JP2023081622A - Vehicle interior component - Google Patents

Abstract

To suppress deterioration of appearance and tactile sensation caused by a storage chamber.SOLUTION: A base material 11 of a vehicle interior component 10 has one side in its own thickness direction as surfaces 14, 17 and the other side as back surfaces 15, 18, and also has an outer surface 26 between the surfaces 14, 17 and the back surfaces 15, 18. A skin layer 31 covers the base material 11 from the front side to form a foam molding space 35 between itself and the base material 11. A foam layer 41 is formed by foaming a foam material in the foam molding space 35. A sealing part 36 is formed by the skin layer 31 contacting a portion of the base material 11 adjacent to the foam molding space 35, and regulates leakage of the foam material from the foam molding space 35. A surface of the portion of the skin layer 31 that covers the foam molding space 35 constitutes a design surface 33. In the base material 11, on an opposite side of the foam molding space 35 across the sealing part 36, a storage chamber 45 is formed to store the foam material that has passed through the sealing part 36.SELECTED DRAWING: Figure 1

Description

TECHNICAL FIELD The present invention relates to a vehicle interior product having a foam layer between a base material and a skin layer.

For example, a vehicle interior part described in Patent Document 1 includes a base material, a skin layer, a foam layer and a sealing portion. The substrate has one surface in its thickness direction as a front surface and the other surface as a back surface. The skin layer forms a foam molding space between itself and the substrate by covering the substrate from the front side. The surface of the skin layer that covers the foam molding space forms a design surface. The foam layer is formed by injecting a foam material into the foam molding space and foaming the foam material. The foam layer imparts a soft feeling to the vehicle interior parts and improves the tactile sensation. The seal portion is formed by bringing the skin layer into contact with a portion of the base material adjacent to the foam molding space, and restricts leakage of the foam material from the foam molding space.

Furthermore, the base material in the vehicle interior product described in Patent Document 1 includes a storage chamber for the foam material. Therefore, the foam material is stored in the storage chamber even after passing through the seal. The foam material is suppressed from leaking to the outside of the vehicle interior trim.

JP 2014-12348 A

However, in the vehicle interior component described in Patent Document 1, the sealing portion and the storage chamber are formed between adjacent foam molding spaces on the back side of the design surface. As a result, the seal portion and the storage chamber create irregularities on the design surface, degrading the appearance of the vehicle interior parts. In addition, the occupant may touch the uneven portion of the design surface of the vehicle interior product. The design surface is not smooth at the uneven portions. Therefore, when the occupant touches the uneven portion, the tactile sensation is lower than that without the uneven portion.

A vehicle interior product that solves the above problems has one surface in its thickness direction as a front surface, the other surface as a back surface, and a base material having an outer surface between the front surface and the back surface. a skin layer that forms a foam molding space between the base material and the base material by covering the base material from the front side; and a foam layer formed by foaming a foam material in the foam molding space, Further, a seal portion is formed by contacting the skin layer with a portion of the base material adjacent to the foam molding space, and the seal portion restricts leakage of the foam material from the foam molding space. In the interior product for a vehicle as described above, the surface of the part of the skin layer that covers the foam molding space constitutes a design surface, and the foam molding space is separated from the base material with the seal portion interposed therebetween. A storage chamber is formed on the opposite side to accommodate the foam material that has passed through the seal.

According to the above configuration, when the vehicle interior component is manufactured, the base material is covered with the skin layer from the front side, so that the foam molding space is formed between the skin layer and the base material. A foam material is injected into this foam molding space. A foam layer is formed in the foam molding space by foaming the injected foam material.

The seal portion is formed by bringing the skin layer into contact with a portion of the base material adjacent to the foam molding space. This sealing portion restricts leakage of the foam material from the foam molding space.
Also, even if the foam material passes through the seal, the foam material is contained in the reservoir. Therefore, leakage of the foam material to the outside of the vehicle interior trim is suppressed.

Here, since the storage chamber is formed in the base material, the vehicle interior parts have not a few irregularities. However, the storage chamber is formed on the base material on the opposite side of the foam molding space with the seal portion interposed therebetween.

On the other hand, the design surface of the vehicle interior part is constituted by the surface of the part of the skin layer that covers the foam molding space.
Therefore, by forming the storage chamber at a location that satisfies the above conditions, the storage chamber is located at a location away from the design surface. Therefore, when an occupant of a vehicle looks at the design surface of the interior part for the vehicle, the uneven portion caused by the formation of the storage chamber is positioned out of the line of sight of the occupant and is invisible or difficult to see by the occupant.

