JP2020097302A - Interior material for vehicle and method for manufacturing interior material for vehicle - Google Patents

Abstract

To further improve design property of an interior material for a vehicle.SOLUTION: An interior material for a vehicle includes: a board body part 21 having a design surface 21A oriented on a side of a vehicle interior; and a stitch pattern 23 provided at the design surface 21A and configuring a pseudo-stitch pattern. The stitch part 23 is constituted of multiple projection parts 24 formed integrally with the board body part 21. An irregularity part 26 of diffusing and reflecting light is formed at a surface 24A of the projection part 24.SELECTED DRAWING: Figure 4

Description

The technology disclosed in the present specification relates to a vehicle interior material and a method for manufacturing a vehicle interior material.

BACKGROUND ART Conventionally, as a vehicle interior material, one having a stitch pattern composed of a sewing thread is known. Further, Patent Document 1 describes a structure in which a plurality of protrusions (protrusions) formed of a resin are arranged in a line to form a pseudo stitch pattern. By forming the pseudo stitch pattern with the plurality of protrusions, it is possible to further improve the productivity as compared with the case where the stitch pattern is formed with the sewing thread.

JP, 2017-213801, A

In Patent Document 1 described above, the interior material main body (base material) that constitutes the design surface of the interior material for vehicle and the stitch member having the protrusions that constitute the pseudo stitch pattern are constituted by different members. It is necessary to assemble the interior material body and the stitch member together. If the interior material main body and the protrusion are integrally formed, the productivity can be further increased. However, if the interior material main body and the protrusion are integrally formed, the interior material main body and the protrusion are made of the same material, so that the textures thereof are the same. When the stitch pattern is formed by the sewing thread, the interior material main body and the sewing thread have different textures. For this reason, if the interior material main body portion and the protrusions have the same texture, the pattern formed by the protrusions is unlikely to look like a stitch pattern, and there is a concern that the design may deteriorate.

The technique disclosed in the present specification has been completed based on the above circumstances, and an object thereof is to further enhance the designability of an interior material for a vehicle.

As a means for solving the above problems, the vehicle interior material disclosed in the present specification is an interior material body portion having a design surface facing the vehicle interior side, and a pseudo stitch pattern provided on the design surface. And a stitch portion that forms a plurality of protrusion portions integrally formed with the interior material main body portion, and the surface of the protrusion portion has an uneven portion that diffuses and reflects light. Is formed.

By forming an uneven portion for diffusing and reflecting light on the surface of the protrusion, it is possible to reduce the gloss of the surface of the protrusion. Thereby, the occupant can visually recognize the stitch portion as a material different from that of the interior material main body portion, and the design can be further enhanced.

A recess is formed in the design surface, the protrusion is provided inside the recess, and the surface of the protrusion is outside the vehicle compartment with respect to the opening edge of the recess in the design surface. It is distributed. If the protrusions and depressions are formed on the surface of the protrusions, dirt easily adheres. In the above configuration, by disposing the surface of the protrusion on the outer side of the vehicle compartment with respect to the opening edge of the recess, it is possible to suppress a situation in which an occupant touches the surface of the protrusion. As a result, it is possible to suppress the situation where dirt adheres to the surface of the protrusion.

Further, the uneven portion may be of nano-order. By having the nano-order fine irregularities, it is possible to more reliably prevent the shape of the irregularities from being visually recognized by an occupant, and it is possible to further enhance the designability.

Further, in order to solve the above problems, a method for manufacturing a vehicle interior material disclosed in the present specification, an interior material main body portion having a design surface facing the vehicle interior side, and provided on the design surface, a pseudo And a stitch portion forming a stitch pattern, wherein the stitch portion is constituted by a plurality of protrusions integrally formed with the interior material main body, A molding step of integrally molding the interior material body portion and the plurality of protrusions with a resin by using the molding die, wherein in the molding step, a molding surface of one of the pair of molding dies is formed. By filling the resin in the recess provided, to form the protrusion according to the shape of the recess, the surface shape of the mold side uneven portion formed on the inner surface of the recess on the surface of the protrusion. By transferring, it is possible to form an uneven portion for diffusing and reflecting light on the surface of the protrusion.

