JP2006281952A - Structure of opening of ceiling material, method for forming opening of ceiling material, and device of forming opening of ceiling material - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide the structure of an opening of a ceiling material capable of being easily formed at low cost by using a punching blade having a simple constitution. <P>SOLUTION: In a part corresponding to a sunroof of the ceiling material 12 having a base material 12a and a skin 12b to cover a surface on an indoor side of the base material 12a, the opening 14 is formed by cutting the base material 12a by leaving the skin 12b. An end face 14a of the opening 14 is formed to be directed in an almost horizontal direction. The remaining part of the skin 12b is folded back, and the end face 14a of the opening 14 is enclosed by the folded back part. <P>COPYRIGHT: (C)2007,JPO&INPIT

Description

  The present invention relates to a structure of a ceiling material opening corresponding to a sunroof of an automobile, a method for forming the ceiling material opening, and a ceiling material opening forming apparatus.

  Conventionally, as a structure of this kind of ceiling material opening, for example, a structure as disclosed in Patent Document 1 has been proposed. In this conventional configuration, as shown in FIG. 8, a ceiling material 31 having a base material 31a made of urethane board and a skin 31b covering the indoor side surface of the base material 31a is provided with the base material 31a and the skin 31b. The opening 32 corresponding to the sunroof is formed. The upper peripheral edge of the opening 32 of the ceiling material 31 is joined to the end of the roof structure 33, and together with the roof structure 33, a molding 34 having a substantially U-shaped cross section is formed on the end surface 32 a of the opening 32 of the ceiling material 31. Covered. A sunshade 35 for opening and closing the sunroof is disposed immediately above the molding 34 so as to be opened and closed by sliding in the front-rear direction.

As another ceiling material opening structure, for example, a structure as shown in FIG. 9 has been proposed. In this conventional configuration, an opening 32 corresponding to the sunroof is formed by cutting the base material 31 a while leaving the skin 31 b on the ceiling material 31. A ceiling bracket 36 is fixed to the periphery of the opening 32 of the ceiling material 31 with an adhesive. Then, the remaining portion of the skin 31 b is folded and bonded, so that the end surface 32 a of the opening 32 is covered together with the end of the ceiling bracket 36.
Japanese Utility Model Publication No.7-190009

  However, in the conventional configuration described in Patent Document 1, since the molding 34 is exposed on the vehicle interior side, there is a problem that the appearance on the vehicle interior side is impaired. On the other hand, in the conventional configuration shown in FIG. 9, since the molding 34 is not used, the appearance from the vehicle interior side is better than the configuration of Patent Document 1.

  However, in the conventional configuration shown in FIG. 9, the end surface 32a of the opening 32 of the ceiling member 31, that is, the cut end surface of the base material 31a is formed so as to face upward, and the waterproof structure is not provided on the cut end surface. . For this reason, in the open state of the sunshade 35, there existed a problem that rain water etc. were easy to saturate into the base material 31a of the ceiling material 31 from the end surface 32a of the opening 32. When rainwater or the like soaks in this way, the ceiling material 31 is discolored or swollen, and the appearance is remarkably impaired.

  In addition, when the opening 32 of the conventional ceiling material 31 shown in FIG. 9 is formed, it is necessary to cut the base material 31a of the ceiling material 31 in a substantially horizontal direction. There is also a problem that the manufacturing cost becomes high.

  That is, when forming the opening 32 of the conventional ceiling material 31, the punching blade 38 is lowered from the upper retracted position while the ceiling material 31 is supported by the jig 37 as shown in FIG. At that position, the base plate 31a is cut while leaving the skin 31b of the ceiling member 31 so as to approach the jig 37 in a substantially horizontal direction. Next, as shown in FIG. 10B, the cut portion of the base material 31 a is peeled off from the remaining portion of the skin 31 b and the ceiling bracket 36 is bonded and fixed to the periphery of the opening 32 of the ceiling material 31. Thereafter, the remaining portion of the skin 31b is folded back so that the end surface 32a of the opening 32 is covered together with the end of the ceiling bracket 36.

