WO2019224148A1

WO2019224148A1 - Vehicular interior component and method of producing the same

Info

Publication number: WO2019224148A1
Application number: PCT/EP2019/062956
Authority: WO
Inventors: Masaru Suzuki; Ryo Nakajima; Takahisa OHNISHI
Original assignee: Covestro Deutschland Ag
Priority date: 2018-05-24
Filing date: 2019-05-20
Publication date: 2019-11-28
Also published as: JP2019202669A

Abstract

There is provided a vehicular interior component capable of reducing manufacturing labor and time, and cost and a method of producing the same. Also provided are a light-weight and highly rigid vehicular interior component and a method of producing the same. A lower trim (1) includes a base member (10) at least containing foaming resin (95), and bosses (20, 30) provided on the base member (10). The lower trim (1) is formed by insert molding. The base member (10) includes a plate-shaped substrate body (11) and base segments (50, 60) projecting in one direction from the substrate body (11) by foaming of the foaming resin. The bosses (20, 30) are bonded to projected end surfaces (52, 62) of the base segments (50, 60).

Description

VEHICULAR INTERIOR COMPONENT AND METHOD OF PRODUCING THE SAME

TECHNICAL FIELD

[0001] The present invention relates to a vehicular interior component and a method of producing the same.

BACKGROUND ART

[0002] Conventionally, a vehicular interior component and a method of producing the same described in Patent Document 1 have been known. The vehicular interior component and the method of producing the same described in Patent Document 1 discloses that, in the bracket 3, the projection 35 provided on the outer surface of the base plate 31 facing the mounting surface of the trim board 2 is melted and welded with the trim board 2 and solidified integrally. Accordingly, the bracket 3 is firmly fixed on the trim board 2.

RELATED ART DOCUMENT

Patent Document

[0003] [Patent Document 1] Japanese Unexamined Patent Application Publication No. 2007-62301

[0004] Problem to be Solved by the Invention In the configuration disclosed in Patent Document 1 , the bracket, which is a resin member, is bonded to the trim board, which is a base member, by welding with melting. In such a configuration, the resin member necessarily includes a base plate (bonding surface) that is along the surface of the base member. However, in a vehicular interior component, the base member may include a section of various surface shapes such as a plane surface or a curved surface. Therefore, various types of resin members having base plates (adhering surfaces) conforming to the shape of the base member are required to be prepared to dispose the resin members on multiple sections of the base member. This increases labors, time and cost in producing the interior component. On the other hand, the vehicular interior component is demanded to be lightweight and highly rigid.

DISCLOSURE OF THE PRESENT INVENTION

[0005] One objective of the present invention is to provide a vehicular interior component and a method of producing the same that reduce manufacturing labor and cost. Another objective of the present invention is to provide a light-weight and highly rigid vehicular interior component and a method of producing the same. [0006] Means for Solving the Problem

According to the present invention, a vehicular interior component includes a base member containing a foaming agent and a resin member, the base member including a substrate body having a plate shape and a base segment projecting from the substrate body in one direction by foaming of the foaming resin and having a projected end surface and the resin member being bonded to the projected end surface of the base segment.

[0007] According to such a vehicular interior component, the base member has the base segment, and the resin member is bonded to the protruding end surface of the base segment, thus the orientation and position of the resin member is adjusted by the base segment, even if the substrate body has segments such as a planar surface segment and/or a curved surface segment. This eliminates the need for preparing various types of resin members conforming to the shape of the substrate body when resin members are to be formed on the base member by insert molding, thereby allowing the resin members having the same shape to be disposed at a plurality of locations on the base member. Also, the base segment is formed by utilizing the foaming of the foaming resin of the base member. Therefore, the base segment may be formed integrally with the substrate body without requiring another separate process.

[0008] In the configuration as described above, the base member may further contain a fiber and the foaming resin may be foamed. According to such a vehicular interior component, the base member containing a fiber may increase rigidity of the vehicular interior component. Also, in the base member containing a fiber, the foaming resin is foamed and this reduces a weight of the vehicular interior component.