Further, as described above, since the storage chamber is positioned away from the design surface, it is difficult for the occupant to touch the storage chamber. Therefore, the tactile sensation caused by touching the uneven portion is less likely to deteriorate.

In the vehicle interior part, the base material includes a general portion and a terminal portion formed at an edge portion of the general portion and having the outer surface, and the terminal portion is closer to the front side than the general portion. It is preferable that the sealing portion is formed by bringing the skin layer into contact with at least the outer surface of the protrusion of the terminal portion.

According to the above configuration, the general portion and the projections of the terminal portion of the base material are covered from the front side by the skin layer, thereby forming a foam molding space between the general portion and the skin layer. A foam material is injected into this foam molding space. A foam layer is formed in the foam molding space by foaming the injected foam material. During the formation of this foam layer, the protrusions have the function of receiving the flow of the injected foam material.

By bringing the skin layer into contact with at least the protrusion of the end portion, the skin layer contacts a portion of the base material adjacent to the foam molding space, thereby forming a seal portion.
In the vehicle interior part, the storage chamber is configured by a notch that opens at a portion of at least the outer surface of the end portion that is opposite to the foam molding space with the seal portion interposed therebetween. is preferred.

According to the above configuration, the notch is opened in at least the outer side surface of the terminal portion, which is located on the opposite side of the foam molding space with the seal portion interposed therebetween. Therefore, when the foam material passes through the seal portion, the foam material is accommodated in the notch from the opening portion of the terminal portion.

Here, in the terminal portion, the protrusion protrudes to the front side more than the general portion. In the base material, the thickness of the terminal portion is larger than the thickness of the general portion due to the protrusion.
Therefore, it becomes easier to form a seal portion and a notch (storage chamber) in the terminal portion.

In addition, when the base material is formed by a resin molding method such as injection molding, a difference in thickness occurs between the general portion and the terminal portion due to the provision of the terminal portion having the protrusion as described above. The greater the difference in thickness, the greater the degree of shrinkage after molding. A dent (dent) called a "sink mark" is formed in the terminal portion, which is a portion with a large thickness, and there is a risk of impairing the appearance of the vehicle interior trim.

In this regard, the formation of the notch in the terminal portion as described above reduces the substantial thickness of the terminal portion. Therefore, the difference between the thickness of the general portion and the substantial thickness of the terminal portion is reduced, and sink marks are less likely to occur after molding of the terminal portion.

In the vehicle interior part, it is preferable that the notch is open across the outer surface and the back surface of the terminal portion.
As in the above configuration, the notch is located in a region on the back surface side including the back surface in the thickness direction of the base material by opening across the outer surface and the back surface of the terminal portion. Therefore, of the outer surface of the terminal portion, the area on the front side is wider than the notch. Therefore, it is possible to form a seal portion that seals a wide area in the thickness direction of the base material.

In the above-described vehicle interior product, the skin layer is brought into contact with a portion of the outer surface of the terminal portion that is adjacent to the opposite side of the seal portion with the storage chamber interposed therebetween. It is preferable that an auxiliary seal portion is further formed for restricting leakage of the foam material.

According to the above configuration, in the auxiliary seal portion, the skin layer is brought into contact with a portion of the outer surface of the terminal portion that is adjacent to the opposite side of the seal portion with the storage chamber interposed therebetween. In addition to the sealing portion, the auxiliary sealing portion also restricts leakage of the foam material. Therefore, it is possible to further improve the sealing performance of the foam material.

According to the vehicle interior product, it is possible to suppress deterioration in appearance and tactile sensation caused by the storage chamber.

1 is a partial cross-sectional view of a vehicle interior component in one embodiment; FIG. It is a partial cross-sectional perspective view of the base material in the said embodiment. FIG. 4 is a partial cross-sectional view showing a state in the middle of forming a skin layer, a foam layer, and a sealing portion using a mold device in the embodiment; FIG. 4 is a partial cross-sectional view illustrating how a seal portion is formed while a foam material is being injected into the foam molding space of FIG. 3 ; FIG. 5 is a partially enlarged cross-sectional view of a portion A of FIG. 4; FIG. 4 is a partial cross-sectional view showing a state in which the intermediate product of the vehicle interior component is taken out from the mold device in the above embodiment. FIG. 3 is a view corresponding to FIG. 2, and is a partial cross-sectional perspective view of a substrate having a modified reservoir. FIG. 8 is a partially enlarged cross-sectional view for explaining how the expected end portion of the skin material is brought into contact with the outer surface of the end portion of the modified example of FIG. 7 to form the seal portion and the auxiliary seal portion; FIG. 3 is a view corresponding to FIG. 2, and is a partial cross-sectional perspective view of a substrate having a modified reservoir. FIG. 3 is a view corresponding to FIG. 2, and is a partial cross-sectional perspective view of a substrate having a modified reservoir.

