JP2022108345A - Deck board for vehicle, and method of manufacturing the same - Google Patents

Abstract

To provide a technique capable of improving an appearance of a deck board for vehicle.SOLUTION: A deck board 1 provided in the cabin SP0 of a vehicle comprises a deck board body 20 and a handle member 50. The deck board body 20 has a top surface 21 and a reverse surface 22, and comprises a recessed part 23 having a recess 24, not reaching the reverse surface 22, on the top surface 21. The handle member 50 is fitted to the deck board 20 to hide a part of the recess 24 except an opening 28 allowing a hand HA1 to be put in the recess 24. The deck board 1 has a gap CL1, which is large enough to put the hand HA1 via the opening 28, in the recess 24 between the handle member 50 and deck board body 20.SELECTED DRAWING: Figure 3

Description

TECHNICAL FIELD The present invention relates to a deck board provided in the interior of a vehicle and a manufacturing method thereof.

A deck board that can be tilted and lifted is sometimes placed on the floor of the luggage compartment of the vehicle. Such deck boards are sometimes provided with an operating handle for facilitating the lifting operation by the crew. Patent Literature 1 discloses a deck board in which a base portion, a gripping lever, and an operation handle including a rotating mechanism for the gripping lever are embedded in a through hole of a deck board body. The base portion is a member divided into a front side base portion exposed on the front side of the deck board and a back side base portion exposed on the back side of the deck board. The front-side base portion has a substantially box-like shape that is open upward. The grip lever is rotatable between a housed position housed in the front base portion and a standing position standing substantially perpendicular to the deck board. Therefore, on the front side of the deck board, the front base portion embedded in the through hole of the deck board can be seen behind the grip lever. An occupant can tilt and lift the deck board by displacing the grip lever to the standing position and gripping it.

JP 2014-83986 A

The front base portion of the operating handle, which includes the rotating mechanism of the grip lever, is large and has a complicated shape. Since such a front base portion is behind the grip lever, the appearance is ostentatious.
Incidentally, the above-mentioned problems also exist in various deck boards provided in the interior of the vehicle.

The present invention discloses a technique capable of improving the appearance of a vehicle deck board.

A vehicle deck board of the present invention is a deck board provided in a vehicle interior,
a deck board body having a front surface and a back surface, the deck board body including a recess having a recess in the surface that does not reach the back surface;
a handle member attached to the deck board body to hide a portion of the recess leaving an opening through which a hand can be inserted into the recess;
It has a mode in which a gap is provided between the handle member and the deck board body in the recess so that a hand can be inserted through the opening.

Further, a method for manufacturing a deck board for a vehicle according to the present invention is a method for manufacturing a deck board provided in a vehicle interior,
The deck board comprises a deck board body having a front surface and a back surface and a recess having a recess on the surface that does not reach the back surface, and a handle member,
a first molding step of press-molding a general portion around the recessed portion in the laminated material in which the skin material disposed on the surface is superimposed on the main body layer;
a second forming step of forming the deck board body having the skin material on the surface including the recess by press-forming the portion of the laminated material surrounded by the press-formed general portion;
A part of the recess is hidden by leaving an opening through which a hand can be inserted into the recess, and a hand can be inserted through the opening between the handle member and the deck board body within the recess. attaching the handle member to the deck board body such that a possible clearance is formed.

ADVANTAGE OF THE INVENTION According to this invention, the technique which can improve the appearance of the deck board for vehicles can be provided.

The figure which shows typically the example of a motor vehicle provided with a deck board. The top view which shows the example of a deck board typically. FIG. 3 is a cross-sectional view of a main part schematically showing an example of a cross-section of the deck board at position A1 in FIG. 2 ; Sectional drawing which shows typically the example of the cross section of the deck board in the position of A2 of FIG. The perspective view which shows typically the example of the recessed part of a deck board main body. The perspective view which shows typically the example by which the handle|steering-wheel member was attached to the recessed part of the deck board main body. The perspective view which shows typically the example by which the support member is arrange|positioned at the back surface of a deck board main body. The perspective view which shows typically the example of the back side of a handle member. The perspective view which shows typically the example of the front side of a support member. The figure which shows typically the example of the shaping|molding method of a deck board main body. Sectional drawing which shows typically the example which attaches a handle member and a support member to a deck board main body.

Embodiments of the present invention will be described below. Of course, the following embodiments are merely illustrative of the present invention, and not all features shown in the embodiments are essential to the solution of the invention.

(1) Overview of technology included in the present invention:
First, an overview of the technology involved in the present invention will be described with reference to the examples shown in FIGS. 1-11. It should be noted that the figures of the present application are diagrams schematically showing examples, and the magnification in each direction shown in these figures may differ, and each figure may not match. Of course, each element of the present technology is not limited to specific examples indicated by reference numerals.
Further, in the present application, the numerical range "Min to Max" means the minimum value Min or more and the maximum value Max or less.

[Aspect 1]
A vehicle deck board 1 according to an aspect of the present technology is a deck board 1 provided in a vehicle interior SP0 and includes a deck board body 20 and a handle member 50, as illustrated in FIG. 3 and the like. The deck board body 20 has a front surface 21 and a back surface 22 and includes a recess 23 having a recess 24 in the front surface 21 that does not reach the back surface 22 . The handle member 50 is attached to the deck board body 20 so as to partially hide the recess 24, leaving an opening 28 into which the hand HA1 can be inserted. The deck board 1 has a clearance CL1 between the handle member 50 and the deck board main body 20 in the recess 24 so that the hand HA1 can be inserted through the opening 28 .

The occupant grips the handle member 50 by inserting the hand HA1 into the gap CL1 between the handle member 50 and the deck board body 20 in the recess 24 from the opening 28 of the recess 24 on the surface of the deck board 1. can lift. In Aspect 1 above, the recessed portion 23 of the deck board body 20 can be seen behind the handle member 50 . Therefore, Aspect 1 can provide a vehicle deck board with an improved appearance.

Here, the deck board can be provided in various places in the interior of the vehicle. may be placed.
In addition, the additional remark mentioned above is applied also to the following aspects.

