Automotive interior trim

Abstract

[Problem] To make it possible to suppress the generation of abnormal noise caused by sliding while providing cushioning properties. [Solution] An armrest 1 comprises a base material 10 having a prescribed shape, and a cover material 20 formed from a resin material and layered on the base material 10. The cover material 20 comprises a front surface 21 having an embossed pattern 23 integrally molded thereon so as to be a design surface, and a rear surface 22 on the base material 10 side. A plurality of recesses 24 are formed in the rear surface 22, which is the surface of the cover material 20 that faces the base material 10, and the region where each recess 24 is formed is not bonded to the front surface of the base material 10.

Description

Automotive interior parts

[0001] The present disclosure relates to automotive interior parts.

[0002] An automotive interior part constituting an instrument panel, a door trim or the like comprises a base material formed of a resin material such as PP or ABS, and a skin material formed of a resin material such as urethane, which is covered on the surface of the base material to form a design surface. The surface (first surface) of the skin material is provided with decorations such as stitch patterns and grain patterns. For example, Patent Document 1 describes an invention of a vehicle interior material in which a foam layer is interposed between a surface covering material (skin material) sewn integrally with a belt-shaped plate by double stitching and a base material, and a region between the base material excluding the foam layer and the skin material is bonded with an adhesive.

[0003] Japanese Patent No. 4933260

[0004] In an interior material in which a skin material and a base material are partially bonded and fixed as in the above-mentioned Patent Document 1, when the range of the non-bonded portion is large, the non-bonded portion of the skin material may slide relative to the base material due to vibration during traveling, operation by a passenger, or the like, which may cause abnormal noise.

[0005] Therefore, an object of the present disclosure is to provide an automotive interior part that can suppress the generation of abnormal noise due to sliding while providing cushioning properties.

[0006] To achieve the above objective, the present disclosure provides an automotive interior part comprising a base material of a predetermined shape and a surface material formed from a resin material and laminated onto the base material, wherein the surface material comprises a first surface on the front side having a textured pattern integrally molded to form a design surface, and a second surface on the base material side, wherein a plurality of recesses are formed on at least one opposing surface of the base material and the surface material, and each recess formation area is not adhered to the other opposing surface. Another aspect of the present disclosure is characterized in that, in the above configuration, the base material has a light source, the surface material is light-transmitting, and the recesses are formed on the second surface. Another aspect of the present disclosure is characterized in that, in the above configuration, a predetermined light-transmitting region on the second surface is thinner than other regions. Another aspect of the present disclosure is characterized in that, in the above configuration, the predetermined light-transmitting region on the second surface is a flat surface without the recesses. Another aspect of the present disclosure is characterized in that, in the above configuration, a shielding layer is formed in a predetermined non-light-transmitting region outside the predetermined light-transmitting region of the second surface to block light from the light source. Another aspect of the present disclosure is characterized in that, in the above configuration, the shielding layer is formed by in-mold coating. Another aspect of the present disclosure is characterized in that, in the above configuration, a partition projection protruding from the second surface is integrally molded at the boundary between the light-transmitting region and the non-light-transmitting region. Another aspect of the present disclosure is characterized in that, in the above configuration, the recess formed in the predetermined light-transmitting region of the second surface is formed with a larger hole diameter than the recess in other regions. Another aspect of the present disclosure is characterized in that, in the above configuration, the recess formed in the predetermined light-transmitting region of the second surface is formed deeper than the recess in other regions. Another aspect of the present disclosure is characterized in that, in the above configuration, the recess formed in the predetermined light-transmitting region of the second surface is formed with a narrower spacing between them than the recess in other regions.Another aspect of the present disclosure is characterized in that, in the above configuration, the surface material comprises a light-transmitting surface layer having the first surface and the second surface, and an elastic layer on which the second surface is laminated, wherein a plurality of second recesses are formed on the surface of the elastic layer facing the substrate, and each of the regions in which the second recesses are formed is not adhered to the substrate. Another aspect of the present disclosure is characterized in that, in the above configuration, an opening or cutout is formed in the region of the elastic layer facing the light-transmitting region of the surface layer.