An embodiment of a vehicle interior product will be described below with reference to FIGS. 1 to 6. FIG.
The vehicle interior product in this embodiment is an interior product that is required to have a soft tactile sensation when touched by an occupant in the vehicle interior. Vehicle interior parts include, for example, vehicle front interior panels such as an instrument panel and a dashboard, which are arranged in the front part of the vehicle interior. A console side is also included as a vehicle interior accessory.

<General configuration of vehicle interior parts>
As shown in FIG. 1, the vehicle interior component 10 has a three-layer structure in which a base material 11, a skin layer 31 and a foam layer 41 are laminated. Next, each layer will be described.

<Base material 11>
As shown in FIGS. 1 and 2 , the base material 11 is a member that forms the framework of the vehicle interior component 10 . The base material 11 is formed by a resin molding method such as injection molding using a hard resin material such as PP (polypropylene).

The base material 11 has a general portion 12 and a terminal portion 21 . The general portion 12 includes a lateral wall portion 13 arranged in a substantially horizontal state, and a vertical wall portion 16 hanging down from the peripheral edge portion of the lateral wall portion 13 . The lateral wall portion 13 has one (upper) surface in its thickness direction as a surface 14 and the other (lower) surface as a back surface 15 . The vertical wall portion 16 has one surface (left side in FIG. 1) as a front surface 17 and the other surface (right side in FIG. 1) as a back surface 18 in its thickness direction.

The terminal portion 21 is formed at the edge portion of the general portion 12 , more specifically at the lower edge portion of the vertical wall portion 16 . The terminal portion 21 has a protrusion 22 that protrudes forward from the surface 17 of the vertical wall portion 16 .
Here, in order to define each portion of the terminal portion 21 , the same direction as the thickness direction of the vertical wall portion 16 (horizontal direction in FIG. 1) is defined as the thickness direction of the terminal portion 21 . The terminal portion 21 has one surface (left side in FIG. 1) as a front surface 24 and the other surface (right side in FIG. 1) as a back surface 25 in its thickness direction. The surface 24 is located on the front side of the surface 17 by the protrusion 22 . On the other hand, back surface 25 is located on the same plane as back surface 18 .

Terminal portion 21 has an outer surface 26 between front surface 24 and back surface 25 . The outer surface 26 has an inclined surface 27 and a horizontal surface 28 that are adjacent to each other in the thickness direction. The horizontal surface 28 is positioned on the back side of the outer surface 26 and is connected to the back surface 25 . The inclined surface 27 is located on the front side of the horizontal surface 28 in the outer surface 26 and is connected to the surface 24 . The inclined surface 27 is inclined with respect to the horizontal surface 28 so as to become higher as it approaches the surface 24 .

<Skin layer 31>
As shown in FIG. 1 , the skin layer 31 is mainly used for the purpose of improving the texture and tactile sensation of the vehicle interior component 10 . The skin layer 31 is formed in a sheet shape with a uniform thickness from synthetic leather (synthetic leather) made of thermoplastic olefinic elastomer (TPO). The skin layer 31 may be made of polyurethane, vinyl chloride, or the like, other than TPO.

The skin layer 31 has a main portion 32 and an end portion 34 . The main portion 32 forms a foam molding space 35 between itself and the general portion 12 by covering the general portion 12 from the front side. The main portion 32 is positioned away from the surfaces 14 , 17 , 24 of the base material 11 toward the front side. The surface of the main portion 32 constitutes the design surface 33 of the vehicle interior component 10 .

The end portion 34 is connected to the edge portion of the main portion 32 and contacts the outer side surface 26 (inclined surface 27 and horizontal surface 28 ) of the terminal portion 21 . The outer surface 26 with which the end portion 34 contacts corresponds to a portion of the base material 11 adjacent to the foam molding space 35 . A seal portion 36 is formed by the end portion 34 and the inclined surface 27 that are in contact with each other.