[Aspect 2]
The deck board body 20 may have a skin material 45 on the surface 21 including the recesses 24 . When the occupant puts his/her hand HA1 into the clearance CL1 between the handle member 50 and the deck board body 20, the hand HA1 touches the skin material 45. - 特許庁Therefore, this aspect can improve the feel of the deck board. Moreover, if the recess 24 of the deck board body 20 has the skin material 45, the appearance of the deck board is further improved.

[Aspect 3]
The recess 24 in the surface 21 may include an unexposed surface 25 hidden by the handle member 50 and an exposed surface 26 not hidden by the handle member 50 . The exposed surface 26 may include an inclined surface 27 in which the recess 24 becomes deeper as it approaches the non-exposed surface 25 . When the occupant puts the hand HA1 into the recess 24, the hand HA1 is guided by the inclined surface 27 to the operating position between the handle member 50 and the deck board body 20. - 特許庁Therefore, this aspect can improve the operability of the deck board. Further, since the hand HA1 in the recess 24 touches the inclined surface 27 of the exposed surface 26, the feel of the deck board is further improved.

[Aspect 4]
The deck board 1 may further include a support member 70 arranged on the back surface 22 of the recess 23 . The handle member 50 may have a first contact portion (eg, rib 52) that contacts the recess 24. As shown in FIG. The support member 70 may have a second contact portion (eg, a rib 72 , a trailing edge 73 and a pedestal portion 75 ) in contact with the back surface 22 . One of the handle member 50 and the support member 70 (the handle member 50 in FIG. 3) has a protrusion (for example, a boss 55) that protrudes toward the other member (the support member 70 in FIG. 3). may The concave portion 23 may have a through hole 29 that connects from the front surface 21 to the back surface 22 and allows the protrusion (55) to pass therethrough. The projecting portion (55) passing through the through hole 29 may be fixed to the other member with a fastening member (for example, screw SC1). In this mode, the load of the handle member 50 gripped by the occupant is transmitted to the support member 70 via the protrusion (55), and the first contact portion (52) of the handle member 50 and the second contact portion of the support member 70 (72, 73, 75). Therefore, this aspect can distribute the load not only on the surface of the deck board but also on the back surface when the deck board is operated.
Here, “first”, “second”, . This remark also applies to the following aspects.

[Aspect 5]
The deck board body 20 includes a first fiber layer 41 containing fibers F1 and binder B1 and extending along the back surface 22, a second fiber layer 42 containing fibers F2 and binder B2 and extending along the front surface 21, and A core layer 43 partially present between the first fiber layer 41 and the second fiber layer 42 may be included. The deepest portion of the recess 24 (for example, the deepest portion 23a) of the recess 23 may not have the core layer 43, and the first fiber layer 41 and the second fiber layer 42 may be integrated. In this aspect, since the first fiber layer 41 and the second fiber layer 42 are integrated at the deepest portion (23a) of the recess 24 of the recess 23, a required strength can be obtained even if the thickness is thin. Further, since the gap CL1 between the handle member 50 and the deck board main body 20 is increased by the amount corresponding to the absence of the core layer 43, it becomes easier to insert the hand HA1 into the gap CL1. Therefore, this aspect can improve the operability of the deck board.

[Aspect 6]
By the way, a method for manufacturing a deck board 1 according to an aspect of the present technology includes a deck board body 20 including a recess 23 having a front surface 21 and a back surface 22 and a recess 24 that does not reach the back surface 22 on the front surface 21; A method of manufacturing a deck board 1 comprising a handle member 50, which includes the following steps, as illustrated in FIGS.
(A) A first forming step ST1 of press-forming the general portion 121 around the portion to be the recess 23 in the laminated material 120 in which the skin material 45 arranged on the surface 21 is superimposed on the main body layer 140 .
(B) The deck board body 20 having the skin material 45 on the surface 21 including the recess 24 is formed by press-molding the portion of the laminated material 120 surrounded by the press-molded general portion 121. Second forming step ST2 to form.
(C) A part of the recess 24 is hidden by leaving an opening 28 in which the hand HA1 can be inserted into the recess 24, and the handle member 50 and the deck board body 20 are positioned within the recess 24. a mounting step ST3 for mounting the handle member 50 to the deck board body 20 so that a clearance CL1 is formed through which the hand HA1 can be put in through the opening 28;

When the portion that will become the recess 23 is press-molded at the same time as the general portion 121, the press molding die will first contact the skin material 45 that will become the recess 23. Therefore, the press molding of the skin material 45 that will become the recess 23 will The skin material 45 in the general portion 121 is pulled. As a result, wrinkles are likely to occur in the skin material 45 around the recess 23 .
In the sixth aspect, the general portion 121 around the recessed portion 23 of the deck board body 20 in the laminated material 120 in which the skin material 45 is superimposed on the main body layer 140 is press-molded and then surrounded by the general portion 121. By press-molding the portion, the occurrence of wrinkles in the skin material 45 is suppressed. Behind the handle member 50 of the manufactured deck board 1, the recess 23 of the deck board body 20 can be seen. Therefore, the sixth aspect can provide a method for manufacturing a vehicle deck board with an improved appearance.

(2) Specific example of vehicle deck board:
FIG. 1 schematically illustrates an automobile 100 (an example of a vehicle) provided with a vehicle deck board 1 . In FIG. 1, the deck board 1 in the closed posture P1 is indicated by a solid line, and the deck board 1 in the open posture P2 is indicated by a chain double-dashed line. FIG. 2 is a plan view schematically illustrating the appearance of the deck board 1 in the closed posture P1 as viewed from the luggage compartment SP2. FIG. 3 schematically illustrates a cross section of the deck board 1 at position A1 in FIG. FIG. 3 shows the area around the recess 23 in the section of the deck board 1 passing through the screw SC1 (an example of the fastening member). An enlarged view of the first fiber layer 41 and the second fiber layer 42 is shown in the lower part of FIG. FIG. 4 schematically illustrates a cross section of the deck board 1 at position A2 in FIG. Elements visible behind the cross-section have been omitted from FIGS. 3 and 4 for clarity. In the drawings shown in the present application, FRONT, REAR, UP, DOWN, LEFT, and RIGHT indicate front, rear, up, down, left, and right, respectively, when looking forward from the vehicle 100 as a reference. Reference D1 indicates the longitudinal direction of the automobile 100, D2 indicates the vertical direction of the automobile 100, and D3 indicates the vehicle width direction of the automobile 100. As shown in FIG. The front-rear direction D1, the vertical direction D2, and the vehicle width direction D3 are assumed to be orthogonal, but even if they are not orthogonal due to design or the like, they are included in the present technology as long as they intersect. It should be noted that "perpendicular" is not limited to strict 90 degrees, and includes deviations from strict 90 degrees due to errors. Also, the sameness in terms of direction, position, etc. is not limited to strict matching, and includes deviation from strict matching due to an error. Furthermore, the description of the positional relationship of each part is merely an example.