[0007] According to this disclosure, a plurality of recesses are formed on at least one opposing surface of the substrate and the surface material, and the area where each recess is formed is not adhered to the other opposing surface, so that cushioning is provided while suppressing the generation of abnormal noise due to sliding. According to another aspect of this disclosure, in addition to the above effect, the substrate has a light source, the surface material is translucent, and the recesses are formed on the second surface, so the recesses can be used as functional members that provide a decorative function, and the design of the first surface (brightness, shading, emphasis of patterns, etc.) can be set widely by the light source, improving the freedom to adjust light transmittance. According to another aspect of this disclosure, in addition to the above effect, a predetermined light-transmitting area on the second surface is thinner than other areas, so the amount of light transmitted in the light-transmitting area increases, making it possible to create a contrast with other areas, leading to a further improvement in the freedom to adjust light transmittance. According to another aspect of this disclosure, in addition to the above effect, a predetermined light-transmitting area on the second surface is a flat area without recesses, so the light-transmitting area can be illuminated evenly and made to stand out. According to another aspect of this disclosure, in addition to the above effects, a shielding layer is formed in a predetermined non-light-transmitting region, making it easy to define the light-emitting area without diffusing light. According to another aspect of this disclosure, in order to achieve the above objective, the shielding layer is formed by in-mold coating, so the shielding layer can be easily applied at the same time as molding. According to another aspect of this disclosure, in addition to the above effects, a partition protrusion is integrally molded at the boundary between the light-transmitting region and the non-light-transmitting region, so the area for forming the shielding layer can be easily set using the partition protrusion as a guide. According to another aspect of this disclosure, in addition to the above effects, the recess formed in the light-transmitting region is formed with a larger hole diameter than the recess in other regions, so the amount of light transmitted in the light-transmitting region is increased, making it possible to create a contrast with the region other than the light-transmitting region, leading to a further improvement in the degree of freedom to adjust the light transmittance. According to another aspect of this disclosure, in addition to the above effects, the recess formed in the light-transmitting region is formed deeper than the recess in other regions, so the amount of light transmitted in the light-transmitting region is increased, making it possible to create a contrast with the region other than the light-transmitting region, leading to a further improvement in the degree of freedom to adjust the light transmittance.According to another aspect of this disclosure, in addition to the above effects, the recesses formed in the light-transmitting region are formed with narrower spacing between them than the recesses in other regions, thereby increasing the amount of light transmitted in the light-transmitting region and creating a clear distinction between it and the regions outside the light-transmitting region, leading to a further improvement in the degree of freedom in adjusting the light transmittance. According to another aspect of this disclosure, in addition to the above effects, a second recess is formed in the elastic layer of the two-layer surface material, and the region where the second recess is formed is not adhered to the substrate, so that the elastic layer in the surface material is provided to further enhance cushioning, while suppressing the generation of abnormal noise due to sliding, even with a two-layer structure. According to another aspect of this disclosure, in addition to the above effects, an opening or cutout is formed in the region of the elastic layer facing the light-transmitting region of the surface layer, so that the light transmittance in the elastic layer can be increased, and the light-emitting function on the surface can be ensured even with a two-layer structure of the surface material.

[0008] This is a partial perspective view of the armrest of Example 1. This is a partially enlarged cross-sectional view of the display operation unit of Example 1. This is a partially enlarged cross-sectional view of the display operation unit showing a modified example of Example 1. This is a partially enlarged cross-sectional view of the display operation unit showing a modified example of Example 1. This is a partially enlarged cross-sectional view of the display operation unit of Example 2. This is a partially enlarged cross-sectional view of the display operation unit showing a modified example of Example 2. This is a partially enlarged cross-sectional view of the display operation unit showing a modified example of Example 2. This is a partially enlarged cross-sectional view of the display operation unit showing a modified example of Example 2. This is a partially enlarged cross-sectional view of the display operation unit of Example 3. This is a partially enlarged cross-sectional view of the display operation unit of Example 4. This is a partially enlarged cross-sectional view of the display operation unit showing a modified example of Example 4. This is a partially enlarged cross-sectional view of the display operation unit of Example 5. This is a partially enlarged cross-sectional view of the display operation unit showing a modified example of Example 5.