By forming irregularities on the surface of the protrusions, the gloss of the surface of the protrusions can be reduced, and the stitches can be visually recognized as a material different from the interior material main body, which improves the design. It can be higher. Moreover, according to the said structure, since a concavo-convex part can be formed in the surface of a protrusion part using a shaping die, productivity can be made higher.

In addition, the molding step is an injection molding step of integrally molding the interior material body portion and the plurality of protrusions by injecting a resin into a molding space formed between the pair of molding dies. Can be something. By injection molding, it is possible to integrally form the protrusion having the uneven portion and the interior material main body.

ADVANTAGE OF THE INVENTION According to this invention, the designability of the interior material for vehicles can be improved more.

The front view which shows the door trim which concerns on Embodiment 1. An enlarged view showing the vicinity of the stitch portion in FIG. Sectional view showing the injection molding process (corresponding to the view taken along line III-III in FIG. 1) The enlarged view which expands and shows the surface vicinity of a protrusion part in FIG. Schematic diagram showing the plating formation process Sectional drawing which shows the injection molding process which concerns on Embodiment 2. The enlarged view which expands and shows the inner surface vicinity of the recessed part of the shaping|molding die which concerns on Embodiment 3. The figure which expands and shows the surface vicinity of the protrusion part which concerns on Embodiment 3. Sectional drawing which shows the modification of Embodiment 1. Sectional drawing which shows the modification of Embodiment 2.

<Embodiment 1>
A first embodiment of the present invention will be described with reference to FIGS. FIG. 1 is a front view showing a vehicle door trim 10 of the present embodiment. The door trim 10 constitutes a vehicle door by being attached to a door inner panel (not shown) constituting a door panel. As shown in FIG. 1, the door trim 10 includes an upper board 20 (vehicle interior material) and a lower board 12. The upper board 20 and the lower board 12 are plate-shaped members made of, for example, a synthetic resin material such as polypropylene, but the material is not limited thereto. The lower board 12 mainly constitutes a lower portion of the door trim 10. The lower board 12 is provided with an inside handle attachment portion 14 for attaching a speaker grill 13 and an inside handle (not shown).

As shown in FIG. 1, the upper board 20 is a long board member extending in the vehicle front-rear direction. The lower end portion 20A of the upper board 20 has a shape along the upper end portion of the lower board 12. The upper board 20 is attached to the lower board 12 by fastening means such as screws and heat caulking. The upper board 20 is provided on the plate-like board main body 21 (interior material main body) having a design surface 21A facing the vehicle interior side (vehicle interior side) and the design surface 21A, and forms a pseudo stitch pattern. And a stitch portion 23. The "stitch pattern" referred to here means a pattern composed of a sewing thread, and the "pseudo stitch pattern" means a pattern having an appearance such as such a stitch pattern.

As shown in FIG. 2, the stitch portion 23 is composed of a plurality of protrusions 24 formed integrally with the board body portion 21. For example, the plurality of protrusions 24 are arranged linearly along the lower end portion 20A of the board main body 21, and the protrusions 24 are long and long in the direction in which the plurality of protrusions 24 are arranged. As shown in FIG. 3, the protrusion 24 has a shape protruding toward the vehicle interior side. In addition, on the back surface 21B (surface on the outside of the vehicle compartment) of the board body 21, a recess 25 that opens to the outside of the vehicle compartment is formed at a location corresponding to the protrusion 24. As a result, the plate thickness of the upper board 20 is set to be substantially the same in the place where the protrusion 24 is formed and the place where the protrusion 24 is not formed.

