Tactile-variable molded article, switch having seamless surface, and method for manufacturing tactile-variable molded article

Abstract

[Problem] To provide a tactile-variable molded article with seamlessly adjustable hardness, a switch having a seamless surface, and a method for manufacturing a tactile-variable molded article. [Solution] A tactile-variable molded article 10 has an outer skin material 21, a base material 23 disposed with a gap 22 between the base material and the outer skin material, and an elastically deformable elastic structure 30 disposed in the gap between the outer skin material and the base material and having a void 31 and a resin support body 32. The tactile-variable molded article 10 has a plurality of regions in which the volume occupancy rate occupied by the support body per unit volume of the elastic structure varies along the plane direction of the outer skin material and the elastic modulus in a direction intersecting the outer skin material varies at different positions in the plane direction.

Description

Touch-variable molded product, switch having a seamless surface, and method for manufacturing a touch-variable molded product

[0008] ,

[0001] The present invention relates to a touch-variable molded product, a switch having a seamless surface, and a method for manufacturing a touch-variable molded product.

[0002] In order to achieve both volume reduction and suppression of reduction in rigidity, a structural component having a lattice structure having a three-dimensional lattice structure is known (see Patent Document 1).

[0003] Japanese Patent Application Laid-Open No. 2015-93461

[0004] The structural component of Patent Document 1 employs a lattice structure for the purpose of maintaining strength (force dispersion) by meat theft, and no proposal regarding touch has been made. [ END]]

[0005] Touch is one of the important senses that is transmitted from the fingertips to the user and gives the user a recognition of the place being touched, a sense of comfort, and a sense of satisfaction.

[0006] Therefore, an object of the present invention is to provide a touch-variable molded product, a switch having a seamless surface, and a method for manufacturing a touch-variable molded product, in which the hardness can be adjusted seamlessly.

[0007] (1) One aspect of the present invention for achieving the above object includes a skin material, a base material disposed with a gap between the skin material, and an elastic structure disposed in the gap between the skin material and the base material and having voids and a resin support. The volume occupancy rate of the support per unit volume of the elastic structure varies along the surface direction of the skin material, and the elastic modulus in a direction intersecting the skin material has a plurality of regions that are different at different positions in the surface direction. It is a touch-variable molded product.

[0008] (2) Another aspect of the present invention comprises a surface material, a base material disposed with a gap between it and the surface material, and an elastically deformable elastic structure disposed in the gap between the surface material and the base material, having voids and a resin support. The volume occupancy rate of the support per unit volume of the elastic structure differs along the depth direction from the surface material toward the base material, and the elastic modulus in the depth direction has multiple regions that differ at different positions in the depth direction, making it a tactile variable molded product.

[0009] (3) Yet another aspect of the present invention comprises the tactile variable molded article described in (1) or (2) above, an elastically deformable switch component that makes contact and separates contacts, and an elastically deformable resin molded article that covers at least the surface side of the switch component. The tactile variable molded article is disposed between the switch component and the resin molded article, and the switch has a seamless surface.

[0010] (4) Yet another aspect of the present invention is a method for manufacturing a tactilely variable molded product, comprising: preparing an elastically deformable elastic structure having voids and a resin support, wherein the elastic structure has a plurality of regions in which the volume occupancy rate of the support per unit volume differs; placing the elastic structure in the gap between a surface material and a base material; injecting a reactive resin into the voids of the elastic structure; and then curing the reactive resin by applying energy from the outside.

[0011] According to the present invention, it is possible to provide a tactile variable molded article with seamlessly adjustable hardness, a switch having a seamless surface, and a method for manufacturing a tactile variable molded article.