[0009] The embodiments of this disclosure will be described below with reference to the drawings. In Examples 2 and later, the same reference numerals are used for components common to Example 1, and redundant descriptions will be omitted.

[0010] Figure 1 is a partial perspective view of an armrest 1, which is an example of an automotive interior part of the present disclosure. The armrest 1 is installed on the inside of the door of an automobile and has a display and operation section 2 on which a surface material 20 is laminated. Figure 2 is a partially enlarged cross-sectional view of the display and operation section 2. The armrest 1 has a base material 10 and a surface material 20 that covers the surface of the base material 10. The base material 10 is a molded product of a resin material such as PP or ABS. The surface material 20 is a molded product of a resin material such as a light-transmitting elastomer, and has a surface 21 that serves as a design surface and a back surface 22, the back surface 22 is laminated to the base material 10 without adhesion. A textured pattern 23 is formed on the surface 21. The surface 21 is an example of the first surface of the present disclosure. The back surface 22 is an example of the second surface of the present disclosure and is an example of the surface facing the base material. A plurality of recesses 24, 24... are formed on part or the entire back surface 22 of the surface material 20. Each recess 24 is hemispherical and arranged at predetermined intervals, for example, in multiple rows in a straight line, in a grid pattern, on concentric circles, or randomly. Therefore, the back surface 22 has a dimple shape.

[0011] In this armrest 1, multiple recesses 24, 24... are formed on the back surface 22 that contacts the base material 10, so the contact area with the base material 10 is smaller than in a case where the recesses 24 are not provided. Therefore, even if the surface material 20 slides against the base material 10 due to vibrations during driving or when a passenger touches the surface material 20, it is less likely to generate abnormal noise. In addition, since an air layer is formed between the surface material 20 and the base material 10 by the recesses 24, cushioning is obtained, which also leads to an improved tactile feel.

[0012] As described above, the armrest 1 of Example 1 includes a base material 10 of a predetermined shape and a surface material 20 formed from a resin material and laminated onto the base material 10. The surface material 20 has a surface 21 on which a textured pattern 23 is integrally molded to form a design surface, and a back surface 22 on the base material 10 side. Multiple recesses 24 are formed on the back surface 22 of the surface material 20, which is the surface facing the base material 10, and the area in which each recess 24 is formed is not adhered to the surface of the base material 10. With this configuration, it is possible to suppress the generation of abnormal noise due to sliding while providing cushioning.

[0013] In Example 1, the recesses are not limited to being provided only on the surface material. For example, as shown in Figure 3, recesses 10a, 10a, etc. of the same shape may also be provided on the surface of the base material 10. In this case, the positions of the upper and lower recesses 24 and recesses 10a may be completely offset so as not to overlap as shown in Figure 3, or they may be arranged so that the two recesses 24 and 10a partially overlap, or so that the two recesses 24 and 10a completely overlap. Also, as shown in Figure 4, the recesses may not be provided on the back surface 22 of the surface material 20, and the recesses 10a may be provided only on the surface of the base material 10. The surface of the base material 10 is an example of a surface facing the surface material of this disclosure.

[0014] In the display operation section 2 of the armrest 1A shown in Figure 5, a circular recessed housing 11 that is recessed inward is integrally formed in the base material 10. A light source 12 is housed in the recessed housing 11. The light source 12 is made up of, for example, one or more LEDs. An outlet 13 for lead wires 14 connected to the light source 12 is formed at the bottom of the recessed housing 11. A recess 24 is also formed in the area facing the light source 12 on the back surface 22 of the surface material 20. This area becomes a circular light-transmitting area 25 in plan view, through which light from the light source 12 located directly behind is transmitted.

[0015] In this armrest 1A, when the light source 12 is energized and emits light, the emitted light passes through the light-transmitting region 25, causing the surface 21 to emit light as indicated by the dotted arrow. At this time, the distance between the light source 12 and the light-transmitting region 25 is short, so light loss can be minimized. Therefore, by changing the thickness of the light-transmitting region 25, or by adding letters, pictures, or patterns to the light-transmitting region 25, it is possible to create shadows on the surface 21 or make letters or pictures stand out. In particular, since recesses 24 are also formed in the light-transmitting region 25, the amount of light transmitted to the light-transmitting region 25 changes for each recess 24, so that shadows can be created even with the same light source 12.

