JP2007038531A - Manufacturing method of molded ceiling - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a manufacturing method of a molded ceiling comprising a roof duct attached on a rear face, which simplifies equipment, reduces man-hours, and eases restrictions on the dimension of the roof duct. <P>SOLUTION: In the manufacturing method of a molded ceiling 10 comprising a roof duct 20 attached in a rear face of a predetermined position, a roof duct 20, is molded in a required shape, and after the trim cut processing, a joining edge 21 along the rim is coated with a hot melt based adhesive 22, the duct 20 is kept to the mold face of a molding upper die 50, and an original material sheet S1 of a substrate 10a subjected to heating softening processing, is thrown in a molding die 40. The hot melt based adhesive 22 of the roof duct 20 is melted by the remaining heat of the whole cloth sheet S1, and thereby the roof duct 20 is unified at the same time when the molded ceiling 10 is pressed/molded by the clamping of the upper/bottom dies 50 and 60. <P>COPYRIGHT: (C)2007,JPO&INPIT

Description

  The present invention relates to a method of manufacturing a molded ceiling having a roof duct attached to the back surface, and in particular, the roof duct can be easily and quickly integrated at a predetermined position on the back surface of the ceiling without being restricted by the shape of the roof duct. The present invention relates to a method for manufacturing a formed ceiling.

  Normally, as an air conditioning system for a roof portion of a vehicle, as shown in FIGS. 9 and 10, a roof duct 3 is attached to the back surface of a molded ceiling 2 mounted on the indoor surface side of the roof panel 1, The roof duct 3 communicates with a pillar duct 4 attached to a pillar portion of the vehicle. The air blown into the vehicle interior is sent from the pillar duct 4 into the roof duct 3 and further sent from the air outlet 5 provided in the molded ceiling 2 into the vehicle interior.

  Next, a conventional method for manufacturing the molded ceiling 2 provided with the roof duct 3 will be briefly described with reference to FIGS. The molded ceiling 2 is configured by adhering a skin 2b to the surface of a base material 2a that is lightweight and has appropriate rigidity and shape retention, and the roof duct 3 is an injection molded body of synthetic resin such as polypropylene, A foamed resin molded body having a non-breathable film attached thereto is used. Then, as shown in FIG. 11, the steps of the conventional manufacturing method are as follows. The base material 2a and the skin 2b are integrally formed in a molding die, subjected to trim piercing treatment, and then the roof duct 3 is separately formed. Mold to the required shape with a mold and trim piercing. Furthermore, after applying a hot-melt adhesive or the like to the peripheral flange in the roof duct 3, it is actually attached and fixed to a predetermined position of the substrate 2a. The conventional configuration and manufacturing method of the molded ceiling 2 provided with the roof duct 3 are described in detail in Patent Document 1.

Japanese Patent No. 3543299

  As described above, the conventional method of manufacturing the molded ceiling 2 uses the dedicated mold equipment for the molded ceiling 2 and the roof duct 3 respectively, and then molds the ceiling 2 and the roof duct 3 after forming them in separate processes. Since it is configured to be bonded and fixed in the process, it has been pointed out that a dedicated mold facility, tools, and man-hours are required, leading to an increase in cost.

  Furthermore, when the roof duct 3 is increased in size, it is necessary to secure a large area of adhesion to the molded ceiling 2. Therefore, the application time of the hot melt adhesive is prolonged, and when the application is completed, it is applied first. Since the adhesive dries, it tends to cause poor adhesion, and reliable adhesive strength cannot be obtained, so there are restrictions on modeling, such as restrictions on the dimensions of the roof duct 3.

  The present invention has been made in view of such circumstances, and the mold equipment can be simplified by inserting a roof duct preformed into a required shape in a molding die and integrally molding the molding ceiling. In addition, an object of the present invention is to provide a method for manufacturing a molded ceiling that can reduce the number of steps, relax the restrictions on the dimensions of the roof duct, and dramatically increase the degree of freedom of modeling.