The vehicle 100 shown in FIG. 1 is a road vehicle designed and equipped to be used on roads. Metal body panels, such as those made of steel, surround a vehicle compartment SP1 and a luggage compartment SP2 to form the vehicle body. forming. The vehicle compartment SP1 and the luggage compartment SP2 are collectively referred to as the interior SP0. Further, the automobile 100 shown in FIG. 1 is a wagon-type passenger automobile provided with a plurality of rows of seats (for example, front seats and rear seats 101 (not shown)) with a rear luggage compartment SP2 connected to the passenger compartment SP1. Of course, automobiles to which the present technology can be applied include so-called station wagons, one-box cars, and the like, as well as automobiles such as sedans that have separate passenger compartments and luggage compartments.

The automobile 100 shown in FIG. 1 includes a rear seat 101 in front of the luggage compartment SP2, a ceiling part 102 above the luggage compartment SP2, an openable and closable back door (Tailgate) 103 behind the luggage compartment SP2, and a back door (Tailgate) 103 behind the luggage compartment SP2. It has an underlying floor 110 and side walls (not shown) on the left and right sides of the luggage compartment SP2. The ceiling part 102 has a structure in which a roof trim is attached to a roof panel, which is a vehicle body panel, for example. When the back door 103 is opened, an opening 104 appears in the rear part of the automobile, and when the back door 103 is closed, the opening 104 is closed. Therefore, the user can put luggage into the luggage compartment SP2 through the opening 104 and take the luggage out of the vehicle 100 through the opening 104 while the back door 103 is open. The floor portion 110 has a mounting portion 111 on which the deck board 1 is mounted, and a storage recess 112 and a groove 113 recessed downward from the mounting portion 111 . The storage recess 112 opens upward and surrounds the storage space SP3 in which the luggage is placed except for the upper part. The deck board 1 placed on the placing portion 111 in the closed posture P1 closes the storage space SP3. When the occupant places the deck board 1 in the open posture P2 and inserts the rear end 13a of the deck board 1 into the groove 113, the floor 110 holds the deck board 1 in the open posture P2. Thereby, the user can put luggage in the storage recess 112 and take the luggage out from the storage recess 112 . A spare tire may be stored in the storage recess 112 .

The deck board 1 is provided in the interior SP0 of the automobile 100, and exhibits a function of hiding the floor of the automobile 100, a function as a luggage storage space, and the like. The deck board 1 shown in FIG. 1 is provided in the luggage compartment SP2.

The deck board 1 shown in FIGS. 1 to 4 includes a front board 11 that is the most forward in the deck board 1, a rear board 13 that is the most rear, and a central board 12 that is between the front board 11 and the rear board 13. contains. The front board 11 and the center board 12 are connected to each other via the front hinge part 14 so as to be capable of bending, and can be folded so that their upper surfaces face each other. The center board 12 and the rear board 13 are connected via a rear hinge part 15 so as to be capable of bending, and can be folded so that their lower surfaces face each other. Although the hinge portions 14 and 15 shown in FIGS. 1 to 4 are integral hinges integrally formed with the boards 11 to 13, the hinge portions 14 and 15 may be separate parts attached to the boards 11 to 13. FIG.

As shown in FIG. 3, the deck board 1 includes a deck board body 20, a handle member 50, and a support member 70. As shown in FIG. The deck board body 20 has a recess 23 with a recess 24 on the front surface 21 that does not reach the back surface 22 . Here, when the deck board 1 is in the closed posture P1 as shown in FIG. The handle member 50 is arranged on the rear side of the recess 24 so as to partially hide the recess 24 leaving an opening 28 on the front side through which the hand HA1 can be inserted into the recess 24 . Between the handle member 50 and the deck board body 20 in the recess 24, there is a clearance CL1 into which the hand HA1 can be inserted through the opening 28.例文帳に追加The support member 70 is arranged on the back surface 22 of the recess 23 . The recess 23 of the deck board body 20 is between the body portion 51 of the handle member 50 and the body portion 71 of the support member 70 . In this state, the handle member 50 and the support member 70 are fixed with screws SC1 (an example of a fastening member). Accordingly, the handle member 50 is attached to the deck board body 20 so as to hide a portion of the recess 24 leaving an opening 28 in which the hand HA1 can be placed.

The deck board body 20 includes a skin material 44 , a first fiber layer 41 , a partial core layer 43 , a second fiber layer 42 and a skin material 45 in order from the bottom layer upward. Between adjacent layers in these layers 41 to 45, there may be an intervening layer such as an adhesive or a film, or there may be no intervening layer. It should be noted that contacting two layers and joining two layers include both the existence of an intervening layer and the absence of an intervening layer therebetween. In this specific example, the deck board body 20 including layers 41-45 is integrated by press molding. The partial core layer 43 is bonded with the first fiber layer 41 on the back side and the second fiber layer 42 on the front side. That is, the core layer 43 is in contact with the fiber layers 41 and 42 . The first fibrous layer 41 and the second fibrous layer 42 are joined to each other at portions where the core layer 43 is absent. That is, the fiber layers 41 and 42 are in contact with each other at the portion where the core layer 43 is absent. A skin material 44 is joined to the first fiber layer 41 on the back side. That is, the first fiber layer 41 is in contact with the skin material 44 . A skin material 45 is joined to the second fiber layer 42 on the front side. That is, the second fiber layer 42 is in contact with the skin material 45 . The fiber layers 41 and 42 and the core layer 43 are collectively referred to as the main body layer 40 .

