JP2006218759A - Molded ceiling material for car and its production method - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a molded ceiling material for a car which has excellent shape holding characteristics over a long time even when glass fibers are not used and is light in weight and low in costs and a method for producing the ceiling material which can give a curved surface by hot-press molding. <P>SOLUTION: In the molded ceiling material for a car having at least three elements of a skin material 43, a paper honeycomb core 20, and semi-rigid or rigid polyurethane foam 42, the paper honeycomb core 20 is incorporated as a ceiling material substrate 41 in a polyurethane foam layer by integral foaming, and a curved surface part molded by hot press is provided. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

  The present invention relates to a molded ceiling material for automobiles and a method for producing the same.

  Conventionally, as a ceiling material for automobile interiors, a molded ceiling material using a semi-rigid or rigid polyurethane foam as a base material of the ceiling material is often used because it is excellent in lightness and sound absorption. As the molded ceiling material for automobiles, the most demanded performance is shape retention, and the first is to maintain the same shape for many years even when it is close to 90 ° C in summer and around -40 ° C in winter. As required.

  Here, as a conventional general-purpose molded ceiling material for automobiles, for example, the one shown in FIG. 17 is known. The ceiling material includes a base material 3 composed of a semi-rigid polyurethane foam 1 and a glass fiber mat 2, a skin material 5 formed on the surface side of the base material 3 with an adhesive 4, and a back surface of the base material 3. It is comprised from the ventilation film 6 formed in the side through the adhesive agent 4. As shown in FIG. Here, the glass fiber mat 2 is used as a reinforcing material for supplementing the rigidity of the semi-rigid polyurethane foam 1 and improving the shape retention. However, glass fiber mats have been avoided because of the recent demand for further weight reduction and the fact that glass components contaminate the inner walls of incinerators when incinerating waste.

  In order to solve this problem, each manufacturer has proposed a ceiling material that does not use glass fiber. For example, Patent Document 1 proposes to use plant fibers such as kenaf fiber and sisal fiber as a reinforcing material. However, in order to give such a plant fiber the same reinforcing effect as glass fiber. The weight per unit area became large, and weight reduction could not be achieved.

  Further, Patent Document 2 proposes a mixture of plant fiber and carbon fiber as a reinforcing material, but carbon fiber is very expensive, so compared to conventional automotive ceiling material using glass fiber. Cost increases. As described above, neither of Patent Documents 1 and 2 has proposed an automobile ceiling material that does not use glass fiber and has a shape retention higher than that of the conventional one at a cost equivalent to that of the conventional one.

  By the way, conventionally, a honeycomb core is known as a representative of rigid materials. This honeycomb core is mainly used as a base material for so-called sandwich panels, which are used as structural panels for buildings, etc., but in order to further increase the rigidity, phenolic resin, epoxy resin, etc. Proposals have been made to fill the foamed resin. For example, Patent Document 3 discloses that a honeycomb core is placed on a foamed epoxy resin undiluted solution applied on a flat surface, and the epoxy foamed resin enters the cell while being foam-cured and filled. Patent Document 4 has also been proposed as a technique similar to this, but it is difficult to reduce the weight of the resin foam because it cannot be used as a highly reactive foamed resin material such as polyurethane foam.

  On the other hand, in Patent Document 5, a sheet-like foamed resin molded in advance to a predetermined density is brought into contact with the honeycomb core for the purpose of obtaining a structure having no variation in filling rate for each cell in any foamed resin. Is pressed to obtain a honeycomb structure having a light weight and a uniform density distribution by embedding a honeycomb core in the foamed resin. However, the honeycomb structure obtained by this method is not sufficiently rigid because the resin foam and the cell wall surface of the honeycomb core are not fixed, and the foamed resin in the cell falls off as soon as it is bent. There was a fear, and it was impossible to use the molded ceiling material for automobiles for the purpose of the present application.

In addition, since the paper honeycomb core (paper honeycomb core) is lightweight, it should be expected to be used for a molded ceiling material substrate for automobiles. However, since a paper honeycomb core does not have thermoplasticity, it cannot be given a curved surface by hot press molding, and has not yet been put into practical use.
JP 2001-47544 A JP 2003-305789 A Japanese Patent Laid-Open No. 11-254563 Actual registration No. 2547420 JP-A-8-258189

  As described above, there has been a demand for a lightweight and low-cost automotive ceiling material that has excellent shape retention over a long period of time as a molded automotive ceiling material without using glass fiber. There was no satisfactory ceiling material.

  The present invention has been made in view of the above circumstances, and an object of the present invention is to obtain a molded ceiling material for automobiles that has excellent shape retention over a long period of time without using glass fibers, and is lightweight and low in cost. And

  The present invention also provides a method for producing an automotive molded ceiling material capable of providing a curved surface by integrally foaming a paper honeycomb core with a foamable polyurethane stock solution and hot press molding in the range of 70 to 220 ° C. With the goal.