As shown in FIG. 4, an uneven portion 26 that diffuses and reflects light is integrally formed on the entire surface 24A of the protrusion 24. The uneven portion 26 has a nano-order. It should be noted that “the uneven portion 26 is of nano-order” means that the height (the difference in height between the adjacent convex portion 26A and the concave portion 26B) X1 of the uneven portion 26 is a value in the range of 1 to 999 nm, and the uneven portion 26. In, the length Y1 between the tips of the adjacent convex portions 26A is a value in the range of 1 to 999 nm.

In this embodiment, a case where the upper board 20 is manufactured by injection molding will be exemplified. Next, the molding apparatus 30 for manufacturing the upper board 20 will be described. As shown in FIG. 3, the molding device 30 includes a pair of molding dies 40 and 50 and an injection device 55. The molding die 40 is, for example, a cavity mold, and the molding die 50 is, for example, a core mold. The surface of the molding die 40 facing the molding die 50 is a molding surface 41 having a shape that follows the design surface 21A of the board body portion 21. The surface of the molding die 50 facing the molding die 40 is a molding surface 51 having a shape that follows the back surface 21</b>B of the board body 21. The molding surface 51 is provided with a convex portion 51A for forming the concave portion 25.

The molding die 40 can be moved toward or away from the molding die 50 by a drive device (not shown) (for example, an electric motor, an air cylinder, a hydraulic cylinder, or the like). As a result, the pair of molding dies 40, 50 can be closed and opened. When the pair of molding dies 40 and 50 are closed, a molding space S1 (cavity) is formed between the pair of molding dies 40 and 50. The injection device 55 is provided in the molding die 50, and the molten resin injected from the injection device 55 is injected into the molding space S1 through the runner 56.

On the molding surface 41 of the molding die 40 (the molding surface of one of the pair of molding dies), a recess 42 for molding the protrusion 24 is formed. The recess 42 has a semicircular shape in cross section, which follows the shape of the protrusion 24. The inner surface 42A of the recess 42 has a shape that follows the surface 24A of the protrusion 24. A plating layer 43 formed by plating is formed on the inner surface 42A of the recess 42 as shown in FIG. The plating layer 43 is a marbling-like plating, and the plating layer 43 forms a fine uneven portion 45 (molding-side uneven portion) formed by plating crystals. The average crystal grain size D1 (average protrusion diameter) of the plating layer 43 is preferably set to a value (nano order) in the range of 1 to 999 nm. That is, it is preferable that the concave-convex portion 45 has a nano-order. When the protrusion 24 is formed by injection molding, the surface shape of the uneven portion 45 is transferred to form the uneven portion 26. In addition, in this embodiment, the length Y1 of the uneven portion 26 is substantially the same as the average crystal grain size D1.

On the molding surface 41, the plating layer 43 is not formed on the portion other than the inner surface 42A of the recess 42. That is, the uneven portion 45 is formed only on the inner surface 42A of the recess 42. FIG. 5 shows a plating forming step of forming the plating layer 43 on the inner surface 42A of the recess 42. In the plating forming step, the mold 40 is dipped in a plating bath 61 (chromium plating bath, Sargent bath) containing chromic acid and sulfuric acid as main components, and connected to a power source 63. Then, the forming die 40 is used as a negative electrode, and the electrode 62 disposed in the plating bath 61 is used as a positive electrode, so that the forming die 40 is electroplated. The molding die 40 is made of, for example, a steel material containing iron as a main component and containing carbon, silicon, manganese, phosphorus, sulfur, etc., but the material of the molding die 40 is not limited to this.

In the plating forming step, a portion of the outer surface of the molding die 40 other than the inner surface 42A of the recess 42 is covered with the insulating coating material 65. In other words, only the inner surface 42A of the recess 42 is exposed. Thereby, in the plating forming step, the chromium ions in the plating bath 61 are reduced and deposited as the plating layer 43 only on the inner surface 42A. The coating material 65 is made of an insulating material that does not melt under the plating conditions, and may be an insulating paint or wax. The coating material 65 is removed from the molding die 40 after the plating forming step is completed. The fineness of the irregularities on the surface of the plating layer 43 can be controlled by the current density and the bath temperature (the temperature of the plating bath 61) in the electroplating conditions. Therefore, by appropriately setting the current density and the bath temperature, the average crystal grain size D1 on the surface of the plating layer 43 can be set to the nano order.