  Thus, when the opening 32 of the ceiling member 31 is formed, for example, as shown in FIG. 10A, the support body 51 that supports the punching blade 38 is moved upward and downward by a cylinder 52 or the like. It is necessary to move to the retracted position. In addition, on the outer peripheral side of the jig 37, as shown in FIG. 11, eight punching blades 38 corresponding to the sides of the opening 32 and the corners are arranged so as to be movable in a radial direction substantially in a horizontal plane, It is necessary to move these punching blades 38 to an outer position and an inner cutting position by the cylinder 53 or the like. For this reason, at the time of cutting, the cutting-related configuration including the punching blade 38 and the like is complicated and expensive.

  In addition, in the cutting method of FIG. 10A, since the punching blade 38 cuts the base material 31a of the ceiling material 31 obliquely with respect to the thickness direction, the cutting accuracy does not come out and the cut surface is not clean. Absent. That is, as described above, the fibers of the base material 31a are arranged in a direction intersecting the thickness direction of the base material 31a. For this reason, when the punching blade 38 enters the substrate 31a from an oblique direction, the fibers are hardly cut and the cut end face becomes fluffy. Therefore, even if the cut end face is covered with the skin 31b in this state, the covering portion may be uneven and the appearance may be deteriorated.

  The present invention has been made paying attention to such problems existing in the prior art. The purpose is to prevent rainwater and the like from penetrating into the ceiling material from the end face of the opening, and using a jig and a punching blade with a simple configuration, opening the ceiling material easily and at low cost, In addition, it is to be able to be formed so as to have a good appearance.

  In order to achieve the above object, in the invention according to claim 1 relating to the structure of the opening of the ceiling material, the substrate has a base material and a skin covering a surface on the indoor side of the base material, and the base material In the ceiling material, an opening corresponding to the sunroof is formed, and an end surface of the opening is formed so as to face substantially in a horizontal direction in a ceiling material in which the end surface of the opening is covered with the folded portion of the skin.

  The invention according to claim 2 is characterized in that, in the invention according to claim 1, the opening is formed by an inner peripheral edge of the flange portion through a flange portion protruding substantially horizontally in the base material. To do.

  In the invention according to claim 3 relating to the method for forming the opening of the ceiling material, a ceiling material having a base material and a skin covering the indoor-side surface of the base material is supported on the jig, and the jig The punching blade is moved almost vertically with respect to the horizontal support surface, and the opening is formed by cutting the substrate while leaving the skin, and the end surface of the opening is covered by folding the remaining part of the skin. It was characterized by that.

The invention according to claim 4 is characterized in that, in the invention according to claim 3, incisions toward the center of the opening are formed in the remaining portions of the skin at the four corners of the opening.
The invention according to claim 5 is characterized in that, in the invention according to claim 4, the end portion of the notch located on the end face side of the opening of the base material is separated from the end face of the opening of the base material. It was.

  According to a sixth aspect of the invention, there is provided a ceiling material opening forming apparatus, wherein the punching blade used in the method for forming a ceiling material opening according to the fourth aspect is formed into a quadrangular annular shape, and inside the four corners of the punching blade. Is provided with a cutting blade extending toward the center of the punching blade.

According to a seventh aspect of the present invention, in the sixth aspect of the present invention, a portion having no cutting edge is formed at the end of the cutting blade on the punching blade side.
(Function)
In the first and third aspects of the invention, the exposed portion to the indoor side is the end face of the base material concealed by the skin, and unlike the conventional configuration described above, it is not necessary to use a molding. The exterior of the vehicle interior can be kept good. Further, since the end face of the opening is formed so as to face substantially in the horizontal direction, it is possible to prevent the possibility of rainwater and the like from entering the ceiling material from the end face of the opening. Moreover, since it is only necessary to cut the base material of the ceiling material in the vertical direction to form an opening, simple cutting comprising a jig for supporting the ceiling material and one annular punching blade movable in a substantially vertical direction With the related configuration, the opening of the ceiling material can be formed easily and at low cost. Furthermore, as described above, since the base material of the ceiling material is cut from the direction orthogonal to the thickness direction, the fibers of the base material are cut without fluffing. For this reason, when the end surface is encapsulated by the skin, irregularities are not formed in the enveloping portion, and a good appearance can be obtained.