  The inventors of the present invention have made various studies using the lightest paper honeycomb core among the honeycomb cores having excellent rigidity. After the foam is integrally foamed with the foamable polyurethane stock solution, the temperature is in the range of 70 to 220 ° C. It has been found that it is possible to impart a curved surface by hot press molding, and that it is also excellent as a molded ceiling material for automobiles because of its excellent shape retention after hot press molding. It came to complete.

  A molded ceiling material for automobiles according to the present invention is a molded ceiling material for automobiles having at least three elements of a skin material, a paper honeycomb core, and a semi-rigid or rigid polyurethane foam layer, wherein the polyurethane foam layer is used as a ceiling material base material. The paper honeycomb core is contained therein by integral foam molding and has a curved surface portion formed by hot press molding.

The method of manufacturing a molded ceiling material for automobiles according to the present invention includes a step of supplying a paper honeycomb core onto the applied foamable polyurethane stock solution after continuously and uniformly applying the foamable polyurethane stock solution on the traveling lower liner. A step of continuously rolling an upper surface liner thereon and foaming and filling the foamable polyurethane stock solution into the cells of the paper honeycomb core, and separating the upper surface liner and / or the lower surface liner, or A process of obtaining a ceiling material body by integrally forming both the upper surface liner and the lower surface liner without peeling, and heat-press-molding the ceiling material body continuously or at a time from 70 to 220 ° C. The method for producing a molded ceiling material for automobiles according to the present invention includes a step of forming on a lower liner that travels. A paper honeycomb core is supplied, and a foamed polyurethane stock solution is continuously and uniformly applied in the cells of the paper honeycomb core, and a top liner is continuously carried on the applied foamed polyurethane stock solution to form a paper honeycomb core. The foaming polyurethane stock solution is foam-filled into the cell and integrated, and the upper liner and / or the lower liner are peeled off, or the upper liner and the lower liner are integrally formed without peeling off the ceiling. The method includes a step of obtaining a material main body, and a step of hot press molding the ceiling material main body at 70 to 220 ° C. continuously or at intervals to form a curved surface portion.

According to the automotive ceiling material of the present invention, it is possible to obtain a molded ceiling material for automobiles that has excellent shape retention over a long period of time without using glass fibers, is lightweight and has excellent sound absorption, and low cost. it can.
In addition, according to the method for manufacturing an automotive ceiling material of the present invention, it is recognized that the paper honeycomb core does not have thermoplasticity and is excellent in rigidity, so that it is impossible to impart a curved surface by hot press molding. Nevertheless, the paper honeycomb core was integrally foamed with the foamable polyurethane stock solution and subjected to hot press molding at a temperature in the range of 70 to 220 ° C., thereby providing a curved surface.

Hereinafter, a molded ceiling material for automobiles and a method for manufacturing the same according to the present invention will be described with reference to the drawings.
As the skin material used in the present invention, it can be appropriately selected from those generally used for automobile ceiling materials, without particular limitation, but particularly for the purpose of not impairing the sound absorption performance. A non-woven fabric or a woven fabric having air permeability is preferable. Two or more of these may be laminated, or may be laminated with a sheet-like flexible polyurethane foam layer to give flexibility and have a high-quality feel.

  As the paper honeycomb core used in the present invention (hereinafter sometimes simply referred to as a honeycomb core), kraft paper or K-liner paper is preferable. The cell shape of the paper honeycomb core is, for example, a hexagonal shape (honeycomb shape) as shown in FIGS. 2A and 2B, and a circular shape (as shown in FIGS. 3A and 3B). S-shaped continuous), corrugated cardboard shape (continuous piece of corrugated cardboard) as shown in FIGS. 4A and 4B, and rib shape (ribs as shown in FIGS. 5A and 5B). 6 (A), (B), origami shape (continuous in origami shape) is exemplified, but many hexagonal cells are arranged in terms of workability and strength. Those are preferred. 2 (A), FIG. 3 (A), FIG. 4 (A), FIG. 5 (A), and FIG. 6 (A) are perspective views of the paper honeycomb core, and FIG. 2 (B) and FIG. ), FIG. 4 (B), FIG. 5 (B), and FIG. 6 (B) are FIG. 2 (A), FIG. 3 (A), FIG. 4 (A), FIG. 5 (A), and FIG. It is a top view of the cell of the paper honeycomb core.

  The thickness (c) of the paper honeycomb core is preferably 3 to 10 mm, particularly 4 to 6 mm in consideration of the product thickness required as a molded ceiling material for automobiles. Here, when the thickness of the paper honeycomb core is less than 3 mm, the rigidity of the formed ceiling material is small, and the initial shape cannot be maintained over a long period of time. On the other hand, if the thickness exceeds 10 mm, the purpose of reducing the weight cannot be achieved.