Next, a method of manufacturing the upper board 20 will be described. The method for manufacturing the upper board 20 of the present embodiment includes an injection molding process. In the injection molding process (molding process), as shown in FIG. 3, the pair of molding dies 40 and 50 are used to integrally mold the board main body 21 and the plurality of protrusions 24 with resin. More specifically, in the injection molding process, the molten resin is injected into the molding space S1 formed between the pair of molding dies 40 and 50. As a result, the molding space S1 and thus the recess 42 are filled with the molten resin, and then the molten resin is cooled and solidified, so that the board main body 21 and the protrusion 24 that follows the shape of the recess 42 are molded. When the protrusion 24 is molded, the surface shape of the uneven portion 45 formed on the inner surface 42A of the recess 42 is transferred to the surface 24A of the protrusion 24, as shown in FIG. As a result, the uneven portion 26 that diffuses and reflects light is formed on the surface 24A of the protrusion 24.

It should be noted that the uneven portion 45 is not formed on the portion of the molding surface 41 other than the inner surface 42A. Therefore, the design surface 21A is a smoother surface than the surface 24A of the protrusion 24. Although FIG. 4 shows a sectional view of the uneven portion 26 and the uneven portion 45, the uneven portion 45 is formed by providing a plurality of convex portions and concave portions over the entire inner surface 42A. The uneven portion 26 formed by transferring the shape of the uneven portion 45 is also configured by providing a plurality of convex portions and concave portions over the entire surface 24</b>A of the protruding portion 24.

In addition, the convex portions and the concave portions that form the concave-convex portion 26 (or the concave-convex portion 45) may be arranged in an irregular pattern, or may be arranged in a regular pattern. Further, the uneven portion 26 (or the uneven portion 45) may be formed by a convex portion and a concave portion having different sizes.

Next, the effect of this embodiment will be described. According to the present embodiment, by forming the uneven portion 26 that diffuses and reflects light on the surface 24A of the protrusion 24, the gloss (and brightness) of the surface 24A of the protrusion 24 is designed without the protrusion 24. It can be made lower than other parts of the surface 21A. Thereby, the occupant can visually recognize the stitch portion 23 as if it is made of a material (texture) different from that of the board body portion 21, and the design can be further enhanced.

Further, the uneven portion 26 has a nano order. By having the nano-order fine irregularities 26, it is possible to more reliably prevent the occupant from visually recognizing the shapes of the irregularities 26, and it is possible to further improve the design.

In addition, the method for manufacturing the upper board 20 of the present embodiment includes an injection molding step of integrally molding the board main body portion 21 and the plurality of protrusions 24 with a resin using the pair of molding dies 40 and 50. In the step, resin is filled in the concave portion 42 provided on the molding surface 41 of the molding die 40 to mold the protrusion 24 that follows the shape of the concave portion 42, and at the same time, the uneven portion formed on the inner surface 42A of the concave portion 42. By transferring the surface shape of 45 to the surface 24A of the protrusion 24, the uneven portion 26 that diffuses and reflects light is formed on the surface 24A of the protrusion 24. With this configuration, since the unevenness portion 26 can be formed on the surface 24A of the protrusion 24 by using the molding die 40, the productivity can be further increased.

In the injection molding process, resin is injected into the molding space S1 formed between the pair of molding dies 40 and 50 to integrally mold the board body 21 and the plurality of protrusions 24. By the injection molding, it is possible to integrally form the protrusion 24 having the uneven portion 26 and the board main body 21. In the present embodiment, the design surface 21A is a flat surface (a surface having no uneven portion), but the uneven surface (for example, a texture pattern, not shown) may be formed on the design surface 21A. Of course, in this case, the size of the concave-convex portion 26 may be set so that the gloss of the surface 24A is lower than the gloss of the design surface 21A. That is, it is sufficient that the uneven portion 26 finer than the uneven portion formed on the design surface 21A is formed on the surface 24A.

