JP2002144976A - Molded ceiling for car and its manufacturing method - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a molded ceiling for a car with excellent sound absorbing performance. SOLUTION: The molded ceiling 10 for car is structured so that an air permeable sheet member 21 allowing air to pass but not allowing liquid and surface cloth with air permeability are laminated fast on a base material 11 to at least its one side.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

The present invention relates to a molded ceiling for a vehicle and a method of manufacturing the same.

[0002]

2. Description of the Related Art In a ceiling of a vehicle such as an automobile, a molded ceiling for a vehicle is attached to the inside of a vehicle body outer plate to provide heat insulation and decorativeness. As the molded ceiling for a vehicle, a polyurethane foam 5 as shown in FIG.
2. A base material 51 including a front glass fiber layer 53, a back glass fiber layer 54, and the like, is provided with a hot air permeable film 55 made of a fabric such as polyester fiber, a plastic sheet, or a nonwoven fabric via a hot melt film 56. The hot-melt film 56 is melted and cured by hot-pressing the laminated product with a heating mold or the like, whereby each member is integrated and fixed in a desired shape. A ceiling 50 is common. In addition, as the base material, in addition to the above examples, a material including a polypropylene layer and a glass fiber layer, a material including corrugated cardboard, and the like can be mentioned. In this type of molded ceiling, as shown in the figure, a backing material 60 is laminated on the back side of the base material 51 (the opposite side of the front cloth 55) via a back side hot melt film 61, and the back side by the heating press is used. The melting and curing of the hot melt film 56 causes the substrate 51
And the lining material 60 are often integrated.

However, the front side hot melt film 5
Although the conventional molded ceiling 50 in which the base material 51 and the surface cloth 55 are bonded by welding of No. 6 occupies a large area in the vehicle interior, it has a problem that the sound absorbing effect on the noise generated in the vehicle interior is not so good. Have been.

[0004] The present inventors diligently studied the cause of the above problem, and found that a part of the sound generated in the vehicle interior was reflected by the front side hot melt film 56 between the base material 51 and the surface cloth 55, It has been found that the cause is that the reflected sound is not absorbed in the base material 51. Therefore, the present inventor has proposed to abolish the hot melt film 56.

However, in the molded ceiling, the base material 51 is impregnated with a curable liquid resin for fixing the shape and the like.
Because the reaction may be cured by the heating press,
With the abolition of the hot melt film 56, during and after the hot press, the curable liquid resin oozes out to the outer cloth and appearance and manufacturing defects occur, so that a new problem occurs. became. Further, in order to prevent the seepage of the curable liquid resin, a resin layer of an acrylic resin or the like may be formed on the base material side (back side) of the front cloth (resin backing treatment). There is a problem that the cost increases and the weight of the molded ceiling increases.

[0006]

DISCLOSURE OF THE INVENTION The present invention has been proposed in view of such a situation, and has excellent sound absorbing performance and eliminates problems such as the curable liquid resin seeping out of a surface cloth during manufacturing. Good workability and appearance during manufacturing,
Moreover, it is an object of the present invention to provide a molded ceiling for a vehicle which is lightweight and advantageous in cost and a method for manufacturing the same.

[0007]

That is, the invention according to claim 1 is a gas-permeable sheet material that allows gas to pass through but at least liquid to at least one side of a self-holding substrate, and a gas-permeable top cloth. A molded ceiling for vehicles, wherein the ceiling is laminated and fixed.

A second aspect of the present invention is characterized in that, in the first aspect, the air-permeable sheet is made of a melt-blown nonwoven fabric or a composite of a meltblown nonwoven fabric and a spunbonded nonwoven fabric.

A third aspect of the present invention is characterized in that, in the second aspect, the basis weight of the melt blown nonwoven fabric is 10 g / m ² or more.

A fourth aspect of the present invention is characterized in that, in any one of the first to third aspects, the base material includes a glass fiber impregnated and cured with a curable liquid resin.

A fifth aspect of the present invention is characterized in that, in any one of the first to third aspects, the base material includes a foam obtained by impregnating and curing a curable liquid resin in a foam.

According to a sixth aspect of the present invention, in any one of the first to third aspects, the base material includes a laminate obtained by impregnating and curing a curable liquid resin in a laminate of a glass fiber and a foam. It is characterized by.