  The cell size (d) of the paper honeycomb core is appropriately determined with respect to the thickness of the honeycomb core from the viewpoint of maintaining the rigidity of the honeycomb core, but is in the range of 3 to 38 mm with respect to the above thickness range. It is preferable that The ratio of the thickness to the cell size (d / c) of 1.0 to 10.0 at this time can most suitably provide a curved surface along the automobile ceiling shape by hot press molding and also maintain rigidity. The resulting honeycomb core can achieve shape retention that can withstand use as a molded ceiling material for automobiles. 2 to 5, the symbol W in the drawings indicates the width of the honeycomb core, and the symbol L indicates the length of the honeycomb core.

  In addition, as shown in FIG. 7, the paper honeycomb core according to the present invention can be provided with a curved surface having an extremely large curvature during press molding by providing a cut 7 in the thickness direction of at least one surface of the honeycomb core. The position, number, and depth of the cuts 7 are appropriately determined according to the final shape of the molded product, and are not particularly limited, but from the standpoint of maintaining strength, the depth is relative to the honeycomb core thickness. It is preferably 50% or less, and particularly preferably 35% or less. Further, the depth and number of the cuts 7 are determined by the shape of various types of automobile ceilings, and may be provided uniformly over the entire surface, and may be provided more particularly on the side portion having a large curvature. It is not necessary to provide it uniformly over the entire area.

The semi-rigid or rigid polyurethane foam used in the present invention is preferably open-celled for the purpose of improving sound absorption performance. The open cell ratio is preferably 70% or more, more preferably 90% or more in accordance with ASTM D2856-70. Here, if the open cell ratio is less than 70%, the sound absorbing performance is lowered, which is not preferable. The preferred density range of the polyurethane foam is 15 to 70 kg / m ³ , in particular 25 to 55 kg / m ³ . Here, if the density is less than 15 kg / m ³ , the rigidity of the ceiling material after molding is small, and the initial shape cannot be maintained over a long period. On the other hand, if the density exceeds 70 kg / m ³ , the rigidity is increased but the weight is increased, and the object of the present application cannot be achieved.

  By the way, an atmospheric pressure difference may occur in the space between the vehicle interior space side and the vehicle body outer plate side with the ceiling material as a boundary when the automobile is running. At this time, if the ceiling material has air permeability, an air flow is generated from the inside of the vehicle toward the space on the outer plate side. At that time, the ceiling material acts as a dust collection filter, and the inside surface of the ceiling material Occurs (so-called air pollution). Therefore, for the purpose of preventing this air pollution, it is common to laminate a non-breathable film (hereinafter referred to as a vent layer) only on the outer surface of the ceiling material base. It can also be laminated on molded automotive ceilings. It is not preferable to provide the ventilation stop layer also on the inner surface of the ceiling material base material because sound absorption characteristics are prevented and sound generated in the vehicle is reflected.

  The gas barrier layer used in the present invention is not particularly limited as long as it is a non-breathable plastic film or a non-breathable non-woven fabric, but it does not interfere with giving a curved surface by hot press molding. A film having appropriate extensibility is preferable, and examples thereof include an olefin film and a urethane film. Among these, a polypropylene film is particularly preferable in that it is low cost. However, because polypropylene has extremely low adhesive strength with urethane, the surface to be bonded has been surface-modified by corona discharge treatment, etc., or has a plurality of fine holes so that the air permeability is not too high. It is preferable that The thickness of the non-breathable plastic film or non-breathable nonwoven plastic film is not particularly limited, but is preferably 15 to 100 μm, particularly preferably 30 to 50 μm from the viewpoint of cost and weight.

  Incidentally, the molded ceiling material for automobiles of the present invention is obtained by obtaining a ceiling material base material in which a paper honeycomb core is contained in a semi-rigid or rigid polyurethane foam layer by integral foam molding, and then using an adhesive. A sheet-like flexible polyurethane foam or a ventilation film may be laminated. Alternatively, when the paper honeycomb core, which is a ceiling material base material, and the polyurethane foam are integrally foam-molded, by supplying a skin material and a gas barrier layer as an upper surface liner or a lower surface liner, respectively, it is integrated with the ceiling material base material. You may make it foam-mold.

  The molded ceiling material for automobiles obtained by the present invention can be given a curved surface by hot press molding the ceiling material body at 70 to 220 ° C. The reason for this is not clear, but only in this temperature range, the foamable polyurethane undiluted solution acts as a plasticizer for the pulp and the like constituting the paper honeycomb core, softening the paper honeycomb, and without buckling. This is because it is possible to give a curved surface by molding. Here, as the foamable polyurethane stock solution, it is preferable to use a semi-rigid or rigid polyurethane foam raw material with good thermoformability. In addition, as the said heat press molding, after heating a ceiling material main body to 70-220 degreeC, you may use the cold press method pressurized with a normal temperature press die, or 70-220 degreeC of normal temperature ceiling material main body may be used. A hot press method in which pressure is applied with a heated press die may be used, and a curved surface following the desired ceiling shape can be formed. The hot press molding may be performed continuously after the ceiling material body is formed, or may be performed after a certain amount of time has passed.

