JP2912161B2 - Interior member with pocket and method of manufacturing the same - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an interior member with a pocket provided with a storage portion for storing drive supplies and the like, for example, on the back of a front seat of an automobile or below a door trim attached to the inner surface of a door. And a method of manufacturing the same.

[0002]

2. Description of the Related Art A part of a substrate of an automobile interior member includes:
2. Description of the Related Art A method of forming a pocket by attaching a cloth, a net, or the like, and a method of forming a pocket at the same time as manufacturing an interior member thereof have been conventionally known.

However, a method of forming a pocket by partially attaching a cloth, a net or the like to a substrate of an interior member is as follows.
The work of attaching the left and right edges and the lower edge to the substrate of the interior member is troublesome, and it requires skill to finish the joints with good appearance.For example, using a U-shaped decorative edge material, cloth, net, etc. Must be attached to the board of the interior member, which is very troublesome. In addition, since the opening of the pocket formed of the cloth or the net does not have a shape maintaining property, it is difficult to insert a thick article into the pocket with one hand.

[0004] In addition, a method of integrally molding a front plate portion forming a pocket by injection molding or the like at the time of manufacturing a base material for an interior member requires a complicated and expensive molding die, and furthermore, a method of forming a molded pocket. When covering the visible outside surface of the base material with the skin layer material, the front plate portion is in the way, and it is not possible to cover the entire visible outside surface of the base material with one skin layer material. In addition, it was necessary to divide the skin layer material into a plurality of sheets, and to attach each one to each part of the base material. For this reason, the operation of attaching the skin layer has to be very troublesome.

[0005]

SUMMARY OF THE INVENTION An object of the present invention is to provide an interior member with a pocket, which eliminates the above-mentioned conventional disadvantages, and a method of manufacturing the same.

[0006]

According to a first aspect of the present invention, there is provided an interior member with a pocket, comprising a main body having a skin layer adhered to a front surface of a base material layer and a lower portion of a back surface of the main body overlapped with the main body. A back plate portion made of a base material layer, and a lower edge of the back plate portion is integrally connected to the back plate portion via a thin hinge portion, and the thin hinge portion is folded back to the front side of the main body portion at the thin hinge portion. A pocket formed by the plate portion, the upper edge being located above the lower edge of the main body portion, and a front plate portion having a skin layer adhered to the front surface of the base material layer, The skin layer is omitted from the surface of the inner backboard.

A second invention of the present application is directed to a back plate comprising a main body having a skin layer adhered to a front surface of a base material layer, and a base material layer spliced to a lower portion on the back side of the main body. And the lower edge of the back plate portion is integrally connected to the back plate portion via a thin hinge portion, and is folded back to the front side of the main body portion at the thin hinge portion to form a pocket with the back plate portion. ,
The upper edge is located above the lower edge of the main body, and the front plate has a skin layer adhered to the front surface of the base material layer. In the method for manufacturing an interior member with a pocket, in which is omitted, a cavity for molding a body portion base layer of the interior member, a front plate portion connected to an edge of the cavity for molding the body portion base layer via a boundary portion At the edge of the cavity for forming the base material layer, and the cavity for forming the front plate portion base material layer, the cavity for forming the back plate portion base material layer connected through a shallow groove portion forming a thin hinge portion, A predetermined amount of the base layer material in a molten state is placed on each cavity of the lower mold engraved on the forming surface, and the cavity for forming the main body base layer and the front plate base layer are formed. After attaching the skin layer material to the molding surface of the upper mold facing the cavity, It is characterized in that the compression molding.

[0008]

Embodiments of the present invention will be described below in detail with reference to the drawings. 1 and 2 show an example of an interior member with a pocket according to the first invention of the present application. FIG. 1 is a perspective view of the interior member 1 as viewed from the front side, and FIG. FIG. The interior member 1 with a pocket shown here comprises a main body 2, a back plate 3, and a front plate 4, and a pocket 6 is formed by the front plate 4 and the back plate 3. The illustrated interior member 1 with a pocket is configured to be mounted and used in a vehicle cabin as described below.

