JP2000318541A - Interior ceiling material for automobile - Google Patents

Abstract

PROBLEM TO BE SOLVED: To lighten the weight of a ceiling material even if a reinforcement part on a base layer is formed, and to prevent a film layer and the like from being damaged by reinforcement part. SOLUTION: In an interior ceiling material of an automobile having a film layer 3 formed on an upper surface of a base layer 2 made of nonwoven fabric, and a reinforcement part 5 for reinforcing the base layer 2, formed on a weak part of a ceiling material body 1 having a facing layer 4 on its lower surface, a reinforcement layer 5a made of a nonwoven fabric of the same quality as that of the base layer 2 but smaller areal density is embedded in the base layer 2 by the needle punching to form the reinforcement part 5.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a vehicle interior ceiling material having an improved reinforcing portion.

[0002]

2. Description of the Related Art Conventionally, a ceiling member a as shown in FIG.

As shown in FIG. 6, the conventional ceiling material a has a structure in which a film layer c for ventilation prevention is provided on the upper surface of a base material layer b made of non-woven fabric and a skin layer d is provided on the lower surface. b
A reinforcing portion e for reinforcing the base material layer b is provided at a substantially central portion on both sides of the substrate.

The conventional reinforcing portion e is formed by fixing a reinforcing member f made of an iron plate to the upper surface of the film layer c by bonding or the like. By reinforcing a weak portion of the base material layer b,
The work of attaching the ceiling member a to the inside of the roof is facilitated, and the ceiling member a is prevented from being bent after the ceiling member a is attached to the inside of the roof.

[0005]

However, since the reinforcing member f is formed of an iron plate, the weight of the ceiling member a increases, and much time is required for the work of attaching the ceiling member a to the inside of the roof. The workability is poor, the ceiling material becomes expensive, and the reinforcing member f may come into contact with the roof, the rain force, or the like to generate abnormal noise.

Further, since a different reinforcing member f is fixed to the base material layer b made of a nonwoven fabric to reinforce the base material layer b, when the ceiling material a is recycled, the reinforcing member f is applied from the base material layer b. It had to be removed, and there were also problems such as difficulty in recycling.

SUMMARY OF THE INVENTION The present invention has been made to solve such a conventional problem, and provides an interior ceiling material of an automobile in which a reinforcing portion is formed by a reinforcing member of the same quality as the base material layer, thereby reducing the weight of the ceiling material. It is another object of the present invention to prevent the film layer and the like from being damaged by the reinforcing portion.

[0008]

In order to achieve the above object, the invention according to claim 1 is directed to a part of a ceiling material body in which a film layer is formed on an upper surface of a base layer made of a nonwoven fabric and a skin layer is formed on a lower surface. In a vehicle interior ceiling material provided with a reinforcing portion for reinforcing the base layer, the reinforcing portion was formed by embedding a reinforcing layer made of a nonwoven fabric of the same material having a smaller basis weight than the base layer in the base layer. Things.

With the above structure, the basis weight of the reinforcing portion is larger than that of the base material layer, so that the base material layer is not stiffened and bent, the damage of the film layer and the like due to the reinforcing portion can be prevented, and the ceiling material can be prevented. Since the weight can be reduced, the workability when installing the ceiling material inside the roof is also very good.

In order to attain the above object, the invention according to claim 2 provides that the basis weight of the reinforcing layer is reduced by half with respect to the basis weight of the base layer.
It is as follows.

With the above structure, when the reinforcing layer is embedded in the base layer, the reinforcing layer can be efficiently embedded, and the reinforcing layer does not protrude from the upper surface of the base layer.

[0012] In order to achieve the above object, the invention according to claim 3 is characterized in that when the reinforcing layer is embedded in the base material layer by forming a thin-walled portion in which both side edges of the reinforcing layer are sequentially thinned, a corner portion of the reinforcing layer is formed. Does not protrude from the upper surface of the base material layer.

With the above configuration, even when the reinforcing layer has a large basis weight and the upper surface of the reinforcing layer protrudes from the upper surface of the base material layer,
The film layer is reliably prevented from being damaged at the corners of the reinforcing layer.