[0012] This is a cross-sectional view showing a tactile variable molded product of Embodiment 1. This is a cross-sectional view showing the tactile variable molded product of Embodiment 1 in an elastically deformed state. This is a cross-sectional view showing a tactile variable molded product of Embodiment 2. This is a cross-sectional view showing a tactile variable molded product of Modification 1 of Embodiment 1. This is a cross-sectional view showing a tactile variable molded product of Modification 2 of Embodiment 1. This is a schematic diagram showing the injection of resin material into the voids of an elastic structure. This is a flowchart showing a method for manufacturing a tactile variable molded product. This is a schematic diagram showing a surface sheet to which a tactile variable molded product has been applied. This is a schematic diagram showing a switch having a seamless surface to which a tactile variable molded product has been applied. This is a schematic diagram showing the switch having a seamless surface of Figure 9 in a state where the contacts are in contact. This is a schematic diagram showing another switch having a seamless surface to which a tactile variable molded product has been applied.

[0013] Hereinafter, embodiments for carrying out the present invention will be described in detail with reference to the drawings. The embodiments shown herein are illustrative examples for embodying the technical idea of ​​the present invention and do not limit the present invention. Therefore, all other implementable forms, examples, and operational techniques that can be conceived by those skilled in the art without departing from the spirit of the present invention are included in the scope and spirit of the present invention, as well as in the claims and their equivalents.

[0014] Furthermore, the drawings attached to this specification may be schematically represented with changes to scale, aspect ratio, shape, etc., from the actual object for the sake of illustration and ease of understanding, but these are merely examples and do not limit the interpretation of the present invention.

[0015] <Embodiment 1> As shown in Figures 1 and 2, the tactile variable molded product 10 of Embodiment 1 comprises a surface material 21, a base material 23 disposed between the surface material 21 and a gap 22, and an elastically deformable elastic structure 30. The elastic structure 30 is disposed in the gap 22 between the surface material 21 and the base material 23 and has a void 31 and a resin support 32. The volume occupancy rate of the support 32 per unit volume of the elastic structure 30 differs along the planar direction of the surface material 21 (left-right direction in the figure). As a result, there are multiple regions where the elastic modulus in the direction intersecting the surface material 21 (up-down direction or diagonal direction intersecting the surface material 21 in the figure) differs at different positions in the planar direction.

[0016] The surface material 21 and the base material 23 are formed from a resin with a relatively high modulus of elasticity, such as acrylic urethane.

[0017] The elastic structure 30 can be formed by additive manufacturing using a 3D printer. In a 3D printer, 3D CAD data is divided into layers, and material is added to each divided layer by stacking layers on top of each other to manufacture a 3D object. As the resin that makes up the support 32, for example, nylon, acrylate resin, ABS resin, etc., can be used. These resins are inexpensive and common. They are also compatible with various manufacturing methods and are suitable for additive manufacturing using 3D printers.

[0018] The elastic structure 30 has voids 31 and a resin support 32, and is not particularly limited as long as it is elastically deformable; various structures can be selected. For example, the elastic structure 30 can have a lattice structure with a three-dimensional grid structure. Since the lattice structure has a regular structure, the mechanical design of the elastic structure 30 becomes easier. The elastic structure 30 can also have a honeycomb structure.

[0019] The volume occupancy rate of the elastic structure 30 is defined as the proportion of the support 32 that occupies per unit volume of the elastic structure 30. Therefore, when the volume occupancy rate is relatively large, there are relatively many support 32 and relatively few voids 31. As a result, the structure becomes "dense" and hard. Conversely, when the volume occupancy rate is relatively small, there are relatively few support 32 and relatively many voids 31. As a result, the structure becomes "sparse" and soft.

[0020] The elastic structure 30 of Embodiment 1 has three regions with different volume occupancy rates along the planar direction of the surface material 21. Of the three regions, the leftmost region 41 has the smallest volume occupancy rate, the most "sparse" structure, and is the softest. Of the three regions, the rightmost region 42 has the largest volume occupancy rate, the most "dense" structure, and is the hardest. The central region 43 has a volume occupancy rate between the left and right regions 41 and 42, and is of intermediate hardness. In this way, the elastic structure 30 has multiple regions (three in the illustrated example) 41, 42, and 43 with different elastic moduli in the direction intersecting the surface material 21 at different positions in the planar direction. The elastic modulus decreases from the rightmost region 42 towards the leftmost region 41.