[0016] In the armrest 1A of Example 2, the base material 10 has a light source 12, the surface material 20 is translucent, and the recess 24 is formed on the back surface 22. Therefore, similar to Example 1, it is possible to suppress the generation of abnormal noise due to sliding while providing cushioning. In particular, since the recess 24 is formed on the back surface 22 which includes a light-transmitting region 25, the recess 24 can be used as a functional part that provides a decorative function, and the design of the surface 21 (brightness, shading, emphasis of patterns, etc.) by the light source 12 can be set to a wide range, improving the degree of freedom in adjusting light transmittance.

[0017] In Example 2, the thickness of the light-transmitting region 25 may be made smaller than the thickness of the regions other than the light-transmitting region 25, as shown in Figure 6. By making the thickness of the light-transmitting region 25 smaller than the other regions in this way, the amount of light transmitted through the light-transmitting region 25 increases, creating a clear distinction between the light-transmitting region 25 and the regions other than the light-transmitting region 25, which leads to an even greater degree of freedom in adjusting the light transmittance. Furthermore, not only the thickness of the light-transmitting region 25, but also the shape of the recesses between the light-transmitting region 25 and the other regions can be changed. Figure 7 shows an example in which the hole diameter of the recess 24a in the light-transmitting region 25 is larger than the hole diameter of the recess 24 in the regions other than the light-transmitting region 25. Figure 8 shows an example in which the depth of the recess 24a in the light-transmitting region 25 is deeper than the hole diameter of the recess 24 in the regions other than the light-transmitting region 25. Figure 9 shows an example in which the spacing between the recesses 24a in the light-transmitting region 25 is narrower than the spacing between the recesses 24 in the regions other than the light-transmitting region 25. In this way, even if the diameter of the recess 24a is increased, the depth is increased, or the spacing is narrowed, the amount of light transmitted in the light-transmitting region 25 increases, making it possible to create a clear distinction between the light-transmitting region 25 and the regions other than the light-transmitting region 25, which leads to a further improvement in the degree of freedom in adjusting the light transmittance. The modification examples in Figures 6 to 9 may be combined with each other.

[0018] In the display operation section 2 of the armrest 1B shown in Figure 10, the back surface 22 of the light-transmitting region 25 of the surface material 20 does not have a recess, and is a flat surface 26 that is circular in plan view and flush with the back surface 22. In this armrest 1B, when the light source 12 is energized and emits light, the emitted light passes through the light-transmitting region 25 and causes the surface 21 to emit light. At this time, since the light-transmitting region 25 facing the light source 12 is a flat surface 26, the light passes through the light-transmitting region 25 evenly, illuminating the surface 21 evenly. Therefore, by adding letters, pictures, or patterns to the light-transmitting region 25, it is possible to create shadows on the surface 21 or make letters or pictures stand out.

[0019] In the armrest 1B of Example 3, the base material 10 has a light source 12, the surface material 20 is translucent, and the recess 24 is formed on the back surface 22. Therefore, similar to Example 1, it is possible to suppress the generation of abnormal noise due to sliding while providing cushioning. In particular, since the light-transmitting area 25 is a flat area 26 without recesses, the surface 21 of the light-transmitting area 25 can be illuminated evenly, making the light-transmitting area 25 stand out. In Example 3, the flat area is not flush with the back surface, but can be formed at the bottom of a recess formed on the back surface, making the flat area thinner.

[0020] In the display operation section 2 of the armrest 1C shown in Figure 11, a shielding layer 27 is formed around the light-transmitting region 25. The shielding layer 27 is formed, for example, by a shielding coating applied to the surface of the substrate 10 in advance using an in-mold coating. In addition to in-mold coating, the shielding layer 27 can also be formed by attaching a shielding film to the surface of the substrate 10, interposing a shielding film between the surface material 20 and the substrate 10, or applying a shielding print to the back surface 22 of the surface material 20 and / or the upper surface of the substrate 10. The area around the light-transmitting region 25 is an example of a non-light-transmitting region in this disclosure.