As shown in FIG. 2, a base end of a hook 91 is fixed to the back side of the main body 2, and a clip seat 92 having a clip locking hole is fixed to the back side of the back plate 3. The hook 91 is locked in a notch formed on the back surface of the front seat of the vehicle (not shown), and the clip protruding from the back surface is also locked in the locking hole of the clip seat 92. . Thus, the interior member 1 with a pocket is attached to the back of the front seat. At this time, the interior member 1 with the pocket is positioned with its front side facing the passenger seated in the rear seat behind the front seat, and the passenger in the rear seat stores travel articles and the like in the pocket 6. Can be. In this manner, the interior member 1 with a pocket is arranged with its front side facing the user, and is used by a user such as a passenger. The hook 91 and the clip seat 92
This constitutes an example of a mounting means for detachably mounting the interior member 1 with a pocket to a mounting portion such as a front seat.

The main body 2 is formed by attaching a skin layer to the front surface of a base layer made of a synthetic resin plate. The back plate 3 is also formed of a substrate layer made of a synthetic resin plate, and the back plate 3 has no or no skin layer attached thereto. Instead, the back plate 3 is substantially composed of only the base material layer.

The upper portion of the back plate portion 3 is overlapped with the lower portion of the back surface side of the main body portion 2. In the example shown, FIG.
As shown in FIG. 2, a plurality of through holes 31 are formed in the upper portion of the back plate portion 3, and a plurality of protrusions 21 provided in the lower portion of the base material layer of the main body portion 2 are inserted into each of the plurality of through holes 31. 2
By locking the spring nut 93 to 1,
The main body 2 and the back plate 3 are overlapped and joined. The back plate portion 3 and the main body portion 2 can be overlapped and joined by other appropriate connecting means.

The front plate portion 4 also has a base layer made of a synthetic resin plate, and a skin layer is adhered to the front surface thereof. At this time, the lower edge of the base material layer of the back plate portion 3 and the lower edge of the base material layer of the front plate portion 4 are integrally connected via a thin hinge portion 5. That is, the front plate portion 4 is integrally connected to the back plate portion 3 via the thin hinge portion 5 at the lower edge of the back plate portion 3, and the front plate portion 4 is located at the thin hinge portion 5. It is folded back to the front side of the main body 2, and the pocket 6
Is formed. The upper edge of the front plate 4 is located higher than the lower edge 22 of the main body 2. The thin hinge portion 5
It is a portion that is thinner than the base material layers of the back plate portion 3 and the front plate portion 4 and is formed so as to be easily bent, so that the front plate portion 4 can be easily folded back to the front side of the main body portion 2. Can be.

As the skin layer to be adhered to the base material layer of the main body 2 and the front plate 4, for example, generally the same or similar cloth as the seat skin can be used. Alternatively, a skin layer formed by integrally laminating a cushion layer made of a resin foam sheet on the skin can be used. The attached state of the base material layers of the main body part 2 and the front plate part 4 and the skin layer thereof will be clarified later in connection with FIGS. 4 to 7.

Further, in this embodiment, the base ends of the connecting bands 94 made of a flexible material such as rubber or cloth are fixed to the left and right upper portions of the front plate portion 4 by an adhesive or the like, respectively. The body 2 is inserted into the mounting hole formed at the tip of the
The upper part of the folded front plate part 4 is connected to the back plate part 3 or the main body part 2 by engaging the protrusion 21 protruded from the front plate part 4 and locking the spring nut 93 to this protrusion 21. The connecting band 94, the mounting hole, the protrusion 21, and the spring nut 93 constitute an example of a holding unit that holds the front plate 4 to the main body 2 or the back plate 3. In place of such a configuration, for example, the left and right side portions 41 of the front plate portion 4 are formed wider than those shown in the drawing to eliminate the gap between the front plate portion 4 and the back plate portion 3. The front plate portion 4 may be held on the main body portion 2 or the back plate portion 3 by engaging the projection 21 with the formed mounting hole and engaging the spring nut 93 with this. In this example, the mounting hole of the front plate 4, the projection 21, and the spring nut 93 constitute holding means for holding the front plate 4 on the main body 2 or the back plate 3.