A seventh aspect of the present invention is characterized in that, in the sixth aspect, the laminate of the glass fiber and the foam has a sandwich structure in which the foam is an intermediate layer and both layers are glass fibers.

According to an eighth aspect of the present invention, in any one of the first to seventh aspects, the air-permeable sheet material and the surface cloth are bonded and integrated by melt-hardening a thermoplastic resin powder. I do.

A ninth aspect of the present invention is a method of manufacturing a molded ceiling for a vehicle, comprising laminating a base material and a surface cloth, and heating and pressing the laminated body to fix and integrate the shape. A gas-permeable but liquid-permeable gas-permeable sheet material is interposed therebetween, and the above members are bonded and integrated.

[0016]

DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention will be described below in detail with reference to the accompanying drawings. 1 is a partial sectional view showing a molded ceiling for a vehicle according to an embodiment of the present invention, FIG. 2 is a schematic diagram showing an example of a method for manufacturing the molded ceiling for the vehicle, and FIG. 3 is a schematic diagram showing a state of sound absorption performance measurement. FIG. 4 is a partial sectional view showing a main part of a molded ceiling for a vehicle according to another embodiment.

A molded ceiling 10 for a vehicle shown in FIG. 1 is attached to the inside of a car body outer panel for heat insulation and decoration in a vehicle interior, and includes a base material 11 and a permeable sheet material 2.
1 and a surface material 31.

The base material 11 is used to maintain the shape of the molded ceiling 10 for a vehicle and to attach the molded ceiling 10 to a vehicle body outer plate, and is made of various materials having excellent self-holding properties (rigidity), heat insulation properties, and workability. . In this embodiment, the substrate 11 has a three-layer structure in which a back glass fiber layer 12, a foam body 13, and a front glass fiber layer 14 are laminated in this order from the back (bottom).

The glass fiber layers 12 and 14 arranged on both sides of the foam 13 are for increasing the rigidity of the base material 11 and are formed by depositing glass fiber chops (cut from long glass fibers). It is made of a layered material or a glass fiber mat. The glass fiber layers 12, 14
Is appropriately determined depending on rigidity and the like required for the molded ceiling 10.

The foam 13 serves as a main body of the substrate 11 and imparts heat insulation and sound absorbing properties to the molded ceiling 10, and a known foam such as a polyurethane foam can be used. The foam may be hard or soft.

The glass fiber layers 12 and 14 and the foam 13
Is made by curing a curable liquid resin (binder) impregnated (attached) to the glass fiber layers 12 and 14. The curable liquid resin also has an effect of fixing the shape of the laminated product (molded ceiling 10) by the curing. Examples of the curable liquid resin include a liquid isocyanate which is inexpensive and has good adhesiveness. The liquid isocyanate is cured by reaction with water in the presence of heat and a catalyst, and functions as an adhesive by the curing. As the liquid isocyanate, a liquid isocyanate can be used without any particular limitation. For example, aromatic TDI (toluene diisocyanate), polymeric MDI (4,4'diphenylmethane diisocyanate), NDI (1,5-naphthalenediisocyanate), TODI (tolidine diisocyanate), PPD
I (paraphenylene diisocyanate), XDI (xylylene diisocyanate), TMXDI (tetramethyl xylene diisocyanate) and modified products thereof. Preferred are polymeric MDI, modified TDI such as urethane modification, allophanate modification, burette modification, carbimide / uretonimine modification, and modified TDI such as modified MDI, MDI, and the like.
The use of mixtures thereof is suitable.

Of these, liquid isocyanates having a viscosity of 3 to 300 cp are more preferable because of their excellent permeability and applicability. Among them, polymeric MDI has a low vapor pressure and a good affinity with glass fibers, and is suitable in terms of reactivity, adhesion, and workability. The type of the liquid isocyanate is appropriately selected and used depending on the adhesiveness, rigidity, reactivity, workability, and the like of the laminate.
Here, in this embodiment, the curable liquid resin is impregnated (adhered) on the front and back surfaces of the foam 13. However, the present invention is not limited to this, and the curable liquid resin is also impregnated inside the foam 13. It may be. As described above, if the foam 13 is also impregnated with the curable liquid resin, the shape of the molded ceiling is more reliably fixed.

