passenger compartment. Therefore, the opening of the through hole 61 on the opposite side of the intermediate layer 4 faces the engine compartment.

[0022] As a result, the expansion space 10, together with the through-hole 61, forms a resonator between the intermediate layer 4 and the base material 6. Therefore, the interior member 1 can attenuate specific frequencies based on the volume of the expansion space 10 and the volume of the through-hole 61. As a result, the interior member 1 can reduce sounds generated in the engine compartment between the intermediate layer 4 and the base material 6. As a result, the interior member 1 can reduce noise transmitted from the engine compartment to the vehicle interior.

[0023] The resonator formed by the extension space 10 and the through-hole 61 can attenuate any frequency by changing the volumes of the extension space 10 and the through-hole 61. In this embodiment, the resonator formed by the extension space 10 and the through-hole 61 mainly attenuates frequencies around 1600 Hz. This allows the interior member 1 to improve the clarity of conversations in the vehicle interior in which the interior member 1 is placed.

[0024] In this embodiment, the volume of the expansion space 10 can be set arbitrarily by changing the shape of the plate-like member 81 including the wall portion 8. For example, the volume of the expansion space 10 can be changed by changing the length by which the plate-like member 81 protrudes from the surface 63 of the base material 6. The volume of the expansion space 10 can also be changed by changing the cross-sectional area of ​​the approximately rectangular shape formed by the plate-like member 81. Furthermore, the volume of the expansion space 10 can also be changed by changing the cross-sectional shape of the plate-like member 81, without being limited to being approximately rectangular. Meanwhile, the volume of the through-hole 61 can be changed by changing the size in the stacking direction H of the base material 6 or by changing the diameter of the through-hole 61.

[0025] The multiple expansion spaces 10 and through holes 61 are continuously arranged between the intermediate layer 4 and the base material 6. In this embodiment, the expansion spaces 10 and through holes 61 are regularly and evenly arranged at predetermined intervals in the width direction W and the depth direction D. The resonators formed by the expansion spaces 10 and through holes 61 are regularly arranged at intervals of approximately 10 mm to 15 mm in the width direction W and the depth direction D. Furthermore, the intervals between the resonators formed by the expansion spaces 10 and through holes 61 may be approximately 5 mm to 50 mm. The resonators formed by the expansion spaces 10 and through holes 61 can be variously changed depending on the volume of the resonator and the size and shape of the interior member. This allows multiple resonators to be arranged between the intermediate layer 4 and the base material 6. As a result, the interior member 1 can reduce noise transmitted from the engine compartment to the vehicle interior regardless of the location where the noise is generated.

[0026] The protrusions 12 protrude from either the surface layer 2 or the intermediate layer 4 and contact the other of the surface layer 2 or the intermediate layer 4. The protrusions 12 protruding from either the surface layer 2 or the intermediate layer 4 may be in at least point contact with the other of the surface layer 2 or the intermediate layer 4. In this embodiment, the protrusions 12 are hemispherical protrusions provided on the surface layer 2, protruding from the surface layer 2 toward the intermediate layer 4, and having their tips in contact with the surface 41 of the intermediate layer 4. The size of the protrusions 12 in the stacking direction H is approximately 1 mm to 3 mm. Furthermore, the size of the protrusions 12 in the stacking direction H may be approximately 0.5 mm to 5 mm. The shape of the protrusions 12 is not limited thereto, and may be a columnar shape with its tips making surface contact, or a rib shape extending in either or both the width direction W and the depth direction D, and various other shapes are possible. In this embodiment, the protrusions 12 are made of the same material as the surface layer 2 and are integrally formed with the surface layer 2.

[0027] A plurality of protrusions 12 are provided on the rear surface 23 of the skin layer 2, and are regularly and evenly arranged at predetermined intervals in the width direction W and the depth direction D. In this embodiment, the protrusions 12 are regularly arranged so that the intervals between them are approximately 10 mm to 15 mm in the width direction W and the depth direction D. Furthermore, the intervals between the protrusions 12 may be approximately 5 mm to 30 mm. The intervals at which the protrusions 12 are arranged can be changed in various ways, along with the size and shape of the protrusions 12 in the stacking direction H.

[0028] As shown in FIG. 3 , the protrusions 12 are disposed in a width direction W or a depth direction D intersecting with the stacking direction H, away from a point P where the tip of the plate-like member 81 including the wall portion 8 contacts the back surface 42 of the intermediate layer 4. That is, in this embodiment, in a plan view along the stacking direction H, the point N where the tip of the protrusions 12 contacts the intermediate layer 4 and the point P where the tip of the plate-like member 81 contacts the back surface 42 of the intermediate layer 4 are displaced from each other. This prevents the protrusions 12 from being pushed back by the plate-like member 81 when a force is applied along the stacking direction H. This allows the feel of the skin layer 2 of the interior member 1 to be uniform regardless of the arrangement of the protrusions 12. As a result, an interior member 1 that feels good to the touch can be provided.

[0029] Furthermore, in this embodiment, in a plan view along the stacking direction H, the protrusions 12 are arranged at approximately the same positions as the through holes 61. However, the number and arrangement of the protrusions 12 are not limited to this, and may be changed in various ways. In a plan view along the stacking direction H, a plurality of protrusions 12 may be arranged for one expansion space 10.