Next, although the manufacturing method of the molded ceiling material for automobiles of the present invention will be described with reference to the drawings, it is not limited to this embodiment.
The molded ceiling material for automobiles according to the present invention is manufactured by the following methods 1) and 2).
1) After continuously and uniformly applying the foaming polyurethane stock solution on the traveling lower surface liner, supplying the paper honeycomb core onto the applied foaming polyurethane stock solution, and further continuously feeding the upper surface liner thereon. Place the foamed polyurethane stock solution into the cells of the paper honeycomb core by foaming and integrate them, and either peel off the upper liner and / or the lower liner, or peel off neither the upper liner nor the lower liner The method includes a step of obtaining a ceiling material body by integrally molding, and a step of forming the curved surface portion by hot press molding the ceiling material body continuously or at a time from 70 to 220 ° C. A manufacturing method of a molded ceiling material for automobiles (first manufacturing method).

  2) Supplying a paper honeycomb core onto the traveling lower liner, and continuously and evenly applying the foamable polyurethane stock solution into the cells of the paper honeycomb core, and continuing the upper liner onto the applied foamed polyurethane stock solution. The foamed polyurethane undiluted solution is foam-filled into the cells of the paper honeycomb core and integrated, and the upper liner and / or the lower liner are peeled off, or both the upper liner and the lower liner are peeled off. A step of obtaining a ceiling material body by integrally forming without forming the surface, and a step of forming the curved surface portion by hot-pressing the ceiling material body continuously or at a time from 70 to 220 ° C. A method for manufacturing a molded ceiling material for automobiles (second manufacturing method).

  The ceiling material body in the present invention refers to a body before hot press molding. For example, a ceiling base material containing a paper honeycomb core in a polyurethane foam layer by integral foam molding, and a lower surface liner and / or an upper surface liner are integrated. Refers to the molded one. Or when both a lower surface liner and an upper surface liner are peeled, it becomes a ceiling material main body or the ceiling material base material itself.

  In the present invention, the expression “continuously or with time” means the following. That is, “continuously” refers to the case where the step of obtaining the ceiling material main body and the step of forming the curved surface portion by hot press forming in the next step are installed on the same line. That is, it refers to a case where hot press molding is performed immediately after the obtained ceiling material body is cut to a desired length. On the other hand, “with time” refers to a case where the step of obtaining the ceiling material body and the step of forming the curved surface portion by hot press molding in the next step are discontinuous in time or space. . In other words, after the obtained ceiling material body is cut to a desired length, it may be stored for a certain period and then processed by a hot press process installed on the extension of the same line, or separated from a remote place. Processing may be performed in a hot press process in the factory.

  8 and 9 are explanatory views of a manufacturing apparatus for manufacturing a molded ceiling material for automobiles according to the present invention, respectively, and correspond to the first and second manufacturing methods, respectively. 8 and 9, reference numerals 23a, 23b, and 23c in the drawings indicate rotatable pin rolls in which a plurality of pins 12 are implanted at regular intervals on the surface. The appearance of the pin rolls 23a, 23b, and 23c is as shown in FIG. On the other hand, a pin belt 13 is installed between the drive roll 16 and the pulley 24a. In addition to the pulley 24a, a pulley (not shown) is provided, and a pin belt is installed between the drive roll 16 and a pulley (not shown). Pins 14 are also planted at regular intervals on the surfaces of the pin belts 13a and 13b. A feed roller 25 a that conveys the lower surface liner 15 is disposed on the upstream side of one drive roll 16. In a predetermined region between the drive roll 16 and the pulleys 24a and 24b, a cure oven 17 for heating the applied foaming polyurethane stock solution 18 is disposed. A coat hanger type die 19 for supplying a urethane foam stock solution 18 onto the lower surface liner is disposed above the drive roll 16. 8 and 9, reference numeral 20 denotes a paper honeycomb core (shown in FIG. 10), reference numeral 21 denotes an upper liner, and reference numeral 22 denotes a winding device that recovers the lower liner from the feed roller 25 a. The paper honeycomb core 20 has a thickness (c) of 3 to 10 mm and a cell size (d) of 3 to 38 mm. Further, reference numerals 25b, 25c and 25d in FIGS. 8 and 9 indicate feed rollers.