[0014]

Embodiments of the present invention will be described below in detail with reference to the drawings.

FIG. 1 is a perspective view showing an interior ceiling material of an automobile.
FIG. 2 is a sectional view taken along the line AA of FIG. 1, FIGS. 3A to 3D are explanatory views showing a forming step, and FIG. 4 is a sectional view of a modification.

In these figures, reference numeral 1 denotes a ceiling material main body, which is formed in a substantially rectangular shape large enough to cover the inner surface of the roof of an automobile (not shown), and a notch 1a is formed at substantially the center on both sides to fit the center pillar. ing.

As shown in FIG. 2, the ceiling material body 1 is
A film layer 3 for ventilation prevention is provided on the upper surface of a base material layer 2 formed of a nonwoven fabric made of ET resin, and a skin layer 4 is provided on the lower surface.
Is provided, and a reinforcing portion 5 is formed in a width direction at a weak portion which is a part of the ceiling material main body 1, for example, at a central portion.

The base layer 2 has a basis weight of, for example, 800 g /
is formed from a nonwoven fabric made of m ^2, also the reinforcing section 5, in order to facilitate recycling of the ceiling material body 1, it is formed by the reinforcing layer 5a of the base layer 2 and the same quality.

For the reinforcing layer 5a, a nonwoven fabric made of PET resin having a basis weight of, for example, 400 g / m ² is used.
The weight of the base material layer 2 and the weight of the reinforcing layer 5a are selected so that the weight of the reinforcing portion 5 is about 1200 g / m ² by performing a needle punching process in a molding process described later.

The basis weight of the base layer 2 and the reinforcing layer 5a increases as the difference increases, but the reinforcing effect increases. However, if the basis weight of the reinforcing layer 5a is too large, the base layer 2 can be reinforced even by needle punching. Since the layer 5a is not embedded and the reinforcing layer 5a projects on the upper surface of the base material layer 2 and causes a step to appear on the skin and causes damage to the film layer 3, the following range is preferable. The basis weight of the base layer 2 400 350 200 The basis weight of the reinforcing layer 5a 800 900 950

Next, a method for forming the ceiling material main body 1 having the above structure will be described with reference to the drawings shown in FIGS.

First, the nonwoven fabric cut to the same size as the reinforcing portion 5 of the base material layer 2 is subjected to a needle punching process using a needle punch 6 in a first step shown in FIG.
The reinforcing layer 5a having a basis weight of about 400 g / m ² shown in FIG.

Next, the obtained reinforcing layer 5a is placed at a predetermined position on the base material layer 2 as shown in FIG. 3C, and a needle for embedding the reinforcing layer 5a into the base material layer 2 in the second step. Perform punch processing.

The reason why the reinforcing layer 5a is fixed to the base layer 2 by needle punching is that the reinforcing layer 5a rises due to the hot air that has passed through the base layer 2 when the base material is heated before molding.
This is to prevent the heating of the substrate.

The ceiling material main body 1 obtained as described above
Has a structure in which the reinforcing layer 5a is embedded in the reinforcing portion 5 of the base material layer 2 as shown in FIG. 3D, and the basis weight of the reinforcing portion 5 is 800 g / m ² of the base material layer 2. about 1200 g / m ² becomes plus basis weight 400 g / m ² of the reinforcing layer 5a, so that a weak part of the base layer 2 can be sufficiently reinforced.

The thickness of the reinforcing layer 5a is suitably about 3 to 5 mm.

If the thickness is larger than this, when the reinforcing layer 5a is embedded in the base material layer 2 by the needle punching process, the reinforcing portion of the base material layer 2 bulges into the interior of the vehicle interior, and the appearance as a ceiling material is impaired. That's why.

As the reinforcing material 5a, a material roll made of a non-woven fabric manufactured in advance is used. When the material roll is used, the needle punching process on both side edges is made stronger than other portions, so that both side edges are formed. By forming the thinned portions 5b which become thinner sequentially, when the reinforcing layer 5a having a large basis weight is embedded in the base material layer 2 by the needle punching process, the upper surface of the reinforcing layer 5a becomes as shown in FIG. Even when the film layer 3 protrudes from the upper surface, the corners of the reinforcing layer 5a do not protrude from the upper surface of the base layer 2, so that the film layer 3 can be prevented from being damaged by the corners of the reinforcing layer 5a.