[0009] Also, the present invention is related to a method of producing a vehicular interior component and the method includes applying foaming resin on a mat made of fiber and obtaining a plate member, applying a greater amount of foaming resin to a section of the plate member, and arranging the plate member in a molding die that is heated and pressing the plate member by the molding die to obtain a base member and the greater amount of the foaming resin is foamed and projects from the base member in one direction to form a base segment projecting from the base member such that a resin member inserted in the molding die is bonded to a projected end surface of the base segment, thereby forming the resin member on the base member by insert molding.

[0010] According to such a method of producing a vehicular interior component, in the forming a resin member, at the place on a plate member having the foaming resin locally applied thereto, the foaming resin is foamed by being heated, thus the base segment is formed integrally with the base member. Then, the resin member, which is inserted into a molding die being bonded to the protruding end surface of a base segment, may be fixed to the base segment (the base member). Therefore, even if the plate member is pressed to obtain a substrate body (the base member) having, e.g., a planar surface segment and/or a curved surface segment, the spaces between the substrate body and the resin member can be filled with the base segment, and then bonded together. This allows the orientation and position of the resin member relative to the base member to be adjusted. Therefore, various types of the resin members conforming to the shape of the substrate body are not necessary to be prepared, thereby allowing the resin members having the same shape to be disposed at a plurality of locations on the base member.

[0011 ] Advantageous Effect of the Invention According to the present invention, a vehicular interior component and a method of producing the same that reduce manufacturing labor and cost are provided. Further, a light-weight and highly rigid vehicular interior component and a method of producing the same are provided.

BRIEF DESCRIPTION OF THE DRAWINGS

[0012] FIG 1 is a perspective view of a lower trim according to an embodiment viewed from a vehicular exterior side.

FIG 2 is an enlarged perspective view illustrating a base member disposed on a planar surface section. FIG 3 is an enlarged perspective view illustrating a base member disposed on an inclined surface section.

FIG. 4 is a perspective view illustrating a plate member. FIG. 5 is a cross-sectional view illustrating the plate member that is arranged in a molding die.

FIG. 6 is a cross-sectional view illustrating the plate member that is pressed by the molding die.

FIG. 7 is a cross-sectional view taken along line A-A of FIG. 1 and illustrating the lower trim that is removed from the molding die.

MODES FOR CARRYING OUT THE INVENTION

[0013] <Embodiment> An embodiment of the present invention will be illustrated with reference to FIGS. 1 to 7. In the description, arrows "Fr" and "Rr" correspond to a front side and a rear side, respectively. Arrows "T" and "B" correspond to an upper side and a lower side, respectively. Arrows "In" and“Out” correspond to a vehicular interior side (a front surface side of the lower trim) and a vehicular exterior side (a rear surface side of the lower trim), respectively. [0014] A lower trim (a vehicular interior component) 1 is located in a lower section of a door trim that is attached to a door panel of a vehicle. As illustrated in FIG. 1, the lower trim includes a door pocket installation segment 2 and a speaker grill mounting segment 3. A door pocket through which an object is put in and taken out is disposed in the door pocket installation segment 2. A speaker grill is disposed in the speaker grill mounting segment 3. The door pocket installation segment 2 extends in a vehicular front-rear direction in an upper section from a center of the lower trim 1. The door pocket installation segment 2 is recessed toward the vehicular exterior side. [0015] Also, the lower trim 1 includes a plate-shaped base member 10; and resin members 20,

30, 40 made of resin and provided at a plurality of locations on the base member 10 from the rear surface side. The lower trim 1 is formed by insert molding as will be described below. The resin members are caulking bosses 20, 30, and brackets 40 for receiving clips. The bosses 20 and 30 are members each having the same shape and material, whereas the installation locations thereof on the base member 10 are different from each other.