  In the present invention, as a method for supplying the paper honeycomb core, a so-called discontinuous supply method (the former) in which the stretched paper honeycomb core is supplied one by one in a fixed size, and a paper honeycomb core in an unstretched state is provided. There is a method (the latter) in which cores are connected to form a substantially endless shape, and the cores are continuously supplied while being stretched. However, the former is not preferable because it takes a lot of work, and there are many portions where each paper honeycomb core becomes a boundary, resulting in a decrease in product yield. On the other hand, the latter is preferable because the production efficiency and yield are high, and the product can be supplied at low cost.

  In the present invention, the position at which the paper honeycomb core is supplied is schematically shown in FIG. 9 after the foamable polyurethane stock solution is applied on the lower liner as schematically shown in FIG. As described above, there are two methods before the foamable polyurethane undiluted solution is applied, but either method can be selected.

  In this production method, as a method of applying the foamable polyurethane stock solution, for example, (1) a method of applying the foamable polyurethane stock solution by discharging it from a nozzle while traversing to a predetermined width, and (2) the foaming property A method of delaying the reactivity of the polyurethane stock solution and applying uniformly using a reverse roll, (3) A method of applying the foamable polyurethane stock solution by a doctor knife method, and (4) Applying the foamable polyurethane stock solution using a die. (4) is most preferable for the following reason.

In the present invention, since the coating amount of the foamable polyurethane stock solution is as very small as 100 to 750 g / m ² , in the method (1), the portion applied by traverse and the portion not applied by the traverse have a uniform foam height. In other words, the thickness of the portion not applied tends to be thin.
Further, in the method (2), if a raw material having high reactivity is used to obtain a low-density semi-rigid or rigid polyurethane foam even if the amount of catalyst is reduced or a delayed catalyst is used, a reverse roll is used. The reaction solution tends to stick to Therefore, there is a limitation that it cannot be used unless it is a high-density polyurethane foam having a low reactivity or a foamed resin stock solution such as phenol foam.

In the method (3), the reaction solution tends to adhere to the doctor knife for the same reason as the method (2), and the raw materials to be used are limited in the same manner as the method (2).
In the method (4), even when a highly reactive raw material such as a semi-rigid or hard foaming polyurethane stock solution is used by using a coat hanger type die under specific conditions, the reaction solution at any location in the die can be obtained. Since the liquid is uniformly discharged in a short time, the reaction liquid does not stick inside the die.

FIGS. 11 to 13 show a coat hanger type die for uniformly applying the foamable polyurethane stock solution used in the present invention. Here, FIG. 11 is a partially broken perspective view of the coat hanger type die, FIG. 12 is a sectional view of the coat hanger type die, and FIG. 13 is a sectional view taken along line XX of FIG.
Reference numeral 31 in the drawing indicates a coat hanger type die composed of die constituting plates 31a and 31b. The die 31 is provided with a manifold 32, an introduction port 33 for introducing a urethane reaction liquid into the manifold 32, and a pressure adjustment groove 34. A plurality of bolts 37 for adjusting the die lip gap 36 between the die lips 35 are embedded in the die constituting plates 31a and 31b. In the figure, numeral 38 indicates the die lip outlet, numeral 39 indicates the die land gap, and numeral 40 indicates the die land.

  As described in Japanese Patent Application No. 2002-340913 filed earlier by the present applicant, the coat hanger type die used in the present invention has a manifold opening angle of 120 to 150 degrees, and the manifold volume and die lip. The ratio of the die volume excluding the volume and the manifold volume is 1: 0.2 to 1: 0.7, and the ratio of the die volume excluding the manifold volume and the manifold volume is 1: 0.1 to 1: 0.7. It can be set to be.

  Here, the manifold angle refers to θ in FIG. If the ratio of the die volume to the manifold excluding the manifold volume and die lip volume in the die and the ratio of the die volume to the manifold excluding the manifold volume are outside the above ranges, the reaction solution residence time at the center of the die is averaged. Compared to the residence time, it is a fraction of 1 to several tenths, but the reaction liquid residence time on the side of the die reaches several times to several tens of times compared to the average residence time. Solidify. The foaming polyurethane stock solution is introduced from the raw material inlet at the center of the coat hanger die, but the manifold is designed so that the manifold cross-sectional area decreases as it goes to the end of the die. By such setting, the discharge amount and the residence time of the urethane reaction liquid in the die are constant over the entire width of the coat hanger die.

  Further, the lower liner and the upper liner shown in the figure are each made of a film (paper) having releasability from polyurethane foam as in the following combinations, or has adhesiveness to polyurethane foam. It can be a sheet. Here, the sheet-like material is a ceiling skin material or a ventilation film that is also a component of the above-described molded ceiling material for automobiles. By appropriately selecting these, it is possible to obtain only the ceiling material base material, or it is possible to obtain a laminated product in which a surface material and a ventilation film are integrally formed on the ceiling material base material. Below, the example of a combination of a lower surface liner and an upper surface liner is given.