[0021] As shown in Figure 2, when the same force is applied to the surface of the skin material 21, the deformation stroke increases as the material becomes softer from the right-hand region 42 to the left-hand region 41.

[0022] Thus, according to the tactile variable molded product 10 of Embodiment 1, the hardness of the molded product can be seamlessly adjusted along the surface direction by the density of the elastic structure 30. Therefore, the tactile sensation perceived by the user in the surface direction can be set to a desired level, providing the user with a sense of comfort and satisfaction.

[0023] <Embodiment 2> The tactile variable molded product 11 of Embodiment 2 differs from the tactile variable molded product 10 of Embodiment 1, which adjusts the elastic modulus in the surface direction, in that it adjusts the elastic modulus in the depth direction. The description of components common to Embodiment 1 will be omitted.

[0024] As shown in Figure 3, in the tactile variable molded product 11 of Embodiment 2, the volume occupancy rate of the support 32 per unit volume of the elastic structure 30 differs along the depth direction (downward in the figure) from the surface material 21 toward the base material 23. As a result, the elastic modulus in the depth direction has multiple regions with different elasticity at different positions in the depth direction.

[0025] The elastic structure 30 of Embodiment 2 has three regions with different volume occupancy rates along the depth direction. Of the three regions, the upper region 51 has the smallest volume occupancy rate, the most "sparse" structure, and is the softest. Of the three regions, the lower region 52 has the largest volume occupancy rate, the most "dense" structure, and is the hardest. The central region 53 has a volume occupancy rate between that of the upper and lower regions 51 and 52, and is of intermediate hardness. Thus, there are multiple regions (three in the illustrated example) 51, 52, and 53 with different elastic moduli in the depth direction at different positions in the depth direction. The elastic modulus decreases from the lower region 52 towards the upper region 51.

[0026] When the surface of the skin material 21 is pressed, it becomes harder from the upper region 51 to the lower region 52, so the deformation stroke becomes larger in the upper region 51.

[0027] Thus, according to the tactile variable molded product 11 of Embodiment 2, the hardness of the molded product can be seamlessly adjusted along the depth direction by the density of the elastic structure 30. Therefore, the tactile sensation in the depth direction perceived by the user can be set to a desired level, providing the user with a sense of comfort and satisfaction. The user can be given multi-stage press sensations and a clicking sensation associated with pressing.

[0028] <Modification 1 of Embodiment 1> As shown in Figure 4, the tactile variable molded product 12 of Modification 1 of Embodiment 1 further has a filler 60 filled in the void 31 of the elastic structure 30. The filler 60 is formed from a resin material having an elastic modulus (m) lower than the elastic modulus (M) of the resin material constituting the support 32 of the elastic structure 30 (M > m). For example, a low-elastic modulus resin such as silicone or urethane can be used as the resin material constituting the filler 60.

[0029] By filling the voids 31 of the elastic structure 30 with the filler 60, the elastic deformation of the elastic structure 30 is assisted. Therefore, even if force is repeatedly applied to the tactile variable molded product 12, buckling and sagging of the support 32 of the elastic structure 30 can be suppressed. In addition, the impact resistance of the elastic structure 30 can be improved. If the elastic modulus of the resin of the filler 60 is higher than the elastic modulus of the resin material constituting the support 32, the initially designed tactile feel cannot be reproduced. By filling the voids 31 with a resin with a low elastic modulus (M > m), the seamless hardness change due to density, which was initially designed, is less likely to be hindered.

[0030] Thus, according to the tactile variable molded product 12 of the modified example 1 of Embodiment 1, by filling it with a low modulus resin (M > m), deformation of the tactile variable molded product 12 can be suppressed, and a highly durable tactile variable molded product 12 can be provided.

[0031] Similarly, the tactile variable molded product 11 (Figure 3) of Embodiment 2 may also further include a filler 60 that is formed from a resin material having a lower elastic modulus (m) than the elastic modulus (M) of the resin material constituting the support 32 of the elastic structure 30 (M > m), and that fills the void 31 of the elastic structure 30.