The fiber layers 41 and 42 have air permeability in the vertical direction D2, which is the thickness direction of the deck board body 20. As shown in FIG. In addition, being breathable means that the air permeability is 0.05 cc/cm ² according to the A method (Fragile method) specified in JIS (Japanese Industrial Standards) L1096: 2010 (fabric test method for woven and knitted fabrics). /sec or more (more preferably 1 cc/cm ² /sec or more, still more preferably 3 cc/cm ² /sec or more). The core layer 43 may have air permeability in the thickness direction (vertical direction D2) of the deck board body 20, but may also have no air permeability. The skin materials 44 and 45 may be air-impermeable or air-permeable in the thickness direction (up-down direction D2) of the deck board body 20 .

The core layer 43 partially exists between the first fiber layer 41 and the second fiber layer 42 .
For the core layer 43, a resin structure containing air, a fiber structure containing fibers and a binder, or the like can be used. The aforementioned resin structure includes a resin molded body such as a foamed resin molded body and a resin blow molded body, a combination of a plurality of resin injection molded bodies, and the like. Synthetic resins (including elastomers) such as thermoplastic resins and thermosetting resins can be used as the resin for forming the resin structure. Polyolefin resins such as polypropylene (PP) resin and polyethylene (PE) resin, polystyrene (PS) resins, acrylonitrile-styrene copolymer (AS) resins, acrylonitrile-butadiene-styrene copolymer (ABS) resins, polyurethane resins, resins modified from these resins, combinations thereof, and the like can be used. Additives such as colorants and fillers may be contained in the above-mentioned resin as long as the effects are not impaired. Foamed resin moldings include foamed resin particle molded bodies in which a large number of foamed resin particles are fused together, foamed resin injection molded bodies, and the like. For example, a large number of expandable resin particles are formed by impregnating a bead-shaped or cylindrical thermoplastic resin with a foaming agent and pre-expanded to a predetermined magnification, and the large number of foamed resin particles are placed in a mold having the shape of a core layer. The expandable resin particles can be filled into the mold and the mold is heated to expand and fuse the large number of expandable resin particles. The particle size of the expanded resin particles can be, for example, 0.6 to 3.0 mm. Also, by injecting a resin material into a mold having the shape of the core layer and foaming it with a foaming agent, an injection foam molded article can be obtained. As the foaming agent, a volatile foaming agent that generates hydrocarbons such as butane and pentane, an inorganic foaming agent that generates carbon dioxide such as ammonium carbonate, and the like can be used.

The apparent density of the core layer 43 is preferably 0.02 to 0.25 g/cm ³ in order to make the deck board 1 lightweight and highly rigid. The thickness of the core layer 43 can be, for example, 5-50 mm, more preferably 10-30 mm.

The first fiber layer 41 shown in FIG. 3 contains fibers F1 and binder B1 and is formed in a shape having unevenness along the back surface 22 of the deck board body 20 . The second fiber layer 42 shown in FIG. 3 contains fibers F2 and binder B2, and is formed in a shape having unevenness along the surface 21 of the deck board body 20. As shown in FIG.

For the fibers F1 and F2, inorganic fibers, synthetic resin fibers such as thermoplastic resin fibers, natural fibers such as cellulosic fibers and animal fibers, combinations thereof, and the like can be used. The fibers F1 and F2 may contain an additive such as a coloring agent as long as the effect is not impaired. Inorganic fibers include glass fibers, carbon fibers, and the like. Synthetic resin fibers include polyester fibers such as polyethylene terephthalate (PET) fibers, polyolefin fibers such as polyamide (PA) fibers and polypropylene (PP) fibers, acrylic (PMMA) fibers, and the like. Synthetic resin fibers include elastomeric fibers. Cellulosic fibers include vegetable fibers such as cotton and hemp, synthetic fibers such as rayon, and the like. Vegetable fibers are also natural fibers. Animal fibers include wool, silk, and the like. The fibers F1 and F2 may be of different types.
The cross-sectional shape of the fibers F1 and F2 is not particularly limited, and may be an ellipse including a perfect circle, a triangle, a flat shape, a hollow shape, or the like.

A thermoplastic binder, a thermosetting binder, or the like can be used for the binders B1 and B2. Polyester resin such as PET resin having a low melting point, polyolefin resin such as PP resin and PE resin, and the like can be used as the thermoplastic binder. Thermoplastic binders include elastomers. The binders B1 and B2 may contain additives such as colorants as long as the effects are not impaired. The binders B1 and B2 may be of different types. When the core layer 43 is thermoplastic, the melting points of the binders B1 and B2 are preferably lower than the melting point of the core layer 43 .

The binder for forming the fiber layers 41 and 42 may be a fibrous thermoplastic binder such as thermoplastic resin fibers. In this case, the fibers F1 and F2 are preferably at least one of thermoplastic fibers having a higher melting point than the binders B1 and B2 and fibers containing non-melting components. The thermoplastic fibers having a higher melting point than the binders B1 and B2 include polyester fibers such as PET fibers having a high melting point, PA fibers, and the like. Fibers containing non-melting components include inorganic fibers, cellulosic fibers, natural fibers, and the like.
Also, the binder for forming the fiber layers 41 and 42 may be a binder contained in the fibers themselves. When the fiber has a conjugate structure such as a core-sheath structure or a side-by-side structure, a binder may be present in the portion exposed to the surface of these structures. For example, when the fiber layers 41 and 42 are formed from raw material fibers having a core-sheath structure, the core portions of the raw material fibers become the fibers F1 and F2, and the sheath portions of the raw material fibers become the binders B1 and B2.

The content ratio of the fibers F1 in the first fiber layer 41 can be, for example, 10 to 90% by weight. The content ratio of the binder B1 in the first fiber layer 41 can be, for example, 10 to 90% by weight. The content ratio of the fibers F2 in the second fiber layer 42 can be, for example, 10 to 90% by weight. The content ratio of the binder B2 in the second fiber layer 42 can be, for example, 10 to 90% by weight.

The fibrous base material for forming the fiber layers 41 and 42 may be a nonwoven fabric such as a short fiber nonwoven fabric or a long fiber nonwoven fabric. Short-fiber nonwoven fabrics include chemical-bonded nonwoven fabrics, thermal-bonded nonwoven fabrics, needle-punched nonwoven fabrics, spunlace nonwoven fabrics, and the like. Long fiber nonwovens include spunbond nonwovens, meltblown nonwovens, and the like.