[0016] The base member 10 is made of a fiber and a foamed resin. Fibers that can be employed include wood fibers obtained by weaving wood fiber, bast plant fibers such as kenaf, inorganic fibers such as glass fibers and carbon fibers, synthetic resin fibers, and the like. Foaming resins are configured to be foamed by being heated to a predetermined temperature or a higher temperature. The foaming resins include, for example, urethane-based foaming resins, epoxy-based foaming resins, and olefin-based foaming resins. Only one of the materials may be used or two or more of the materials may be used. Among these resins, urethane-based foaming resins are preferably used.

[0017] Also, the base member, in a plate-shaped substrate body 11, includes a planar surface segment 12, an inclined surface segment 13, and a curved surface segment 14. The planar surface segment 12 is located under the door pocket installation segment 2 and forms a plane surface. The inclined surface segment 13 is located above the door pocket installation segment 2 and forms an inclined surface that inclines downward as it extends toward a vehicle compartment exterior side. The curved surface segment 14 is the lower end portion located below the planar surface segment 12 and forms a curved surface being curved toward the vehicle compartment exterior side as it extends toward the lower side.

[0018] As shown in FIG. 2, the planar surface segment 12 has a base segment 50 tapered

(having a diameter reduced tip) and protruded from the planar surface segment 12 toward the vehicle compartment exterior side by the foaming of the foaming resin. The base segment 50 includes an edge section 51 that has a round shape projecting from the planar surface segment

12 and forming an edge of the base segment 50 and a projected end surface 52 that is a surface facing the vehicle compartment exterior side at the projected end. The tapered base segment 50 that includes the rounded edge section 51 and therefore a basal section of the base segment 50 is less likely to break, even if a force acts on the base segment 50.

[0019] The vehicle compartment exterior side of the base segment 50 has a boss 20 (indicated by two-dot chain lines) disposed thereon. The boss 20 includes a base plate 21 and a columnar segment 22 that protrudes outward from the base plate 21 toward the vehicle compartment exterior side and forms a columnar shape having a hollow interior. The rear surface of the base plate 21 (a vehicle compartment interior side surface) is bonded to the projected end surface 52 of the base segment 50. It is to be noted that the rear surface of the base plate 21 is an uneven surface having concave and convex shapes, and this increases a bonding surface area of the base plate 21 bonded to the projected end surface 52 of the base segment 50.

[0020] On the other hand, the inclined surface segment 13 includes a base segment 60 formed thereon. The base segment 60 projects from the inclined surface segment 13 toward the vehicle compartment exterior side by the foaming of the foaming resin, as shown in FIG. 3. The basal portion of the base segment 60 is shaped to follow the inclined surface of the inclined surface segment 13. The base segment 60 has an edge section 61 and a projected end surface 62. The edge section 61 has a round shape projecting from the inclined surface segment 13 and forms an edge of the base segment 60. The projected end surface 62 is a surface facing the vehicle compartment exterior side at the projected end of the base segment 60.

[0021] The base segment 60 has a boss 30 on the vehicle compartment exterior side thereof (indicated by two-dot chain lines). The boss 30 has the same configuration as that of the boss 29 (see FIG. 2). That is, the boss 30 has a base plate 31 and a columnar segment 32. The rear surface of the base plate 31 (a vehicle compartment interior side surface: a bonding surface) is bonded to the projected end surface 62 of the base segment 60.

[0022] Here, the projected end surface 62 of the base segment 60 on the inclined surface segment 13 is parallel to the projected end surface 52 of the base segment 50 on the planar surface segment 12 illustrated in FIG. 2. The projected end surfaces 52, 62 face the vehicle compartment exterior side. Therefore, the bosses 20 and 30 provided on the base member 10 are directed or projected in the same direction.

