JP2009132294A - Molded ceiling for vehicle and its manufacturing method - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a molded ceiling for a vehicle which has an excellent sound absorbing performance and enables the rolling work of a skin material in the terminal processing of the molded ceiling to be easily carried out while keeping a surface material beautiful, and also to provide its manufacturing method. <P>SOLUTION: The molded ceiling for the vehicle is formed by laminating as the surface material 20 a nonwoven fabric 18 comprising a PET fiber on a base material 14 through a nonwoven fabric 17 and sticking them using an adhesive infiltrated into a polyurethane foam 11. The basic weight of the nonwoven fabric 17 is made to be in a range of 10 to 30 g/m<SP>2</SP>. <P>COPYRIGHT: (C)2009,JPO&INPIT

Description

  The present invention relates to a molded ceiling for a vehicle having sound absorbing properties and a method for manufacturing the same.

On the ceiling of a vehicle such as an automobile, a ceiling material is attached to the inside of the roof of the vehicle body, and this ceiling material is required to have functions such as sound absorption as well as heat insulation and decoration.
The present applicant has already proposed a molded ceiling for a vehicle made of a laminated material as shown in Patent Document 1. As shown in FIG. 5, the molded ceiling for the vehicle has a laminated structure in which a back material 16, a hot melt film 15, a back glass fiber layer 13, a polyurethane foam 11, and a front glass fiber layer 12 are laminated in this order. A sound absorbing performance improving material 21 and a front cloth 24 are laminated on the surface side (inside the room) of the base material 14. The sound absorbing performance improving material 21 is made of, for example, a polypropylene non-woven fabric, and the front cloth 24 has an acrylic resin foam layer 23 laminated on the back surface of a front cloth material 22 such as a polyester non-woven cloth. And the base material 14, the sound absorption performance improving material 21, and the front cloth 24 are bonded and integrated with a binder. The molded ceiling 40 for a vehicle having this structure has the effect of absorbing and not reflecting the sound from the passenger compartment, contributing to the realization of a quiet passenger compartment.

  Moreover, although the structure of a base material differs from said vehicle molded ceiling, the sound-absorbing material for vehicles is proposed as what is used for a molded ceiling etc. (refer patent document 2). The base material in this sound-absorbing material is formed, for example, by heat-softening a material made of glass fiber and PP fiber and then cold press-molding, and a bulky and flexible low density nonwoven fabric is interposed between the base material and the skin. To improve sound absorption.

On the other hand, although it does not touch the sound absorption performance at all, in the molded ceiling for vehicles, in order to make it easy to peel the skin material from the base material when processing the trimming at the edge or opening, the base material and the skin material An example in which a non-woven fabric is interposed between them is disclosed (see Patent Document 3). The processing uses a cutter knife or the like to cut the base material from the back of the ceiling, cut off part of the base material, leaving the skin material, and adhesive on the back surface of the skin material from which the base material has been removed. Is applied, and the skin material is wound around the back side of the base material and bonded. As a particularly preferable configuration in the manufacturing method, an example is disclosed in which a skin material is laminated in the order of a fabric, a urethane foam sheet, a nonwoven fabric, and paper, and each is welded by a frame laminating method to form a laminated body. And the adhesive agent which adhere | attaches a base material and a skin material does not soak into the nonwoven fabric etc. which are laminated | stacked on the surface side of paper. Moreover, the range of the basis weight of the paper on which was 5 to 200 g / ^{m 2,} the preferred basis weight and 25 g / ^{m 2,} the range of the basis weight of the nonwoven fabric on which the 5 to 200 g / ^{m 2,} a preferred basis weight 40 g / It is set to m ^2.
JP 2001-301539 A (refer to [0022], [0024], [0025]) JP 2002-215169 A (refer to [0031] and [0039]) JP 2007-030773 A (see [0010])

  However, in the molding of the molded ceiling shown in FIG. 5, the base material 14, the sound absorption performance improving material 21, and the front cloth 24 are bonded and integrated with a binder. It is necessary to prevent the adhesive used for bonding the fiber layer 12, the sound absorption performance improving material 21, and the front cloth 24 from oozing out to the surface of the front cloth 24 to impair the appearance. In that respect, in Patent Document 1, the acrylic resin-based foam layer 23 has a binder-sealing effect. However, the method of forming the acrylic resin-based foam layer 23 on the back surface of the front cloth material 22 is, for example, while stirring a resin raw material in which an additive such as a foaming aid or a crosslinking agent is mixed with acrylic latex with a mixer or the like. It is performed by mixing air, discharging and foaming the back surface of the front cloth material 22 and curing. For this reason, it is impossible to wipe out the problem of cost that it takes a considerable amount of man-hours.

