Multilayer composite interior component

Patent metadata

Field	Value
Publication number	US-10160404-B2
Application number	US-201515535953-A
Country	US
Kind code	B2
Filing date	Dec 16, 2015
Priority date	Dec 19, 2014
Publication date	Dec 25, 2018
Grant date	Dec 25, 2018

Abstract

Provided is a multilayer composite interior component in which boundary protrusions (20b) aligned in a row on both sides of a parting line (L) are arranged in a staggered manner so as to bend toward the boundary protrusions (20b) in the row opposite thereto. In this way, even when the boundary protrusions (20b) are separated from the parting line (L) by a predetermined distance (g1, g2) in order to maintain the strength of a divided mold, the boundary protrusions (20b) bend and deform so as to fill in an empty part in the vicinity of the parting line (L) when a surface layer member (16) is pressed by fingers or a hand. As a result, a feeling of unevenness resulting from decreases in reaction force in the vicinity of the parting line (L) is minimized, thus making it possible to obtain a more uniform texture.

First claim

The invention claimed is:

1. A multilayer composite interior component comprising:
a first member; and
a second member that is arranged on the first member, wherein
the second member is formed using a plurality of separate molds,
the second member includes
a plurality of general projections, each projecting toward the first member, wherein the general projections are bent by contact with the first member, and
a plurality of boundary projections located between a mold separation line of the separate molds and the general projections and projecting toward the first member, wherein the boundary projections are bent by contact with the first member,
the boundary projections are arranged at equal intervals in rows along the mold separation line at opposite sides of the mold separation line, and
each interval of the boundary projections is shorter than a distance between the general projections located adjacent to each other along the mold separation line.

2. The multilayer composite interior component according to claim 1 , wherein
the second member includes a projection surface on which the boundary projections project, and
the boundary projections project in a state inclined toward the mold separation line relative to a normal line that is orthogonal to the projection surface of the second member.

3. The multilayer composite interior component according to claim 1 , wherein
the boundary projections are located at opposite sides of the mold separation line, and
the boundary projections located at one side of the mold separation line are not opposed to the boundary projections located at the other side of the mold separation line.

4. The multilayer composite interior component according to claim 1 , wherein
the second member includes an ornamental surface located at a side opposite to the general projections and the boundary projections,
the boundary projections include a first projection located at a position separated from the mold separation line by a first distance and a second projection located at a position separated from the mold separation line by a second distance that differs from the first distance, and
the first projection and the second projection are alternately arranged as viewed from the mold separation line.

5. The multilayer composite interior component according to claim 1 , wherein
each of the general projections and the boundary projections includes a basal portion and a distal portion and is formed by a conical body, the contour of which is gradually decreased from the basal portion toward the distal portion, and
the basal portion has a cross section that has a line-symmetric shape and extends longer in a perpendicular direction than in a particular direction, wherein the perpendicular direction is orthogonal to the particular direction.

6. The multilayer composite interior component according to claim 5 , wherein
the boundary projections include a third projection arranged to be directed in a first direction that extends away from the mold separation line and a fourth projection arranged to be directed in a second direction that extends toward the mold separation line,
each of the first direction and the second direction corresponds to the particular direction,
the second direction intersects the first direction, and
the third projection and the fourth projection are alternately arranged as viewed from the mold separation line.

7. The multilayer composite interior component according to claim 1 , wherein
a plurality of polygons, each of which has sides, forms a lattice pattern when each side of the polygons overlaps a side of an adjacent one of the polygons, and
the general projections are arranged on each side of the polygons.

8. The multilayer composite interior component according to claim 7 , wherein
the first member includes a joining surface,
the second member includes a plate portion located parallel to the joining surface of the first member,
the plate portion includes the general projections,
the general projections have a flexural rigidity against a load applied in a direction orthogonal to the plate portion, wherein the flexural rigidity is anisotropic in the vicinity of an axis that is orthogonal to the plate portion,
each of the general projections is configured to be bent in one direction that extends in the vicinity of the axis as the distal portion slides on the joining surface,
the lattice pattern has a honeycomb shape in which equilateral hexagons having a fixed size are continuously repeated,
each side of the equilateral hexagons has one of the general projections arranged thereon, and
a bending direction of the general projections is alternately changed to an inner side and an outer side at the sides arranged about a center of each of the equilateral hexagons.

9. A multilayer composite interior component comprising:
a first member including a predetermined joining surface; and
a second member arranged on the first member and formed from an elastically deformable synthetic resin, wherein
the second member includes a plate portion that is substantially parallel to the joining surface,
the plate portion includes a plurality of projections, each projecting toward the joining surface to define a gap between the plate portion and the joining surface,
each of the projections includes a distal portion,
the second member is arranged on the first member with the distal portions of the projections in contact with the joining surface,
the distal portions of the projections are pressed and elastically deformed by the joining surface thereby producing a cushioning effect,
the second member includes a surface located at a side of the projections and formed using a plurality of separate molds,
boundary projections located at each of opposite sides of a mold separation line of the separate molds are arranged in one row at equal intervals along the mold separation line,
the boundary projections have a flexural rigidity against a load applied in a direction orthogonal to the plate portion, wherein the flexural rigidity is anisotropic in the vicinity of an axis that is orthogonal to the plate portion,
each of the boundary projections includes a distal portion and is configured to be bent in one direction that extends in the vicinity of the axis as the distal portion slides on the joining surface,
the boundary projections located at the opposite sides of the mold separation line are arranged to be bent toward the boundary projections located in an opposing row,
each of the boundary projections is located at an intermediate portion of adjacent ones of the boundary projections located in the opposing row, and
the boundary projections are laid out in a staggered arrangement.

10. The multilayer composite interior component according to claim 9 , wherein
the boundary projections have the same shape,
each of the boundary projections includes a basal portion and has a center line that is inclined at the basal portion relative to a direction orthogonal to the plate portion,
each of the boundary projections is bent in an inclination direction that corresponds to one direction that extends in the vicinity of the axis, and
the boundary projections located at the opposite sides of the mold separation line are arranged in rows so that the inclination directions of the boundary projections are the same in each row.

11. The multilayer composite interior component according to claim 10 , wherein
the second member includes a general region separated from the mold separation line,
a plurality of general projections is arranged in the general region,
a plurality of polygons, each of which has sides, forms a lattice patt

Assignees

• Toyota Tekko Kk

Inventors

• Miyashita Osamu
• Onuma Kenji
• Yoshida Kenichi

Classifications

• Y10T428/24182

  Inward from edge of web or sheet · CPC title

• B32B5/024

  Woven fabric · CPC title

• B32B27/30

  comprising vinyl {(co)polymers; comprising acrylic (co)polymers} · CPC title

• B32B27/32

  comprising polyolefins {(comprising vinyl (co)polymers or acrylic (co)polymers B32B27/30)} · CPC title

• B32B27/12

  next to a fibrous or filamentary layer · CPC title