In the invention according to the second aspect, since the opening is formed in the base material through the flange portion extending substantially in the horizontal direction, the rigidity of the peripheral edge of the opening can be increased to ensure the strength.
In the invention according to claim 4, when the remaining part of the skin at the four corners of the opening is formed with a cut toward the center part of the opening, the remaining part is folded to cover the end face of the substrate. Excessive tension and wrinkles can be suppressed and the appearance can be improved by opening and overlapping the cut portions.

  In the invention according to claim 5, since the end portion located on the end face side of the opening of the base material in the incision is separated from the end face of the opening of the base material, the end face of the opening of the base material is covered. Thus, even if the skin is folded back, the cuts are not exposed and the appearance can be improved.

  In the invention described in claim 6, the cutting blade extending toward the center portion of the punching blade can form a cut toward the center portion of the opening in the remaining portion of the skin at the four corners of the opening. The same effect can be obtained.

  In the seventh aspect of the present invention, an opening forming apparatus for obtaining the operation of the fifth aspect of the present invention can be realized.

  As described above, according to the present invention, the end edge of the opening is not required to be a molding, and rainwater and the like can be prevented from penetrating into the ceiling material from the end surface of the opening, thereby preventing discoloration and swelling, and the ceiling material The appearance of the sunroof can be improved. Moreover, the opening of a ceiling material can be formed easily and at low cost by using a jig and a punching blade having a simple configuration.

(First embodiment)
Below, 1st Embodiment of this invention is described based on FIGS.
As shown in FIG. 1, a ceiling material 12 disposed on the indoor side of a roof structure 11 of a body in a roof of an automobile covers a base material 12a made of urethane board and a surface on the indoor side of the base material 12a. And an outer skin 12b made of fabric or the like. In addition, although this ceiling material 12 is not shown in figure, the thin glass fiber layer provided in the front and back both sides | surfaces of the base material 12a, the resin film layer for the hot melt provided in the surface of the glass fiber layer of an outdoor side, A thin coating layer made of a nonwoven fabric or the like outside the resin film layer is provided, and a multilayer structure is formed.

  As shown in FIGS. 1 and 2, a protruding portion 13 that protrudes toward the outdoor side is formed at a portion corresponding to the sunroof of the ceiling material 12. An opening 14 corresponding to the sunroof is formed at the top of the raised portion 13 of the ceiling material 12 by cutting the base material 12a while leaving the skin 12b. In this case, the opening 14 is formed on the outer peripheral edge of the top of the raised portion 13 while leaving a flange portion 15 having a predetermined width protruding substantially in the horizontal direction. Further, the end face 14a of the opening 14 is formed so as to face substantially the horizontal direction by cutting the base material 12a of the ceiling material 12 in the vertical direction. Note that, as a pretreatment, the raised portion 13 is formed with an opening 14b smaller than the opening 14 by a laser beam, a water jet, or the like, and then an opening 14 corresponding to the sunroof is formed by a punching blade 22 described later. .

  A ceiling bracket 16 is fixed to the upper peripheral edge of the opening 14 of the ceiling material 12 with an adhesive. Then, the end portion 14 a of the opening 14 is encapsulated together with the end portion of the ceiling bracket 16 by folding the remaining portion that becomes the folded portion of the skin 12 b of the ceiling material 12 onto the ceiling bracket 16. A sunshade 17 for opening and closing the sunroof is disposed on the folded portion of the skin 12b of the ceiling member 12 so as to be opened and closed by sliding in the front-rear direction.

  As shown by a two-dot chain line in FIG. 1, a sunroof opening 44 is formed in the roof panel 41 constituting the outer surface of the vehicle roof, and a glass 42 is fitted in the opening 44 so as to be openable and closable. . Further, a frame member 43 for closing that portion is disposed and fixed between the opening 44 portion of the roof panel 41 and the opening 14 portion of the ceiling member 12.