(A) Lower liner: releasable film (paper), upper liner: releasable film (paper)
(B) Bottom liner: releasable film (paper), top liner: venting film
(C) Lower surface liner: releasable film (paper), upper surface liner: skin material
(D) Lower surface liner: air-proofing film, upper surface liner: releasable film (paper)
(E) Bottom liner: skin material, top liner: Ventilation film
(F) Lower surface liner: Ventilation-preventing film, Upper surface liner: Skin material Here, when using a skin material as the upper surface liner, a nonwoven fabric or woven fabric subjected to sealing treatment so that the foaming polyurethane stock solution does not penetrate. A cloth may be used. However, in that case, it is necessary to make the sealing treatment to such an extent that it does not become air-impermeable. Specifically, what melt | dissolved resin which has adhesiveness with urethane in the solvent is sprayed in the shape of a dot by spray etc., and what aimed at coexistence of a sealing effect and air permeability is used. In addition, even if there is almost no air permeability when sprayed, it can be used without any problem as long as the air permeability is ensured when it is subsequently formed as an automobile ceiling material.

  By the way, when supplying a non-stretched honeycomb core while being stretched, if the stretch rate is not constant, the physical properties such as density, weight and rigidity of the obtained ceiling material will not be uniform. It is necessary to keep the supply constant.

  In the present invention, it is assumed that the first stretching device (pin tenter) illustrated in FIGS. 8 and 14 and the second stretching device (pin roll) illustrated in FIG. It is said.

(First extension device)
As shown in FIG. 8 and FIG. 14, the first extension device includes pin belts 13a and 13b that are paired on both the left and right sides with respect to the traveling direction of the lower surface liner 15, between a drive roll 16 and a pulley 24a. A pin tenter that is stretched. The pin tenter further includes a pulley (not shown) on the opposite side of the pulley 24a. A plurality of pins 14 are provided at regular intervals on the surface of the pin belts 13a and 13b, and one cell of the paper honeycomb core 20 is fitted to one pin 14. Thereby, the shape of the said cell can be made into a fixed shape by conveying the paper honeycomb core 20 while extending.

(Second extension device)
This second extension device shows pin rolls 23a and 23b shown in FIGS. 8 and 16, and a plurality of pins 12 are implanted at regular intervals on the surface as shown in FIG. The second expansion device further includes two pin rolls (not shown). Similarly to the pin belt, one cell of the paper honeycomb core 20 is fitted to one pin 12, serves as a brake for the paper honeycomb core 20 to be conveyed, and the shape of the cell is made constant. it can.

Hereinafter, a molded ceiling material for automobiles according to an embodiment of the present invention and a manufacturing method thereof will be described with reference to the drawings.
Example 1
Reference numeral 41 in FIG. 1 indicates a ceiling material base material composed of a hexagonal paper honeycomb core 20 and a semi-rigid polyurethane foam layer 42 that is uniformly filled in the gap 20 a of the paper honeycomb core 20. A skin material 43 made of a polyester fiber woven fabric is formed on the front surface side of the ceiling material base 41, and a ventilation stop film 45 made of a corona discharge treatment PP film is formed on the back surface side. In the ceiling material main body 44 having such a structure, the paper honeycomb core 20 is contained in the semi-rigid polyurethane foam layer 42 by integral foam molding, and a curved portion (not shown) is formed by press molding at a portion corresponding to a curved portion of the automobile. ) Is provided.

The ceiling material having the above configuration is manufactured using, for example, the above-described manufacturing apparatus of FIG.
That is, first, a urethane foam stock solution 18 is applied from a coat hanger type die 19 onto a PET film while conveying a releasable PET film (hereinafter simply referred to as a PET film) as a lower surface liner 15 by a driving roll 16 in a certain direction. It was applied continuously and uniformly. Subsequently, the paper honeycomb core 20 was supplied onto the PET film coated with the urethane foam stock solution 18 on the downstream side. Further, a corona discharge-treated PP film as the upper liner 21 is continuously carried thereon, and the foamed polyurethane stock solution 18 is foam-filled into the cells of the paper honeycomb core 20 to be integrated into a ceiling material body 44. . Thereafter, the ceiling material main body 44 was heated at 110 ° C. by the curing oven 17, and then the PET film was peeled by the winding device 22 on the downstream side. Finally, after the skin material 43 was adhered to one side of the ceiling material main body 44 with an adhesive, it was immediately hot-press molded at about 130 ° C. to form a curved surface portion, and a molded ceiling material for automobiles was manufactured.

  According to Example 1, it is possible to obtain a molded ceiling material for automobiles that has excellent shape retention over a long period of time without using glass fibers as in the prior art, and that is lightweight and low in cost.

  In addition, according to Example 1, the paper honeycomb core 20 does not have thermoplasticity and is excellent in rigidity, but it has been recognized that it is impossible to impart a curved surface by hot press molding. The paper honeycomb core 20 was integrally foamed with the foamable polyurethane stock solution and subjected to hot press molding at about 130 ° C., thereby providing a curved surface.