<Foam layer 41>
The foam layer 41 is a layer for imparting a soft feeling to the vehicle interior component 10, and is formed by foaming the foam material M1 (see FIG. 4) in the foam molding space 35. As shown in FIG. The foam layer 41 is formed of a urethane resin foam in this embodiment. In this case, the foaming material M1 is a mixture of two main raw materials such as polyol and isocyanate with a catalyst, a foaming agent, a foam stabilizer, and the like.

Further, the vehicle interior component 10 of this embodiment includes a storage chamber 45 .
<Storage Chamber 45>
As shown in FIGS. 1 and 2, the storage chamber 45 is a space (chamber) that can accommodate the foam material M1 even if the foam material M1 passes through the seal portion 36. As shown in FIG. The storage chamber 45 is configured by a cutout 46 formed in the base material 11 . In the present embodiment, the notch 46 is formed in a portion (horizontal surface 28 ) of the outer surface 26 opposite to the foam molding space 35 across the seal portion 36 and adjacent to the outer surface 26 of the back surface 25 . It has an opening that straddles the area. The notch 46 has a rectangular cross-sectional shape.

Here, the direction orthogonal to the thickness direction (vertical direction) of the lateral wall portion 13 and the thickness direction (horizontal direction in FIG. 1) of the vertical wall portion 16 (the direction orthogonal to the paper surface in FIG. 1) is defined as the depth direction. do. The cutouts 46 are formed at a plurality of locations in the terminal portion 21 spaced apart from each other in the depth direction.

Next, the operation of this embodiment configured as described above will be described. In addition, effects caused by the action will also be described.
<(1) Method for Forming Skin Layer 31, Foam Layer 41, and Seal Portion 36>
When carrying out this method, as shown in FIG. 3, a skin material 51 larger than the skin layer 31, a base material 11 (see FIG. 2) separately formed by a resin molding method such as an injection molding method, and a mold A device 60 is used.

The skin material 51 includes a scheduled main portion 52 that is to be shaped (formed) to become the main portion 32 of the skin layer 31 and a scheduled end portion 53 that is to be formed to become the end portion 34 . , and a part to be cut 54 to be cut after the formation of the epidermal layer 31 .

The mold device 60 includes a first mold 61 having a molding recess 62 and a second mold 71 having a base 72 and a molding projection 73 . At least one of the first molding die 61 and the second molding die 71 is provided so as to be vertically movable. Due to this vertical movement, the first molding die 61 and the second molding die 71 approach and separate from each other.

Molded recess 62 has an opening 63 at its lower end and an inner lateral wall 64 at its upper end. The molded recess 62 also has an inner vertical wall surface 65 between the opening 63 and the inner horizontal wall surface 64 . The inner lateral wall surface 64 of the molding recess 62 and the upper portion of the inner vertical wall surface 65 form a shaping surface 66 for shaping the presumed main portion 52 to form the main portion 32 . The lower part of the inner vertical wall surface 65 constitutes an inner surplus surface 67 along which the planned end portion 53 and the planned excision portion 54 are laid.

A plurality of first air suction passages (not shown) are formed in the first molding die 61 , and one end of each first air suction passage is opened at the forming surface 66 . A plurality of air supply passages (not shown) are formed in the first molding die 61 , and one end of each air supply passage is opened at the inner surplus surface 67 .

On the other hand, the molded convex portion 73 protrudes upward from the base portion 72 . The molded protrusion 73 has an outer lateral wall surface 74 at its upper end and an outer vertical wall surface 75 between the base portion 72 and the outer lateral wall surface 74 . The outer lateral wall surface 74 and the upper portion of the outer vertical wall surface 75 constitute an attachment surface 76 on which the substrate 11 is attached. The lower portion of the outer vertical wall surface 75 constitutes an outer surplus surface 77 with which the portion to be excised 54 is in close contact (see FIG. 4).

A plurality of second air suction passages (not shown) are formed in the second molding die 71 , and one end of each of the second air suction passages is opened at the outer surplus surface 77 .
When forming the skin layer 31, the foam layer 41, and the seal portion 36, first, the first mold 61 and the second mold 71 are separated, that is, the mold device 60 is opened.

The base material 11 is put on the adherend surface 76 of the molded protrusion 73 . The back surface 15 of the lateral wall portion 13 is brought into contact with the outer lateral wall surface 74 , and the back surface 18 of the vertical wall portion 16 is brought into contact with the outer vertical wall surface 75 .
A skin material 51 is placed near the molding recess 62 of the first mold 61 . The skin material 51 is heated to 180° C. or higher by a heater (not shown) and softened.