The air permeability in the thickness direction (vertical direction D2) of each of the fiber layers 41 and 42 can be, for example, 1 to 200 cc/cm ² /sec. The thickness of each fiber layer 41, 42 can be, for example, 0.8-2.4 mm, more preferably 1.0-2.2 mm. The basis weight of the fiber layers 41 and 42 can be, for example, 300-2000 g/m ² , more preferably 400-1100 g/m ² .

The skin material 44 shown in FIG. 3 appears on the back surface 22 of the deck board body 20 and is formed in a shape having unevenness. The skin material 45 shown in FIG. 3 appears on the surface 21 of the deck board body 20 and is formed in a shape having unevenness.

As the skin materials 44 and 45, fibrous skin materials such as carpets, woven fabrics, and knitted fabrics can be used. Needle-punched carpet, tufted carpet, etc. can be used for the carpet. A needle-punched carpet is a carpet obtained by needling a non-woven fabric to entangle the fibers to form fluff on the surface. The skin materials 44 and 45 may have a backing layer such as synthetic resin (including elastomer) or rubber. The skin materials 44 and 45 may be of different types.

The basis weight of the skin material 44 appearing on the back surface 22 of the deck board body 20 can be, for example, 30 to 400 g/m ² , more preferably 50 to 300 g/m ² . The basis weight of the skin material 44 appearing on the back surface 22 of the deck board body 20 can be, for example, 50 to 500 g/m ² , more preferably 70 to 400 g/m ² .

The deck board body 20 has a skin material 45 on the surface 21 including the recesses 24 of the recesses 23 . Therefore, the skin material 45 can be seen behind the handle member 50 attached to the deck board body 20, and the appearance of the deck board 1 around the recess 23 is good.

For the handle member 50 and the support member 70, a resin material molded product such as an injection molded product can be used. Various synthetic resins (including elastomers) can be used as the resin material described above, and additives may be added. Thermoplastic resin materials such as thermoplastic resins are preferable from the viewpoint of ease of molding. Polyolefin resins such as PP resins and PE resins, polycarbonate (PC) resins, acrylonitrile styrene acrylate (ASA) resins, ABS resins, AS resins, polyamide resins, combinations thereof, and the like can be used as the thermoplastic resins described above. , fibers and other additives may be included. Inorganic fibers such as glass fibers and carbon fibers, vegetable fibers such as kenaf, combinations thereof, and the like can be used for the above fibers.

The structures of the recess 23 of the deck board body 20, the handle member 50, and the support member 70 will be described below with reference also to FIGS. FIG. 5 schematically illustrates the recess 23 of the deck board body 20 without the handle member 50 attached. FIG. 6 schematically illustrates how the handle member 50 is attached to the recess 23 of the deck board body 20 . FIG. 7 schematically illustrates how the support member 70 is arranged on the back surface 22 of the deck board body 20 . FIG. 8 schematically illustrates the back side of the handle member 50. As shown in FIG. The back side of the handle member 50 is a portion facing the recess 24 of the deck board body 20 . FIG. 9 schematically illustrates the front side of the support member 70 . The front side of the support member 70 is a portion facing the back surface 22 of the deck board body 20 .

As described above, the recess 23 of the deck board body 20 has a recess 24 on the surface 21 that does not reach the back surface 22 . As shown in FIGS. 3, 5 and 6, recess 24 includes a non-exposed surface 25 hidden by handle member 50 and an exposed surface 26 not hidden by handle member 50 . In the vicinity of the boundary between the non-exposed surface 25 and the exposed surface 26, the recess 24 is the deepest portion 23a. Although the deepest portion 23a is shown in the exposed surface 26 in FIG. It may exist, or it may exist on the non-exposed surface 25 . As shown in FIGS. 3 and 4, the bottommost portion 23b of the concave portion 23 is located at a position corresponding to the deepest portion 23a on the back surface 22, and is below the portion of the deck board body 20 where the core layer 43 exists. out. As a result, the clearance CL1 between the handle member 50 and the deck board body 20 is wide, and the hand HA1 can be easily inserted into the clearance CL1. As shown in FIG. 4, the back surface 12b of the central board 12 has a recess to prevent interference with the lowermost portion 23b of the rear board 13 when the boards 12 and 13 are bent.

As shown in FIG. 3 , in a cross section along the front-rear direction D1, the exposed surface 26 has an inclined surface 27 in which the recesses 24 become deeper toward the rear side, that is, the recesses 24 become deeper toward the non-exposed surface 25. It includes an inclined surface 27 that is Since the inclined surface 27 is smooth in the cross section along the front-rear direction D1, the feel of the recess 24 is good, and the back of the handle member 50 looks good. As shown in FIGS. 5 and 6, in the width direction (vehicle width direction D3) of the deck board body 20, the exposed surface 26 is deepest at the center, and becomes deep in a curve from left to right toward the deepest portion. there is Since the exposed surface 26 is smooth in the width direction (D3), the feel of the recesses 24 is good, and the back of the handle member 50 looks good.

As shown in FIG. 3, in a cross section along the front-rear direction D1, the non-exposed surface 25 includes an inclined surface in which the depression 24 becomes deeper toward the front side. Therefore, in this respect as well, the feel of the recesses 24 is good. As shown in FIGS. 3 and 5, the recess 23 has a plurality of through-holes 29 that extend from the surface 21 to the back surface 22 and allow bosses 55 (examples of protrusions) of the handle member 50 to pass therethrough. Each through-hole 29 shown in FIG. 5 is arranged near the left and right in the vicinity of the rear portion of the recess 23 . In the width direction (D3) of the deck board body 20, the non-exposed surface 25 is deepest at the center and becomes deeper in a curve shape from left to right toward the deepest portion except near the through holes 29. As shown in FIG. Since the non-exposed surface 25 is smooth in the width direction (D3), the feel of the recesses 24 is good.

As shown in FIG. 3, the deepest portion 23a of the concave portion 23 where the recess 24 is the deepest has no core layer 43, and the first fiber layer 41 and the second fiber layer 42 are integrated. Since the first fiber layer 41 and the second fiber layer 42 are integrated at the deepest portion 23a of the recess 23, a required strength can be obtained even if the thickness is small. In addition, since the gap CL1 between the handle member 50 and the deck board body 20 increases due to the absence of the core layer 43, it is easy to insert the hand HA1 into the gap CL1.