The interior member 1 with a pocket described above comprises:
Since the main body portion 2, the back plate portion 3 and the front plate portion 4 have a base layer made of a synthetic resin plate having a predetermined rigidity, the shape of the upper opening of the pocket 6 is maintained. Here, a thick article or the like can be easily inserted. Further, the pocket 6 can be formed only by folding back the front plate portion 4 connected to the back plate portion 3 via the thin hinge portion 5 toward the front side, and the lower edge of the front plate portion is stitched to the lower edge of the back plate portion 3. No extra work is required. In addition, since a skin layer for decoration is adhered to the front surfaces of the main body 2 and the front plate 4, the appearance can be luxurious. On the other hand, since the skin layer is not substantially adhered to the base material layer of the back plate portion 3 and the skin layer is omitted on the surface of the back plate portion in the pocket, the interior member with the pocket is not provided. 1 can be reduced. Since the upper edge of the front plate portion 4 is located above the lower edge 22 of the main body portion 2, the back plate portion 3 is hidden by the front plate portion 4 and is not normally seen by a user. Even if the skin layer is not provided in the part 3, the appearance of the interior member 1 with a pocket does not deteriorate.

Next, an example of a method of manufacturing the interior member 1 with a pocket shown in FIGS. 1 and 2, that is, an embodiment of the second invention of the present application will be described. First, a molding die including an upper die 7 and a lower die 8 as shown in FIG. 4 is prepared. The molding surface of the lower die 8 includes a cavity 82 for molding a main body base material layer for forming the base material layer of the main body 2 in the interior member 1 with pockets shown in FIGS. Cavity 84 for forming the front plate base material layer for forming the base material layer of No. 4
In addition, a cavity 83 for forming a back plate base material layer for forming the base material layer of the back plate 3 is carved. The cavity 84 for molding the front plate base material layer is connected to the edge of the cavity 82 for molding the main body base material layer via a boundary 86, and the cavity 83 for forming the back plate base material layer is formed of a front plate part. The edge of the cavity 84 for forming the base material layer is connected via a shallow groove portion 85 for forming the thin hinge portion 5 shown in FIGS. Also, on the molding surface of the lower die 8, a plurality of projections 21 for forming a plurality of projections 21 for overlapping and joining the lower part on the back side of the main body part 2 and the upper part on the front side of the back plate part 3 shown in FIGS. And a projection 88 for forming a plurality of through holes 31 are formed.

Here, each cavity 8 of the lower die 8 described above is used.
As shown in FIG. 5, a predetermined amount of the base material layer 61 in a molten state is placed on the base material layers 2, 83, and 84, and the cavity 82 for forming the body base material layer and the front plate base material layer are formed. After one skin layer material 71 is adhered to a portion of the molding surface of the upper mold 7 that faces the cavity 84, the upper mold 7 and the lower mold 8 are clamped by a compression device (not shown) to form a base material layer. The material 61 is compression molded. Next, after the cooling step is completed, when the mold is opened, a molded product as shown in FIG. 6 is obtained.

A portion indicated by reference numeral 26 of the molded product is a boundary portion corresponding to the boundary portion 86 of the lower die 8, and the base layer material 61 does not exist in this portion. Such a boundary 26
When the skin layer material 71 is cut, the main body portion 2 of the interior member 1 shown in FIGS. 1 and 2 and the front plate portion 4 and the back plate portion 3 integrally connected via the thin hinge portion 5 are obtained. .

Next, the back plate 3 and the front plate 4 are turned upside down, and each projection 21 of the main body 2 is inserted into each through hole 31 (FIG. 3) of the back plate 3 as shown in FIG. A spring nut 93 is fitted to each projection 21, and the front plate 4 is folded back to the front side of the main body 2 at the thin hinge portion 5 as shown in FIG. When the upper right and left sides of the front plate portion 4 are connected to the main body portion 2 or the back plate portion 3, the interior member 1 with a pocket shown in FIGS. 1 and 2 is completed.