  In order to solve the above-mentioned problems, the present invention is formed by laminating a skin if desired on the surface of a base material having a shape-retaining property and integrating a roof duct for air conditioning on the back surface. In the manufacturing method of the molded ceiling to be mounted on the indoor surface side of the roof panel, the molded upper and lower sides are formed in a state in which the adhesive is applied along the base side joining edge of the roof duct that has been molded into a required shape and trimmed. A material setting process for holding the heat-softened raw sheet in the mold upper and lower molds while holding it on the mold surface of one of the molds, and clamping the mold upper and lower molds, The base material is molded by drawing into a required shape, and the adhesive applied to the joint edge of the roof duct is heated and softened by the residual heat of the raw sheet to function as an adhesive medium. Roof duct on the back Characterized in that comprising a unifying step of the molding process as well as the roof duct integrated to the substrate.

  Here, the molded ceiling may be laminated with a skin on the surface of the base material, but can also be constituted by a single base material. Further, the material of the base material is not particularly limited as long as it is a material that can be cold press-molded because the method of the present invention performs insert molding using the residual heat of the base material. Preferably, it is light and has a suitable shape retaining property, heat insulation and sound absorption performance. For example, a thermoplastic resin plate mixed with a filler such as glass fiber, a PPO (polyphenylene oxide) foamed resin base material, or the like can be used. In addition, when using the skin, as the material of the skin, cushioning layers such as polyurethane foam, polypropylene foam, polyethylene foam, etc. are provided on the back of the fabric skin and synthetic resin sheet such as nonwoven fabric and cloth, or on the fabric sheet and synthetic resin sheet. A lined laminated sheet material can also be used. On the other hand, although the material and molding method of the roof duct are not limited, for example, the use of a roof duct formed by thermoforming a foamed resin material is preferable in terms of light weight and excellent mass productivity. For example, a PPO (polyphenylene oxide) foamed resin material is preferable.

  As an adhesive to be applied to the roof duct, a hot melt adhesive can be applied in a bead shape, or a hot coat adhesive can be applied in a planar shape using a roll coater. The melt adhesive can be applied in the form of a web or in the form of a spray. In addition, double-sided adhesive tape can be used, and thermosetting resin that reacts with the heat of the base material to bond and heat-reactive adhesives can be used. Yes.

  Therefore, according to the method of the present invention, after setting the roof duct formed in advance into a required shape and coated with an adhesive along the joining edge portion on the mold surface of one of the upper and lower molds, If the base sheet of the base material is heated and softened, it is put into a molding die and the upper and lower molds are clamped, so that the pre-inserted roof duct can be firmly integrated at a predetermined position on the base material. Therefore, since the method of insert-molding the roof duct is used, the equipment used for the integration process of the molded ceiling and the roof duct, which has been conventionally required, can be eliminated, and the integration man-hours can be omitted.

  In addition, the bonding strength between the roof duct and the molded ceiling is such that the adhesive applied in advance to the roof duct is sufficiently melted by the residual heat of the raw sheet, so that adhesion failure or the like does not occur and the roof has a large size. Even if the application area of the adhesive is over a wide range accompanying the use of the duct, the adhesive does not dry out and solidify, and the adhesive function does not deteriorate, so a strong bonding strength of the roof duct can be obtained, And since there is no restriction | limiting in the dimension of a roof duct, the modeling freedom degree of a roof duct can be improved.

  Next, in a preferred embodiment of the method of the present invention, a vacuum suction mechanism is attached to the molding die that holds the roof duct, and the roof duct is held at a predetermined position of the molding die by a vacuum suction force. It is characterized by being. According to this embodiment, the vacuum suction mechanism is attached to the molding die on the side that holds the roof duct, and the roof duct is securely held in the molding die by using this vacuum suction force. Therefore, it is possible to attach the roof duct with high accuracy.

  Further, in a further preferred embodiment of the present invention, when the molded upper and lower molds are clamped, compressed air is supplied into the roof duct and the product surface side in the roof duct mounting area is pressed against the mold surface of the molded lower mold. It is characterized in that the shape is formed with high accuracy. And according to this embodiment, since compressed air is supplied into the roof duct, it is possible to accurately shape the surface portion of the molded ceiling in the roof duct mounting area, and the appearance of the molded ceiling Good performance can be maintained.