[0032] <Modification 2 of Embodiment 1> As shown in Figure 5, the tactile variable molded product 13 of Modification 2 of Embodiment 1 has a through hole 23a formed in the base material 23.

[0033] By forming the through-holes 23a in this way, it becomes easier to inject the resin material constituting the filler 60 into the voids 31 of the elastic structure 30 through the through-holes 23a. As a result, the time required to manufacture the variable-touch molded product 13 can be shortened, contributing to cost reduction.

[0034] The method for injecting the resin material into the voids 31 of the elastic structure 30 is not particularly limited. The resin material can be injected into the voids 31 under pressure, or it can be injected into the voids 31 using capillary force.

[0035] For example, as shown in Figure 6, resin material can be injected into the voids 31 of the elastic structure 30 by a dipping method. The resin material is injected into the voids 31 of the elastic structure 30 through the structure end 30a where the voids 31 of the elastic structure 30 are open, or through holes 23a formed in the base material 23 (see Figure 5). In the dipping method, the resin can be filled into the voids 31 by capillary force simply by dipping the variable-touch molded product 13 before filling.

[0036] <Manufacturing Method> The manufacturing method for the tactile variable molded products 12 and 13 will be explained with reference to Figure 7.

[0037] The manufacturing of the tactile variable molded products 12 and 13 is carried out through the following steps: preparation of the elastic structure 30 (step S11), placement of the elastic structure 30 (step S12), injection of the reactive resin (step S13), and curing of the reactive resin (step S14).

[0038] First, an elastically deformable elastic structure 30 is prepared, which has a void 31 and a resin support 32, and has multiple regions in which the volume occupancy rate of the support 32 per unit volume is different (step S11).

[0039] Next, the elastic structure 30 is placed in the gap 22 between the surface material 21 and the base material 23 (step S12).

[0040] Next, the reactive resin is injected into the voids 31 of the elastic structure 30 (step S13). The reactive resin is injected into the voids 31 of the elastic structure 30 through the open structure end 30a and / or through holes 23a formed in the base material 23. In the dip method, the reactive resin fills the voids 31 of the elastic structure 30 by capillary force.

[0041] As described above, the reactive resin used for the filler 60 is a resin material having a lower elastic modulus (m) than the elastic modulus (M) of the resin material constituting the support 32 of the elastic structure 30 (M > m).

[0042] Subsequently, energy is applied from an external source to cure the reactive resin (step S14). The energy can be infrared irradiation, heating, microwaves, etc.

[0043] In this way, the tactile variable molded articles 12 and 13 with seamlessly adjustable hardness can be manufactured.

[0044] <Example of Application of Tactile Variable Molded Article 1> As shown in FIG. 8, the tactile variable molded articles 10 to 13 can be applied to the skin sheet 70.

[0045] When the volume occupancy rate of the elastic structure 30 is relatively large, the structure becomes "dense" and is hard to deform (at the position of arrow 71). Conversely, when the volume occupancy rate is relatively small, the structure becomes "sparse", soft, and the stroke of elastic deformation becomes large (at the position of arrow 72). By applying this characteristic, the hardness can be changed seamlessly within a single skin sheet 70.

[0046] <Example of Application of Tactile Variable Molded Article 2> As shown in FIGS. 9 and 10, the tactile variable molded article can be applied to a switch 80 having a seamless surface.

[0047] The switch 80 includes a tactile variable molded article, a switch component 81, and a resin molded body 82. The tactile variable molded article can be any of the tactile variable molded articles 10 to 13 described above. In this Example of Application 2, the tactile variable molded article 10 with the hardness adjusted along the surface direction described in Embodiment 1 is applied. The switch component 81 has two conductive contacts 83 and 84. The switch component 81 is configured to be elastically deformable to perform contact and separation of the contacts 83 and 84. The resin molded body 82 is configured to at least cover the surface side of the switch component 81 and be elastically deformable. And the tactile variable molded article 10 is disposed between the switch component 81 and the resin molded body 82.