As shown in FIG. 8, the main body 2 of the interior member 1 includes a base material layer 61A molded from the base material 61 shown in FIG. 5 and a skin material 71 shown in FIG. And a skin layer 71A attached to the front surface of the base material layer 61A.
And The front plate portion 4 is also made of the base material 6.
1 and a skin layer material 71, and a skin layer 71 adhered to the surface on the front side of the base layer 61B.
B. Similarly, the back plate portion 3 also has a base layer 61C molded from the base layer material 61, and a skin layer portion 71C with the skin layer 71B protruding is adhered to an extremely small portion thereof. The sticking area is only a part, and the back plate portion 3 is substantially composed of only the base material layer 61C. Main unit 2
Also, the skin layer is not substantially adhered to the back surface of the front plate portion 4. Although no skin layer is stuck to the front surface of the back plate portion 3, this portion is hidden by the front plate portion 4,
The appearance of the interior member 1 with a pocket does not deteriorate.

According to the manufacturing method described with reference to FIGS. 4 and 5, the main body 2, the back plate 3, and the front plate 4 can be simultaneously formed by a molding die having an extremely simple structure. Cost can be reduced. In addition, since the cavity 82 for molding the main body base material layer and the cavity 84 for molding the front plate base material layer are continuously arranged in the lower die 8 via the boundary 86, these cavities 82 are formed. , 84, one skin layer material 71 can be adhered to the base layer material 61, and the yield of the skin layer material 71 can be improved.

As shown in FIG. 5, when the base material 61 in a molten state is placed on each of the cavities 82, 83 and 84 of the lower die 8, it is disclosed in, for example, JP-A-62-181111. As described above, it is preferable that the base layer material in the molten state measured on the molding surface of the lower mold is distributed and arranged at a predetermined position by using a distribution device.

When placing the molten base layer material 61 on the forming surface of the lower mold 8, the cavity 82 for forming the main body base layer and the cavity 84 for forming the front plate base layer are formed.
The base material 61 is separated from the boundary 86 so that the base material 61 does not flow into the boundary 86 between
A predetermined amount is placed. In the example of FIG. 5, two pieces of the base layer material 61 are arranged separately from each other. Thereby, since the base material does not exist at the boundary 26 of the molded article shown in FIG. 6, the boundary 26 can be easily separated.

Further, the base layer material 61 is placed in the shallow groove portion 85 for forming the thin hinge portion 5 so that a weld line formed by joining two molten resin masses flowing under pressure during mold clamping is not located. It is desirable to place it on the molding surface. In the example shown in FIG. 5, with the shallow groove portion 85 as the center,
On the left and right sides, the base layer material for the back plate portion 3 and the front plate portion 4 is arranged in a lump. When the weld line is located at the thin hinge part 5, when this part is bent,
Although this easily breaks, the above-described measures can avoid this problem.

The interior member with a pocket according to the present invention can be mounted not only on the back of the front seat of an automobile but also on a door trim and the like, and is also used in passenger compartments of railway cars, aircraft, ships, etc., and in theaters. It is possible.

As the base layer material 61, various kinds of thermoplastic synthetic resins can be used. Since the thin hinge portion 5 is formed of this material, the fatigue strength against the repeated bending load applied to the thin hinge portion 5 is reduced. It is particularly preferable to use a large polyolefin resin.

[0027]

According to the interior member with the pocket according to the first aspect, the pocket can be formed only by folding back the front plate portion continuous with the back plate portion at the hinge portion, and thus the lower edge of the back plate portion and the front plate portion. Can save the trouble of suturing. In addition, a skin layer is stuck on the base material layer of the main body part and the front plate part, so that the outer surface can be luxurious, and conversely, the skin layer is omitted on the surface of the back plate part in the pocket. Therefore, the cost of the interior member with a pocket can be reduced.

The method for manufacturing an interior member with a pocket according to the second aspect is one method for obtaining the interior member with a pocket. The method for manufacturing the interior member with a pocket uses a mold having a very simple structure, and a main body, a back plate, and a mold. Since the front plate portion can be molded at the same time, the production cost of the mold is reduced.