When using the vehicle sound-absorbing material disclosed in Patent Document 2 as a molded ceiling, it is bulky and flexible when trimming the opening and end of the interior lamp mounting part and winding the skin on the back side of the base material and fixing it. By separating at the portion of the low-density nonwoven fabric having properties, a part of the base material is removed leaving the epidermis. Adhesion between the base material and the nonwoven fabric in the molding of the molded ceiling prior to this processing is performed without using the breathable adhesive (cobweb-like hot melt), so that the adhesive stays on the nonwoven fabric surface and does not penetrate into the nonwoven fabric. Is called. The nonwoven fabric is close to the natural state because it is not impregnated with the adhesive. Therefore, when removing a part of the base material from the skin, the portion where the nonwoven fabric is destroyed and separated is not constant, and the back surface of the skin from which the base material has been removed remains in a state where the nonwoven fabric is uneven, In addition, the nonwoven fabric may become fluffy. Therefore, the operation of applying an adhesive to the back surface and bonding and fixing the skin to the back surface of the base material is difficult to be performed under certain conditions. In particular, if the basis weight of the nonwoven fabric is 100 to 400 g / m ² , which is preferable in Patent Document 2, the thickness is assumed to be 3 to 7 mm, and a maximum level difference of about 6 mm may occur. By the way, in the same document, the basis weight of the epidermis is preferably 50 to 100 g / m ² .

  On the other hand, according to the method for manufacturing a molded ceiling for a vehicle disclosed in Patent Document 3, the non-adhesive permeable paper is used for the skin material because each laminated material is welded by a frame laminating method. Since it is in a natural state, it seems that a part of the base material can be easily removed from the skin material as in the case of Patent Document 2. However, like the hot melt film described as a problem of the prior art in Patent Document 1 and described as reflecting sound, the paper does not absorb sound and is reflected indoors, so that a sound absorbing effect is obtained. However, there remains a problem as a molded ceiling for vehicles that is required.

  The present invention has been made paying attention to such problems, and the object thereof is a molded ceiling for a vehicle excellent in sound absorption performance, and the surface material is kept beautiful and the molded ceiling is An object of the present invention is to provide a molded ceiling for a vehicle and a method of manufacturing the same that can easily carry out the work of enveloping the skin material in terminal processing or the like.

In order to solve the above-mentioned problem, the invention of the molded ceiling for vehicles according to claim 1 is the molded ceiling for vehicles formed by laminating a surface material on a base material via a nonwoven fabric, and the basis weight of the nonwoven fabric is 10 to 30 g / it is characterized in that it is m ^2.

According to a second aspect of the present invention, in the molded ceiling for a vehicle according to the first aspect, the surface material is a nonwoven fabric made of PET fiber, and the basis weight is 140 to 220 g / m ^2. It is.

According to a third aspect of the present invention, in the molded ceiling for a vehicle according to the first aspect, the surface material is obtained by laminating a nonwoven fabric made of PP, PET or PA fibers on the back surface of a tricot made of PET fibers. The basis weight of the tricot is 80 to 200 g / m ² , and the basis weight of the nonwoven fabric is 50 to 150 g / m ² .

  Invention of Claim 4 is the molded ceiling for vehicles as described in any one of Claim 1 thru | or 3. WHEREIN: The said base material is a back material, a hot-melt film, a back side glass fiber layer, a polyurethane foam, The front glass fiber layer is laminated and bonded in this order.

  According to a fifth aspect of the present invention, in the molded ceiling for a vehicle according to any one of the first to fourth aspects, the surface material, the nonwoven fabric, and the base material are bonded and integrated by an adhesive that exudes from the base material. It is characterized by being made.