The substrate 11 is made of the above foam 13
Is not limited to a sandwich structure in which the glass fiber layers 12 and 14 are formed on both sides of the intermediate layer. Of the layers 12 to 14 constituting the base material 11, layers are appropriately omitted or changed, or It is also possible to add new layers. For example, as the substrate structure other than the above, a single-layer structure of a glass fiber layer, a single-layer structure of a foam, a two-layer structure of a foam and a glass fiber layer, a structure including a foam and a carbon fiber layer, a polypropylene layer or Structure consisting of a glass fiber layer,
Structure consisting of polyethylene layer and glass fiber layer, single layer structure of polystyrene layer, structure consisting of polystyrene layer and glass fiber layer, structure consisting of polystyrene layer and carbon fiber layer,
Examples include a single-layer structure of the PET layer, a structure including the PET layer and the glass fiber layer, a structure including the PET layer and the carbon fiber layer, and a structure including corrugated cardboard.

In the illustrated example, the backing material 1 is provided on the back side of the base material 11, here, on the back side of the back glass fiber layer 12.
5 are laminated via a backside hot melt 16, and the base material 11 and the backing material 15 are bonded and integrated by welding of the backside hot melt 16. The lining material 15 is a molded ceiling 1
0, which protects the back surface and facilitates the release of the molded ceiling 10 from the heating mold during the hot pressing when molding the molded ceiling 10 and is made of a nonwoven fabric, a plastic sheet, or the like. The back side hot melt 16 includes a backing material 15.
Is adhered to the base material 11 and is made of a material that melts when heated and exhibits adhesiveness. Adhesion of the base material 11 and the backing material 15 with the backside hot melt 16 in this manner has the effect of preventing the ventilation of the base material 11 and preventing the molded ceiling 10 from being stained due to the ventilation, and also has the effect of forming. In this case, it is possible to prevent the curable liquid resin from seeping out to the backing material 15 side during the heating press. Examples of the back side hot melt 16 include EVA (ethylene vinyl acetate copolymer), EAA
(Copolymer of ethylene and acrylic acid), EMA (copolymer of ethylene and methyl acrylate), EMA (copolymer of ethylene and methyl methacrylate), EMAA (copolymer of ethylene and methacrylic acid) Melting point 70-1 consisting of polyolefin copolymer or polymer alloy
00 ° C thermoplastic resin, polypropylene, polyamide (nylon), PET (polyethylene terephthalate)
And a polymer alloy with a thermoplastic resin having a melting point of 110 to 200 ° C.

The base material 11 and the backing material 15 can be integrated without using the back side hot melt 16. For example, the adhesiveness of a curable liquid resin at the time of hot pressing described below is used. Further, the backing material 15 may be omitted in some cases.

The air-permeable sheet material 21 enhances the sound absorbing performance of the molded ceiling 10, and more specifically, enhances the transmission of sound generated in the vehicle interior to the base material 11 (particularly, the foam 13). Further, it is to prevent the liquid resin impregnated in the base material 11 from penetrating to the outer cloth 31 when the laminated material to be the molded ceiling 10 is heated and pressed. The gas permeable sheet 21 has a property of allowing gas to pass therethrough but not liquid. Specifically, a nonwoven fabric or the like made of polypropylene, polyester, polyethylene, PET, polyamide, styrene-based resin, or the like is used as the air-permeable sheet material 21.
It can be mentioned as. In particular, the basis weight is 10 g
/ M ² or more (10 to 10 in consideration of cost and weight reduction)
100 g / m ² ) nonwovens are suitable. If the basis weight is less than 10 g / m ² , the property of allowing the gas to pass but not the liquid may not be sufficiently obtained. Further, it is preferable to use a nonwoven fabric having a fiber diameter of 3 to 15 μm and an average fiber interval of 20 μm, since the property that the gas passes but the liquid does not pass is sufficiently satisfied. More preferably, use is made of a melt-blown nonwoven fabric in which filaments of 1 denier or less are woven by a known melt-blowing method using polypropylene, polyester, polyethylene, PET, polyamide, styrene-based resin or the like. The melt blow method is a method in which a melted ultrafine short fiber is taken out from a nozzle or the like, blown off with hot air, thinned, and a nonwoven fabric is woven.