  As described above, the method for manufacturing a molded ceiling according to the present invention sets the roof duct in the form of an insert in a molding die in a state where an adhesive is applied to the joint edge of the roof duct preformed in a required shape in advance. After that, the base sheet of the base material is put into a molding die after being heat-softened, and the base sheet is drawn into the required shape by clamping the molding die. At the same time, the residual heat of the raw sheet is used to melt the roof duct adhesive sufficiently to integrate the molded ceiling and roof duct, eliminating the conventionally required integration steps. The equipment and jigs required for integration can be eliminated, which can lead to significant cost reductions, and the adhesive can be sufficiently melted by the residual heat of the base material. With the passage of The adhesive function of the adhesive is reduced, there is no risk of poor adhesion, the adhesive strength can be maintained constantly, and there is no restriction on the dimensions of the roof duct, and the degree of freedom in molding the product can be improved. It has the effect.

  Hereinafter, an embodiment of a method for manufacturing a molded ceiling according to the present invention will be described in detail with reference to the accompanying drawings. It should be noted that the gist of the present invention is as described in the appended claims, and the embodiments described below are merely examples of the present invention.

  FIGS. 1 to 8 show an embodiment of the present invention. FIG. 1 is a perspective view of a molded ceiling produced by the method of the present invention as seen from the rear side of the product, and FIG. 2 is an interior surface of the roof panel of the molded ceiling. FIG. 3 is an explanatory view showing the overall configuration of a molding die used for carrying out the method of the present invention, FIG. 4 is a process chart diagram showing an outline of the method of the present invention, and FIG. Thru | or FIG. 8 is explanatory drawing which shows each process of this invention method.

  1 and 2, a molded ceiling 10 manufactured by the method of the present invention is formed into a required shape, and is configured by attaching a skin 10b to the surface of a base material 10a that holds the shape of the product. A cap-like roof duct 20 is bonded and fixed from approximately the center to the latter half of the back surface of the base material 10a of the molded ceiling 10. More specifically, the molding ceiling 10 is cold-press molded by attaching a skin 10b made of a cloth sheet such as cloth or nonwoven fabric to the surface of a base material 10a made of a thermoplastic resin plate mixed with a filler such as glass fiber. Therefore, it is formed into a curved shape that is slightly curved inward. Moreover, the roof duct 20 attached to the back surface of the molded ceiling 10 uses a PPO (polyphenylene oxide) foamed resin material in this embodiment, and this roof duct 20 is located at a predetermined position on the back side of the molded ceiling 10. Bonded and fixed. That is, a joining edge portion 21 is formed along the product periphery of the roof duct 20, and is bonded and fixed via a hot-melt adhesive 22 coated on the joining edge portion 21. The space defined between the roof duct 20 and the molded ceiling 10 is an air-conditioned space, and the air supplied from the pillar duct (not shown in FIGS. 1 and 2) into the roof duct 20 is supplied to the molded ceiling 10. The air is blown to the vehicle interior side through the opened air outlet 11.

  In the present invention, the roof duct 20 can be insert-molded on the molded ceiling 10 to simplify equipment costs, reduce the number of man-hours, and maintain the adhesive strength of the roof duct 20 firmly. The feature is that restrictions on the dimensions of the duct 20 can be relaxed. The molded ceiling 10 is attached to the roof panel 30 by attaching the clip 13 or the like mounted on the clip mounting seat 12 into the attachment hole 32 of the reinforcement 31 of the roof panel 30.