<Embodiment 2>
Next, a second embodiment of the present invention will be described with reference to FIG. The same parts as those in the above-described embodiment are designated by the same reference numerals, and overlapping description will be omitted. In the upper board 120 of the present embodiment, the recess 127 is formed in the design surface 21A of the board body 21. The recess 127 is opened to the inside of the vehicle compartment, and the protrusion 24 is provided inside the recess 127. As a result, the surface 24A of the protrusion 24 is disposed on the outside of the vehicle compartment (outside of the vehicle compartment, the right side in FIG. 6) with respect to the opening edge 128 of the recess 127 in the design surface 21A (the portion that surrounds the recess 127). There is.

In addition, on the back surface 21</b>B of the board main body 21, a recess 125 that opens to the outside of the vehicle compartment is formed at a location corresponding to the protrusion 24. As a result, the plate thickness of the upper board 120 is set to be substantially the same in the place where the protrusion 24 is formed and the place where the protrusion 24 is not formed. Also in the present embodiment, the upper board 120 is molded by injecting resin into the molding space S2 formed between the pair of molding dies 140 and 150, and the plating layer is formed on the inner surface 42A of the recess 42. 43 is formed. Further, the molding surface 151 of the molding die 150 is formed with a convex portion 151</b>A for forming the concave portion 125.

If the uneven portion 26 is formed on the surface 24A of the protrusion 24, dirt (for example, occupant's sebum or fingerprint dirt) easily adheres. In the present embodiment, by disposing the surface 24A of the protrusion 24 on the outer side of the vehicle compartment than the opening edge 128 of the recess 127, it is possible to prevent the occupant's hand or the like from touching the surface 24A of the protrusion 24. .. As a result, it is possible to suppress the situation where dirt adheres to the surface 24A of the protrusion 24.

<Embodiment 3>
Next, a third embodiment of the present invention will be described with reference to FIGS. The same parts as those in the above-described embodiment are designated by the same reference numerals, and overlapping description will be omitted. In the above embodiment, the method of forming the uneven portion 45 by forming the plating layer 43 on the inner surface 42A of the recess 42 of the molding die 40 has been illustrated. On the other hand, in the present embodiment, the concave-convex portion 245 is formed by performing the etching process on the inner surface 42A of the concave portion 42.

As shown in FIG. 7, in the etching process of performing the etching process on the inner surface 42A, the etching process is performed on the inner surface 42A with the etching mask 270 formed on the inner surface 42A. As a result, the concave portion 245A is formed by removing the portion of the molding die 40 that is not covered by the etching mask 270. As a result, the concave-convex portion 245 can be formed. Note that, as the etching treatment, for example, it is possible to form the fine uneven portion 245 by using plasma etching, which is preferable. The type of etching treatment is not limited to dry etching such as plasma etching, and may be wet etching.

Then, by performing injection molding using the molding die 40 having the concavo-convex portion 245, the shape of the concavo-convex portion 245 is transferred to the surface 24A of the protrusion 24, and the concavo-convex portion 226 is formed on the surface 24A, as shown in FIG. It is formed. In the present embodiment, the height X21 of the uneven portion 226 is set to a value in the range of 1 to 999 nm, and the length Y21 between the tips of the adjacent convex portions in the uneven portion 226 is a value of the range of 1 to 999 nm. It is preferably set.