(Example 2)
Next, the case where the molded ceiling material for automobiles of FIG. 1 is manufactured using the manufacturing apparatus of FIG. 9 will be described.
First, the paper honeycomb core 20 was supplied onto the corona discharge PP film as the traveling lower liner 15, and the foamable polyurethane stock solution 18 was applied continuously and uniformly into the cells of the paper honeycomb core 20. Subsequently, the skin material as the upper liner 21 is continuously carried on the foamable polyurethane stock solution 18 to integrate the corona discharge PP film, the paper honeycomb core 20 and the skin material, and into the cells of the paper honeycomb core 20. The foamable polyurethane stock solution 18 was foam-filled and integrated to obtain a ceiling material body 44. Thereafter, the ceiling material main body 44 is heated at about 110 ° C. by the cure oven 17 and the next day this is hot press-molded at about 130 ° C. in a separate line hot press process to form a curved surface portion, as shown in FIG. A molded ceiling material for automobiles was manufactured.

  According to Example 2, since the skin material is integrally formed as an upper surface liner, a step of attaching the skin material later using an adhesive is unnecessary, and the mass productivity is excellent.

  Note that the present invention is not limited to the above-described embodiment as it is, and can be embodied by modifying the constituent elements without departing from the scope of the invention in the implementation stage. For example, a case where a semi-rigid polyurethane foam layer is used as the resin foam and the temperature at the time of press molding is set to an arbitrary value has been described. However, the embodiment is not limited to the above-described embodiment. In addition, various inventions can be formed by appropriately combining a plurality of components disclosed in the embodiment. For example, you may delete all the components shown by embodiment. Furthermore, constituent elements over different embodiments may be appropriately combined.

Sectional drawing of the molded ceiling material for motor vehicles based on this invention. Explanatory drawing which shows the cell shape of the honeycomb core which makes hexagonal shape. Explanatory drawing which shows the cell shape of the honeycomb core which makes circular shape. Explanatory drawing which shows the cell shape of the honeycomb core which makes a cardboard shape. Explanatory drawing which shows the cell shape of the honeycomb core which makes a rib shape. Explanatory drawing which shows the cell shape of the honeycomb core which makes origami shape. The perspective view which shows the example which provided the notch in the thickness direction of the single side | surface of a honeycomb core. Explanatory drawing which shows typically an example of the manufacturing apparatus which manufactures the molded ceiling material for motor vehicles of this invention. Explanatory drawing which shows typically the other example of the manufacturing apparatus which manufactures the molded ceiling material for motor vehicles of this invention. The perspective view of the paper honeycomb core used for the manufacturing apparatus of FIG.8 and FIG.9. The partial fracture perspective view of the coat hanger die used for the present invention. Sectional drawing of the coat hanger die used for this invention. Sectional drawing which follows the XX line of FIG. Explanatory drawing when the manufacturing apparatus of FIG. 8 is seen from the coat hanger die upstream side. Explanatory drawing when the manufacturing apparatus of FIG. 9 is seen from the coat hanger die upstream side. The perspective view of the pin roll used for the manufacturing apparatus of FIG.8 and FIG.9. Sectional drawing of the molding ceiling material for motor vehicles of the conventional structure which uses glass fiber.

Explanation of symbols

  7 ... Cut, 12, 14 ... Pin, 13a, 13b ... Pin belt, 15 ... Lower liner, 16 ... Drive roll, 17 ... Cure oven, 18 ... Foaming urethane foam stock solution, 19 ... Coat hanger type die, 20 ... Paper honeycomb Core, 20a ... gap, 21 ... top liner, 22 ... winding device, 23a, 23b, 23c ... pin roll, 24a ... pulley, 25a, 25b, 25c, 25d ... feed roller, 42 ... semi-rigid polyurethane layer, 43 ... Skin material, 44 ... ceiling material body, 45 ... air-venting layer.

Claims (23)