As described above, the handle member 50 is attached to the deck board body 20 so as to hide a portion of the recess 24 leaving an opening 28 through which the hand HA1 can be placed within the recess 24. As shown in FIG. As shown in FIGS. 3 and 8, the handle member 50 includes a body portion 51 and a plurality of cylindrical bosses 55 projecting from the body portion 51 toward the support member 70 . Thus, handle member 50 is an example of one member and support member 70 is an example of the other member. The body portion 51 has a plurality of ribs 52 (example of first contact portion) on the back side. Some of the ribs 52 are connected to the boss 55 and some are separated from the boss 55 . A part of the plurality of ribs 52 is in contact with the recess 24 of the recess 23 so as to bite into the recess 24 . The rear edge 53 of the body portion 51 bites into the deck board body 20 around the rear edge of the recess 24 . If the trailing edge 53 contacts the recess 24, the trailing edge 53 is also an example of the first contact portion. Each boss 55 has a hollow portion 56 along the direction in which the boss 55 protrudes (vertical direction D2). A factory worker can screw the screw SC1 into the boss 55 by screwing the screw SC1 into the hollow portion 56 .

As described above, the support member 70 is arranged on the back surface 22 of the recess 23 . As shown in FIGS. 3 and 9, the support member 70 includes a body portion 71 and a plurality of pedestals 75 (examples of second contact portions) protruding from the body portion 71 toward the deck board body 20. ing. The body portion 71 has a plurality of ribs 72 (an example of a second contact portion) on the front side. Although the plurality of ribs 72 are connected to the pedestal portion 75 , the body portion 71 may have ribs separated from the pedestal portion 75 . A portion of the multiple ribs 72 is in contact with the back surface 22 of the recess 23 . A trailing edge 73 (an example of a second contact portion) of the body portion 71 bites into the rear surface 22 of the deck board body 20 near the trailing edge of the recess 23 . Each pedestal portion 75 has a screw insertion hole 76 through which the screw SC1 can be passed along the thickness direction (vertical direction D2) of the deck board body 20 . The screw insertion hole 76 has a size that does not allow the head of the screw SC1 to pass therethrough. As shown in FIGS. 8 and 9, there are two combinations of bosses 55 and pedestals 75 .

As illustrated in FIG. 11, an operator inserts the bosses 55 of the handle member 50 into the through holes 29 of the deck board body 20, and inserts the screws SC1 into the hollow portions 56 of the bosses 55. The handle member 50 and the support member 70 can be secured together by threading and then screwing. As a result, both members 50 and 70 are attached to the deck board main body 20 while sandwiching the deck board main body 20 therebetween. In this state, it can be said that both members 50 and 70 sandwiching the deck board main body 20 are fastened together. With the handle member 50 attached to the deck board body 20, as shown in FIG. It has a clearance CL1 that allows In the deck board 1 shown in FIG. 3, the bosses 55 passing through the through holes 29 are fixed to the support member 70 with screws SC1. As a result, the load of the handle member 50 gripped by the passenger is transmitted from the boss 55 to the support member 70, and the first contact portion (52) of the handle member 50 and the second contact portions (72, 73, 72, 73, 70) of the handle member 50 are transferred. 75).

(3) Specific example of manufacturing method for vehicle deck board:
FIG. 10 schematically illustrates a molding method of the deck board body 20. As shown in FIG. 11 schematically illustrates how the handle member 50 and the support member 70 are attached to the deck board body 20. FIG.
The manufacturing method shown in FIGS. 10 and 11 includes a first molding process ST1, a second molding process ST2, and an attachment process ST3.

A press molding machine 200 shown in FIG. It is equipped as The die 214 is a master block in which an insert die 216 that is relatively movable in the thickness direction (vertical direction) of the deck board body 20 is fitted. The insert mold 216 is a partial mold that is used by being fitted into the mother mold, and is a movable type also called a slide mold. The nesting mold 216 has a mold surface shaped to match the recess 24 of the deck board body 20 . Mold 212 and molds 214, 216 can be moved toward and away from each other. The mold 212 may be fixed and the molds 214 and 216 may be movable, the mold 212 may be movable and the mold 214 may be fixed, or both the mold 212 and the molds 214 and 216 may be movable. It may be of a movable type.

The press mold 210 has a perforation structure 220 for forming the through holes 29 shown in FIGS. The perforation structure 220 includes a projecting portion 222 for perforation projecting from the mold surface of the nesting mold 216 toward the lower mold 212 , and a lower mold part 222 at a position corresponding to the projecting portion 222 so as to be separated from the nesting mold 216 . It has a receiving portion 224 recessed from the mold surface of 212 .

The press-molded deck board body 20 is formed according to the following procedure. Here, it is assumed that the binders B1 and B2 of the fiber layers 41 and 42 are thermoplastic, and the core layer 43 is made of a material that has a higher melting point than the binders B1 and B2 or does not melt.

First, a laminated material 120 (see FIG. 10) in which the skin material 44 arranged on the back surface 22, the main body layer 140 to be the main body layer 40, and the skin material 45 arranged on the front surface 21 are laminated in this order is preheated. Preliminary heat treatment is performed. The body layer 140 includes, in order from the bottom layer upwards, a first fiber layer 41, a partial core layer 43, and a second fiber layer . A cavity is present in a portion of the laminate material 120 where the core layer 43 is absent, and the first fiber layer 41 and the second fiber layer 42 are separated from each other in the cavity. In the preheating treatment, the lamination material 120 is heated by a preheating device to a temperature higher than the softening point of the binders B1 and B2, preferably higher than the melting point.
Next, as shown in the upper part of FIG. 10, a lamination material setting process is performed to set the preheated lamination material 120 on the lower mold 212 . Note that the preheating treatment may be performed while the lamination material 120 is set in the mold 212 .