  Next, the overall configuration of the molding die 40 used when the method of the present invention is performed and the process chart of the method of the present invention will be described with reference to FIGS. First, in FIG. 3, the molding die 40 is roughly composed of a molding upper die 50 and a molding lower die 60, and the molding upper die 50 can be moved up and down by a predetermined stroke by an elevating cylinder 51. A recess 52 for setting the roof duct 20 is formed on the mold surface 50, and a vacuum suction mechanism 53 is attached to the recess 52. As the vacuum suction mechanism 53, a vacuum suction hole 531 is formed in the surface of the concave portion 52 of the molding upper die 50, and communicates with the vacuum chamber 532 behind the vacuum chamber 532. The vacuum suction pump 534 is connected, and the vacuum suction pipe 533 is provided with an opening / closing valve 535. Although not shown, cooling upper pipes 50 and lower mold 60 are provided with cooling pipes for cooling the heat-softened raw sheet in a predetermined pattern.

  Next, the outline of the method of the present invention will be described. That is, the method of the present invention is intended to insert-mold the roof duct 20, and will be described below with reference to the process chart of FIG. 4 and the process explanatory diagrams of FIGS. First, as shown in FIG. 5, the roof duct 20 is formed into a required shape using a PPO (polyphenylene oxide) foamed resin material, and a hot-melt adhesive 22 is formed on a flange-like joint edge 21 along the periphery. Apply. As this coating method, it is appropriate to uniformly apply the hot melt adhesive 22 in a planar shape using a roll coater in order to prevent air leakage, and also the adhesive strength is increased and the time required for application is increased. However, the hot melt adhesive 22 can be applied in a bead shape, a web shape, or a spray coating, and a double-sided adhesive tape. It is also possible to use a thermosetting resin or a heat-reactive adhesive even if they are bonded using the above.

  Next, when the molding upper and lower molds 50, 60 in the molding die 40 are in the mold open state, the roof duct 20 shown in FIG. 5 is set in the recess 52 of the molding upper mold 50. At this time, as shown in FIG. 6, the vacuum suction mechanism 53 attached to the molding upper die 50 is driven, and the roof duct 20 is securely held on the mold surface of the molding upper die 50 by the vacuum suction force. Next, as shown in FIG. 7, in this state, the raw fabric sheet S1 of the base material 10a and the raw fabric sheet S2 of the skin 10b, which are the materials of the molded ceiling 10, are set. (It is not shown in the figure.) The roof duct 20 is held on the molding upper die 50 by using the vacuum suction mechanism 53. However, the roof duct 20 is held on the molding upper die 50 by using an adsorption action such as a suction cup or a set pin. Also good.

  Next, as shown in FIG. 8, the elevating cylinder 51 is operated to lower the forming upper mold 50 by a predetermined stroke, and by drawing the upper and lower molds 50, 60, the raw sheet S1 is drawn into a required shape, At the same time as the base material 10a is molded, the skin 10b is integrated with the surface of the base material 10a. And also about the roof duct 20 currently hold | maintained at the shaping | molding upper mold | type 50 at the time of shaping | molding of this shaping | molding ceiling 10, the hot-melt-type adhesive agent 22 fuse | melts with the residual heat of original fabric sheet S1, and fully exhibits an adhesive function. Thus, it is firmly integrated into a predetermined position on the back surface of the base material 10a.

  As described above, in the method of the present invention, the roof duct 20 is inserted in advance in the molding die 40 for integrating the base material 10a and the skin 10b, and the roof duct 20 is integrally formed simultaneously with the molding of the molded ceiling 10. Therefore, the conventional process of pasting the molded roof duct and the molded ceiling together with a crimping die can be abolished, and the conventional mold equipment and integration process are no longer required, improving productivity. it can. Furthermore, also regarding the adhesive strength of the roof duct 20, the hot melt adhesive 22 can be sufficiently softened by the residual heat of the raw sheet S1 that is the material of the substrate 10a. Accordingly, the adhesiveness of the hot-melt adhesive 22 can be fully utilized, and even if the size of the roof duct 20 is increased and the application area of the hot-melt adhesive 22 is increased, the adhesive strength is reduced. Therefore, restrictions on the dimensions of the roof duct 20 can be relaxed, and the degree of freedom in forming the roof duct 20 can be greatly improved. Further, in the press molding step shown in FIG. 8, if compressed air is blown into the space between the roof duct 20 and the molded ceiling 10, the shape of the product surface on this molded ceiling 10 can be accurately formed.