Also, a composite material in which a spunbonded nonwoven fabric (reinforced nonwoven fabric obtained by solidifying long fibers) or a spunlace laminated on the meltblown nonwoven fabric by a known spunbonding method using polypropylene, PET or the like for reinforcement is used. The body may be a breathable sheet material 21. In this case, there is an advantage that the strength of the air-permeable sheet material is increased, inconveniences such as breakage at the time of hot press described later and the like are eliminated, and the moldability is excellent.

The bonding between the base material 11 and the air-permeable sheet-like material 21 is performed by the reaction hardening of the curable liquid resin impregnated in the base material 11. Here, since the gas-permeable sheet material 21 has a property of impervious to liquid as described above, the gas-permeable sheet material 21 is hardened at the time of the above-mentioned curing (to be precise, at the time of hot pressing described later and thereafter). The curable liquid resin does not exude to the outer cloth side of the object 21.

The outer cloth 31 is for decorating or protecting the surface of the molded ceiling 10. As the surface cloth 31, a breathable material is used, and a nonwoven fabric such as a polyester nonwoven fabric, a woven fabric (knitted surface fabric), a fabric such as a polyester fiber, a urethane laminate, a TPO (polyolefin thermoplastic elastomer), a PVC ( Plastic sheets such as polyvinyl chloride).

The outer cloth 31 and the breathable sheet 21 are
In this embodiment, the thermoplastic resin powder M such as polypropylene, polyethylene, or EVA interposed between the outer cloth 31 and the air-permeable sheet material 21 is bonded and integrated by melting and curing. In addition, in order to suppress a decrease in the air permeability of the outer cloth 31 and the air-permeable sheet material 21, the thermoplastic resin powder M is made into a powder shape (extremely small particles) so as to be in a scattered point shape as in the embodiment. Is desirable. Further, in this embodiment, the powdery thermoplastic resin powder M was used as the gas permeable sheet material 2.
1 is attached to the side surface of the top cloth, and the top cloth 31 is laminated thereon, and then heated and pressed to melt and harden the thermoplastic resin powder M, and thus the top cloth 31 and the breathable sheet material 21 are performed. Of course, the thermoplastic resin powder is adhered to the back surface of the surface cloth 31, and the surface cloth 31 and the air permeable sheet 21 are laminated and heated and pressed to bond the surface cloth 31 and the air permeable sheet 21. May be. Also,
The thermoplastic resin powder may be rubbed into the air-permeable sheet material 21, or a non-woven fabric woven using fibers (double structure fibers) whose surfaces are coated with a thermoplastic resin may be ventilated. The surface cloth 3 may be used as the conductive sheet material 21.
1 and the air-permeable sheet material 21 can be bonded and integrated.

The method of bonding the outer cloth 31 and the air-permeable sheet material 21 is not limited to the above example. For example, as shown in FIG. 4 showing a main part of a molded ceiling 10N for a vehicle according to another embodiment, a hot melt is formed on a surface side of a breathable sheet material (melt blow nonwoven fabric) 21 by using a known embossing process or the like. A film piece (made of the same material as the backside hot melt 16) H is partially embedded, and the surface cloth 31 and the air-permeable sheet material 21 are bonded by the bonding action of the hot melt film piece H. Is also good. In this case, the hot melt film piece H
It is necessary to set the size of each hot melt film piece H and the distance between the hot melt film pieces H. When a non-woven fabric made of a styrene resin is used as the breathable sheet material 21, the non-woven fabric is melted at 80 to 160 ° C., so that an adhesive medium such as the thermoplastic resin powder or hot melt film is unnecessary. Become.

Next, an example in which the above-mentioned molded ceiling 10 for a vehicle is manufactured by the manufacturing method according to the ninth aspect of the present invention will be described. In the following example, in order to increase production efficiency, an example is shown in which each member is continuously supplied using a conveyor to form a laminated material, and the laminated material is cut into a predetermined size after being integrated, The present invention is not limited to this, and the members cut to a predetermined size in advance may be sequentially stacked without using a conveyor.

First, in this example, as shown in FIG. 2, a backing material 15 and a backside hot melt film 16 disposed on the upper surface thereof are continuously supplied in one direction by a conveyor F in a stacked state. Then, on a back side hot melt film 16 at a predetermined position on the conveyor F, a glass fiber chop 12A cut to a predetermined size is sprayed,
The back side glass fiber layer 12 is formed by depositing a predetermined weight. A glass fiber mat may be laminated on the backside hot melt film 16 instead of the glass fiber chop 12A.