[0021] In this armrest 1C, when the light source 12 is energized and emits light, the emitted light passes through the light-transmitting region 25, causing the surface 21 to emit light. Here, since a shielding layer 27 is formed around the light-transmitting region 25, the light does not diffuse, causing the light-transmitting region 25 to emit light locally. Therefore, by applying letters, pictures, or patterns to the surface 21 of the surface material 20, it is possible to create shadows on the surface material 20 or make the letters or pictures stand out.

[0022] In the armrest 1C of Example 4, the base material 10 has a light source 12, the surface material 20 is light-transmitting, and the recess 24 is formed on the back surface 22. Therefore, similar to Example 1, it is possible to suppress the generation of abnormal noise due to sliding while providing cushioning. In particular, since a shielding layer 27 that shields light from the light source 12 is formed in the area other than the light-transmitting region 25, the light-emitting area on the surface 21 can be easily defined without diffusing the light. Also, since the shielding layer 27 is formed by in-mold coating, the shielding layer 27 can be easily applied at the same time as molding. In Example 4, a partition projection 28 can also be integrally formed on the back surface 22 of the surface material 20 between the light-transmitting region 25 and the shielding layer 27, as shown in Figure 12. The partition projection 28 is cylindrical in shape and protrudes toward the base material 10 side and reaches into the housing recess 11. The partition projection 28 houses the light source 12 within the housing recess 11. The shielding layer 27 is formed in the area outside the partition projection 28. By integrally molding a partition projection 28 protruding from the back surface 22 at the boundary between the light-transmitting region 25 and the other region, the area for forming the shielding layer 27 can be easily determined using the partition projection 28 as a guide.

[0023] In the display operation section 2 of the armrest 1D shown in Figure 13, the surface material 20 has a two-layer structure consisting of a surface layer 30 and an elastic layer 35. The surface layer 30 is a molded product of a resin material such as a light-transmitting elastomer. The elastic layer 35 is a molded product of a foamed resin material such as urethane. The surface layer 30 has a first surface 31 and a second surface 32. A textured pattern 33 is formed on the surface 31. Multiple hemispherical recesses 34, 34... similar to those in Embodiment 1 are formed on the back surface 32, and the back surface 32 is bonded to the surface of the elastic layer 35. However, the back surface 32 may not be bonded to the surface of the elastic layer 35. Here, multiple hemispherical recesses 37, 37... similar to those of the recesses 34 are formed on the back surface 36 of the elastic layer 35, and the back surface 36 is laminated to the surface of the base material 10 without being bonded. The recesses 37 are an example of the second recess of this disclosure.

[0024] In this armrest 1D, multiple recesses 37, 37... are formed on the back surface 36 of the elastic layer 35 that contacts the base material 10, so the contact area with the base material 10 is smaller than when the recesses 37 are not provided. Therefore, even if the surface material 20 slides against the base material 10 due to vibrations during driving or when a passenger touches the surface material 20, it is less likely to generate abnormal noise. In addition, since an air layer is formed between the base material 10 and the surface material 20 by the recesses 37, cushioning is obtained, which also leads to an improved tactile feel. In particular, since recesses 34 are also formed on the back surface 32 of the surface layer 30 laminated on the elastic layer 35, the cushioning is further enhanced.

[0025] Thus, the armrest 1D of Example 5 includes a base material 10 of a predetermined shape and a surface material 20 formed of a resin material and laminated onto the base material 10. The surface material 20 consists of a surface layer 30 that is translucent and has a surface 31 and a back surface 32, and an elastic layer 35 on which the back surface 32 is laminated. Multiple recesses 37 are formed on the surface of the elastic layer 35 that faces the base material 10, and the area in which each recess 37 is formed is not adhered to the base material 10. With this configuration, the cushioning is further enhanced by providing the elastic layer 35 on the surface material 20, and even with a two-layer structure, the generation of abnormal noise due to sliding can be suppressed.