A sixth aspect of the present invention is a method for manufacturing a molded ceiling for a vehicle according to any one of the first to fifth aspects, wherein the method is a method for manufacturing a molded ceiling for a vehicle, the back material and the hot melt film. A non-woven fabric and a surface material having a basis weight of 10 to 30 g / m ² on the surface side of the base material on which the back side glass fiber layer, at least the surface of the polyurethane foam with the adhesive adhered, and the front side glass fiber layer laminated in this order After the laminated material is cut into a predetermined length, the hot melt film is melted by heat at the time of hot press forming the laminated material, and the glass fiber layer and the back material are formed. Adhering and exuding the adhesive from the base material by pressing pressure, impregnating the nonwoven fabric with the adhesive and adhering to the back surface of the surface material to bond and form each material constituting the laminated material It is characterized by.

(Function)
According to the molded ceiling for a vehicle of the present invention, a base material and a surface material are bonded through a non-woven fabric having a basis weight of 10 to 30 g / m ² , in other words, a thin non-woven fabric, using an adhesive that exudes from the base material side. Are connected. Therefore, if there is a relatively small amount of adhesive, the adhesive that oozes from the substrate side impregnates the nonwoven fabric, and part of the adhesive oozes out and adheres to the back surface of the surface material. The material is bonded. For example, if a non-woven fabric having a basis weight outside the range of 40 g / m ² is used, a relatively large amount of adhesive must be used to impregnate the non-woven fabric with the adhesive and further adhere to the back surface of the surface article. It will be necessary. Then, when it appears in the direction where there is much error of the amount of adhesive used in the production line, there is a possibility that the adhesive may ooze out to the surface without staying on the back surface of the surface material. If the adhesive is set to a small amount in order to prevent the adhesive from exuding to the surface, an error that is insufficient with respect to the amount of adhesive necessary for bonding the nonwoven fabric and the surface material may occur. When the amount of the adhesive is small, a part of the surface material may be lifted and appear as an uneven pattern. However, if a non-woven fabric with a weight per unit area as in the present invention is used, the amount of adhesive can be reduced, and even if an error occurs in the quantitative control of the adhesive, the adhesive oozes out on the surface of the surface material. In addition, it is possible to prevent the surface material from floating due to insufficient adhesive.

According to the method for manufacturing a molded ceiling for a vehicle of the present invention, the base material and the surface material are adhesively bonded through a nonwoven fabric having a basis weight of 10 to 30 g / m ² , in other words, a thin nonwoven fabric. Therefore, since the predetermined amount of adhesive can be set to a relatively small amount, even if an error occurs in the coating amount, the amount becomes small, so that stable control of the coating amount on the polyurethane foam constituting the substrate can be achieved. It becomes possible.

  According to the present invention, a molded ceiling for a vehicle having excellent sound absorption performance, the molded ceiling for a vehicle capable of easily entraining a skin material in a terminal processing or the like of the molded ceiling while keeping the surface material beautiful, and A manufacturing method thereof can be provided.

(First embodiment)
Hereinafter, an embodiment of a molded ceiling for a vehicle embodying the present invention will be described with reference to FIGS. In addition, about the same structure as a prior art, the same code | symbol used in the description shall be used.

  FIG. 1 is a cross-sectional view showing a part of a molded ceiling 10 for a vehicle according to the present embodiment. A back material 16, a hot melt film 15, a back side glass fiber layer 13, a polyurethane foam 11, and a front side glass fiber layer 12 are laminated in order from the bottom of FIG. In the present embodiment, in the manufacturing method described later, ordinary MDI (diphenylmethane diisocyanate) as an adhesive impregnated in the soft polyurethane foam 11 oozes out from the polyurethane foam 11, and the back glass fibers are formed on both sides thereof. The layer 13 and the front glass fiber layer 12 are bonded. Furthermore, the nonwoven fabric 17 and the surface material 20 are laminated on the front side of the front glass fiber layer 12, and the nonwoven fabric 17 is impregnated with the adhesive that has passed through the front glass fiber layer 12, and a part of the nonwoven fabric 17 oozes out to the front side. It adheres to the back surface of the material 20. Further, the back side of the back glass fiber layer 13 and the back material 16 are bonded via a molten hot melt film 15. In this way, the vehicle molded ceiling 10 is adhesively bonded as a laminate. The hot melt film 15 is not limited to a single layer, and a plastic film having a melting temperature higher than the melting temperature of the hot melt film 15 may be laminated and used on the back glass fiber layer 13 side of the hot melt film 15. The plastic film forms a layer having the effect of preventing airflow on the base material 14. At that time, the adhesion between the back glass fiber layer 13 and the hot melt film 15 is performed by an adhesive B (shown in FIG. 4) that exudes from the back glass fiber layer 13.