[0029]

According to the present invention, as described in detail above, a reinforcing layer made of a nonwoven fabric of the same material having a smaller basis weight than that of the base material layer is embedded in a part of the ceiling material main body by needle punching to form a reinforcing portion. This makes it possible to prevent the film layer and the like from being damaged and to reduce the weight of the ceiling material, as compared with the conventional one reinforced with a reinforcing member such as an iron plate. And, by this weight reduction, workability at the time of attaching the ceiling material to the inside of the roof is remarkably improved, and a lightweight reinforcing layer is formed at a weak portion of the base material layer to be reinforced, and at the time of installation work, Improved handling,
There is no need to worry that some of the ceiling material will hang, and since the base material layer and the reinforcement layer are made of the same material, when recycling the ceiling material,
There is no need to remove the reinforcing layer, which facilitates recycling.

Further, since the reinforcing layer is embedded in the base material layer, problems such as damage to the film layer due to the corners of the reinforcing layer can be eliminated, and the reinforcing layer comes into contact with the roof or the reinforcement. Therefore, there is no problem such as generation of abnormal noise while the vehicle is running.

Further, since the reinforcing layer is embedded in the base material layer by the needle punching process, the reinforcing portion can be formed without using an adhesive or the like, and the thin portions are formed on both edges of the reinforcing layer in advance. If a reinforcing layer with a large basis weight is used, even if the upper surface of the reinforcing layer protrudes from the upper surface of the base material layer, the film layer will not be damaged at the corners of the reinforcing layer.

[Brief description of the drawings]

FIG. 1 is a perspective view showing an indoor ceiling material of an automobile according to an embodiment of the present invention.

FIG. 2 is a sectional view taken along line AA of FIG.

FIGS. 3 (a) to 3 (d) are explanatory views showing a step of forming a reinforcing portion provided on the interior ceiling material of the automobile according to the embodiment of the present invention.

FIG. 4 is a cross-sectional view showing a modified example of a reinforcing portion provided on an indoor ceiling material of an automobile according to an embodiment of the present invention.

FIG. 5 is a perspective view showing a conventional interior ceiling material of an automobile.

FIG. 6 is a sectional view taken along line BB of FIG. 5;

FIG. 7 is an explanatory diagram showing a problem of a conventional ceiling material of an automobile.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Ceiling material main body 1a Notch 2 Base material layer 3 Film layer 4 Skin layer 5 Reinforcement part 5a Reinforcement layer 5b Thin part 6 Needle punch

 ────────────────────────────────────────────────── ─── Continuing on the front page (72) Inventor Noriaki Yokohama 3316 Miyayama, Samukawa-cho, Koza-gun, Kanagawa Prefecture Kasai Kogyo Co., Ltd. F-term in the Samukawa head office factory (reference) 3D023 BA01 BA04 BB03 BC01 BD01 BE04 BE06 BE10 BE22 BE31 4F100 AK42 AT00B AT00C BA03 BA10B BA10C DG15A DG15C DH00A DH00C EC09A EC14A GB33 JH01 JL03 JL05 JL16

Claims (3)

[Claims] 1. A vehicle interior ceiling material comprising a base material layer made of a nonwoven fabric, a film layer formed on an upper surface, and a skin layer formed on a lower surface partly provided with a reinforcing portion for reinforcing the base material layer on a part of the ceiling material body. An interior ceiling material for an automobile, wherein the reinforcement portion is formed by embedding a reinforcement layer made of a nonwoven fabric of the same material having a smaller basis weight than the base material layer in the ceiling material main body. 2. The interior ceiling material of an automobile according to claim 1, wherein the basis weight of the reinforcing layer is less than or equal to に 対 し of the basis weight of the base layer. 3. A thin portion in which both side edges of the reinforcing layer are sequentially thinned is formed so that, when the reinforcing layer is embedded in the base layer, the corners of the reinforcing layer do not protrude from the upper surface of the base layer. The interior ceiling material of an automobile according to claim 1 or 2.