Next, a method for forming the opening of the ceiling member 12 configured as described above will be described.
When forming the opening of the ceiling member 12, as shown in FIG. 3A, first, the raised portion 13 of the ceiling member 12 in which the opening 14b is formed as a pretreatment is placed on the horizontal support surface of the jig 21. To support. In this state, the punching blade 22 is moved close to the upper surface of the jig 21 along the vertical direction, and the base material 12a is cut leaving the skin 12b of the ceiling material 12, thereby forming the opening 14.

  In this case, as shown in FIGS. 3 (a), 4 (a) and 5, the punching blade 22 used for cutting the base material 12a is formed in a substantially quadrangular ring shape, and a blade portion 22a is provided at the lower end edge thereof. It has been.

  A pair of cutting blades 23 project from the inner peripheral four corners of the punching blade 22 toward the central portion of the punching blade 22, and the lower end of the cutting blade 23 is lower than the blade portion 22 a of the punching blade 22. The blade part 23a located below is provided. A cutout portion 23b is formed on the punching blade 22 side of the blade portion 23a, that is, the base end portion side, and a blade edge is not provided at that portion. Then, when forming the flange portion 15 and the opening 14 by punching and cutting the base material 12a of the ceiling material 12 with the punching blade 22, the cutting blade 23, as shown in FIG. Two cuts 12c toward the center of the opening 14 are formed at four corners of the corresponding skin 12b. In this case, since the cutting edge is not formed on the base end portion side of the cutting blade 23, the end portion on the end surface 14a side of the opening 14 of the notch 12c cut by the cutting blade 23 is separated from the end surface 14a. Yes.

  Next, as shown in FIG. 3 (b), the cut portion of the base material 12 a of the ceiling material 12 is peeled off from the remaining portion of the skin 12 b and the ceiling bracket 16 is bonded and fixed to the periphery of the opening 14 of the ceiling material 12. To do. Thereafter, as shown in FIG. 3C, the remaining portion of the skin 12 b protruding from the base material 12 a is folded back toward the end of the ceiling bracket 16, so that the end surface 14 a of the opening 14 is wrapped together with the end of the ceiling bracket 16. Cover and fix with adhesive. In this way, the end surface of the base material 12a is concealed by the skin 12b. Further, in this case, since the notches 12c are formed in advance at the four corners of the remaining portion of the skin 12b corresponding to the opening 14 as described above, the skin 12b is opened or overlapped to open the skin 12b. The four corners can be folded back without excessive tension or wrinkles. In addition, since the end of the notch 12c on the end surface 14a side of the opening 14 is separated from the end surface 14a, even if the skin 12b is folded back so as to cover the end surface 14a of the opening 14, the notch 12c is cut into the end surface 14a. 12c is not exposed and the appearance can be improved.

  As described above, in the structure of the opening of the ceiling material 12 of this embodiment, the exposed portion to the indoor side is the end surface of the base material 12a concealed by the skin 12b, which is different from the conventional configuration described above. Therefore, the appearance from the vehicle interior side can be kept good.

  Moreover, since the end surface 14a of the opening 14 is formed so as to be directed substantially in the horizontal direction, it is possible to prevent rainwater or the like from penetrating into the ceiling material 12 from the end surface 14a of the opening 14, and accordingly, by rainwater soaking. Discoloration and swelling can be prevented and good appearance can be maintained.

  Furthermore, since the opening 14 is formed in the base material 12a through a flange portion 15 extending in a substantially horizontal direction, the flange portion 15 can ensure a predetermined strength at the periphery of the opening 14 of the ceiling material 12. In addition, the vibration of the opening 14 and the occurrence of chattering noise caused by the vibration can be suppressed.

  Moreover, when the opening 14 is formed in the ceiling material 12, the base material 12a of the ceiling material 12 may be cut in the vertical direction without being cut in the horizontal direction. Therefore, unlike the conventional configuration, a simple cutting-related structure having one annular punching blade 22 movable only in a substantially vertical direction can be used. Manufacturing cost can be reduced.

  Further, as described above, since the base material 12a of the ceiling material 12 is cut from the direction orthogonal to the thickness direction, the fibers of the base material 12a are effectively cut, and therefore the cut end face 14a is clean. is there. For this reason, when the end surface 14a is encapsulated by the skin 12b, no irregularities are formed in the enveloping portion, and a good appearance can be obtained.