Next, a polymeric MDI (curable liquid resin) 35 is sprayed on the back glass fiber layer 12. Since the polymeric MDI is composed of one liquid, there is no need to adjust the viscosity of each liquid as compared with a two-part polyurethane adhesive, and the polymeric MDI is less expensive than a two-part polyurethane adhesive. . Further, in this embodiment, the catalyst solution 36 is sprayed on the back glass fiber layer 12 in order to accelerate the reaction hardening of the polymeric MDI. Examples of the catalyst solution 36 include an aqueous solution of dimethylethanolamine and an aqueous solution of dimethylethanolamine / triethylenediamine. Polymeric MDI 35 sprayed on the back glass fiber layer 12
The catalyst solution 36 is impregnated (adhered) to the surface and inside of the back glass fiber layer 12 and is held by the back glass fiber layer 12.

Then, a plate-shaped foam (polyurethane foam in this example) 13 cut into a predetermined size is supplied onto the back glass fiber layer 12 and laminated. This foam 1
The size of 3 is determined according to the desired size of the molded ceiling 10. Subsequently, a predetermined amount of a glass fiber chop 14A is sprayed on the upper surface of the foam 13 to form the front glass fiber layer 14. The glass fiber chop 14A to be sprayed here may be the same type, size and amount as the glass fiber chop 12A previously sprayed, or may be different. Further, a glass fiber mat may be laminated on the foam 13 in place of the glass fiber chop 14A. Further, the foam 13 may be continuously supplied onto the back glass fiber layer 12 from a roll or the like.

After the formation of the front glass fiber layer 14, a polymeric MDI (curable liquid resin) 37 and a catalyst solution 38 are sprayed on the glass fiber layer 14. The catalyst solution 38 is the same as the catalyst solution 36,
The spray amount of the polymeric MDI 37 and the catalyst solution 38 is appropriately determined. Here, the sprayed polymeric MDI 37 and catalyst solution 38 penetrate and are retained on the surface and inside of the front glass fiber layer 14.

Next, the air-permeable sheet material (in this example, a polypropylene melt-blown nonwoven fabric) 21 is laminated on the front side glass fiber layer 14, and a powdery thermoplastic resin powder (EVA in this example) is placed thereon. Spray M as appropriate. In this example, 50 to 60 g / m of the thermoplastic resin powder M is used.
Sprayed at a rate of ² .

Thereafter, a top cloth (polyester nonwoven fabric in this example) 31 is laminated on the air-permeable sheet 21. In addition, the said cloth 31 can be suitably selected according to the physical properties, use, etc. required of the molded ceiling 10 for vehicles.

Then, the laminate in which the above members are laminated is sent by the conveyor F to the position of a cutting jig C such as a cutter, where it is cut into a predetermined size. At this time, in this example, since the foam 13 has a predetermined size in advance, another member, that is, the breathable sheet material 21 or the top cloth 31 is cut at a position which is an end of the foam 13. .

Next, the cut laminate 10A is
It is arranged between a heating die P composed of a lower die P1 and an upper die P2 and is heated and pressed. The lower mold P1 and the upper mold P2 have a mold surface (inner surface) shape adapted to the outer surface of the molded ceiling 10 for a vehicle, and a heater and a heat medium pipe are disposed inside. To a predetermined temperature.
The mold surface temperature, press pressure, and press time are appropriately set in consideration of the material and the like of each member. In this example, the mold surface temperature is 13
0 ° C., press pressure 2.5 kg / cm ² , press time 3
0 to 15 seconds.

By this heating press, the laminate 10
A is shaped into a mold surface shape, and the glass fiber layer 1
Polymeric MDI3 impregnated and held in 2,14
5 and 37 are between the glass fiber layers 12 and 14 and the foam 13, and between the front glass fiber layer 14 and the breathable sheet 21.
Partially exudes between the glass fiber layers 12, 14 and the foam 13 due to the heat of the mold surface, between the front glass fiber layer 14 and the gas permeable sheet material 21, and between the glass fiber layers 13, 14. Initiates the curing reaction within. Then, the polymeric MDIs 35, 37 are connected to the glass fiber layer 12,
14 rapidly cures by the action of the catalyst solutions 36 and 38 attached to the foam 13 and the glass fiber layers 12 and 14.
And the air-permeable sheet material 21 are bonded and integrated, and their shapes are fixed. At this time, since the air-permeable sheet material 21 does not allow liquid to pass through, the polymeric MDI does not exude to the outer cloth 31 side.