The nonwoven fabric 17 of the present embodiment is a spunbonded nonwoven fabric made of PP (polypropylene) fibers, the basis weight is 20 g / m ² , and the thickness is as thin as approximately 0.2 mm. Therefore, the non-woven fabric 17 is impregnated with the adhesive that has passed through the front glass fiber layer 12, and a part of the non-woven fabric 17 oozes out to the front side of the non-woven fabric 17 and adheres to the back surface of the surface material 20 to bond the non-woven fabric 17 and the surface material 20. For this purpose, a small amount of the adhesive that oozes out from the front glass fiber layer 12 is sufficient.

The surface material 20 of the present embodiment is a nonwoven fabric 18 made of PET (polyethylene terephthalate) fiber, and its basis weight is 180 g / m ² . Although the surface material 20 has sound absorbing performance, since there is no sound reflecting material between the nonwoven fabric 17 and the base material 14, the sound absorbing performance of the nonwoven fabric 17 and the base material 14 is further added, and excellent sound absorbing performance is obtained. A formed ceiling will be formed. An example of the sound absorbing performance is shown in Table 1.

ここに用いられた試験片は、上記表面材２０を、上記不織布１７を介して通常の基材１４に積層し車両用成形天井１０を形成した一部である。また、試験方法はＪＩＳ Ａ １４０５に準拠して行われた。表１に表されているように、各周波数に対する吸音率の数値が、本実施形態の車両用成形天井１０は成形天井に求められる吸音性能を備えていることを示している。

The test piece used here is a part in which the surface material 20 is laminated on the normal base material 14 through the nonwoven fabric 17 to form the molded ceiling 10 for the vehicle. The test method was performed in accordance with JIS A 1405. As shown in Table 1, the numerical value of the sound absorption coefficient for each frequency indicates that the vehicle molded ceiling 10 of the present embodiment has a sound absorbing performance required for the molded ceiling.

Although the Example which is 20 g / m < ² > was shown as a suitable fabric weight of the nonwoven fabric 17, since an adhesive agent does not ooze out to the surface of the surface material 20, and the nonwoven fabric 17 and the surface material 20 adhere | attach with appropriate adhesive strength. In addition, the basis weight of the nonwoven fabric 17 is essential to be 10 to 30 g / m ² . Table 2 shows various evaluations of the molded ceiling 10 for a vehicle, with the nonwoven fabric 17 within the range of the basis weight as an example and the nonwoven fabric 17 outside the range as a comparative example.

ここで用いられた試験片は、表１に示す試験に用いられたものと同様の表面材２０を用い、不織布１７の目付を５〜１５０ｇ／ｍ^２の範囲で七通りに変化させ、それぞれを通常の基材１４に積層し車両用成形天井１０を形成した一部である。その際、剥離強度はＪＩＳ Ｋ ６８５４ ９−１に準拠して測定した。

The test piece used here uses the same surface material 20 as that used in the test shown in Table 1, and the basis weight of the nonwoven fabric 17 is changed in seven ways in the range of 5 to 150 g / m ^2. It is a part of the laminated base 10 formed on a normal base material 14 to form a vehicle molded ceiling 10. At that time, the peel strength was measured in accordance with JIS K 6854 9-1.

  First, each item in Table 2 will be described. A peel strength of 50 or more indicates that the material is broken when the surface material 20 is forcibly peeled, and a value of 5 or less indicates that peeling is easy and the strength value is so small that it cannot be measured. “Ease of peeling of the base material” means ease when a part of the base material 14 is manually removed from the surface material 20, and x is difficult enough to cause material destruction of the surface material 20. ◯ indicates that the work can be performed without any particular difficulty, and ◎ indicates that the work can be performed so easily that almost no force is required.

  Appearance defects were evaluated visually for “bleed out” and visually and touched for “skin lift”. Regarding “bleed out”, × represents a state in which the pattern can be visually recognized by bleeding of the adhesive, ○ represents a state in which the bleeding of the adhesive cannot be visually recognized from the surface of the surface material 20, and ◎ represents the surface of the surface material 20 The state shows a state where there is no problem at all. In addition, regarding “skin lifting”, xx indicates a state where almost the entire surface material 20 is floating from the base material 14, and x indicates that the surface material 20 is partially lifted on the entire surface. The state where the uneven pattern is formed is shown. Δ indicates a state in which a convex portion due to the float of the skin may appear on a part of the surface material 20, and ○ indicates a state in which the surface material 20 forms a shape (design shape) along the cavity surface of the press die. Is shown.