[0023] A device 4 of producing the lower trim 1 will now be described. As shown in FIG. 5, the device 4 includes a molding die 5 that presses a plate member 90, which will be described later, from upper and lower sides and molds the base member shown in FIG. 6. As shown in FIG. 5, the molding die 5 includes an upper die 70 (a first die) and a lower die 80 (a second die). The upper die 70 is disposed on the upper side and presses the plate member 90 from the surface side that is to be the front surface (the vehicle compartment interior side surface) of the base member. The lower die 80 is disposed on the lower side so as to face the upper die 70 and presses the plate member 90 from the surface side that is to be the rear surface (the vehicle compartment exterior side surface) of the base member 10. It should be noted that, the plate member 90, as shown in FIG. 4, is a plate-shaped member obtained by applying a foaming resin 95 to the front and rear surfaces of a mat 91 made of fiber.

[0024] As shown in FIG. 5, the upper die 70 is movable in a vertical direction with respect to the lower die 80 by means of a driving device (e.g., an electric motor, an air cylinder, or a hydraulic cylinder). FIG. 5 shows that the upper die 70 is moved away from the lower die 80 and the molding die 5 is in an open state (opened condition). FIG. 6 shows that the upper die 70 approached the lower die 80 and the plate member 90 is pressed by means of the molding die 5 and the molding die 5 is in a closed state (closed condition).

[0025] As shown in FIG. 5, the upper die 70 and the lower die 80 have respective door pocket installation segment-forming surfaces 71 , 81 for forming the door pocket installation segment

2 (see FIG. 1) on the left side from a middle section. The upper die 70 and the lower die 80 press the plate member 90 with the door pocket installation segment-forming surfaces 71, 81 and form the door pocket installation segment 2. The door pocket installation segment-forming surface 71 of the upper die 70 is a surface of a section of the upper die 70 projecting downwardly and is contacted with and presses the front surface of the plate member 90. Also, the door pocket installation segment-forming surface 81 of the lower die 80 is a surface of a section of the lower die 80 recessed downwardly and is contacted with and presses the rear surface of the plate member 90. The two door pocket installation segment-forming surfaces 71, 81 are opposite each other in the vertical direction.

[0026] Also, the upper die 70 and the lower die 80 have respective planar surface segment-forming surfaces 72, 82 extending in a horizontal direction on the right side from the door pocket installation segment forming surfaces 71 and 81. The upper die 70 and the lower die 80 press the plate member 90 with the planar surface segment-forming surfaces 72, 82 and form the planar surface segment 12 (see FIG. 1). The planar surface segment-forming surface 72 of the upper die 70 extends in the horizontal direction and presses plate member 90 from the front surface side. Also, the planar segment-forming surface 82 of the lower die 80 extends in the horizontal direction and presses the plate member 90 from the rear surface side. The two planar segment-forming surfaces 72, 82 are opposite each other in the vertical direction.

[0027] Further, the upper die 70 and the lower die 80 have inclined surface segment-forming surfaces 73 and 83 on the left side of the door pocket installation segment forming surfaces 71 , 81. The upper die 70 and the lower die 80 press the plate member 90 to form the inclined surface segment 13 (see FIG. 1). The inclined surface segment-forming surface 73 of the upper die 70 is a surface that is contacted with and presses the plate member 90 from the front surface side, and is an inclined surface that is inclined downward as it extends toward the right side. Also, the inclined surface segment-forming surface 83 of the lower die 80 is a surface that is contacted with and presses the plate member 90 from the rear surface side, and is an inclined surface that is inclined downward as it extends toward the right side. The two bevel segment-forming surfaces 73, 83 are opposite each other in the vertical direction.

[0028] The lower die 80 has spaces S l and S2 in the vicinity of the middle sections of the planar surface segment-forming surface 82 and the inclined surface segment-forming surface 83, respectively. The spaces S l and S2 are formed by being recessed downward on the planar surface segment-forming surface 82 and the inclined surface segment-forming surface 83. The space in the vicinity of the middle section of the planar surface segment-forming surface 82 and that of the inclined surface segment-forming surface 83 may be simply referred to as the space Sl and the space S2, respectively, for the sake of convenience.