When the heating is finished, the mold device 60 is clamped as shown in FIG. When the molds are clamped, in the process in which the first molding die 61 and the second molding die 71 approach each other, the molding protrusions 73 enter the molding recesses 62 together with the base material 11 .

Air between the presumed main portion 52 and the forming surface 66 is vacuum-sucked through the first air suction passage. Of the skin material 51 , the planned main portion 52 facing the forming surface 66 is deformed (shaped) so as to follow the shape of the forming surface 66 . Thus, the main portion 32 of the skin layer 31 is formed. At this time, the planned end portion 53 and the planned excision portion 54 of the skin material 51 are in a state along the inner surplus surface 67 and separated from the terminal portion 21 and the outer surplus surface 77 .

(1-1) Here, in the present embodiment, the protrusion 22 protrudes further to the front side than the vertical wall portion 16 . Therefore, the foam molding space 35 can be formed by covering the general portion 12 and the projecting portion 22 from the front side with the presumed main portion 52 .

(1-2) In this embodiment, an inner surplus surface 67 is formed in the lower portion of the molding recess 62 and an outer surplus surface 77 is formed in the lower portion of the molding projection 73 . Therefore, between the inner vertical wall surface 65 and the outer vertical wall surface 75 and between the base portion 72 and the terminal portion 21, a deformation space 78 for deforming the planned end portion 53 and the planned excision portion 54 is formed. can do.

Vacuum suction through the first air suction passage is then stopped. At approximately the same timing as this stop timing, as shown in FIGS. 3 to 5, injection of the foam material M1 into the foam molding space 35 is started.

(1-3) As shown in FIG. 4, when the foam material M1 is injected into the foam molding space 35 to some extent, the air in the deformation space 78 is vacuum-sucked as indicated by an arrow B. As shown in FIG. Vacuum suction is performed by sucking the air between the planned end portion 53 and the portion to be cut 54 and the outer surplus surface 77 in the deformation space 78 through the second air suction passage. A suction force acts on the planned end portion 53 and the planned resection portion 54 from the side of the outer surplus surface 77 . Since the skin material 51 is softened by heating as described above, it can be easily deformed. Therefore, the suction force causes the portion to be removed 53 to deform to follow the outer surface 26 and the portion to be removed 54 to follow the shape of the outer surplus surface 77 .

Substantially simultaneously with the vacuum suction, air is blown onto the planned end portion 53 and the planned excision portion 54 as indicated by an arrow C from the opening of the air supply passage in the inner surplus surface 67 . Due to this air, a pressing force acts on the planned end portion 53 and the planned resection portion 54 . Therefore, the expected end portion 53 is deformed so as to follow the outer surface 26 further. In addition, the portion to be excised 54 is deformed so as to follow the outer surplus surface 77 even further.

Vacuum suction and air blowing performed in the deformation space 78 bring the expected end portion 53 into close contact with the inclined surface 27 to form the seal portion 36 . Further, the portion to be excised 54 is brought into close contact with the outer surplus surface 77 .

The foam material M1 injected into the foam-molding space 35 tries to expand to the end portion 21 located at the end of the foam-molding space 35 while undergoing a foaming reaction and a resinification reaction.
(1-4) In the terminal portion 21 , the inner side surface 23 of the protrusion 22 that protrudes forward from the general portion 12 is positioned at the end of the foam molding space 35 . The inner surface 23 is substantially orthogonal to the flow direction of the foam material M1. Therefore, the protrusion 22 can exhibit the function of receiving the flow of the foam material M1.

(1-5) The foam material M1 reaching the terminal portion 21 tries to pass between the base material 11 and the skin layer 31 (skin material 51) below the surface 24 of the terminal portion 21. The foaming material M1 here includes not only the foaming material M1 itself, but also gas generated by foaming the foaming material M1, foamy fluid (unsolidified foam such as viscous urethane), and the like.

In this regard, in the present embodiment in which the seal portion 36 is formed below the surface 24 of the terminal portion 21 , the expected end portion 53 is in close contact with the inclined surface 27 . Therefore, the seal portion 36 restricts the foam material M1 from leaking out through the space between the inclined surface 27 and the expected end portion 53 .

(1-6) In the present embodiment, a notch 46 is opened at a portion of the outer surface 26 opposite to the foam molding space 35 with the seal portion 36 interposed therebetween.
Therefore, even if the foam material M1 passes through the seal portion 36, the foam material M1 can be accommodated in the notch 46 (storage chamber 45) from the opening portion of the outer surface 26 (horizontal surface 28).