Also, the backside hot melt film 16 between the backside glass fiber layer 12 and the backing material 15 is melted by the heat of the mold surface during the hot pressing, and the backside glass fiber layer 12 and the backing material 15 are bonded. In addition, the thermoplastic resin powder M between the breathable sheet material 21 and the surface cloth 31 melts,
By the subsequent curing, the air-permeable sheet material 21 and the surface cloth 31
Are bonded and integrated.

Thereafter, the laminated product 10B having been bonded and fixed in shape is pressed with a trimming mold T or the like, and the laminated product 1B is pressed.
Unnecessary portions around the periphery of 0B are cut off to obtain a desired molded ceiling 10 for a vehicle shown in FIG. Thus, the molded ceiling 10 for vehicles
Is manufactured, the molded ceiling 10 can be obtained very efficiently.

In order to confirm the sound absorbing effect of the vehicular molded ceiling 10 according to one embodiment of the present invention obtained by the above-described manufacturing examples, the sound absorbing performance was measured as follows. In this measurement, according to JIS-A-1405, a sample piece S of a predetermined size is prepared from the molded ceiling 10 as shown in FIG. 3 and the sample piece S is 1000 mm in length (100 to 100 mm).
1600 Hz measurement) or 300 mm (800 to 650
A sound source Y that emits sounds of various frequencies is arranged at one end of a cylindrical member X made of 0 Hz measurement), and a sound source Y that emits sounds of various frequencies is arranged at the other end. By measuring the volume with the microphone Z, the vertical sound absorption coefficient ([initial (setting) volume value−measured volume value] / initial volume value × 100) for each frequency was measured. In addition, the base material 51 described with reference to FIG.
The sound absorption performance of the molded ceiling 50 of the comparative example in which the hot melt film 56 is disposed between the hot melt film 56 and the top cloth 55 was measured in the same manner. The measurement results are shown in Table 1 below.

[0045]

[Table 1]

As is clear from Table 1, the molded ceiling 10 for the vehicle of the embodiment has a larger sound absorption coefficient as a whole than the molded ceiling 50 for the vehicle of the comparative example, and has a high sound absorbing effect. You can see that. In particular, it can be confirmed that the sound absorption effect of the high frequency range sound is significantly improved.

Further, in the molded ceiling 10 for a vehicle of the embodiment,
At the time of hot pressing at the time of production and after the production,
Exudation of the curable liquid resin to one side was not observed. Therefore, it can be said that the defects in the appearance and the manufacturing described in the section of the related art could be solved.

[0048]

As shown and described above, in the molded ceiling for a vehicle according to the present invention, the front side hot melt film between the substrate and the surface cloth is eliminated, and the ventilation between the substrate and the surface cloth is eliminated. Since the conductive sheet is provided, the sound generated in the vehicle compartment is transmitted well into the base material, and the sound absorbing effect is dramatically improved. In addition, since the gas-permeable sheet material allows gas to pass therethrough but does not allow liquid to pass through, it is possible to eliminate problems such as the curable liquid resin seeping out of the surface cloth at the time of manufacturing the molded ceiling and thereafter, The appearance and productivity of the molded ceiling for vehicles are improved. Further, since the backing treatment of the outer cloth as described in the section of the related art is not required, it is possible to avoid inconveniences such as an increase in cost and an increase in the weight of the molded ceiling.

In particular, the air-permeable sheet material may be a melt-blown non-woven fabric or a composite of a melt-blown non-woven fabric and a spun-bonded non-woven fabric according to the second aspect of the present invention.
The weight per unit area of the melt blown nonwoven fabric is 10
g / m ² or more, the air-permeable sheet-like material has sufficient air-permeability and non-liquid-permeability, the sound absorption performance of the molded ceiling for vehicles is improved, and the curable liquid resin for the top cloth is used. The effect of preventing seepage is further enhanced.

Further, when the base material is configured as in the inventions of claims 4 to 7, the base material, and eventually the molded ceiling for a vehicle, can be made excellent in rigidity, heat insulation, workability and economy. Very useful.