(Second Embodiment)
Next, a second embodiment of the present invention will be described focusing on the differences from the first embodiment.
In the second embodiment, as shown in FIGS. 6 and 7, the opening 14 is provided at the upper end of the inclined portion of the raised portion 13 without providing the flange portion 15 on the peripheral edge of the raised portion 13 of the ceiling material 12. Directly formed. Also in this embodiment, as shown in FIG. 6, by cutting the base material 12 a of the ceiling material 12 in the vertical direction with the annular punching blade 22, the end surface 14 a of the opening 14 is directed substantially in the horizontal direction. Is formed.

Therefore, in the second embodiment, the same effects as in the first embodiment can be obtained except for the effects related to the flange portion 15.
In particular, in the second embodiment, since the flange portion 15 of the base material 12a is not present, the appearance is neat and the appearance can be improved.

(Example of change)
In addition, this embodiment can also be changed and embodied as follows.
Cutting the opening 14 of the ceiling material 12 using a cutting device other than the cutting blade, for example, a laser processing machine, so that the skin 12b is not cut.

  -The thing other than a urethane board, for example, a nonwoven fabric, should be used as the base material 12a of the ceiling material 12.

The principal part sectional view showing the structure of the opening of the ceiling material of a 1st embodiment. The perspective view which shows a ceiling material. (A)-(c) is principal part sectional drawing which shows the method of forming the opening of the ceiling material of FIG. 1 in order. (A) is a perspective view which shows the punching blade used for formation of the opening of FIG. 3, (b) is a partial top view which shows the part of an opening. The fragmentary perspective view which expands and shows a part of punching blade of FIG. The principal part sectional drawing which shows the structure of opening of the ceiling material of 2nd Embodiment. FIG. 7 is an essential part cross-sectional view illustrating a method of forming the ceiling material opening of FIG. 6. The principal part sectional drawing which shows the structure of the opening of the conventional ceiling material. The principal part sectional drawing which shows the structure of the opening of another conventional ceiling material. (A) (b) is principal part sectional drawing which shows the method of forming the opening of the ceiling material of FIG. 9 in order. The perspective view which shows the punching blade used for formation of the opening of FIG.

Explanation of symbols

  DESCRIPTION OF SYMBOLS 12 ... Ceiling material, 12a ... Base material, 12b ... Skin, 12c ... Cut, 14 ... Opening, 14a ... End surface, 15 ... Flange part, 21 ... Jig, 22 ... Punching blade, 23 ... Cutting blade

Claims (7)

A ceiling having a base material and a skin covering a surface on the indoor side of the base material, wherein the base material has an opening corresponding to the sunroof, and an end face of the opening is covered by a folded portion of the skin In the material,
An opening structure of a ceiling material, wherein an end face of the opening is formed so as to face a substantially horizontal direction. The structure of the opening of the ceiling material according to claim 1, wherein the opening is formed by an inner peripheral edge of the flange portion through a flange portion protruding substantially horizontally in the base material. A base material and a ceiling material having a skin covering the indoor side surface of the base material are supported on a jig, and the punching blade is moved substantially vertically to the horizontal support surface of the jig, A method for forming an opening in a ceiling material, characterized in that an opening is formed by cutting a base material while leaving an epidermis, and an end surface of the opening is covered by folding back a remaining part of the epidermis. 4. The method for forming an opening in a ceiling material according to claim 3, wherein a cut toward the center of the opening is formed in a remaining portion of the skin at the four corners of the opening. 5. The method for forming an opening in a ceiling material according to claim 4, wherein an end portion of the notch located on the end face side of the opening of the base material is separated from the end face of the opening of the base material. The punching blade used in the method for forming an opening in the ceiling material according to claim 4 is formed into a quadrangular annular shape, and a cutting blade extending toward the center of the punching blade is provided inside the four corners of the punching blade. A ceiling material opening forming apparatus characterized by the above. The ceiling material opening forming apparatus according to claim 6, wherein a portion having no cutting edge is formed at an end of the cutting blade on the punching blade side.

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