JP2006198964A - Molded ceiling material for vehicle and its manufacturing method - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To obtain a molded ceiling material in which a core material layer, reinforcing layers and a skin layer are laminated, which excels in manufacturing cost and productivity by bonding the core material and the skin without using an adhesive without using the adhesive, and also excels in sound absorption property as a molded ceiling. <P>SOLUTION: The molded ceiling material for vehicle is formed by laminating, on both sides of the core material layer 2, film layers 3, 4 as reinforcing layers consisting of a polypropylene film or a polyethylene film; heating the film layers to provide fluidity to cause the film layers to penetrate the surface of the core layer 2 to form a hardened thermoplastic sheet ; and laminating the skin layer 5 on the outside of one of the film layers and the rear paper layer 6 on the outside of the other film layers. Many through holes 7 are formed at least in the film layer 3 of the skin side. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

  The present invention relates to a lightweight molded ceiling material for a vehicle excellent in manufacturability and a method for producing the same.

  2. Description of the Related Art As a molded vehicle ceiling, there is known a molded ceiling in which urethane or the like is used as a core material, reinforcing layers are provided on both sides thereof, and a skin layer is provided on the outer side thereof. In this case, as the reinforcing layer, a glass mat or vegetable fiber coated with (impregnated with) a resinous adhesive is sandwiched on both sides of the core material in order to reinforce the core material and obtain adhesive strength between the skin and the backside paper. There are many things in As the skin layer, a nonwoven fabric, a woven fabric, a knitted fabric, a plastic sheet or the like is used.

  For example, urethane or the like is used as a core material, a glass fiber reinforcement layer is provided on both sides thereof, and a skin layer is provided on the outside thereof. A nonwoven fabric, a woven fabric, a plastic sheet is used as the skin fabric, and acrylic is used on the inside. A laminate obtained by laminating a foam layer is known (see, for example, Patent Document 1).

  In addition, urethane is used as a core material, and reinforcing layers are provided on both sides, and a skin layer is provided on the outside. The reinforcing layer is a natural material instead of glass fiber and has excellent recyclability. The thing using the plant fiber which was made is known (for example, refer patent document 2).

Further, although it is a vehicle interior material such as a door trim and a roof trim, a core material made of a foam of a semi-rigid urethane resin, a reinforcing film fixed to at least one surface of the core material, and a fibrous structure or A trim material for vehicle interior comprising a back surface having foam and a skin fixed to the core member via the film, wherein the trim material for vehicle interior is formed of a mixture of a thermoplastic olefin and polypropylene. It is known (see, for example, Patent Document 3).
JP 2001-301539 A JP 2001-47544 A Japanese Patent Application Laid-Open No. 07-195578

  In Patent Document 1, a glass fiber layer is provided on both sides of a polyurethane foam layer, and a skin layer is provided on the outside of the glass fiber layer, and a sound absorption made of a nonwoven fabric or a glass mat is provided between the glass fiber layer and the skin layer. The thing which arrange | positioned the performance improvement material is disclosed.

  However, since glass fiber is used, when the molding terminal generated during product molding is disposed of, or when incinerated to process used products, the molten glass adheres to the incinerator wall surface, thereby increasing the incinerator life. I have a problem of significant inhibition.

  Moreover, in patent document 2, since a reinforcement layer is a vegetable fiber, it is excellent compared with a glass fiber regarding the point of an incinerator lifetime.

  However, natural fibers cause an environmental problem that VOCs such as formaldehyde are mainly generated although they are in minute amounts during incineration. Furthermore, there arises a problem that the molded interior material is deformed during use due to expansion and contraction or a decrease in rigidity when the plant fiber absorbs moisture. Particularly, a three-dimensionally three-dimensionally molded ceiling material such as a ceiling material cannot be used as a product because it is greatly deformed due to factors such as expansion / contraction and rigidity reduction. That is, if the glass fiber is replaced with plant fiber and the plant fiber is used alone, the function as the reinforcing layer is insufficient and cannot be put into practical use.

  Further, in Patent Document 3, since the reinforcing layer is neither glass fiber nor plant fiber, there is no problem in Patent Documents 1 and 2 and the like.