Further, if the air-permeable sheet material and the top cloth are bonded and integrated by melting and curing of the thermoplastic resin powder as in the invention of claim 8, the air-permeable sheet material and the surface cloth can be combined with the air-permeable sheet material. A cloth can be easily glued together,
The adhesive strength is sufficient, and the sound absorbing effect of the molded ceiling for vehicles is not reduced.

Further, when a molded ceiling for a vehicle is manufactured as in the method invention of claim 9, a molded ceiling exhibiting the above effects can be obtained with high working efficiency.

[Brief description of the drawings]

FIG. 1 is a partial sectional view showing a molded ceiling for a vehicle according to an embodiment of the present invention.

FIG. 2 is a schematic view showing an example of a method for manufacturing the molded ceiling for a vehicle.

FIG. 3 is a schematic diagram showing a state of sound absorption performance measurement.

FIG. 4 is a partial sectional view showing a main part of a molded ceiling for a vehicle according to another embodiment.

FIG. 5 is a partial cross-sectional view showing an example of a conventional molded ceiling for a vehicle.

[Explanation of symbols]

 REFERENCE SIGNS LIST 10 Molded ceiling for vehicle 11 Base material 12 Back glass fiber layer 13 Foam 14 Front glass fiber layer 21 Breathable sheet material 31 Surface cloth 35, 37 Curable liquid resin M Thermoplastic resin powder

──────────────────────────────────────────────────の Continued on the front page (51) Int.Cl. ⁷ Identification symbol FI Theme coat ゛ (Reference) B29K 105: 08 B29K 105: 08 B29L 31:58 B29L 31:58 F term (Reference) 3D023 BA01 BA03 BB03 BC01 BD01 BE04 BE06 BE20 BE31 4F100 AG00A AG00D AG00E AK01A AK01G AT00A BA03 BA05 BA10A BA10C BA10E BA13 DE01G DG01A DG01D DG01E DG11C DG15B DG18B DJ01A EC03G EC18G EC182 EH012 EJ08A EJ08G EJ172 EJ422 EJ82A GB33 JB12A JB16G JD02B JD02C JH01 JJ02 JK01 JK06 JL02 JL05 JL11 YY00B 4F211 AA36 AD04 AD16 AD17 AD18 AG03 AG20 AH26 TA03 TA04 TC05 TD11 TH06 TJ30 TN43 TN44 TN55 TN60 TQ04 TQ10

Claims (9)

[Claims] 1. A molded ceiling for vehicles, wherein a gas-permeable but liquid-permeable gas-permeable sheet material and a gas-permeable top cloth are laminated and fixed to at least one side of a self-holding base material. . 2. The molded ceiling for a vehicle according to claim 1, wherein the air-permeable sheet is formed of a melt-blown non-woven fabric or a composite of a melt-blown non-woven fabric and a spun-bonded non-woven fabric. 3. The meltblown nonwoven fabric has a basis weight of 10 g.
/ M ² or more, the molded ceiling for vehicles according to claim 2, characterized in that: 4. The molded ceiling for a vehicle according to claim 1, wherein the substrate includes a glass fiber impregnated and cured with a curable liquid resin. 5. The base material includes a foam obtained by impregnating and curing a curable liquid resin in a foam.
The molded ceiling for vehicles according to any one of claims 1 to 3. 6. The substrate according to claim 1, wherein the substrate includes a laminate of a glass fiber and a foam, which is obtained by impregnating and curing a curable liquid resin. Molded ceiling for vehicles. 7. The molded ceiling for a vehicle according to claim 6, wherein the laminate of the glass fiber and the foam has a sandwich structure in which the foam is an intermediate layer and both layers are glass fibers. 8. The molding for vehicles according to claim 1, wherein the air-permeable sheet material and the surface cloth are bonded and integrated by melt-hardening of the thermoplastic resin powder. ceiling. 9. A method of manufacturing a molded ceiling for a vehicle in which a base material and a surface cloth are laminated, and the laminated body is hot-pressed to fix the shape and adhere integrally, wherein a gas is interposed between the substrate and the surface cloth. A method for manufacturing a molded ceiling for a vehicle, comprising interposing a gas-permeable sheet material that passes through but does not allow liquid to pass therethrough, and adhesively integrates the above members.