JP2008150005A - In-cabin ceiling material of automobile - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a lightweight in-cabin ceiling material of an automobile at low cost. <P>SOLUTION: The ceiling material comprises a first layer 2 with a ventilation-stopping film layer 6 being laminated on a lower side of a back side layer formed of a nonwoven fabric, a second layer 3 with a web layer 8 having air permeability and consisting of a thermoplastic resin being laminated on an upper side of a base material layer 7 and a reinforcing material layer 9A having adhesive function being laminated on a lower surface of the base material layer 7, and a third layer 4 with a surface skin layer 10 being adhered to a lower side of a surface layer formed of a nonwoven fabric. The first layer 2, the second layer 3 and the third layer 4 are successively and integrally adhered with each other by melting an adhesive component by heating with hot air the web layer 8 and the reinforcing layer 9A constituting the second layer 3. <P>COPYRIGHT: (C)2008,JPO&INPIT

Description

  The present invention relates to an automobile interior ceiling material having sound absorbing properties and sound insulating properties.

  Conventionally, a back layer made of a nonwoven fabric is interposed on the surface of a base material layer through a film layer in the interior of an automobile.

  Further, there is a structure in which a surface layer made of a nonwoven fabric is bonded to the lower surface of the base material layer via a web layer, and the surface of the surface layer is further covered with a skin layer.

  The conventional indoor ceiling material having the above structure has a first layer in which a film layer is previously laminated on a back surface layer, a second layer in which a web layer is laminated on a base material layer, and a skin layer bonded to a surface layer. Three layers were manufactured in advance, and after cutting each of these layers into a predetermined shape, the layers were integrated by pressure molding between molds composed of a male mold and a female mold.

  However, in the conventional indoor ceiling material, when the first layer, the second layer, and the third layer are integrally formed using a mold, the second layer and the third layer are previously formed of the base material layer and the second layer. The web layer of the layer is heated with hot air to melt the web layer and the surface layer is adhered to the base material layer by hot melt of the web layer. The first layer and the second layer are the base material layer heated. Since the film layer is melted by heat, the heat of the base material layer is cooled by the time it is laminated, and becomes below the melting point of the film layer. When the ceiling material is fixed to the roof, the adhesive portion may be peeled off.

Therefore, the present applicant has already proposed an indoor ceiling material as shown in FIG. 5 (see Patent Document 1).
JP 2000-318540 A.

  According to FIG. 5, the indoor ceiling material has air permeability on the upper and lower surfaces of the first layer 2 in which the film layer 6 is laminated on the lower surface of the back layer made of nonwoven fabric and the base material layer 7 made of nonwoven fabric such as PET. And a second layer 3 in which web layers 8 and 9 made of a thermoplastic resin are laminated, and a third layer 4 in which a skin layer 11 is bonded to the lower surface of a surface layer 10 made of a nonwoven fabric. The second layer 3 is heated with hot air so that the web layers 8 and 9 are melted and interposed between the first layer 2 and the third layer 4, and each of these layers 2, 3 and 4 is pressed by a mold. The first layer 2 and the third layer 4 are bonded and integrated by hot-melting the web layers 8 and 9 by molding.

However, according to the indoor ceiling material as shown in FIG. 4, the base material layer 7 is made of a non-woven fabric such as PET, thereby obtaining the rigidity of the whole ceiling material and suppressing heat deformation. It is difficult to drop the fabric weight of No. 7, for example, it is practically constructed with a fabric weight of 800 to 1000 g / m ² , but denies that it is very unsatisfactory for the recent demand for weight reduction of automobiles. In addition, the handleability of the product is also inferior.

  Moreover, in order to ensure the heat-resistant deformation property of the PET nonwoven fabric in the base material layer 7, binder fibers, low melting point PET, or the like is used, but such a material leads to an increase in the cost of the molded ceiling material itself. become.

  Then, in view of this point, the present invention aims to provide a lightweight and low-cost automobile molded ceiling material.