  However, when this material is used as a molded ceiling, the urethane foam core material is completely covered with a polypropylene film, so that there is a problem that the sound absorbing function is insufficient and the commercial property as a molded ceiling is remarkably lowered.

  An object of the present invention is to use a reinforcing material in place of glass fiber or plant fiber and to obtain a material excellent in sound absorption as a molded ceiling.

  In order to achieve this object, in the present invention, polypropylene film or polyethylene film is used as a reinforcing material in place of glass fiber or plant fiber, and a large number of through-holes are formed in the film for sound absorption as a molded ceiling. I tried to be excellent.

  Specifically, in the invention according to claim 1, the molded ceiling material for a vehicle includes a core material layer made of urethane foam, a polypropylene film layer bonded to both sides of the core material layer, and one polypropylene film layer. Consists of a skin layer bonded to the outside and a back material layer laminated on the outside of the other polypropylene film layer as necessary, and at least a number of through-holes are formed in the polypropylene film layer on the skin side It is.

  According to a second aspect of the present invention, a molded ceiling material for a vehicle is joined to a core material layer made of urethane foam, a polyethylene film layer joined to both sides of the core material layer, and the outside of one polyethylene film layer. It consists of a skin layer and a back material layer laminated on the outside of the other polyethylene film layer as needed, and has a structure in which a number of through holes are formed at least in the polyethylene film layer on the skin side.

  A third aspect of the present invention is the molded ceiling material for a vehicle according to the first or second aspect, wherein the opening area ratio of the through holes is 1 to 65%.

  According to a fourth aspect of the present invention, in the molded ceiling member for a vehicle according to the first or second aspect, the size of the through hole is a diameter of 0.05 mm to 5 mm.

  According to a fifth aspect of the present invention, in the molded ceiling material for a vehicle according to any one of the first to fourth aspects, the film layer has a thickness of 15 μm to 200 μm.

  According to a sixth aspect of the present invention, in the molded ceiling material for a vehicle according to any one of the first to fifth aspects, a reinforcing layer is formed by laminating a fiber layer made of reinforcing fibers on one side or both sides of the film layer. It is the composition which consists of.

  A seventh aspect of the present invention is a molded ceiling member for a vehicle according to any one of the first to fifth aspects, wherein the reinforcing fiber is mixed with the film layer and the reinforcing layer is integrally formed.

The invention of claim 8 is the vehicle formed ceiling material according to claim 7, fibers for reinforcement, the structure is a basis weight range of ^{15g / m 2 ~300g / m 2} .

  The invention of claim 9 is the molded ceiling material for vehicles according to any one of claims 6 to 8, wherein the reinforcing fiber is at least one of natural plant fibers including kenaf, sisal, hemp, cactus, bamboo, and wood. It is the structure which combines.

  A tenth aspect of the present invention is the molded ceiling material for a vehicle according to any one of the sixth to ninth aspects, wherein the reinforcing fibers include inorganic fibers such as carbon and basalt.

  An eleventh aspect of the invention is the molded ceiling member for a vehicle according to any one of the sixth to tenth aspects, wherein the reinforcing fiber has a fiber length of 10 to 100 mm and a fiber thickness of 1.0 mm or less. is there.

  A twelfth aspect of the present invention is the molded vehicle ceiling material according to any of the seventh to eleventh aspects, wherein the reinforcing layer has a thickness of 0.1 mm to 3 mm.

  The invention of claim 13 includes a core layer made of urethane foam, a polypropylene film layer or a polyethylene film layer bonded to both sides of the core layer, and a skin layer bonded to the outside of the one film layer, A formed ceiling material comprising a back material layer such as a nonwoven fabric or paper laminated on the outside of the other film layer as required, and at least a number of through holes are formed in the film layer on the skin side A manufacturing method is prepared in which a large number of through holes are formed in at least the film layer on the skin side. Next, by heating the film layer on both sides of the urethane foam sheet-like core material to 150 to 250 ° C., the film layer is given fluidity within the surface of the sheet-like core material. A thermoplastic sheet-like core material in which both surfaces are cured is produced. After that, before molding, the thermoplastic sheet-like core material is reheated to 150 to 250 ° C. so as to be moldable, and a skin material is stacked on one side of the heated sheet-like core material, and on the other side. It is characterized in that it is set in a cold mold for molding ceiling and pressure-molded with the back material stacked as necessary.