A molded ceiling material for automobiles having at least three elements of a skin material, a paper honeycomb core, and a semi-rigid or rigid polyurethane foam layer,
A molded ceiling material for automobile, wherein the polyurethane foam layer includes a paper honeycomb core as a ceiling material base material by integral foam molding and has a curved surface portion formed by hot press molding. 2. The molded ceiling material for an automobile according to claim 1, wherein a non-breathable plastic film or a non-breathable non-woven fabric is integrated on one surface of the ceiling material base material. The molded ceiling material for automobile according to claim 2, wherein the non-breathable plastic film is an olefin film or a urethane film. 4. The molded ceiling material for an automobile according to claim 1, wherein the paper honeycomb core is made of kraft paper or K-liner paper. 5. The molded ceiling material for an automobile according to claim 1, wherein a plurality of cuts are provided in at least one surface of the paper honeycomb core in the thickness direction of the honeycomb core. The paper honeycomb core has a thickness (c) in the range of 3 to 10 mm and a cell size (d) in the range of 3 to 38 mm, and the ratio (d / c) of the thickness (c) to the cell size (d) is 1. The molded ceiling material for automobiles according to any one of claims 1 to 5, wherein the molded ceiling material is in a range of 0 to 10.0. The weight of the said ceiling material base material exists in the range of 200-800 g / m < ² >, The molded ceiling material for motor vehicles in any one of the Claims 1 thru | or 6 characterized by the above-mentioned. After continuously and evenly applying the foamable polyurethane stock solution on the traveling lower surface liner, supplying the paper honeycomb core onto the applied foamable polyurethane stock solution, and further continuously feeding the upper surface liner thereon The foaming polyurethane stock solution is foam-filled into the cells of the paper honeycomb core and integrated, and the upper liner and / or the lower liner are peeled off, or the upper liner and the lower liner are not peeled off, and they are integrally formed. A step of obtaining a ceiling material main body, and a step of forming the curved surface portion by hot press molding the ceiling material main body continuously or at a time from 70 to 220 ° C. Manufacturing method of molded ceiling material. Supplying the paper honeycomb core onto the traveling lower liner, continuously and uniformly applying the foamable polyurethane stock solution into the cells of the paper honeycomb core, and continuously applying the upper liner onto the applied foamed polyurethane stock solution A process of carrying and foaming and filling the foamed polyurethane stock solution into the cells of the paper honeycomb core to integrate, and the upper liner and / or the lower liner are peeled off, or neither the upper liner and the lower liner are peeled off A step of obtaining a ceiling material body by integrally forming the surface material, and a step of forming the curved surface portion by hot press molding the ceiling material body continuously or at a time from 70 to 220 ° C. A method for manufacturing a molded ceiling material for automobiles. 10. The method for producing a molded ceiling material for an automobile according to claim 8, wherein a coat hanger die is used for continuously and uniformly applying the foamable polyurethane stock solution. The weight of the said ceiling base material exists in the range of 200-800 g / m < ² >, The manufacturing method of the molded ceiling material for motor vehicles in any one of Claims 8 thru | or 10 characterized by the above-mentioned. The method for producing a molded ceiling material for an automobile according to any one of claims 8 to 11, wherein at least the upper liner is a sheet-like material that can adhere to the polyurethane foam layer. The method for producing a molded ceiling material for an automobile according to any one of claims 8 to 11, wherein at least the lower liner is a sheet-like material that can adhere to the polyurethane foam layer. The method for producing a molded ceiling material for an automobile according to claim 12, wherein the sheet-like material is a resin film subjected to corona discharge treatment or a resin film subjected to drilling treatment. The method for producing a molded ceiling material for an automobile according to any one of claims 12 and 13, wherein the sheet-like material is a nonwoven fabric or a woven fabric. The method for producing a molded ceiling material for an automobile according to any one of claims 8 to 11, wherein at least the upper liner is a film having releasability with respect to the polyurethane foam layer or paper having releasability. The method for producing a molded ceiling material for an automobile according to any one of claims 8 to 11, wherein at least the lower liner is a film having releasability with respect to the polyurethane foam layer or paper having releasability. The method for manufacturing a molded ceiling material for an automobile according to any one of claims 8 to 17, wherein the paper honeycomb core is made of kraft paper or K-liner paper. The method for manufacturing a molded ceiling material for an automobile according to any one of claims 8 to 18, wherein a plurality of cuts are provided on at least one surface of the paper honeycomb core in the thickness direction of the paper honeycomb core. The paper honeycomb core has a thickness (c) in the range of 3 to 10 mm and a cell size (d) in the range of 3 to 38 mm, and the ratio (d / c) of the thickness (c) to the cell size (d) is 1. The method for producing a molded ceiling material for an automobile according to any one of claims 8 to 19, wherein the method is in a range of 0 to 10.0. 21. The molded ceiling for an automobile according to claim 8, wherein the method for supplying the paper honeycomb core is a method for supplying the paper honeycomb core in an unexpanded state while continuously stretching the paper honeycomb core by a stretching device. A method of manufacturing the material. The extension device is a pin tenter that is arranged in pairs on the left and right sides of the traveling paper honeycomb core and runs in parallel with the lower surface liner, and the cells of the paper honeycomb core are fitted into the pins of the pin tenter. The method for producing a molded ceiling material for an automobile according to claim 21, wherein the sheet is conveyed at a constant expansion rate so as to have a uniform cell shape. The stretching device is a rotating pin roll in which a plurality of pins are provided at regular intervals, and paper honeycomb core cells are fitted into the pins of the pin roll, and conveyed at a constant stretching rate so as to form a uniform cell shape. The method for producing a molded ceiling material for an automobile according to claim 21, wherein:

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