Comprehensive evaluation is evaluated by combining the above “easiness of peeling of the base material” and “poor appearance”, x and Δ are difficult to adopt as the nonwoven fabric 17 of the molded ceiling 10 for a vehicle, and ○ can be adopted. Show. Since Comparative Example 1 is an item of the ease of peeling of the base material 14, the overall evaluation is x, and Comparative Examples 2 to 4 are Δ or x based on the evaluation of skin float. Examples 1 to 3 in which the basis weight of the nonwoven fabric 17 is in the range of 10 to 30 g / m ² indicate that the evaluation of ◯ is given as the molded ceiling 10 for a vehicle.

The surface material 20 is not limited to the surface material 20 used in the above embodiment, and the basis weight can be appropriately selected from the range of 140 to 220 g / m ² . When the basis weight of the surface material 20 is below 140 g / ^{m 2,} even basis weight of the nonwoven fabric 17 is a 10 g / ^{m 2,} there is a fear of bleeding of the surface material 20 surface of the adhesive. In addition, if the basis weight of the surface material 20 exceeds 220 g / m ² , the surface material 20 of the vehicle molded ceiling 10 becomes heavy, which not only contributes to a reduction in the weight of the vehicle but also increases costs.

(Another example of surface material)
In the above embodiment, the nonwoven fabric 18 made of PET fibers is used as the surface material 20, but the surface material 20 is not limited to this. For example, as shown in FIG. 2, when a high-class feeling is expressed in the passenger compartment, a nonwoven fabric 29 made of PET fibers is laminated on the back surface of a tricot 28 made of PET fibers as the surface material 20, and the tricot 28 The fabric weight of 80 to 200 g / m ² and the fabric weight of the nonwoven fabric 29 may be 50 to 150 g / m ² . If the basis weight of the tricot 28 is less than 80 g / m ² and the basis weight of the nonwoven fabric 29 is less than 50 g / m ² , even if the basis weight of the nonwoven fabric 17 is 10 g / m ² , the adhesive oozes out to the surface of the surface material 20. There is a risk. Further, if the basis weight of the tricot 28 exceeds 200 g / m ² and the basis weight of the nonwoven fabric 29 exceeds 150 g / m ² , the surface material 20 of the molded ceiling 10 for the vehicle becomes heavy, which is a factor that impairs weight reduction of the vehicle. This is not preferable because it increases the cost. In addition, as a back material of the tricot 28 which consists of PET fiber, the nonwoven fabric 29 which consists of PP or PA (polyamide) fiber other than PET fiber can be used. In that case, about the fabric weight of the nonwoven fabric 29 which consists of PP fiber or PA fiber, it needs to exist in the same range as the case of the nonwoven fabric 29 which consists of the said PET fiber.

(Trimming)
In the trimming process of the molded ceiling 10 for a vehicle using the nonwoven fabric 17 having a basis weight in the range of 10 to 30 g / m ² , the situation where the surface material 20 is wound around the back surface of the base material 14 and bonded and fixed is shown in FIG. explain.

FIG. 3A shows a state immediately before a cut is made using a cutter C in a part of the end of the ceiling material 10 b in which the nonwoven fabric 17 and the surface material 20 are laminated and formed on the base material 14. Then, as shown in FIG. 3B, after the cut is made, a part of the base material piece 14 a of the base material 14 is separated from the end portion 26 of the base material 14 and the surface material 20 and removed. At this time, the base material piece 14a and the surface material 20 are easily separated at the portion of the nonwoven fabric 17 having a basis weight in the range of 10 to 30 g / m ² . As shown in FIG. 3 (c), after the base material piece 14 a and the nonwoven fabric 17 are removed, a known urethane adhesive is applied to the back surface of the surface material 20. And as shown in FIG.3 (d), the surface material 20 is wound in the back surface 27 side of the base material 14, and the trimming process is completed by adhesively fixing the back surface of the surface material 20 to the edge part 26 and the back surface 27. To do.

