Vehicle interior materials

Abstract

To provide a vehicle interior material of which an elastic material is prevented from being peeled off from a base material at a terminal part.SOLUTION: A vehicle interior material 1 includes a base material 6 having a plurality of ribs 13, and an elastic material 7 having a terminal part 15 as a part corresponding to positions of the ribs 13, and filled at least between the ribs 13 and integrally formed with the base material 6. The elastic material 7 catches the ribs 13 of the base material 6 by shrinkage, and the elastic material 7 is prevented from being peeled off from the base material 6 at the terminal part 15.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to a vehicle interior material in which an elastic body is laminated on a base material. [Background technology]

[0002] Conventionally, interior materials for vehicles such as automobiles have a base material made of synthetic resin or the like, an elastic material made of urethane or the like to provide cushioning, and the surface side of the base material and the elastic material are covered with a skin. The elastic material is molded integrally with the base material by insert molding or the like (see, for example, Patent Document 1). [Prior art documents] [Patent documents]

[0003] [Patent Document 1] JP 2011-143782 A (pages 8-10, Figures 1-6) Summary of the Invention [Problem to be solved by the invention]

[0004] When the contact surface between the base material and the elastic material is constant, the adhesive strength between the base material and the elastic material is likely to be weak in an intermediate body in which the base material and the elastic material are integrally insert-molded, and the elastic material is likely to peel up from the end portion. Therefore, in this configuration, when the intermediate body is covered with the skin, the boundary between the base material and the elastic material may peel up, which may degrade the appearance.

[0005] The present invention has been made in consideration of the above points, and has as its object to provide a vehicle interior material in which an elastic material is made less likely to peel off from the end portion of a base material. [Means for solving the problem]

[0006] The vehicle interior material according to claim 1 includes a base material having a plurality of ribs, and an elastic material having terminal portions corresponding to the ribs, the elastic material being filled at least between the ribs and integrally molded with the base material, the ribs being located near the terminal portions of the base material. and protruding toward the elastic material side of the base material, The elastic material covers the entire outer surface of the base material. and covering the entire rib. It is what is placed.

[0007] The vehicle interior material according to claim 2 is the vehicle interior material according to claim 1, wherein the elastic material is made of a foam material.

[0008] The vehicle interior material according to claim 3 is the vehicle interior material according to claim 1 or 2, further comprising a skin that covers at least a part of the elastic material.

[0009] The vehicle interior material according to claim 4 is the vehicle interior material according to any one of claims 1 to 3, which is a cover for a console box for a vehicle. [Effects of the Invention]

[0010] According to the vehicle interior material of claim 1, the elastic material presses into the ribs of the base material as it shrinks, making it difficult for the elastic material to peel off from the end portion of the base material.

[0011] According to the vehicle interior material of claim 2, in addition to the effect of the vehicle interior material of claim 1, the elastic material shrinks greatly after molding, and the elastic material can be more firmly attached to the base material.

[0012] According to the vehicle interior material of claim 3, in addition to the effects of the vehicle interior material of claim 1 or 2, the design of the vehicle interior material can be improved.

[0013] According to the vehicle interior material of claim 4, in addition to the effects of the vehicle interior material of any one of claims 1 to 3, it is possible to provide a console box that is excellent in cushioning properties and appearance. [Brief explanation of the drawings]

[0014] [Figure 1] FIG. 1(a) is a perspective view showing a base material of a vehicle interior material according to a first embodiment of the present invention, FIG. 1(b) is a cross-sectional view of the same vehicle interior material at a position corresponding to II in FIG. 1(a), and FIG. 1(c) is a cross-sectional view of an intermediate body at a position corresponding to II-II in FIG. [Figure 2] FIG. 2 is a perspective view showing a console box provided with the same vehicle interior material. [Figure 3] 3 is a cross-sectional view showing a part of a manufacturing process of the same vehicle interior material. FIG. [Figure 4] 4 is a view seen from the direction of arrow Z in FIG. 3. [Figure 5] FIG. 4 is a cross-sectional view showing a part of a vehicle interior material according to a second embodiment of the present invention. DETAILED DESCRIPTION OF THE INVENTION

[0015] A first embodiment of the present invention will be described below with reference to the drawings.