  The invention of claim 14 includes a core layer made of urethane foam, a polypropylene film layer or polyethylene film layer bonded to both sides of the core layer, and a skin layer bonded to the outside of the one film layer; A formed ceiling material comprising a back material layer such as a nonwoven fabric or paper laminated on the outside of the other film layer as required, and at least a number of through holes are formed in the film layer on the skin side A manufacturing method is prepared in which a large number of through holes are formed in at least the film layer on the skin side. Next, the film layer is overlaid on both sides of the urethane foam sheet-like core material, and a skin material is provided on the outer side of the film layer on one side, and a back material is provided on the outer side of the film layer on the other side as required. By heating each layer to 150 to 250 ° C., fluidity is imparted to the film layer so as to penetrate into the surface of the sheet-like core material, and adhesion to the skin layer is imparted. The molded product is set in a cold mold for molding ceiling and is subjected to pressure molding.

  According to the first aspect of the present invention, the polypropylene film is disposed on both sides of the urethane core material, and the film is heated to impart fluidity to permeate the surface of the core material. The core material and the skin can be fixed via a film without using an adhesive. Therefore, no adhesive is required, and the material cost and processing time can be reduced by that much, resulting in excellent productivity. In particular, since a large number of through holes are formed in the film, it is possible to obtain a molded ceiling material excellent in sound absorption and silencing performance in combination with the foamable urethane core material.

  According to the second aspect of the present invention, a molded ceiling material excellent in sound absorption and silencing performance as in the first aspect can be obtained.

  According to the invention of claim 3, it is possible to obtain a molded ceiling material that is excellent in sound absorption and silencing performance and at the same time has excellent shape followability during molding and shape retention during use.

  According to the invention of claim 4, it is possible to obtain a molded ceiling which is further excellent in sound absorption and silencing performance and at the same time has excellent shape followability during molding and shape retention during use.

  According to the invention of claim 5, since a thin film may be used, the formed ceiling material can be reduced in weight, and handling during work, transportation, etc. is facilitated.

  According to the invention of claim 6, an excellent reinforcing function and adhesive function can be obtained. In particular, since the shape retention is good, it is suitable for a three-dimensional molded ceiling or a molded ceiling with a large area. In addition, the film does not ooze out to the skin side, and the appearance on the surface side is very good.

  According to the seventh aspect of the present invention, when the molded ceiling receives an environmental history such as a temperature change or a humidity change, it is extremely excellent in deformation resistance against a shape change. In particular, since the shape retention is good, it is suitable for a three-dimensional molded ceiling or a molded ceiling with a large area.

  According to the eighth aspect of the present invention, it is possible to obtain a high-strength material that has elongation that can follow deformation during molding.

  According to the invention of claim 9, plant fibers are advantageous for pollution problems at the time of disposal and are easy to dispose and recycle.

  According to the invention of claim 10, a further excellent reinforcing function and adhesive function can be obtained.

  According to invention of Claim 11, mixing of fibers can be ensured and the fiber body in which the fiber fully entangled is obtained.

  According to invention of Claim 12, since a reinforcement layer is obtained as a thin sheet | seat, it can reduce in weight and a thing with a good shape followable | trackability is obtained.

  According to the invention of claim 13, no adhesive is required, the processing effort can be reduced, and the productivity is excellent. In particular, a molded ceiling having good shape retention can be obtained by the film, and a large number of through holes are formed in the film, so that a molded ceiling material having excellent sound absorption and silencing performance can be obtained.

  According to the fourteenth aspect of the present invention, a molded ceiling with good shape retention can be obtained by a simple molding method, and a large number of through holes are formed in the film. Can be obtained.

  Embodiments of the present invention will be shown below to specifically describe the present invention. FIG. 1 shows a perspective view of a molded ceiling material for automobiles according to an embodiment of the present invention, and FIG. 2 shows a partial sectional view of FIG. As shown in FIG. 1, the molded ceiling material 1 is formed in a three-dimensional shape with a recessed center. A part and B part of FIG. 1 show a part which is greatly deformed three-dimensionally because a front sun visor (not shown) of the formed ceiling material is provided. As shown in FIG. 2, the molded ceiling material 1 has a cross-section in which film layers 3 and 4 made of polypropylene film or polyethylene film are disposed on both sides of the urethane foam core material layer 2, respectively. The skin layer 5 and the back paper layer 6 (back material layer) are bonded to the other side, respectively. As shown in FIG. 3, the film layers 3 and 4 are provided with a large number of through holes 7. Of course, the present invention can be applied to a ceiling material for vehicles other than automobiles.