[0048] By configuring in this way, the switch 80 has a seamless surface, and when the switch 80 is operated, only the switch 80 portion sinks (see FIG. 10). According to this switch 80, there is no seam like a touch panel, and a pushing feeling can be produced like a general mechanical switch.

[0049] <Application Example 3 of Tactile Variable Molded Product> As shown in Figure 11, the tactile variable molded product can be applied to a switch 85 having a seamless surface, similar to Application Example 2. The explanation of the parts common to Application Example 2 will be omitted.

[0050] In this third application example, a tactile variable molded product 11, whose hardness is adjusted along the depth direction as described in Embodiment 2, is used. With this switch 85, similar to the switch 80 in Application Example 2, there are no seams like a touch panel, and it can produce a pressing sensation similar to a general mechanical switch. Furthermore, it can provide the user with multi-stage pressing sensations and a clicking sensation associated with pressing.

[0051] The above describes the manufacturing methods for the tactile variable molded articles 10-13, the switch 80 having a seamless surface, and the tactile variable molded articles 12 and 13 of the present invention. However, the present invention is not limited to the configurations described in the embodiments and modifications described above, and can be modified as appropriate based on the claims.

[0052] The following embodiments are also included in the scope of the present invention: a tactile variable molded article according to claim 3 having the features of claim 4; and a switch 80 having a seamless surface according to claim 6, to which the tactile variable molded article according to any one of claims 3 to 5 is applied.

[0053] 10: Tactile variable molded product 11: Tactile variable molded product 12: Tactile variable molded product 13: Tactile variable molded product 21: Surface material 22: Gap 23: Base material 23a: Through hole 30: Elastic structure 30a: End of structure 31: Void 32: Support 60: Filler 70: Surface sheet 80: Switch 81: Switch component 82: Resin molded product 83: Contact 84: Contact 85: Switch

Claims

1. A tactile variable molded product comprising: a surface material; a base material disposed with a gap between it and the surface material; and an elastically deformable elastic structure disposed in the gap between the surface material and the base material, having voids and a resin support, wherein the volume occupancy rate of the support per unit volume of the elastic structure differs along the surface direction of the surface material, and the elastic modulus in the direction intersecting the surface material differs at different positions in the surface direction in which a plurality of regions exist.

2. A tactile variable molded product comprising: a surface material; a base material disposed with a gap between it and the surface material; and an elastically deformable elastic structure disposed in the gap between the surface material and the base material, having voids and a resin support, wherein the volume occupancy rate of the support per unit volume of the elastic structure differs along the depth direction from the surface material toward the base material, and the elastic modulus in the depth direction has multiple regions that differ at different positions in the depth direction.

3. The tactile variable molded article according to claim 1 or 2, further comprising a filler formed from a resin material having a lower elastic modulus than the elastic modulus of the resin material constituting the support of the elastic structure, and filling the void of the elastic structure.

4. The tactile variable molded article according to claim 1 or 2, wherein the elastic structure has a lattice structure.

5. The base material has through holes, the tactile variable molded article according to claim 3.

6. A switch having a seamless surface, comprising: a tactile variable molded article according to claim 1 or 2; an elastically deformable switch component that makes contact and separates contacts; and an elastically deformable resin molded article that covers at least the surface side of the switch component, wherein the tactile variable molded article is disposed between the switch component and the resin molded article.

7. A method for manufacturing a tactilely variable molded product, comprising: preparing an elastically deformable elastic structure having voids and a resin support, wherein the elastic structure has a plurality of regions in which the volume occupancy rate of the support per unit volume differs; placing the elastic structure in the gap between a surface material and a base material; injecting a reactive resin into the voids of the elastic structure; and then curing the reactive resin by applying energy from the outside.

8. The method for manufacturing a tactile variable molded article according to claim 7, wherein the reactive resin is injected into the void of the elastic structure through the open end of the elastic structure and / or through holes formed in the substrate.

9. The method for manufacturing a tactile variable molded article according to claim 7 or 8, wherein the reactive resin is filled into the voids of the elastic structure by capillary force.

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