Therefore, it is possible to prevent the foam material M1 from leaking out of the vehicle interior component 10 . In addition, it is possible to prevent the foam material M1 from entering and clogging the second air suction passage.

(1-7) In particular, in the present embodiment, the cutouts 46 are formed at a plurality of locations separated from each other in the depth direction.
Therefore, the foam material M1 that has flowed through the seal portion 36 in the thickness direction can be stored in the storage chamber 45 that is closest to the location through which the foam material M1 has passed, among the plurality of storage chambers 45 .

(1-8) In the present embodiment, the seal portion 36 is formed by deforming the expected end portion 53 by vacuum suction and air blowing and bringing it into close contact with the inclined surface 27 .
Therefore, the following various effects are obtained.

<1-8A> Freedom in the shape of the terminal portion 21, in particular, in the shape of the outer surface 26, to which the expected end portion 53 can be brought into close contact, and further in the shape of the sealing portion 36, which can seal the foam material M1. degree can be increased.

In this respect, the present embodiment is superior to the case where the skin material is pressed against the base material by a molding die, a jig, or the like.
<1-8B> In the conventional method of forming a seal portion by pressing a part of the skin material against the base material by clamping the mold device, depending on the shape of the seal portion, the skin material and the mold device may be separated from each other. strongly interferes. This strong interference can create wrinkled seals. In this case, problems such as deterioration in the appearance of the skin layer at the seal portion and unstable sealing performance may occur.

On the other hand, in the present embodiment in which the sealing portion 36 is formed by vacuum suction and air blowing, the skin material 51 and the mold device 60 do not strongly interfere with each other, and the sealing portion 36 is less likely to wrinkle. It is possible to prevent deterioration of the appearance of the seal portion 36 and unstable sealing performance due to wrinkles.

(1-8C) The expected end portion 53 contacts the outer surface 26 more strongly than the case where the expected end portion 53 is deformed by only one of vacuum suction and air blowing to bring it into contact with the outer surface 26. can be made It is possible to form the seal portion 36 with higher sealing performance by enhancing the adhesion of the expected end portion 53 to the inclined surface 27 .

(1-8D) If the foam layer is exposed at the end of the vehicle interior trim, it is necessary to cover and hide the exposed portion with another part.
On the other hand, in the present embodiment, the terminal portion 21 of the base material 11 is positioned at the end portion of the vehicle interior component 10 . A planned end portion 53 of the skin material 51 covers the terminal portion 21 . Therefore, the foam layer 41 is not exposed at the end of the vehicle interior component 10 . It is not necessary to cover and hide the exposed portion with another part.

As for the case where the foam layer is exposed, for example, when a seal portion is formed outside the vehicle interior component in a state of being connected to the vehicle interior component, and after the foam layer is formed, the seal portion is excised. are mentioned. In this case, the foam layer is exposed at the excised portion.

By the way, by hardening the foam material M1 injected into the foam molding space 35, an intermediate product 81 in which the base material 11 and the skin layer 31 are integrated by the soft foam layer 41 is produced as shown in FIG. can get.

Subsequently, the injection of foam material M1, the vacuum suction and the blowing of air are stopped. The mold device 60 is opened and the intermediate product 81 is taken out. When the portion to be removed 54 of the skin material 51 is removed from the intermediate product 81 at, for example, a location D indicated by a dashed line in FIG. 6, the intended vehicle interior component 10 shown in FIG. 1 is obtained.

<(2) Appearance and tactile sensation of the vehicle interior product 10>
As shown in FIG. 1 , formation of the storage chamber 45 in the base material 11 causes the vehicle interior component 10 to have not a little unevenness.

(2-1) However, in the present embodiment, the storage chamber 45 is formed on the opposite side of the foam molding space 35 with the seal portion 36 interposed in the base material 11 (terminal portion 21).
On the other hand, the design surface 33 of the vehicle interior component 10 is configured by the surface of the portion of the skin layer 31 that covers the foam molding space 35 .

Accordingly, the storage chamber 45 is positioned away from the design surface 33 . Therefore, when an occupant looks at the design surface 33 of the interior component 10 for a vehicle, the uneven portion generated due to the formation of the storage chamber 45 is positioned out of the line of sight of the occupant and is invisible or difficult to see by the occupant. .

Further, as described above, since the storage chamber 45 is positioned away from the design surface 33, it is difficult for the occupant to touch the uneven portion. Therefore, the tactile sensation caused by touching the uneven portion is less likely to deteriorate.