  In order to achieve the above object, the molded ceiling material according to the present invention has a first layer in which a gas barrier film layer is laminated on the lower surface of a back layer made of nonwoven fabric, and has air permeability on the upper surface of the base material layer, And a web layer made of a thermoplastic resin and a second layer formed by laminating a reinforcing material layer having an adhesive function on the lower surface of the base material layer, and a skin layer on the lower surface of the surface layer made of nonwoven fabric. The first layer, the second layer, and the third layer are formed by melting the adhesive component by heating the web layer and the reinforcing material layer, which are formed of the bonded third layer and constituting the second layer, with hot air. The layers are formed by sequentially bonding and integrating the layers.

  With this configuration, the second layer is formed by laminating a reinforcing material layer having an adhesive function on the lower surface of the base material layer, and the web layer and the reinforcing material layer constituting the second layer are heated with hot air to bond the adhesive material. By melting the components and sequentially bonding and integrating the first layer, the second layer, and the third layer, the base material layer substantially has a sandwich structure of the air blocking film layer and the reinforcing material layer. Therefore, the rigidity of the entire ceiling material is increased, the handling property of the product is improved, and the heat deformation performance can be improved.

In addition, in relation to the above, even if the basis weight of the PET nonwoven fabric constituting the base material layer is reduced to, for example, 400 to 600 g / m ² , the required rigidity can be obtained and the weight of the automobile can be reduced. Accordingly, the reduction in the amount of binder fibers added and the use of low-melting point PET are no longer necessary, thereby contributing to reduction in manufacturing costs.

  Furthermore, even if the direction of the fibers of the PET nonwoven fabric is juxtaposed in the direction perpendicular to the width direction of the ceiling material in order to form the base material layer, the rigidity of the entire ceiling material can be secured and the ceiling material itself The sound absorbing performance can be improved while ensuring the thickness of the material, and the handling property can be further improved.

  Further, the present invention is characterized in that the gas barrier film layer is constituted by a gas barrier reinforcing film layer.

  The air-proof reinforcing film layer may be, for example, any one or any two of a nonwoven fabric made of PET, a web mainly made of synthetic fibers made from a papermaking method, or a web made mainly of inorganic fibers also made from a papermaking method. It is conceivable to use a film layer composed of the above combinations.

  With this configuration, the rigidity of the base layer in the second layer can be further increased, the handling of the product can be improved, the weight of the base layer can be further reduced, and the amount of binder fibers added can be reduced. The manufacturing cost can be greatly reduced.

  In the present invention configured as described above, the second layer is configured by laminating a reinforcing material layer having an adhesive function on the lower surface of the base material layer, and the web layer and the reinforcing material layer constituting the second layer The base material layer is substantially made of an air-proofing film layer and a reinforcing material by heating and hot air to melt the adhesive component and sequentially bonding and integrating the first layer, the second layer, and the third layer. Since it becomes a sandwich structure with the layers, the rigidity of the whole ceiling material is increased, the handling property of the product is improved, and the heat deformation performance can be improved.

In addition, in relation to the above, the present invention can obtain the required rigidity even if the basis weight of the PET nonwoven fabric constituting the base material layer is reduced to, for example, 400 to 600 g / m ^2. Accordingly, the reduction in the amount of binder fibers and the use of low-melting point PET are no longer necessary, which contributes to a reduction in manufacturing costs.

  Furthermore, the present invention can ensure the rigidity of the entire ceiling material even when the fibers of the PET nonwoven fabric are juxtaposed in the direction perpendicular to the width direction of the ceiling material in order to constitute the base material layer. The sound absorbing performance can be enhanced while ensuring the thickness of the ceiling material itself, and the handling property can be further improved.

  Hereinafter, the best mode for carrying out the present invention will be described with reference to the drawings.

  FIG. 1 is a perspective view showing an indoor ceiling material of an automobile, and FIG. 2 is a cross-sectional view taken along the line AA of FIG. 1 depicting one embodiment according to the present invention. Note that portions corresponding to the conventional configuration will be described using the same reference numerals.