  In an embodiment of the present invention, a polypropylene foam film or a polyethylene film provided with through-holes 7 is infiltrated into the surface of urethane foam, and a thermoplastic foam urethane sheet having a cured surface is obtained. If the opening area ratio of the through-holes 7 in the polyethylene film is large, the rigidity is weak and the film is cracked or torn during molding. On the other hand, if the opening area ratio is small, there is no sound absorption performance and it cannot be used as a molded ceiling. Therefore, the open area ratio of the through hole 7 is preferably 1 to 65%, and particularly preferably 5 to 50%. These through-holes 7 may be evenly opened on the entire surface of the molded ceiling 1 or the number and size of the through-holes 7 are reduced in the portion where the follow-up deformability during molding is large, and the other portions are penetrated. It is also possible to increase the number of holes 7. Or it is also possible to increase the number of the through-holes 7 of the part for which sound absorption performance is requested | required, and to reduce others.

  Further, by providing the through holes 7, when the film is further heated to have fluidity, it quickly penetrates into the uneven surface of the foamed urethane core 2 and the uneven surface of the foamed urethane core 2. It has the merit that the adhesiveness with is strong.

  In the present embodiment, if the size of the through hole 7 is too large, the rigidity becomes weak, and if it is too small, the sound absorbing performance is insufficient. Therefore, the diameter is preferably 0.05 mm to 5 mm, and more preferably 0.1 mm to A diameter of 1 mm is desirable. The shape of the through hole 7 is not limited to a round cross section, and may be an ellipse or the like.

  In the present embodiment, when the thickness of the film layers 3 and 4 is increased, the fluidity is deteriorated, the adhesiveness with the core material 2 is inferior, and conversely, if the film layers are too thin, the surface portion of the surface portion is infiltrated into the core material 2 surface. Since the strength becomes insufficient, the thickness is preferably 15 μm to 200 μm, and particularly preferably 30 μm to 150 μm.

  In this embodiment, a reinforcing layer can be formed by reinforcing fibers on the film layers 3 and 4 on both sides including only the skin side or the back side. This reinforcing layer may be provided so that a fiber layer is laminated on the outer side of the film layer, or may be mixed and provided integrally when forming the film. Alternatively, a part of reinforcing fibers may be mixed and a fiber layer may be further laminated on the outside. The thickness of this reinforcing layer is preferably 0.1 mm to 3 mm. Within this range, the mixed sheet can be made thinner and lighter, and it is easy to follow the shape change during molding. In particular, a range of 0.2 mm to 1 mm is desirable.

  Each fiber bundle used as the reinforcing fiber preferably has a diameter of 1.0 mm or less and a length of 10 to 100 mm. The diameter of the fiber bundle is the length of the shorter diameter when the cross section is not circular. If the diameter exceeds 1.0 mm, fiber irregularities appear on the surface of the molded product, and the appearance is remarkably impaired. More preferably, the diameter is 0.5 mm or less.

  If the length of the fiber bundle is less than 10 mm, the required reinforcing effect cannot be obtained, and conversely, if the fiber is too long, the fibers cannot be uniformly entangled with each other. Furthermore, the thing of 30 mm-50 mm is preferable. In addition, it is not necessary to arrange all the lengths to have uniform lengths, and may have different lengths as long as the length is in the above range.

  When one fiber is very thin such as carbon fiber, the fibers are used in bundles. In addition, if the plant fiber is thin, it is made into a fiber bundle. However, a thick fiber having a fiber diameter of about 0.5 mm may be used as it is, and the fiber bundle means a fiber bundle including these. To do.

  The reinforcing fiber may be a sheet in which at least two kinds of fiber bundles of carbon fiber, basalt, plant fiber, and synthetic fiber are mixed. In the reinforcing layer in that case, the wire diameter (thickness) of each fiber bundle is Those composed of short fibers having a diameter of 1.0 mm or less and a length of 10 to 100 mm are preferable. If the wire diameter is large, the fibers are easily slipped, resulting in insufficient adhesive strength with the filler fibers. Moreover, although the unevenness | corrugation of a fiber may appear on the molded article surface and an external appearance may be impaired remarkably, it can prevent that this unevenness | corrugation appears on the surface by setting it as the said range.