[0016] In Fig. 2, reference numeral 1 denotes a vehicle interior material. In this embodiment, the vehicle interior material 1 is a lid used for a console box 2, which is a storage device for a vehicle such as an automobile. In other words, the vehicle interior material 1 can open and close the opening of a main body 3 attached to the vehicle body.

[0017] The vehicle interior material 1 also serves as an armrest when it closes the opening of the main body 3. For example, the vehicle interior material 1 is supported by the main body 3 so as to be rotatable or slidable. Furthermore, the vehicle interior material 1 is locked to the main body 3 by a locking mechanism 4 in a state in which the opening is closed.

[0018] The console box 2 forms part of a center console located between the front seats of the vehicle, i.e., the driver's seat and the passenger seat, and will be described as an example in which the vehicle interior material 1 rotates up and down relative to the main body 3. Hereinafter, directions such as the front-to-rear direction, both sides, and up and down will be described based on the state in which the console box 2 is attached to the vehicle body. In the drawings, the arrow FR direction is the forward direction, the arrow RR direction is the rearward direction, the arrow L direction is the leftward direction, the arrow R direction is the rightward direction, the arrow U direction is the upward direction, and the arrow D direction is the downward direction. The console box 2 is used for interior use in the center console, instrument panel, etc. of the vehicle. In the illustrated example, the vehicle interior material 1 is formed in a rectangular shape, but is not limited to this and may be any shape depending on the shape of the installation position, the desired design, etc.

[0019] 1(b), the vehicle interior material 1 is arranged such that a base material 6, an elastic material 7, and a skin body 8 are stacked one on top of the other. The vehicle interior material 1 is arranged such that the skin body 8 side is the occupant side, front side, obverse side, or design side, and the base material 6 side is the anti-occupant side, rear side, or reverse side.

[0020] The substrate 6 shown in Figures 1(a) to 1(c) is made of a material such as synthetic resin. The substrate 6 is made of a material harder than the elastic material 7. The substrate 6 includes a substrate main body 10. The substrate main body 10 is the main body that forms the largest part of the substrate 6. In this embodiment, the substrate main body 10 is formed in a substantially rectangular shape. In the example shown, the substrate main body 10 is elongated in the front-rear direction and has a narrow rectangular shape in the left-right direction. The substrate main body 10 may be curved into a three-dimensional shape so that it is convex upward.

[0021] In addition, side wall portions 11 are continuous with both side portions of the substrate main body portion 10. In this embodiment, the side wall portions 11 are formed so as to be continuous with the long sides, i.e., the left and right side edges, of the substrate main body portion 10. The side wall portions 11 extend downward relative to the substrate main body portion 10. The side wall portions 11 are continuous over the entire both side portions of the substrate main body portion 10. Preferably, the side wall portions 11 are inclined so as to gradually widen laterally from the substrate main body portion 10.

[0022] In the illustrated example, a flange portion 12 is continuous with the side portion, i.e., the tip portion, of each side wall portion 11. The flange portion 12 is continuous with the side portion of the side wall portion 11 opposite the base body portion 10. The flange portion 12 extends laterally from the side wall portion 11. In this embodiment, the flange portion 12 protrudes laterally from the lower end portion of the side wall portion 11. The flange portion 12 is continuous along the entire side portion of the side wall portion 11.