  1 and 2, reference numeral 1 denotes a ceiling material body. As shown in FIG. 2, the first layer 2, the second layer 3, and the third layer 4 that are pre-formed are integrally formed by a method described later. It has a 7-layer structure.

That is, the first layer 2 is composed of a back surface layer 5 formed of a nonwoven fabric made of PET and PE fibers having a basis weight of about 15 to 40 g / m ^2, and a ventilation film layer 6 laminated on the lower surface of the back surface layer 5. For the air-blocking film layer, a thermoplastic film in which an olefin resin film having a thickness of about 70 to 90 μm or a urethane resin film is laminated in two or three layers is used.

The second layer 3 is made of PET fiber having a basis weight of 400 to 600 g / m ² , or a base material layer 7 made of a nonwoven fabric obtained by uniformly mixing PET fiber with a binder fiber or the like at a ratio of about 50:50, and a base material layer 7. The web layer 8 laminated on the upper surface of the substrate and the reinforcing material layer 9A laminated on the lower surface of the base material layer 7, and the base material layer 7 is subjected to a surface strengthening treatment by needle punching in order to strengthen the surface. .

The web layer 8 uses a spider web-like hot melt material made of a low melting point (110 to 150 ° C.) PET resin having a basis weight of about 15 to 30 g / m ² , and the reinforcing material layer 9A is made of a PET non-woven fabric. A film layer made of any one of a combination of two or more webs mainly made of synthetic fibers manufactured by a papermaking method, or a web mainly made of inorganic fibers manufactured also from a papermaking method is used. Has been.

  The third layer 4 includes a surface layer 10 formed of a nonwoven fabric similar to the back layer 5 and a skin layer 11 adhered to the lower surface of the surface layer 10, and the skin layer 11 is a tricot or jersey cloth, a nonwoven fabric, or the like. Is used.

  Next, a method for forming the indoor ceiling material configured as described above will be described with reference to FIG.

  The first layer 2, the second layer 3, and the third layer 4 are formed in advance in separate steps or are ready-made, and the layers 2, 3, and 4 are cut into a predetermined shape.

  Next, as shown in FIG. 3A, in the state where the periphery of the second layer 3 is clamped by the clamping means 13, the hot air is passed through the second layer 3 by blowing the hot air on the reinforcing material layer 9A side. The web layer 8 and the reinforcing material layer 9A provided on the upper and lower surfaces of the base material layer 7 are melted by hot air overheating.

  When the hot air heating of the second layer 3 is completed in this way, as shown in FIG. 3B, the first layer 2 and the second layer are interposed between the metal molds 14a and 14b. 3 and the third layer 4 are interposed in this order, the female mold 14a and the male mold 14b are combined and pressurized, and integrated molding is performed as shown in FIG.

  At this time, since the base layer 7 is heated in advance by heating with hot air and the web layer 8 and the reinforcing material layer 9A are in a molten state, the second layer 3 has the film layer 6 of the first layer 2 and the third layer 3. The surface layer 10 of the layer 4 has a seven-layer structure in which the web layer 8 and the reinforcing material layer 9A are firmly bonded and integrated by hot melt.

  With this configuration, the second layer 3 is configured by laminating the reinforcing material layer 9A having an adhesive function on the lower surface of the base material layer 7, and the web layer 8 and the reinforcing material layer 9A configuring the second layer 3 are formed. The base material layer 7 is substantially made of the air-proofing film layer 6 by heating the hot air to melt the adhesive component and bonding and integrating the first layer 2, the second layer 3, and the third layer 4. And the reinforcing material layer 9A, the overall rigidity of the ceiling material body 1 is increased, the handling property of the product is improved, and the heat-resistant deformation performance can be improved.

Further, in relation to the above, even if the basis weight of the PET nonwoven fabric constituting the base material layer 7 is reduced to, for example, 400 to 600 g / m ² , the required rigidity can be obtained and the weight of the automobile can be reduced. As a result, the reduction in the amount of binder fibers added and the use of low-melting point PET are no longer necessary, contributing to a reduction in manufacturing costs.