[0026] In Example 5, the recesses in the surface layer and the recesses in the elastic layer do not have to completely overlap as in the above example. The upper and lower recesses may partially overlap or may be arranged so as not to completely overlap. The size, depth, and arrangement of the upper and lower recesses may also be changed. Furthermore, similar to Example 2, the base material 10 may have a housing recess 11 to house the light source 12, as shown in Figure 14. In this case, a light-transmitting region 25 is formed in the surface layer 30. An opening or cutout may be provided in the region of the elastic layer 35 facing the light-transmitting region 25 of the surface layer 30. Figure 14 shows an example in which an opening 38 is provided. By providing an opening 38 in the region of the elastic layer 35 facing the light-transmitting region 25 of the surface layer 30 in this way, the light transmittance of the elastic layer 35 can be increased, and the light-emitting function of the surface layer 30 can be ensured even if the surface material 20 has a two-layer structure. This opening may be larger or smaller than in the above example.

[0027] The following describes some common modifications to each embodiment. The recess is not limited to a hemispherical shape and can be modified as appropriate. The recess may also be cylindrical, truncated cone, or prism-shaped. The recess provided on the base material can also be modified in the same way. The armrest itself can also be modified as appropriate. For example, the position and shape of the display operation unit may differ from those in the above embodiment. There may be multiple display operation units, each equipped with one or more of the above embodiments. Any of the above embodiments may be provided in locations other than the display operation unit. The housing recess for the light source is not limited to a circular shape in plan view and can be modified as appropriate to match the shape and size of the area to be illuminated. For example, the housing recess can be made rectangular or oval in plan view, or it can be formed in a linear (groove-like) shape to arrange multiple light sources. This disclosure is not limited to seat components (center console, armrest, etc.) but can also be applied to other automotive interior parts such as instrument panels and door panels.

[0028] 1, 1A to 1D... Armrest, 2... Display operation section, 10... Base material, 10a, 24, 25a, 34, 37... Recess, 11... Retaining recess, 12... Light source, 20... Surface material, 21, 31... Surface, 22, 32... Back surface, 23, 33... Textured pattern, 25... Light transmission area, 26... Flat part, 27... Shielding layer, 28... Partition protrusion, 30... Surface layer, 35... Elastic layer, 38... Opening.

Claims

1. An automotive interior part comprising a base material of a predetermined shape and a surface material formed from a resin material and laminated onto the base material, wherein the surface material comprises a first surface on the front side having a textured pattern integrally molded to form a design surface, and a second surface on the base material side, and a plurality of recesses are formed on at least one opposing surface of the base material and the surface material, and the area in which each recess is formed is not adhered to the other opposing surface.

2. The automotive interior part according to claim 1, wherein the base material has a light source, the surface material is translucent, and the recess is formed on the second surface.

3. The automotive interior part according to claim 2, wherein a predetermined light-transmitting region on the second surface has a smaller thickness than other regions.

4. The automotive interior part according to claim 2, wherein the predetermined light-transmitting region on the second surface is a flat portion without the recess.

5. The automotive interior part according to claim 2, wherein a shielding layer that blocks light from the light source is formed in a predetermined non-light-transmitting region outside the predetermined light-transmitting region on the second surface.

6. The automotive interior part according to claim 5, wherein the shielding layer is formed by an in-mold coating.

7. The automotive interior part according to claim 5, wherein a partition projection protruding from the second surface is integrally molded at the boundary between the light-transmitting region and the non-light-transmitting region.

8. The automotive interior part according to claim 2, wherein the recess formed in a predetermined light-transmitting region on the second surface is formed with a larger hole diameter than the recess in other regions.

9. The automotive interior part according to claim 2, wherein the recess formed in a predetermined light-transmitting region on the second surface is formed to be deeper than the recess in other regions.

10. The automotive interior part according to claim 2, wherein the recesses formed in a predetermined light-transmitting region on the second surface are formed with a narrower spacing between them than the recesses in other regions.

11. The automotive interior part according to claim 2, wherein the surface material comprises a translucent surface layer having the first surface and the second surface, and an elastic layer on which the second surface is laminated, and a plurality of second recesses are formed on the surface of the elastic layer facing the substrate, and the region in which each of the second recesses is formed is not adhered to the substrate.

12. The automotive interior part according to claim 11, wherein an opening or cutout is formed in the region of the elastic layer opposite to the light-transmitting region of the surface layer.

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