[0023] In addition, a plurality of ribs 13 are formed on the substrate 6. The ribs 13 are located at the terminal portion of the substrate 6, i.e., near the outer edge of the substrate 6. In this embodiment, the ribs 13 are formed on one longitudinal end and both side portions of the substrate 6. In the example shown in the figure, the ribs 13 are formed on the front end, which is one longitudinal end of the substrate main body 10, and on the flange portions 11 on both side portions. The ribs 13 protrude toward the elastic material 7 side of the substrate 6, i.e., the surface side, and penetrate into the elastic material 7. The ribs 13 are positioned at equal or approximately equal intervals from one another. In this embodiment, the intervals between the ribs 13 are set to 10 mm, but are not limited to this and can be changed as appropriate depending on the material of the substrate 6, the raw materials and foaming rate of the elastic material 7, which will be described later, and the like.

[0024] The ribs 13a located at the front end of the substrate 6 (substrate main body 10) are formed to extend in the front-rear direction and the up-down direction, and are positioned apart from each other in the left-right direction.

[0025] The ribs 13b located on both sides (flange portions 12) of the base material 6 are formed to extend in both directions, i.e., the left-right direction and the up-down direction, and are spaced apart from each other in the front-rear direction. In this embodiment, the ribs 13b are formed across the outer surfaces of the side wall portions 11 and the flange portions 12.

[0026] The elastic material 7 is made of an elastic material. Preferably, the elastic material 7 is made of a foam material such as urethane having cushioning properties. That is, the elastic material 7 is preferably a so-called urethane foam, which is made by finely foaming a soft foamed polyurethane resin. The elastic material 7 has an outer edge, i.e., a terminal portion 15, at a position corresponding to the ribs 13, and is filled at least between the ribs 13 and molded integrally with the base material 6. In this embodiment, the elastic material 7 is arranged to cover the entire or almost the entire outer surface of the base material 6. The terminal portion 15 is located adjacent to and flush with the tip of the flange portion 12 of the base material 6.

[0027] The elastic material 7 is integrally formed with a general portion 17 that covers the majority of the base material 6 and a filling portion 18 that fills between the ribs 13 of the base material 6. The general portion 17 covers the portion that extends from the outer surface of the base material main body portion 10 of the base material 6 to the outer surface of the side wall portion 11. The filling portion 18 forms part of the terminal portion 15 of the elastic material 7, and is filled between the ribs 13a and 13b, and is attached to the ribs 13a and 13b.

[0028] The skin body 8 is a member that constitutes the design surface of the vehicle interior material 1. The skin body 8 is formed in a sheet shape that is thinner than the elastic material 7. In this embodiment, the skin body 8 is formed in a thin film shape. The skin body 8 is disposed so as to cover at least the entire surface of the elastic material 7. The skin body 8 may be formed from leather, synthetic resin, or the like.

[0029] When manufacturing the vehicle interior material 1, a molding die 20 shown in Figures 3 and 4 is used, and a base material 6 that has been separately molded in advance is set in the molding die 20 to integrally mold the elastic material 7, thereby using insert molding.

[0030] The molding die 20 has one die 22 and another die 23. The one die 22 has a set portion 25 on which the substrate 6 is set. In this embodiment, the set portion 25 is a convex portion formed according to the shape of the substrate 6. The one die 22 also has an alignment portion 26 outside the set portion 25. The other die 23 has a recess 28 facing the set portion 25. The other die 23 also has an alignment portion 29 outside the recess 28 that abuts against the alignment portion 26 of the one die 22. The one die 22 and the other die 23 are fixed in a state where they abut against each other at the alignment portions 26, 29, and a space (cavity) is formed between the set portion 25 (the substrate 6 set in the set portion 25) and the recess 28. The molding die 20 may also have a slide core or the like depending on the required shape of the vehicle interior material 1 (FIG. 1(b)).

[0031] The molding die 20 is opened, and the substrate 6 is set in the set portion 25 of one of the dies 22, and the alignment portions 26, 29 are butted together to close the molding die 20. The synthetic resin raw material R is stirred and mixed by the mixer portion and injected into the space between the set portion 25 and the recess 28, and the molten resin raw material RE fills the space between the substrate 6 and the recess 28 while foaming, and is laminated on the substrate 6 as an elastic material 7.