[0030] Next, an interior member 1 according to another embodiment of the present disclosure will be described with reference to Fig. 4. Fig. 4 is a perspective view showing an outline of a substrate 60 according to another embodiment of the present disclosure. In describing this embodiment, only the differences from the interior member 1 according to the embodiment shown in Figs. 1 to 3 will be described.

[0031] As shown in Fig. 4, in this embodiment, plate-like members 801 including wall portions 80 are continuously provided on the base material 6. That is, the plate-like members 801 extend along the width direction W and the depth direction D, and when they intersect, an expansion space 10 partitioned by the wall portions 80 is formed. The expansion spaces 10 are repeatedly arranged continuously in the width direction W and the depth direction D, sandwiching the plate-like members 801 therebetween. This makes it possible to increase the number of resonators formed by the expansion spaces 10 and the through-holes 61.

[0032] However, the resonator formed by the expansion space 10 and the through-hole 61 may be provided continuously or discontinuously between the intermediate layer 4 and the substrate 6, and may be disposed at any position in the width direction W and the depth direction D. Furthermore, the expansion space 10 and the through-hole 61 may all be configured as resonators with the same volume, or may be configured as multiple resonators with different volumes.

[0033] Next, a method for manufacturing an interior member 1 according to an embodiment of the present disclosure will be described with reference to Fig. 5. As shown in Fig. 5, the method for manufacturing an interior member 1 according to the present disclosure includes a preparation step S1, a positioning step S2, and a joining step S3.

[0034] In the preparation step S1, the surface layer 2, the intermediate layer 4, and the substrate 6 are prepared. The substrate 6 is previously provided integrally with a plate-like member 81 including a wall portion 8. The surface layer 2 is previously provided integrally with a protrusion 12.

[0035] In the positioning step S2, the substrate 6, intermediate layer 4, and skin layer 2 are stacked and arranged in this order from bottom to top along the stacking direction H. Here, the substrate 6 is arranged so that the plate-like member 81 including the wall portion 8 faces the intermediate layer 4. Furthermore, the skin layer 2 is arranged so that the protrusion 12 does not overlap with the plate-like member 81 of the substrate 6 in a plan view along the stacking direction H.

[0036] In the bonding step S3, the skin layer 2, the intermediate layer 4, and the base material 6 are bonded together to form the interior component 1. A variety of bonding methods can be used, including covering the skin layer 2 with the intermediate layer 4 and the base material 6 in a room temperature environment, bonding using an adhesive, and heating to melt a portion and then pressing the layers together.

[0037] Furthermore, in this embodiment, the skin layer 2, the intermediate layer 4, and the base material 6 are bonded together at the same time, but the present disclosure is not limited to this. That is, it is possible to apply a manufacturing method in which the skin layer 2 and the intermediate layer 4 are bonded together in advance and then integrated with the base material 6, or in which the base material 6 and the intermediate layer 4 are bonded together in advance and then integrated with the skin layer 2. However, various methods can be used in performing the positioning step S2 and the bonding step S3 depending on the application and shape of the interior member 1.

[0038] As described above, according to the present disclosure, a novel interior member can be provided. [Explanation of symbols]

[0039] 1: Interior material 2: Surface layer (first layer) 21: Design surface 4: Intermediate layer (second layer) 6: Base material (third layer) 61: Through-hole 8: Wall portion 10: Expansion space 12: Protrusion H:Lamination direction

Claims

1. a first layer consisting only of a skin material made of synthetic leather having a designed surface; a second layer disposed on the opposite side of the design surface of the first layer and including a sound absorbing and / or vibration damping material; a third layer disposed on the opposite side of the second layer from the first layer, the third layer having a through hole penetrating toward the second layer; a protrusion protruding from the first layer and in contact with the second layer; a wall portion provided in one or both of the second layer and the third layer and extending along the stacking direction; an expansion space defined by the wall portion, the second layer, and the third layer, the expansion space including an opening of the through hole in a part of the third layer; In a plan view along the stacking direction, a location where a tip of the protruding portion contacts the second layer and a location where a tip of the wall portion contacts the second layer or the third layer are displaced from each other. Interior parts.

2. A first layer having a design surface; a second layer disposed on the opposite side of the design surface of the first layer and including a sound absorbing and / or vibration damping material; a third layer disposed on the opposite side of the second layer from the first layer, the third layer having a through hole penetrating toward the second layer; a protrusion protruding from the first layer and in contact with the second layer; a wall portion provided in one or both of the second layer and the third layer and extending along the stacking direction; an expansion space defined by the wall portion, the second layer, and the third layer, the expansion space including an opening of the through hole in a part of the third layer; the protrusion is hemispherical or columnar; In a plan view along the stacking direction, a location where a tip of the protruding portion contacts the second layer and a location where a tip of the wall portion contacts the second layer or the third layer are displaced from each other. Interior parts.

3. A first layer having a design surface; a second layer disposed on the opposite side of the design surface of the first layer and including a sound absorbing and / or vibration damping material; a third layer disposed on the opposite side of the second layer from the first layer and having a through hole penetrating toward the second layer; a protrusion protruding from the second layer and in contact with the first layer; a wall portion provided in one or both of the second layer and the third layer and extending along the stacking direction; an expansion space defined by the wall portion, the second layer, and the third layer, the expansion space including an opening of the through hole in a part of the third layer; In a plan view along the stacking direction, a location where a tip of the protruding portion contacts the first layer and a location where a tip of the wall portion contacts the second layer or the third layer are displaced from each other. Interior parts.

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