(Production method)
A method for manufacturing the molded ceiling 10 for a vehicle according to the embodiment will be described with reference to FIG. 4 as a case where the surface material 20 shown in another example is used. In the manufacturing method described below, a belt conveyor type manufacturing method for continuously supplying materials will be described. However, after the materials are cut into predetermined dimensions in advance, a manufacturing method of laminating them may be adopted. Good. In particular, when a soft polyurethane foam is used as the polyurethane foam 11, a continuous production method is suitable. On the other hand, when a semi-rigid or rigid polyurethane foam is used as the polyurethane foam 11, it is difficult to prepare the polyurethane foam 11 in a roll shape, so the flat polyurethane foam 11 is cut into a predetermined size and laminated. It is better to adopt the manufacturing method to do.

  First, the surface material 20 is prepared by bonding the nonwoven fabric 29 to the back surface of the tricot 28 by the frame laminating method. Next, the hot melt film 15 is laminated on the back material 16 unwound from the roll, and the glass fiber cut to a predetermined length is sprayed on the hot melt film 15 moving downstream, and the back side glass fiber layer 13 and To do. Further, the sheet-like soft polyurethane foam 11 unwound from the roll is immersed in an adhesive B made of ordinary MDI, and the amount of the adhesive B impregnated into the polyurethane foam 11 between the rolls R1 and R2 is determined. Control to quantitative. The polyurethane foam 11 impregnated with the adhesive B is supplied onto the back glass fiber layer 13, and the glass fiber cut into a predetermined length is sprayed on the polyurethane foam 11 to form the front glass fiber layer 12. And the laminated material obtained by laminating | stacking the nonwoven fabric 17 and the surface material 20 on the front side glass fiber layer 12 in this order is cut | disconnected to predetermined length, and the laminated body 10a is obtained. By putting this laminated body 10a into a hot press die P and performing hot press molding, a ceiling material 10b before trimming is obtained as a molded ceiling 10 for a vehicle. In this hot press molding, the adhesive B impregnated in the polyurethane foam 11 oozes out to the back glass fiber layer 13 and the front glass fiber layer 12 and further impregnates the nonwoven fabric 17, and then a part of the adhesive B is back of the surface material 20. It adheres to and hardens when heated. At that time, the hot melt film 15 heated at the same time is melted to adhere the back surface of the back glass fiber layer 13 and the back material 16. Furthermore, if the trimming process demonstrated using FIG. 3A is given to this ceiling material 10b, the molded ceiling 10 for vehicles will be completed.

  In the above embodiment, a soft polyurethane foam is used as the polyurethane foam 11. However, when a semi-rigid or hard polyurethane foam is used, the adhesive B penetrates into the polyurethane foam 11 having many closed cells. Absent. Therefore, the supply of the adhesive B to the polyurethane foam 11 is performed by applying to the surface of the polyurethane foam 11.

Therefore, according to the molded ceiling 10 for a vehicle of the said embodiment and its manufacturing method, the following effects can be acquired.
(1) In the above embodiment, since the basis weight of the nonwoven fabric 17 is in the range of 10 to 30 g / m ² , the nonwoven fabric 17 is impregnated with the adhesive B that has exuded from the base material 14 and part thereof is stained. When the base material 14, the nonwoven fabric 17 and the surface material 20 are bonded to the back surface of the surface material 20, the amount of the adhesive that oozes out can be controlled to a predetermined amount. Therefore, it is possible to prevent the adhesive from oozing out on the surface of the surface material 20, and to keep the surface of the surface material 20 beautiful.

(2) In the above embodiment, since the basis weight of the nonwoven fabric 17 is in the range of 10 to 30 g / m ² , a part of the base material 14 is peeled off from the surface material 20 and separated from the end of the base material 14 and the like. When removing, the nonwoven fabric 17 is easily destroyed, and the uneven surface of the nonwoven fabric 17 does not remain on the back surface of the surface material 20. Therefore, it is possible to stably perform a trimming process in which an adhesive is applied to the back surface of the surface material 20, and the surface material 20 is wound around the back surface 27 of the base material 14 to be bonded and fixed.

  (3) In the above embodiment, since the surface material 20 having a relatively heavy weight per unit area of the nonwoven fabric 17 is used, the surface material 20 has not only a sound absorbing performance but also an adhesive B that exudes from the nonwoven fabric 17. The allowable amount, that is, the amount that can keep the adhesive inside is large. Therefore, since the adhesive B does not ooze out to the surface of the surface material 20, the surface of the surface material 20 can be kept beautiful.