After that, as shown from the upper part to the middle of FIG. 10, in the first forming step ST1, a first forming process is performed to press-form the general portion 121 around the portion to be the concave portion 23 in the laminated material 120 . The press molding machine 200 brings the lower mold 212 and the upper molds 214 and 216 close to each other while retracting the insert mold 216 away from the lower mold 212 to press mold the general part 121 . As a result, in the general portion 121, the skin material 44, the first fiber layer 41, the core layer 43, the second fiber layer 42, and the skin material 45 are combined with binders B1 and B2, an adhesive (not shown), and It is strongly fused to any of the thermoplastic films.
When the part that will become the recessed part 23 is press-molded at the same time as the general part 121, the upper die first contacts the skin material 45 that will become the recessed part 23, so the skin material 45 that will become the recessed part 23 is press-molded to form the general part. The skin material 45 at the portion 121 is pulled. As a result, wrinkles may occur in the skin material 45 around the recess 23 . In particular, among the skin materials 45 in the general portion 121, the skin materials 45 in the vicinity of the four corners 24c (see FIG. 5) of the recesses 24 are likely to be wrinkled. In the first forming step ST1 described above, since the skin material 45 in the portion that will become the recess 23 is not press-molded, the occurrence of wrinkles in the skin material 45 in the general portion 121 is suppressed.

In the second forming step ST2 after the first forming step ST1, as shown from the middle to the lower part of FIG. process. The press molding machine 200 brings the nesting die 216 close to the lower die 212, press-molds the portion surrounded by the press-molded general portion 121, and causes the projections 222 of the perforation structure 220 to pass through the recesses 23. A through hole 29 is formed. As a result, the first fiber layer 41 and the second fiber layer 42 are bonded together by at least one of the binder B1, the adhesive (not shown), and the thermoplastic film (not shown) in the portion of the laminate material 120 where the core layer 43 is absent. Strongly fused. In addition, in the portion of the laminate material 120 that includes the recesses 23, the skin material 44 and the first fiber layer 41 are firmly fused by at least one of the binder B1, the adhesive (not shown), and the thermoplastic film (not shown). to wear Furthermore, in the portion of the laminate material 120 that includes the recesses 23, the skin material 45 and the second fiber layer 42 are firmly fused by at least one of the binder B2, an adhesive (not shown), and a thermoplastic film (not shown). to wear

As described above, the deck board body 20 having the skin material 45 on the surface 21 including the recesses 24 is formed. If the press molding die 210 does not have the perforation structure 220, perforation processing for forming the through holes 29 in the recesses 23 may be performed after the second molding step ST2.

As described above, in the laminate material 120 in which at least the skin material 45 is superimposed on the main body layer 140, after the general portion 121 around the portion to be the recess 23 of the deck board body 20 is press-molded, the portion including the recess 23 is formed. The press molding suppresses wrinkles in the skin material 45 . Therefore, the manufacturing method of this specific example can manufacture a vehicle deck board with an improved appearance.

After forming the deck board main body 20, in the mounting step ST3 shown in FIG. The operator passes the bosses 55 of the handle member 50 through the through-holes 29 of the deck board body 20, and inserts the screws SC1 into the hollow portions 56 of the bosses 55 through the screw-insertion holes 76 of the support member 70, and then screws them. You can do it. As a result, the boss 55 passing through the through hole 29 is fixed to the support member 70 with the screw SC1, the handle member 50 and the support member 70 are fixed to each other, and both members 50 and 70 are attached to the deck board body 20. FIG. As shown in FIG. 3, the handle member 50 attached to the deck board body 20 hides part of the recess 24 leaving an opening 28 through which the hand HA1 can be placed. A clearance CL1 is formed between the handle member 50 and the deck board body 20 in the recess 24 so that the hand HA1 can be inserted through the opening 28 .

(4) Functions and effects of the vehicle deck board according to the specific example:
The occupant grips the handle member 50 by inserting the hand HA1 into the gap CL1 between the handle member 50 and the deck board body 20 in the recess 24 from the opening 28 of the recess 24 on the surface of the deck board, thereby gripping the rear board 13 ( The deck board 1) can be lifted so as to be tilted. In the automobile 100 shown in FIG. 1, when the deck board 1 is in the closed posture P1, the occupant holds the handle member 50 with the hand HA1 and lifts the front side of the rear board 13, thereby bending the deck board 1. When the occupant inserts the rear end 13a of the rear board 13 into the groove 113, the deck board 1 is held on the floor 110 in the open position P2. When the deck board 1 is in the open posture P2, the occupant grips the handle member 50 with the hand HA1 and slightly lifts the rear board 13, whereby the rear end 13a of the rear board 13 is pulled out of the groove 113. When the occupant pulls the rear board 13 rearward from this state to deploy the deck board 1 substantially horizontally, the deck board 1 is placed on the placing portion 111 of the floor portion 110 in the closed posture P1.

Since the occupant's hand HA1 put in the recess 24 to operate the deck board 1 is guided by the inclined surface 27 to the operating position between the handle member 50 and the deck board body 20, the deck board can be operated with good performance. be. Since there is no core layer 43 in the deepest part 23a of the recess 23, the operability of the deck board 1 is also wide in this respect. is good. In addition, since the lowermost portion 23b of the concave portion 23 protrudes below the portion where the core layer 43 exists in the deck board body 20, the clearance CL1 for inserting the hand HA1 is wide, and the deck board 1 is also improved in this respect. Good operability. Furthermore, since the handle member 50 does not have a complicated mechanism, this specific example can reduce the weight of the deck board 1, improve the operability of the deck board 1, and reduce the cost of the deck board 1. - 特許庁

When the occupant grips the handle member 50 with the hand HA1 and lifts the deck board 1, the load of the handle member 50 gripped by the occupant is distributed not only to the surface 21 of the deck board body 20 but also to the back surface 22 via the boss 55. do. The handle member 50 gripped by the hand HA1 is also supported by the rear edge 53 with the boss 55 as a fulcrum. Therefore, the deck board 1 of this specific example has a stable operational feeling.

Since the recessed portion 23 of the deck board body 20 can be seen behind the handle member 50, the appearance of the deck board 1 behind the handle member 50 is good. Since the handle member 50 does not have a complicated mechanism, the deck board 1 does not look ostentatious. In addition, since the skin material 45 is present in the recess 24 of the deck board body 20, the hand HA1 placed in the gap CL1 between the handle member 50 and the deck board body 20 touches the skin material 45, and the deck board 1 is touched. is good. Furthermore, since the hand HA1 in the recess 24 touches the inclined surface 27 of the exposed surface 26, the feel of the deck board is good in this respect as well.