As a result, it is possible to suppress deterioration in the appearance and tactile feel of the vehicle interior component 10 due to the provision of the storage chamber 45 .
<(3) About Resin Molding of Base Material 11>
When the base material 11 is formed by a resin molding method such as an injection molding method, a difference in thickness occurs between the general portion 12 and the terminal portion 21 by providing the terminal portion 21 having the projecting portion 22 as described above. . The greater the difference in thickness, the greater the degree of shrinkage after molding. A dent (hollow) called a "sink" is generated in the terminal portion 21, which is a portion with a large thickness, and there is a possibility that the appearance of the vehicle interior component 10 is spoiled.

In this regard, the formation of the notch 46 in the terminal portion 21 as described above reduces the substantial thickness of the terminal portion 21 . The difference between the thickness of the general portion 12 and the substantial thickness of the terminal portion 21 is reduced, and sink marks are less likely to occur after the terminal portion 21 is molded.

<(4) Other Matters>
(4-1) The terminal portion 21 is thicker than the general portion 12 due to the protrusion 22 projecting to the front side from the general portion 12 (vertical wall portion 16).

Therefore, it becomes easier to form the seal portion 36 and the notch 46 (storage chamber 45 ) in the terminal portion 21 .
(4-2) The notch 46 is opened across the outer surface 26 and the back surface 25 of the terminal portion 21, so that the notch 46 extends across the back surface 25 in the thickness direction of the terminal portion 21. located in the region of the back side including A region of the outer surface 26 of the terminal portion 21 on the front side is wider than the notch 46 . Therefore, the seal portion 36 that seals a wide area in the thickness direction of the terminal portion 21 can be formed, and higher sealing performance can be obtained.

(4-3) In the present embodiment, shaping of the skin layer 31, formation of the foam layer 41, and formation of the sealing portion 36 are performed using a small number of molds such as the first mold 61 and the second mold 71. Moreover, it can be done in a short time.

It should be noted that the above-described embodiment can also be implemented as a modified example in which this is changed as follows. The above embodiments and the following modifications can be combined with each other within a technically consistent range.

<Regarding the shape of the vehicle interior component 10>
The shape of the vehicle interior component 10 may be changed to a shape different from that of the above embodiment, provided that it has a three-layer structure in which the base material 11, the skin layer 31 and the foam layer 41 are laminated.

<Regarding the position of the notch 46 (storage chamber 45) in the terminal portion 21>
- As shown in FIGS. 7 to 10, the notch 46 is opened only on the outer side surface 26 out of the back surface 25 and the outer side surface 26 . A portion of the planned end portion 53 is brought into contact with a portion of the outer surface 26 that is adjacent to the opposite side of the seal portion 36 across the storage chamber 45, whereby the auxiliary seal portion 37 (see FIG. 8) ) may be formed.

This auxiliary seal portion 37 can prevent the foam material M1 from leaking from the storage chamber 45 . Since the auxiliary sealing portion 37 restricts the leakage of the foam material M1, the sealing performance of the foam material M1 can be further improved.

<Resin Material Forming Foam Layer 41>
- The foam layer 41 may be made of a foam of a resin different from the urethane resin.

<Regarding the seal portion 36>
- The seal portion 36 may be formed by contacting the outer surface 26 of only the protrusion 22 of the terminal portion 21 with the skin layer 31 . Also, the seal portion 36 may be formed by contacting the skin layer 31 across the protrusion 22 and a portion on the back side thereof.

<Regarding the shape of the notch 46 (storage chamber 45)>
- As shown in FIG.7 and FIG.10, the notch 46 may be formed in groove shape extended in the said depth direction.

According to this modification, it is possible to cope with the case where a large storage chamber 45 is required. Further, the foam material M1 that has passed through the seal portion 36 can be stored in the storage chamber 45 from any position in the depth direction.

- As shown in FIG. 9, the notches 46 may be formed at a plurality of locations spaced apart from each other in the depth direction.
<Regarding the cross-sectional shape of the notch 46 (storage chamber 45)>
- As shown in FIGS. 7 to 10, the cross-sectional shape of the notch 46 (storage chamber 45) may be changed to a shape different from the cross-sectional shape of the above embodiment.

The notch 46 in FIGS. 7 and 8 has a triangular cross-sectional shape, the notch 46 in FIG. 9 has a trapezoidal cross-sectional shape, and the notch 46 in FIG. 10 has a rectangular (rectangular) cross-sectional shape. have.
In the modified example of FIG. 9, the inner surface 46a on the front side of the notch 46 is formed horizontally. 7 and 8, the inner surface 46a on the front side of the notch 46 is inclined so as to become lower as the surface 24 is approached. As the inclination of the inner surface 46a becomes steeper, the cross-sectional shape of the notch 46 becomes smaller. Therefore, it is desirable to set the inclination of the inner surface 46a according to the size of the notch 46 required.