[0029] The boss 20 and the boss 30 having the same shape and the same material are respectively disposed (inserted in the molding die 5) in the space S l and the space S2. The boss 20 is inserted in the space S l such that that the columnar segment 22 is on the lower side and the base plate 21 is on the upper side. Also, the boss 30 is inserted in the space S2 such that the columnar segment 32 is on the lower side and the base plate 31 is on the upper side. That is, the bosses 20, 30 are inserted in the spaces S l and S2, respectively, so as to face the same direction. The bosses 20, 30 are arranged such that axes thereof are parallel to each other.

[0030] Next, a method of producing the lower trim 1 will be described. It should be noted that, in FIG. 4, the upper side face of the mat 91 is a rear surface and the lower side face is a front surface. Also, in FIG. 5, the upper side face of the mat 91 is the front surface and the lower side face is the rear surface. Broadly speaking, the method of producing the lower trim 1 includes a plate member forming process and a resin member forming process. In the plate member forming step, the mat 91 made of the fiber is coated with the foaming resin 95 to form the plate member 90 as shown in FIG. 4. In the resin member forming process, the bosses 20, 30 are formed on the plate member 90 by insert molding as shown in FIGS. 5 to 7.

[0031] <Plate Member Forming Process>

In a step of forming the plate member, as shown in FIG. 4, the foaming resin 95 (indicated by dots) is applied on the front and rear surfaces of the plate-shaped mat 91 made of fibers (indicated by wave-shaped lines) by a device to form the plate member 90. At this time, a greater amount of the foaming resin 95 is locally applied to sections of the rear surface of the plate member 90 where the bosses 20, 30 are to be formed. Then, the plate member 90 includes connection segments 92, 93 that contain relatively greater amount of the foaming resin 95 as compared with other segments.

[0032] <Resin Member Forming Process>

In a step of forming the resin member, as shown in FIG. 5, the plate member 90 is disposed between the upper die 70 and the lower die 80 of the molding die 5 in the open state. At this time, the plate member 90 is disposed such that the rear surface thereof faces the lower die 80 and the front surface thereof faces the upper die 70 and the connection segments 92, 93 are positioned to face the respective spaces Sl , S2 of the lower die 80.

[0033] When the upper die 70 is moved closer to the lower die 80 while being pressed at a predetermined pressure and heating the molding die 5 to a foaming temperature at which the foaming resin 95 is foamed or a temperature higher than the foaming temperature, the molding die 5 becomes in the closed state in which the base member 10 (the plate member 90) is pressed as shown in FIG. 6. The foaming resin 95 is heated by the molding die 5 and foamed, while a part of the foaming resin 95 is impregnated into the mat 91 made of the fiber.

[0034] As shown in FIGS. 5 and 6, the plate member 90 is pressed by the molding die 5 such that the base member 10 having a shape that follows the molding surfaces of the upper die 70 and the lower die 80 is obtained. The base member 10 has the door pocket installation segment 2 that is molded by the door pocket installation segment-forming surfaces 71 , 81. Also, the substrate body 11 has the planar surface segment 12 that is molded by the planar surface segment-forming surfaces 72 and 82 and the inclined surface segment 13 that is molded by the inclined surface segment-forming surfaces 73 and 83.

[0035] Here, the plate member 90 includes the connection segments 92, 93 that are to be the planar surface segment 12 and the inclined surface segment 13 and are opposed to the respective spaces S l and S2. A greater amount of the foaming resin 95 is locally applied to the connection segments 92, 93. Therefore, if the foaming resin 95 contained in the connection segments 92, 93 is heated by the molding die 5, the foaming resin 95 contained in the connection segments 92, 93 are foamed so as to fill the spaces between the substrate body 11 and the base plates 21 , 31 of the bosses 20, 30, as shown in FIG. 6.