When the front side base member and the back side base member are embedded in a relatively large through-hole of the deck board main body, the embedded front side base member is behind the deck board operating handle instead of the deck board main body. In addition, when the deck board is molded such that a handle member having a recess and a handle as a member separate from the deck board body is embedded in the deck board body, behind the handle is a handle member separate from the deck board body. . In these cases, the look behind the handle is monotonous. Further, the front side base member and the handle member embedded in the deck board body are likely to be misaligned, and are likely to be misaligned in the direction of rotation along the surface of the deck board body, and are likely to rattle. Compared to these cases, the handle member 50 of the deck board 1 of this specific example has less displacement, less deviation in the rotational direction along the surface 21 of the deck board body 20, and less rattling.

(5) Modification:
Various modifications of the present invention are conceivable.
For example, the vehicle deck board to which the present technology can be applied is not limited to the foldable deck board 1 having a plurality of divided boards, and may be a single non-foldable deck board.
The arrangement of the handle member 50 with respect to the recess 24 is not limited to the rear side of the recess 24, but may be the front side of the recess 24, the left side of the recess 24, the right side of the recess 24, or the like. That is, the arrangement of the opening 28 with respect to the recess 24 is not limited to the front side of the recess 24, but may be the rear side of the recess 24, the right side of the recess 24, the left side of the recess 24, or the like. For example, the handle member of a non-collapsible single deck board may be positioned in front of the recess to partially hide the recess, leaving an opening at the rear to allow access to the recess.
The deck board 1 may be separately provided with a lock mechanism for releasably fixing the deck board 1 to another portion of the automobile 100 .

The projecting portion that passes through the through hole 29 of the deck board body 20 is not limited to being provided on the handle member 50 like the boss 55 described above, and may be provided on the support member 70 . In this case, the support member 70 as one member is provided with a projecting portion projecting toward the handle member 50 as the other member.

In addition, when the core layer 43 is present in the deepest portion 23a of the concave portion 23, when the protruding portion of the handle member 50 is welded to the supporting member 70, when the deck board 1 does not have the supporting member 70, etc. The basic effect of improving appearance is obtained.

(6) Knot:
INDUSTRIAL APPLICABILITY As described above, according to the present invention, it is possible to provide techniques and the like capable of improving the appearance of vehicle deck boards in various aspects. Of course, the above-described basic actions and effects can be obtained even with a technique consisting only of the constituent elements of the independent claims.
In addition, a configuration in which each configuration disclosed in the above examples is replaced with each other or the combination thereof is changed, and each configuration disclosed in the known technology and the above example is replaced with each other or the combination thereof is changed. , etc. can also be implemented. The present invention also includes these configurations and the like.

1 ... deck board,
11... front board, 12... center board, 12b... back side, 13... rear board, 13a... rear end,
20... deck board body, 21... front side, 22... back side,
23... recessed part, 23a... deepest part, 23b... lowest part,
24... recess, 25... non-exposed surface, 26... exposed surface, 27... inclined surface,
28... opening, 29... through hole,
40... Main body layer, 41... First fiber layer, 42... Second fiber layer, 43... Core layer,
44, 45 ... Skin material,
50... Handle member, 51... Body part, 52... Rib (example of first contact part), 53... Rear edge,
55...Boss (example of projecting part), 56...Hollow part,
70 ... support member,
71... main body portion, 72... rib (example of second contact portion), 73... trailing edge (example of second contact portion),
75... Pedestal portion (example of second contact portion), 76... Screw insertion hole,
DESCRIPTION OF SYMBOLS 100... Automobile, 101... Rear seat, 102... Ceiling part, 103... Back door, 104... Opening,
DESCRIPTION OF SYMBOLS 110... Floor, 111... Placement part, 112... Storage recessed part, 113... Groove,
120... Laminated material, 121... General part, 140... Main body layer,
200... Press molding machine, 210... Press molding die, 212, 214... Mold, 216... Insertion die,
220... Perforated structure, 222... Convex part, 224... Receiving part,
B1, B2...binders,
CL1... Gap,
D1... front-back direction, D2... up-down direction, D3... vehicle width direction,
F1, F2... fiber,
HA1... hand,
SC1: screw (example of fastening member),
SP0... Interior, SP1... Car room, SP2... Luggage room, SP3... Storage space,
ST1... First forming process, ST2... Second forming process, ST3... Mounting process.

Claims (6)

A deck board provided in the interior of a vehicle,
a deck board body having a front surface and a back surface, the deck board body including a recess having a recess in the surface that does not reach the back surface;
a handle member attached to the deck board body to hide a portion of the recess leaving an opening through which a hand can be inserted into the recess;
The deck board has a gap between the handle member and the deck board main body in the recess so that a hand can be inserted through the opening. 2. The deck board according to claim 1, wherein said deck board body comprises a skin material on said surface including said recess. the recess in the surface includes an unexposed surface hidden by the handle member and an exposed surface not hidden by the handle member;
The deck board according to claim 1 or 2, wherein the exposed surface includes an inclined surface in which the recess becomes deeper as it approaches the non-exposed surface. Further comprising a support member arranged on the back surface of the recess,
The handle member has a first contact portion in contact with the recess,
The support member has a second contact portion in contact with the back surface,
one of the handle member and the support member has a protrusion projecting toward the other member;
The recess has a through hole that connects from the front surface to the back surface and allows the protrusion to pass through,
The deck board according to any one of claims 1 to 3, wherein the protruding portion passing through the through-hole is fixed to the other member with a fastening member. The deck board body includes a first fiber layer along the back surface containing fibers and a binder, a second fiber layer containing fibers and a binder along the front surface, the first fiber layer and the second fiber a core layer partially present between the layers,
The deepest part of the recess according to any one of claims 1 to 4, wherein the core layer is absent and the first fiber layer and the second fiber layer are integrated. deck board. A method for manufacturing a deck board provided in a vehicle interior, comprising:
The deck board comprises a deck board body having a front surface and a back surface and a recess having a recess on the surface that does not reach the back surface, and a handle member,
a first molding step of press-molding a general portion around the recessed portion in the laminated material in which the skin material disposed on the surface is superimposed on the main body layer;
a second forming step of forming the deck board body having the skin material on the surface including the recess by press-forming the portion of the laminated material surrounded by the press-formed general portion;
A part of the recess is hidden by leaving an opening through which a hand can be inserted into the recess, and a hand can be inserted through the opening between the handle member and the deck board body within the recess. attaching the handle member to the deck board body such that a possible gap is formed.

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