<Other Embodiments>
The present invention is not limited to the embodiments described by the above description and the drawings, and the following embodiments are also included in the technical scope of the present invention.
(1) In the above embodiment, the method of manufacturing the upper boards 20 and 120 by injection molding has been illustrated, but the method is not limited to this. The upper board may be manufactured by press molding using a pair of press molds. In the press molding, the preboard containing at least a resin is heated to be softened, and the upper board 20 is molded by pressing with a pair of press molding dies. At this time, by transferring the shape of the uneven portion formed on the press mold onto the surface 24A of the protrusion 24, the uneven portion 26 can be formed on the surface 24A.
(2) In the above-described first embodiment, the configuration in which the recess 25 is formed on the back surface 21B of the board body 21 is illustrated, but as shown in FIG. 9, the configuration may be such that the recess 25 is not formed. .. Further, in the second embodiment, the configuration in which the concave portion 125 is formed on the back surface 21B of the board main body portion 21 is illustrated, but as shown in FIG. 10, the concave portion 125 may not be formed.
(3) In the above embodiment, the upper board is illustrated as the vehicle interior material, but the present invention is not limited to this. The vehicle interior material may be a vehicle interior material (instrument panel, luggage trim, package tray, etc.) other than the door trim. The vehicle interior material may be an interior material mounted on a vehicle other than a vehicle.
(4) The shapes of the projecting portion 24 and the uneven portion 26 are not limited to those exemplified in the above embodiment, and can be changed as appropriate.
(5) In the above embodiment, the concave-convex portion 26 has a nano-order, but the concave-convex portion 26 is not limited to this.
(6) In the above embodiment, the plating layer is chromium, but the plating layer is not limited to this. For example, the plating layer may be made of a metal other than chromium (such as nickel or copper). Further, the configuration of the plating bath is not limited to the above. For example, a silicofluoric acid bath containing chromic acid, sulfuric acid, and silicofluoric acid as main components may be used as the plating bath.

20, 120... Upper board (vehicle interior material), 21... Board main body portion (interior material main body portion), 21A... Design surface, 23... Stitch portion, 24... Projection portion, 24A... Projection surface, 26, 226 ... concavo-convex portion, 40, 140... Mold (one of the pair of molds), 41... Molding surface (molding surface of one of the pair of molds), 42... Recess (one mold) Molded surface of mold), 42A... Inner surface of recessed part, 45, 245... Concavo-convex part (concavo-convex part on mold side), 50, 150... Mold, 127... Recessed part formed on design surface, 128... Opening edge of the concave portion on the design surface, S1, S2... Molding space

Claims (5)

An interior material body portion having a design surface facing the vehicle interior side;
A stitch portion provided on the design surface and forming a pseudo stitch pattern;
The stitch portion is composed of a plurality of protrusions formed integrally with the main body of the interior material,
An interior material for a vehicle, wherein an uneven portion for diffusing and reflecting light is formed on a surface of the protrusion. A recess is formed on the design surface,
The protrusion is provided inside the recess,
The interior material for a vehicle according to claim 1, wherein the surface of the projecting portion is arranged on the outer side of the vehicle compartment with respect to an opening edge portion of the recess in the design surface. The interior material for a vehicle according to claim 1 or 2, wherein the uneven portion has a nano-order. An interior material main body portion having a design surface facing the vehicle interior side, and a stitch portion provided on the design surface and forming a pseudo stitch pattern, wherein the stitch portion is integrally formed with the interior material main body portion. A method of manufacturing an interior material for a vehicle, which comprises a plurality of formed protrusions,
A molding step of integrally molding the interior material body and the plurality of protrusions with a resin using a pair of molding dies;
In the molding step, by filling a resin into a concave portion provided on the molding surface of one of the pair of molding dies, the protruding portion that follows the shape of the concave portion is molded, and A method for producing an interior material for a vehicle, comprising forming a concave-convex portion for diffusing and reflecting light on the surface of the protrusion by transferring the surface shape of the mold-side concave-convex portion formed on the inner surface to the surface of the protrusion. The molding step is an injection molding step of integrally molding the interior material body and the plurality of protrusions by injecting a resin into a molding space formed between the pair of molding dies. 4. The method for manufacturing a vehicle interior material according to item 4.

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