[0036] In this state, the molding die 5 is held for a predetermined time, and then the base member 10 is cooled and solidified. Subsequently, the molding die 5 is opened and the molded member is removed from the molding die 5. Then, as shown in FIG. 7, the base segments 50, 60 protruding from the substrate body 11 (the plate member 90) toward the vehicle compartment exterior side are formed on the planar surface segment 12 and the inclined surface segment 13, respectively. Further, the base plates 21 , 31 of the bosses 20, 30 are bonded to the projected end surfaces 52, 62 of the base segments 50, 60. In this manner, the lower trim 1 is produced.

[0037] Subsequently, the advantageous effects of this embodiment will be described. In this embodiment, the lower trim 1 at least includes the base member 10 made of the foaming resin 95 and the bosses 20, 30 provided on the base member 10 and the lower trim 1 is formed by insert molding. The base member 10 includes the plate-shaped substrate body 11 and the base segments 50, 60 that project from the substrate body 11 in one direction by the foaming of the foaming resin 95. The bosses 20, 30 are bonded to the projected end surfaces 52, 62 of the base segments 50, 60.

[0038] According to such a lower trim 1 , the base member 10 has the base segments 50, 60 and the bosses 20, 30 are bonded to the projected end surfaces 52, 62 of the base segments 50, 60. According to such a configuration, the orientation and the position of the bosses 20, 30 are adjusted, even if the substrate body 11 includes the planar surface segment 12 having a flat surface and the inclined surface segment 13 having an inclined surface. This eliminates need for preparing various types of bosses (resin members) conforming to the shape of the substrate body 11 in forming the bosses 20 and 30 on the base member 10 by insert molding. The resin members having the same shape can be disposed at a plurality of locations on the base member 10. Also, the base segments 50, 60 are formed by the foaming of the foaming resin 95 constituting the base member 10. Therefore, the base segments 50, 60 are formed integrally with the substrate body 11 and another process for providing the base segments 50, 60 is not necessary.

[0039] Also, the base member 10 contains a fiber and the foaming resin 95 is foamed. According to such a lower trim 1 , the base member 10 containing the fiber may increase rigidity of the lower trim 1. In addition, the foaming resin 95 is foamed in the base member 10 containing the fiber and this leads to light weighting of the lower trim 1.

[0040] In this embodiment, the method of producing the lower trim 1 including the base member 10 made of at least a fiber and the foaming resin 95 and the bosses 20, 30 provided on the base member 10. The method includes the plate member forming process and the resin member forming process. In the plate member forming process, the plate member 90 is formed by applying the foaming resin 95 on the mat 91 made of the fiber. In the resin member forming process, the bosses 20, 30 are formed on the plate member 90 by insert molding. In the plate member forming process, the foaming resin 95 is locally applied to sections of the plate member 90 where the bosses 20, 30 are to be formed. In the resin member forming process, the plate member 90 is pressed by the heated molding die 5 to obtain the base member 10. On the sections (the connection segments 92, 93) of the plate member 90 where the foaming resin 95 is locally applied, the foaming resin 95 is foamed by being heated to form the base segments 50, 60 projecting in one direction from the plate member 90. The bosses 20, 30 inserted within the molding die 5 are bonded to the projected end surfaces 52, 62 of the base segments 50, 60.

[0041] According to the method of producing such a lower trim 1 , in the resin member forming process, on the sections (the connection segments 92, 93) of the plate member 90 where the foaming resin 95 is locally applied, the foaming resin 95 is foamed by being heated so that the base segments 50, 60 are integrally formed with the substrate body 11. Further, the bosses 20, 30 that have been inserted into the molding die 5 are bonded to the projected end surfaces 52, 62 of the base segments 50, 60. Thus, the bosses 20, 30 may be fixed to the base segments 50, 60 (the base member 10). Therefore, even if the plate member 90 is pressed and the obtained substrate body 11 (base member 10) includes e.g., the planar surface segment 12 having a flat surface and the inclined surface segment 13 having an inclined surface, the spaces between the substrate body 11 and the bosses 20, 30 may be filled with the base segments 50, 60 and then bonded together. Whereby, the orientation and the position of the bosses 20, 30 relative to the base member 10 may be adjusted. This eliminates the need for preparing various types of bosses (resin members) conforming to the shape of the substrate body 11 , thereby providing the resin members having the same shape at a plurality of locations on the base member 10.