[0032] At this time, the molten resin raw material RE foams so as to encase the ribs 13 .

[0033] Thereafter, as the molding die 20 is cooled, the elastic material 7 contracts in the direction (arrow X) in which it bites into the ribs 13 at the positions that sandwich the ribs 13, as shown in Figure 1(c), and is fixed to the substrate 6. After the elastic material 7 has solidified, the molding die 20 is opened, and the intermediate body is removed from the molding die 20. After flash and the like are removed from the intermediate body, the skin body 8 is attached and the vehicle interior material 1 is completed.

[0034] The skin body 8 may be attached to the intermediate body in a later process by gluing or sewing, or the skin body 8 may be set together with the substrate 6 in the recess 28 of the other die 23 of the molding die 20, and the elastic material 7 may be filled in the space between the substrate 6 and the skin body 8.

[0035] Thus, according to the first embodiment, the positions corresponding to the plurality of ribs 13 provided on the substrate 6 are defined as terminal portions 15, and the elastic material 7 is filled at least between the ribs 13 to be molded integrally with the substrate 6, so that the elastic material 7 grips the ribs 13 of the substrate 6 as it shrinks, making it less likely for the elastic material 7 to peel off from the terminal portions 15 of the substrate 6. In particular, the substrate 6 and the elastic material 7 are structurally fixed by biting into the ribs 13 rather than being bonded using a chemical reaction, so that the compatibility between the materials is less affected, and a wider range of materials can be used for the substrate 6.

[0036] Furthermore, by forming the elastic material 7 from a foam material, the elastic material 7 shrinks significantly after molding, and the elastic material 7 can be attached to the base material 6 more firmly.

[0037] By covering at least a portion of the elastic material 7 with the skin 8, the design of the vehicle interior material 1 can be improved.

[0038] By using this vehicle interior material 1 as a cover for a console box 2 for a vehicle, it is possible to provide a console box 2 that is excellent in cushioning properties and appearance.

[0039] In the first embodiment described above, even if the rib 13 is formed along the edge of the base material 6, for example, along the flange portion 12, as in the second embodiment shown in Figure 5, the contracted elastic material 7 will bite into the rib 13, making it difficult for the elastic material 7 to peel off from the terminal portion 15 of the base material 6, and similar effects to those of the first embodiment described above can be achieved.

[0040] In each of the above-described embodiments, the rib 13 is basically formed on the peripheral edge of the base material 6, but is not limited thereto and may be located in the center of the base material 6. Even in this case, as long as the position where the rib 13 is formed corresponds to the terminal portion 15 of the elastic material 7, the same effect can be achieved.

[0041] Furthermore, the vehicle interior material is not limited to a console box lid, and may be used as any vehicle interior material. [Industrial Applicability]

[0042] The present invention can be suitably used as a cover for a console box provided in the passenger compartment of a vehicle. [Explanation of symbols]

[0043] 1. Vehicle interior materials 2 Console box 6 Base material 7 Elastic material 8 Epidermal body 13 Ribs 15 Terminal

Claims

1. a substrate having a plurality of ribs; an elastic material having terminal portions at positions corresponding to the ribs, filled at least between the ribs, and integrally molded with the base material; the rib is located near an end portion of the base material and protrudes toward the elastic material side of the base material, The elastic material is disposed so as to cover the entire outer surface of the base material and the entire rib. A vehicle interior material characterized by:

2. The elastic material is made of a foam material.

2. The vehicle interior material according to claim 1.

3. A skin covering at least a portion of the elastic material is provided.

3. The vehicle interior material according to claim 1 or 2.

4. A lid for a console box for a vehicle 4. The vehicle interior material according to claim 1, wherein the interior material is a woven fabric.

Images