  The gist of the present invention is that the roof duct 20 is insert-molded when the molded ceiling 10 is molded, and the vacuum suction mechanism 53 is used to hold the roof duct 20 to the molding upper mold 50. At the time of molding, a pneumatic force may be applied instead of the vacuum suction mechanism to increase the adhesive strength of the roof duct 20 and to smoothly perform the demolding action from the molding die. Further, the roof duct 20 can be held on the molded lower mold 60 side. Furthermore, although the roof duct 20 is insert-molded, in addition to the roof duct 20, it is also possible to insert-mold accessory parts such as a clip mounting seat and a shock absorbing pad.

It is the perspective view which looked at the molding ceiling manufactured by the method of this invention from the back side. It is sectional drawing which shows the structure of the shaping | molding ceiling shown in FIG. It is explanatory drawing which shows the whole structure of the shaping die used for this invention method. It is a process chart figure showing the outline of the method of the present invention. It is explanatory drawing which shows the application | coating process of the hot-melt-type adhesive agent in the manufacturing method of the molded ceiling which concerns on this invention. It is explanatory drawing which shows the setting process of the roof duct to the shaping die in the manufacturing method of the shaping | molding ceiling which concerns on this invention. It is explanatory drawing which shows the setting process of each raw fabric sheet | seat of the base material and skin in the manufacturing method of the molded ceiling which concerns on this invention. It is explanatory drawing which shows the formation process of the shaping | molding ceiling in the manufacturing method of the shaping | molding ceiling which concerns on this invention, and the integration process of a roof duct. It is explanatory drawing which shows the air conditioning system of the roof part of a vehicle. It is explanatory drawing which shows the structure which attaches a roof duct to the conventional shaping | molding ceiling. It is a chart figure which shows the manufacturing process of the shaping | molding ceiling provided with the conventional roof duct.

Explanation of symbols

DESCRIPTION OF SYMBOLS 10 Molding ceiling 10a Base material 10b Skin 11 Air outlet 12 Clip mounting seat 13 Clip 20 Roof duct 21 Joint edge 22 Hot-melt-type adhesive 30 Roof panel 31 Reinforce 32 Mounting hole 40 Molding die 50 Molding upper mold 51 Lifting Cylinder 52 Concave portion 53 Vacuum suction mechanism 60 Molding lower mold S1 Original sheet (base material)
S2 Original sheet (skin)

Claims (3)

It is formed by laminating a skin (10b) on the surface of a base material (10a) having a shape-retaining property, if desired, and a roof duct (20) for air conditioning integrated on the back surface. In the manufacturing method of the molded ceiling (10) to be mounted on the indoor surface side of the panel (30),
Either one of the upper and lower molds (50, 60) in a state in which the adhesive (22) is applied along the base-material-side joining edge (21) of the roof duct (20) that has been molded into a required shape and trimmed. A material setting step of holding the raw sheet (S1) heated and softened into the upper and lower molds (50, 60) while being held on the mold surface of the side mold (50);
The upper and lower molds (50, 60) are clamped, the raw sheet (S1) is drawn into the required shape to form the base material (10a), and the residual heat of the original sheet (S1) causes the roof A base for integrating the roof duct (20) on the back surface of the substrate (10a) by heating and softening the adhesive (22) applied to the joint edge (21) of the duct (20) to function as an adhesive medium. A material molding process and a roof duct integration process;
A method for producing a molded ceiling, comprising:   A vacuum suction mechanism (53) is attached to the molding die (50) that holds the roof duct (20), and the roof duct (20) is held at a predetermined position of the molding die (50) by a vacuum suction force. The method for producing a shaped ceiling according to claim 1, wherein When the molded upper and lower molds (50, 60) are clamped, compressed air is supplied to the inside of the roof duct (20), and the product surface side in the mounting area of the roof duct (20) is pressed against the mold surface of the molded lower mold (60). 3. The method for producing a molded ceiling according to claim 1, wherein the shape is accurately formed.

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