In addition, technical ideas that can be grasped from each of the above embodiments will be described together with their effects.
(A) a substrate comprising a general portion and a terminal portion formed at an edge portion of the general portion;
a skin layer including a main portion that covers the general portion from the front side, and an end portion that forms a seal portion by contacting the outer surface of the terminal portion;
A mold apparatus applied to a vehicle interior part comprising a foam layer formed between the general portion and the main portion, and comprising a first mold having a molding recess and a second molding mold having a molding projection. and a skin material having a scheduled main portion and a scheduled end portion to form the main portion, the foam layer, and the sealing portion, the method comprising:
After the base material is attached to the molding convex portion and the skin material placed in the first molding die is softened by heating, the mold device is clamped to obtain the main portion planned portion and the Forming a foam molding space between the general parts and forming a deformation space adjacent to the foam molding space,
subsequently forming the main portion by deforming the presumed main portion by vacuum suction so as to follow the shape of the molding recess;
While the foam layer is formed by injecting the foam material into the foam molding space, the planned end portion of the deformation space is sucked toward the surplus surface outside the molding projection, and the inside of the molding recess is sucked. Air is blown out from the surplus surface toward the expected end portion to bring the expected end portion into contact with the outer surface of the terminal portion to form the seal portion.

According to the above method, the foam molding space and the deformation space are formed by clamping the mold device. The main part is formed by shaping the main part of the softened skin material by vacuum suction. A foam layer is formed by injecting a foam material into the foam molding space. The planned end portion arranged in the deformation space is attracted to the outer surplus surface side of the forming convex portion. Air is blown out from the inner surplus surface of the molded recess toward the intended end portion. The intended end portion is brought into contact with the outer surface of the terminal portion to form a seal portion.

In this manner, vacuum suction and air blowing are performed in the deformation space, so that the expected end portion is deformed in the deformation space to form a seal portion. Therefore, it is possible to increase the degree of freedom in the shape of the end portion, in particular, the shape of the outer surface with which the expected end portion of the skin material can be brought into close contact, and further the degree of freedom in the shape of the sealing portion.

DESCRIPTION OF SYMBOLS 10... Interior components for vehicles 11... Base material 12... General part 14, 17... Front surface 15, 18... Back surface 21... Terminal part 22... Projection 26... Outer surface 31... Skin layer 33... Design surface 35... Foam molding space 36 ... Seal portion 37 ... Auxiliary seal portion 41 ... Foam layer 45 ... Storage chamber 46 ... Notch M1 ... Foam material

Claims (5)

a substrate having one surface in its thickness direction as a front surface, the other surface as a back surface, and an outer surface between the front surface and the back surface;
a skin layer that forms a foam molding space between itself and the base material by covering the base material from the front side;
a foam layer formed by foaming a foam material in the foam molding space; and a seal portion by contacting a portion of the base material adjacent to the foam molding space with the skin layer. is formed, and leakage of the foam material from the foam molding space is restricted by the seal portion,
In the skin layer, the surface of the part covering the foam molding space constitutes a design surface,
An interior component for a vehicle, wherein a storage chamber for storing the foamed material that has passed through the seal portion is formed in the base material on the opposite side of the foam molding space with the seal portion interposed therebetween. The base material includes a general portion and a terminal portion formed at an edge portion of the general portion and having the outer surface,
The terminal portion has a protrusion projecting to the front side from the general portion,
2. The vehicle interior component according to claim 1, wherein the seal portion is formed by bringing the skin layer into contact with at least the outer surface of the protrusion of the terminal portion. 3. The vehicle according to claim 2, wherein the storage chamber is formed by a notch that opens at a portion of at least the outer surface of the terminal portion that is opposite to the foam molding space with the seal portion interposed therebetween. interior goods. 4. The vehicle interior component according to claim 3, wherein the notch is open across the outer surface and the back surface of the terminal portion. Leakage of the foam material from the storage chamber is prevented by bringing the skin layer into contact with a portion of the outer surface of the terminal portion that is adjacent to the side opposite to the seal portion with the storage chamber interposed therebetween. 5. The vehicle interior part according to any one of claims 2 to 4, further comprising an auxiliary sealing portion for regulation.

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