  Further, if the length is long, handling is difficult, and it is not possible to sufficiently mix with the filled fibers, that is, entanglement, but by being in the above range, mixing with the filled fibers can be sufficiently performed.

  The weight ratio of the carbon fiber and the plant fiber / synthetic fiber is preferably 70-30% of the plant fiber / synthetic fiber with respect to 30-70% of the carbon fiber. By setting it as this range, it has suitable tensile strength and can make both joining state favorable. In the production of a mixed sheet of carbon fiber and vegetable fiber / synthetic fiber, a thin film is formed by making a paper sheet from a mixed liquid material in which these fibers are mixed.

  Examples of the plant fiber include those obtained by branch cutting or pulverizing a plant mainly composed of cellulose, and plant fibers such as hemp, kenaf, sisal fiber, bamboo fiber, cactus, and wood fiber. Wood fiber is derived from wood. Examples of this tree include cedar, pine, zelkova, hinoki, hiba, cherry blossom, poplar, and cocoon. This plant fiber has a reinforcing function similar to the carbon fiber, is easy to stretch as compared with the carbon fiber, and is excellent in bondability. Therefore, it is preferable to mix an appropriate amount with the carbon fiber.

  As the synthetic fiber, a thermoplastic resin such as polyethylene, polypropylene, or polyester is used. Since this synthetic fiber has a binder function of carbon fiber and plant fiber, when this synthetic fiber is included, the binder can be eliminated or reduced.

  The manufacturing method of the molded ceiling in this invention is demonstrated. As one manufacturing method, a foamed urethane core material and a film having a large number of through holes are overlapped, and this is heated with a mold heated to, for example, about 150 ° to 250 ° C. for 15 to 60 seconds. Thus, a plate-like sheet is manufactured. In this case, if the heating temperature is high or the heating time is long, the film does not remain on the surface of the core material but penetrates into the core material, which is not good. On the other hand, if the heating temperature is low or the heating time is short, the film is not melted sufficiently and sufficient fluidity cannot be obtained. In particular, the heating temperature is preferably in the range of 170 ° C to 220 ° C, and the heating time is preferably 25 to 45 seconds.

  In this manner, a plate-like thermoplastic sheet is produced in which the film layers are adhered and hardened on both sides of the urethane foam core material. It is a simple plate-like sheet that has hardened on both sides, is easy to handle, and is easy to transport and stack. In order to prevent adhesion to the mold, a film layer or mold may be coated with a Teflon (registered trademark) coat or the like.

  When forming into a molded ceiling, it is heated again within the above temperature and time range at a temperature relatively lower or shorter than the above temperature to give the plate-like sheet formability and the film with the skin layer. Give adhesiveness. A skin material is stacked on one outer side of this heated plate-shaped sheet, and a back material such as a nonwoven fabric or paper is stacked on the other outer side if necessary, and set in a cold mold (not shown) for forming ceiling. Then, pressure molding is performed to form a molded ceiling. It should be noted that the back material such as non-woven fabric and paper is stacked to prevent the film from adhering to the molding die and to prevent the rattling noise when the wire harness is assembled on the back surface of the molding ceiling and the molding ceiling itself is the body. This is to prevent hitting the member with a rusting noise or abnormal noise. In this method, since it is not necessary to heat the mold, the mold equipment can be made compact and low in cost.

  Another manufacturing method will be described. A film in which a large number of through holes are formed on both sides of the urethane foam core material is overlaid, and a skin material on one side and a backside paper on the other side are prepared. This laminated product is heated to, for example, about 150 ° to 250 ° C. and held for 15 to 60 seconds to impart fluidity to the film, impart moldability, and allow the core material, skin material, and backside paper to be in close contact with each other. After that, the heated one is set in a cold mold for a molding ceiling and pressure-molded at once. This method requires only one heating step and is excellent in productivity.