[0042] <Other Embodiments>

The present invention is not limited to the embodiments illustrated by way of the description and drawings above, the following examples, for instance, are also included in the technical scope of the present invention; furthermore, various modifications besides the following may be made within the scope without departing from the subject matter.

[0043] (1) Other than the embodiment mentioned above, a section where the base segment is formed may be changed as appropriate. In the embodiment mentioned above, the base segments are formed on the planar surface segment and the inclined surface segment on the rear surface side of the substrate body, but is not limited thereto. For example, a base segment may be formed on the curved surface segment. Also, a base segment may be formed on the front surface side of the substrate body (the plate member). In such a configuration, a resin member is disposed on the vehicle compartment interior side of the base segment and bonded to the base segment.

[0044] (2) Other than the embodiments mentioned above, the resin member bonded to the base segment may be changed as appropriate. In the embodiments mentioned above, the resin members bonded to the base segment are the bosses 20, 30, but are not limited thereto. For example, the resin member bonded to the base segment may be a bracket 40. This allows an orientation and a position of the bracket 40 to be adjusted.

[0045] (3) The vehicular interior component and the method of producing the same exemplified in the embodiments described above are not limited to those provided for vehicles but may be provided in various conveyances. For example, the vehicular interior component and the method of producing the same may be applied for ground conveyances such as trains and amusement vehicles, flight vehicles such as airplanes and helicopters, as well as marine and/or underwater conveyances such as vessels and submarines as. Explanation of Symbols

[0046] 1 : lower trim (vehicular interior component); 2: door pocket installation segment; 3: speaker grill fitting segment; 5: molding die; 10: base member; 11 : substrate body; 12: planar surface segment; 13: inclined surface segment; 14: curved surface segment; 20, 30: boss (resin member); 21 , 31 : base plate; 22, 32: columnar segment; 40: bracket; 50, 60: base segment; 52, 62: projected end surface; 70: upper die; 80: lower die; 90: plate member; 91 : mat; 92, 93: connection segment; 95: foaming resin

Claims

1. A vehicular interior component comprising: a base member containing a foaming resin, the base member including a substrate body having a plate shape and a base segment projecting from the substrate body in one direction by foaming of the foaming resin and having a projected end surface; and a resin member that is bonded to the projected end surface of the base segment.

2. The vehicular interior component according to claim 1, wherein the base member further contains a fiber and the foaming resin is foamed.

3. The vehicular interior component according to one of claims 1 and 2, wherein the base segment includes base segments having projected end surfaces, and the projected end surfaces are parallel to each other.

4. The vehicular interior component according to any one of claims 1 to 3, wherein the base segment contains a greater amount of the foaming resin than other sections of the base member.

5. A method of producing a vehicular interior component, the method comprising: applying foaming resin on a mat made of fiber and obtaining a plate member; applying a greater amount of foaming resin to a section of the plate member; and arranging the plate member in a molding die that is heated and pressing the plate member by the molding die to obtain a base member and the greater amount of the foaming resin is foamed by heat and projects from the base member in one direction to form a base segment projecting from the base member such that a resin member inserted in the molding die is bonded to a projected end surface of the base segment, thereby forming the resin member on the base member by insert molding.

6. The method according to claim 5, wherein the molding die includes a first die and a second die and the plate member is arranged between the first die and the second die, and the resin member is put in a recess of the second die and the greater amount of the foaming resin is foamed into the recess and projects toward the resin member in the recess such that the base segment is formed and the resin member is bonded to the projected end surface of the base segment.

7. The method according to one of claims 5 and 6, wherein the resin member is put in the recess such that a bonding surface of the resin member is parallel to a surface of the plate member. The method according to one of claims 6 and 7, wherein the foaming resin is foamed to fill a space between the base member and the resin member in the recess.