  (4) In the above embodiment, since the surface material 20 is formed by laminating a non-woven fabric made of PET fiber on the back surface of a tricot made of PET fiber, a molded ceiling 10 for a vehicle with a high-class feeling can be obtained.

(5) In the above embodiment, since the basis weight of the non-woven fabric 17 is in the range of 10 to 30 g / m ² , the non-woven fabric 17 is impregnated with the adhesive B exuded from the base material 14 and a part thereof is stained. When the base material 14, the nonwoven fabric 17, and the surface material 20 are bonded to each other by sticking out to the back surface of the surface material 20, the bonding can be performed with a small amount of adhesive. Therefore, control of the adhesive B in a production line becomes comparatively easy, and the manufacturing method which can supply the stable adhesive B can be provided.

(Example of change)
In addition, you may change the said both embodiment as follows.
-In the said embodiment, when forming a glass fiber layer on both surfaces of the polyurethane foam 11, the glass fiber cut | judged to predetermined length was supplied (spread), However, after forming the nonwoven fabric sheet of glass fiber previously Then, it may be supplied.
In the above embodiment, a spunbond nonwoven fabric made of PP fibers is used as the nonwoven fabric 17, but the nonwoven fabric 17 is not limited to this, and a non-woven fabric that is partially welded and strong, for example, a thermal bond nonwoven fabric made of synthetic fiber Or a melt blown nonwoven fabric.

The partial cross section figure of the molding ceiling for vehicles of this invention. The partial cross section figure of another example of the molded ceiling for vehicles of the present invention. (A), (b), (c), (d) is a partial cross-sectional view for explaining the skin entrainment process step by step by removing a part of the substrate. The front view which shows typically the manufacturing method of the molded ceiling for vehicles of this invention. The partial cross section figure of the molded ceiling for vehicles of a prior art.

Explanation of symbols

  B ... Adhesive, 10 ... Molded ceiling for vehicle, 11 ... Polyurethane foam, 12 ... Front glass fiber layer, 13 ... Back glass fiber layer, 14 ... Base material, 15 ... Hot melt film, 16 ... Back material, 17, 18, 29 ... non-woven fabric, 20 ... surface material, 27 ... back surface, 28 ... tricot.

Claims (6)

The vehicle forming the ceiling formed by laminating a surface member via a nonwoven fabric base material, molded ceiling vehicle basis weight of the nonwoven fabric is characterized in that it is a 10 to 30 g / m ^{2. 2. The} molded ceiling for a vehicle according to claim 1, wherein the surface material is a non-woven fabric made of PET fibers and has a basis weight of 140 to 220 g / m ² . The surface material is obtained by laminating a non-woven fabric made of PP, PET or PA fibers on the back surface of a tricot made of PET fiber, the basis weight of the tricot is 80 to 200 g / m ² , and the basis weight of the non-woven fabric is It is 50-150 g / m < ² >, The molded ceiling for vehicles of Claim 1 characterized by the above-mentioned.   4. The substrate according to any one of claims 1 to 3, wherein a back material, a hot melt film, a back glass fiber layer, a polyurethane foam, and a front glass fiber layer are laminated and bonded in this order. The molded ceiling for a vehicle according to one item.   The molded ceiling for vehicles according to any one of claims 1 to 4, wherein the surface material, the nonwoven fabric, and the base material are bonded and integrated with an adhesive that exudes from the base material. A method for producing a molded ceiling for a vehicle, comprising a back material, a hot melt film, a back glass fiber layer, a polyurethane foam having an adhesive attached to at least the surface, and a surface of a base material on which a front glass fiber layer is laminated in this order After the laminated material obtained by laminating the nonwoven fabric having a basis weight of 10 to 30 g / m ² and the surface material is cut to a predetermined length, the heat generated when the laminated material is subjected to hot press molding is subjected to hot press molding. The hot melt film is melted to adhere the glass fiber layer and the back surface material, and the adhesive is oozed out from the base material by pressing pressure, and the non-woven fabric is impregnated with the adhesive and adhered to the back surface of the surface material. 6. The method for manufacturing a molded ceiling for a vehicle according to claim 1, wherein the members constituting the laminated material are bonded to each other. 7.

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