  When tricot is used as the skin material, when the film is reheated to a temperature at which the film softens, hair fall may occur or light may be emitted. Therefore, in the case of this skin, it is preferable to adopt the former molding method instead of the latter molding method in which urethane foam core material, film, skin and back paper are heated and molded at a time.

As the skin sheet, tricot, moldable knit, fabric, non-woven fabric, suede-like synthetic leather, PVC (polyvinyl chloride) leather, TPE (thermoplastic elastomer) sheet and the like are used. The back paper may be a simple film layer, or a non-woven fabric of about 25 g / m ² may be provided inside the film.

  Next, specific examples will be described.

Example 1
As the core material layer 2 according to the above-described embodiment, a hard urethane foam sheet (1200 mm × 1600 mm × thickness 5.5 mm) having CS hardness of 32 and having open cells having a unit area weight of 200 g / m ² was prepared. Further, a tricot-made skin was prepared as the skin layer 5, and a release paper was prepared as the release layer 6. Further, as the film layers 3 and 4, a polypropylene film having a thickness of 50 μm in which through holes 7 having a hole diameter of 0.5 mm were opened with an opening area ratio of 5% was prepared.

  This film was stacked on both sides of the core material, set in a sheet molding die heated to 180 ° C., and pressed for 30 seconds to form a sheet. After leaving this sheet for one day, it was set again in a sheet molding die heated to 180 ° C. and pressed for 20 seconds to be ready for molding. The heated sheet was set in a cold mold to form a molded ceiling material.

  As a comparative example for comparison, a polypropylene film having no through hole 7 was also molded in the same manner.

  As a result, even the portion A and portion B in FIG. 1 of the present Example 1 was sufficiently stretched to follow and could be molded without being thinned or torn. On the other hand, although the thing of the comparative example was able to shape | mold, thickness was a little thin in the A part and B part of FIG.

  In order to compare the sound-absorbing performance as a molded ceiling, samples having a through hole opening area of 5%, 20%, and 60% were prepared as samples a, b, and c of Example 1, and compared with comparative examples. . The result is shown in FIG. Samples a, b, and c of Example 1 have a bending strength of 15 N / 50 mm or more, a sufficient strength at the time of molding, and a sound absorption performance of 38% / 2 kHz or more, exhibiting sufficient sound absorption. ing. On the other hand, in the comparative example, the bending strength was sufficient, but there was no sound absorbing property and the performance as a molded ceiling was insufficient.

(Example 2)
As Example 2, a laminate of the film of Example 1 and a reinforcing fiber layer was prepared. This reinforcing fiber layer has a fiber length of 50 mm and a fiber bundle thickness of 0.5 mm. The thickness of the laminate of film and fiber is a weight of 80 g / m ² of mixed fiber of carbon fiber and sisal fiber. 4 mm.

  And the molded ceiling was produced similarly to the said Example 1. FIG. In Example 2, even the A part and the B part in FIG. 1 were sufficiently stretched and followed, and could be formed without being thinned or torn. In particular, since it has a reinforcing fiber layer, it has excellent rigidity and not only excellent followability to follow deformation at the time of molding, but also the center does not sag after molding, and a molded ceiling with a large area or deep It had sufficient practicality as a molded ceiling.

  The present invention provides a molded ceiling material in which a core material layer, a reinforcing layer, and a skin layer are laminated, and is excellent in manufacturing cost and productivity by bonding the core material and the skin without using an adhesive. It is extremely useful because it can be obtained with excellent properties, and has high industrial applicability.

FIG. 1 is a perspective view showing a molded ceiling material according to an embodiment of the present invention. FIG. 2 is a partial cross-sectional view of a molded ceiling material. FIG. 3 is a partially enlarged plan view of the film. FIG. 4 is a graph showing the bending rigidity and sound absorption of the example.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Molding ceiling material 2 Foam urethane core material layer 3 Film layer 4 Film layer 5 Skin layer 6 Back surface paper layer (back surface material layer)
7 Through hole

Claims (14)