  Furthermore, even if the direction of the fibers of the PET nonwoven fabric is juxtaposed in the direction perpendicular to the width direction of the ceiling material body 1 in order to form the base material layer 7, the overall rigidity of the ceiling material body 1 can be ensured. At the same time, the sound absorbing performance can be enhanced while ensuring the thickness of the ceiling material body 1 itself, and the handling property can be further improved.

  FIG. 4 is a sectional view showing another embodiment according to the present invention.

  According to FIG. 4, there is a feature in that it is constituted by an air-proofing reinforcing film layer 6 </ b> A instead of the air-proofing film layer 6 in the above-described embodiment, and other configurations are the same as those in the above-described embodiment.

  The air-proof reinforcing film layer 6A is, for example, any one or any two of a web mainly made of synthetic fibers manufactured from a PET nonwoven fabric, a papermaking method, or a web mainly made of inorganic fibers also manufactured from a papermaking method. It is comprised using the film layer which consists of the above combination.

  With this configuration, the rigidity of the base material layer 7 in the second layer 3 can be further increased, the handling of the product can be improved, the weight of the base material layer 7 can be further reduced, and the amount of binder fibers added can be reduced. The manufacturing cost of the ceiling material body 1 can be greatly reduced.

  As described above, in the present invention, the second layer is formed by laminating the reinforcing material layer having an adhesive function on the lower surface of the base material layer, and the web layer and the reinforcing material layer constituting the second layer. Is heated and heated to melt the adhesive component, and the first layer, the second layer, and the third layer are bonded and integrated. Therefore, the rigidity of the whole ceiling material is increased, the handling property of the product is improved, and the heat deformation performance can be improved.

In addition, in relation to the above, the present invention can obtain the required rigidity even if the basis weight of the PET nonwoven fabric constituting the base material layer is reduced to, for example, 400 to 600 g / m ^2. Accordingly, the reduction in the amount of binder fibers and the need to use low melting point PET are no longer necessary, which contributes to cost reduction.

  Furthermore, the present invention can ensure the rigidity of the entire ceiling material even when the fibers of the PET nonwoven fabric are juxtaposed in the direction perpendicular to the width direction of the ceiling material in order to constitute the base material layer. The sound absorbing performance can be enhanced while ensuring the thickness of the ceiling material itself, and the handling property can be further improved.

  From the above, the present invention is suitable for automobile interior ceiling materials having sound insulation.

FIG. 1 is a perspective view showing an interior ceiling material of an automobile. It is sectional drawing which follows the AA line of FIG. 1 which drew one embodiment which concerns on this invention. It is explanatory drawing which shows the formation process of the indoor ceiling material of the motor vehicle shown in FIG. It is sectional drawing in alignment with the AA line of FIG. 1 which drew the form of the other field which concerns on this invention. It is sectional drawing which shows the indoor ceiling material of the conventional motor vehicle.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Ceiling material main body 2 1st layer 3 2nd layer 4 3rd layer 5 Back layer 6 Ventilation film layer 6A Venting reinforcement film layer 7 Base material layer 8 Web layer 9A Reinforcement material layer 10 Surface layer 11 Skin layer

Claims (2)

  The base layer is formed by laminating a first layer in which an air-blocking film layer is laminated on the lower surface of a back layer made of nonwoven fabric, and a web layer made of a thermoplastic resin having air permeability on the upper surface of the base material layer. The second layer is formed by laminating a reinforcing material layer having an adhesive function on the lower surface of the substrate, and the third layer having a skin layer bonded to the lower surface of the surface layer made of nonwoven fabric, and constitutes the second layer. The web layer and the reinforcing material layer are heated and heated to melt the adhesive component so that the first layer, the second layer, and the third layer are sequentially bonded and integrated. Indoor ceiling material. 2. The indoor ceiling material for an automobile according to claim 1, wherein the air-proofing film layer is formed of a air-proofing reinforcing film layer.

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