Further, since the cavity for forming the main body base layer and the cavity for forming the front plate base layer are continuously arranged in the lower die of the mold, the cavity is formed by these cavities. One continuous skin layer material can be adhered to the base layer material, thereby improving the yield of expensive skin layer material. In addition, since the skin layer is adhered to a required portion of the base material layer at the same time as the formation of the base material layer, the manufacturing process is simplified and beautifully finished.

[Brief description of the drawings]

FIG. 1 is a perspective view showing a structure on the front side of an interior member with a pocket.

FIG. 2 is a perspective view showing a structure of a back surface side of the interior member with a pocket shown in FIG. 1;

FIG. 3 is a perspective view showing a state before the front plate portion of the interior member with pockets shown in FIG. 1 or 2 is folded into the front side, viewed from the back side.

FIG. 4 is a cross-sectional view illustrating an example of a molding die for manufacturing an interior member with a pocket.

FIG. 5 is a cross-sectional view showing a state in which the mold shown in FIG. 4 is opened, and a base material is disposed on a molding surface.

6 is a cross-sectional view of a molded product that has been compression molded from the state of FIG. 5 and has been taken out of a molding die.

7 is a cross-sectional view when the molded article of FIG. 6 is separated into two parts and then assembled.

8 is a cross-sectional view showing a state where the thin hinge portion is folded back from the state of FIG.

[Explanation of symbols]

 REFERENCE SIGNS LIST 1 interior member with pocket 2 main body 3 back plate 4 front plate 5 thin hinge portion 6 pocket 7 upper die 8 lower die 22 lower edge 61 base layer material 61A base layer 61B base layer 61C base layer 71 skin Layer material 71A Skin layer 71B Skin layer 82 Cavity for molding main body base material layer 83 Cavity for forming back plate base material layer 84 Cavity for forming front plate base material layer 85 Shallow groove portion 86 Boundary portion

──────────────────────────────────────────────────続 き Continuation of the front page (56) References JP-A-4-356241 (JP, A) JP-A-7-32881 (JP, A) JP-A-1-204821 (JP, A) 511 (JP, U) Shokai 55-174017 (JP, U) Shokai 6-85110 (JP, U) Shokai 1-96323 (JP, U) (58) Field surveyed (Int. Cl. ⁶ , DB name) B60R 7/04 B60J 5/00 501 B60J 5/04

Claims (2)

(57) [Claims] 1. A main body having a skin layer adhered to a front surface of a base material layer, a back plate made of a base material layer superposed and joined to a lower portion on the back side of the main body, and The lower edge is integrally connected to the back plate portion via a thin hinge portion, and is folded at the thin hinge portion to the front side of the main body portion to form a pocket with the back plate portion, and the upper edge is below the main body portion. located above the rim, and Ri Do and a front plate portion which skin layer is adhered to the front surface of the substrate layer, on the surface of the back plate portion of the pocket
Pocket interior member skin layer that has been omitted. 2. A skin layer is adhered to a front surface of a base material layer.
Main body, base material overlapped on the lower part on the back side of the main body
Backboard consisting of layers and a thin hinge at the lower edge of the backboard
Through the back plate part and the thin hinge part
By the way, it is folded back to the front side of the main body and
The upper edge is higher than the lower edge of the main body
And a skin layer is adhered to the surface on the front side of the base material layer.
With the front plate that is
How to manufacture interior parts with pockets where the skin layer is omitted
In the method, a cavity for forming a main body base layer of the interior member, a cavity for forming a front plate base material layer connected to an edge of the cavity for forming the main body base layer via a boundary portion, and At the edge of the cavity for forming the plate base material layer, the cavity for forming the back plate base material layer which continues through the shallow groove portion forming the thin hinge portion is formed in each of the lower molds carved on the molding surface. A predetermined amount of the base layer material in a molten state is placed on the cavity, and the molding surface of the upper die facing the cavity for forming the main body base layer and the cavity for forming the front plate base layer. A method for producing an interior member with pockets, comprising: after forming a skin layer material, compressing the base layer material.