Necessary on the outside of the core layer made of urethane foam, the polypropylene film layer bonded to both sides of the core layer, the skin layer bonded to the outside of one polypropylene film layer, and the other polypropylene film layer It consists of a back material layer that is laminated according to the
A molded ceiling material for a vehicle, wherein a plurality of through holes are formed in at least a polypropylene film layer on the skin side. Necessary on the outer side of the core layer made of urethane foam, the polyethylene film layer bonded to both sides of the core layer, the skin layer bonded to the outside of one polyethylene film layer, and the other polyethylene film layer It consists of a back material layer that is laminated according to the
A molded ceiling material for a vehicle, wherein a plurality of through holes are formed in at least a polyethylene film layer on the skin side. In the molded ceiling material for vehicles according to claim 1 or 2,
The molded ceiling material for a vehicle, wherein an opening area ratio of the through holes is 1 to 65%. In the molded ceiling material for vehicles according to claim 1 or 2,
The molded ceiling material for a vehicle, wherein the through hole has a diameter of 0.05 mm to 5 mm. The molded ceiling material for a vehicle according to any one of claims 1 to 4,
A molded ceiling material for vehicles, wherein the film layer has a thickness of 15 μm to 200 μm. The molded ceiling member for a vehicle according to any one of claims 1 to 5,
A molded ceiling material for vehicles, wherein a reinforcing layer is formed by laminating a fiber layer made of reinforcing fibers on one side or both sides of a film layer. The molded ceiling member for a vehicle according to any one of claims 1 to 5,
A molded ceiling material for a vehicle, wherein reinforcing fibers are integrally formed by mixing reinforcing fibers in a film layer. In the molded ceiling material for vehicles according to claim 7,
Fibers for reinforcement, the vehicle molding ceiling material, which is a basis weight range of ^{15g / m 2 ~300g / m 2} . The molded ceiling member for a vehicle according to any one of claims 6 to 8,
A molded ceiling material for vehicles, wherein the reinforcing fiber is a combination of at least one natural plant fiber including kenaf, sisal, hemp, cactus, bamboo, and wood. The molded ceiling member for a vehicle according to any one of claims 6 to 9,
A molded ceiling material for vehicles, wherein the reinforcing fibers include inorganic fibers such as carbon and basalt. The molded ceiling member for a vehicle according to any one of claims 6 to 10,
A molded ceiling material for a vehicle, wherein the reinforcing fiber has a fiber length of 10 to 100 mm and a fiber thickness of 1.0 mm or less. The molded ceiling member for a vehicle according to any one of claims 7 to 11,
A molded ceiling material for a vehicle, wherein the reinforcing layer has a thickness of 0.1 mm to 3 mm. A core layer made of urethane foam, a polypropylene film layer or a polyethylene film layer bonded to both sides of the core layer, a skin layer bonded to the outside of the film layer on one side, and a film layer on the other side A method for producing a molded ceiling material for a vehicle, comprising a back material layer such as a nonwoven fabric or paper laminated on the outside as required, wherein a number of through holes are formed in the film layer on the skin side,
Prepare at least a number of through-holes in the film layer on the skin side,
By heating the film layer on both sides of the urethane foam sheet-like core material to 150-250 ° C., the film layer is given fluidity and penetrated into the surface of the sheet-like core material. , To produce a thermoplastic sheet core material with both surfaces cured,
Then, before molding, the thermoplastic sheet-like core material is reheated to 150 to 250 ° C. to be in a moldable state,
With the skin material layered on one side of the heated sheet-like core material and the back material on the other side, if necessary, it is set in a cold mold for molding ceiling and pressure molded. A method for producing a molded ceiling material for a vehicle. A core layer made of urethane foam, a polypropylene film layer or a polyethylene film layer bonded to both sides of the core layer, a skin layer bonded to the outside of the film layer on one side, and a film layer on the other side A method for producing a molded ceiling material for a vehicle, comprising a back material layer such as a nonwoven fabric or paper laminated on the outside as required, wherein a number of through holes are formed in the film layer on the skin side,
Prepare at least a number of through-holes in the film layer on the skin side,
The film layer was overlaid on both sides of the urethane foam sheet-like core material, and a skin material was laminated on the outside of the film layer on one side, and a back material was laminated on the outside of the film layer on the other side as needed. By heating the material to 150 to 250 ° C., the fluidity is imparted to the film layer so as to penetrate into the surface of the sheet-like core material and the adhesiveness with the skin layer is imparted.
Thereafter, the heated product is set in a cold mold for a molded ceiling and pressure-molded, and a method for producing a molded ceiling material for a vehicle is provided.

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