JP2013136309A - Molded ceiling member for vehicle - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a molded ceiling which can be reduced in weight by using a glass fiber made of a continuance single yarn and does not have such a problem as cracking even if molded with a deep molding depth.SOLUTION: A molded ceiling member for a vehicle includes a base layer 11 made of a hard urethane, front and back glass fiber reinforcing layers 12 and 14 joined to both surfaces of the base layer 11, respectively, a skin layer 13 joined to the exterior of the front glass fiber reinforcing layer 12, and a back layer 15 joined to the exterior of the back glass fiber reinforcing layer 14. At least either of the front glass fiber reinforcing layer 12 and the back glass fiber reinforcing layer 14 is made of a glass sheet film 20 manufactured by using a glass fiber filament 21 made of a continuance yarn.

Description

  The present invention relates to a molded ceiling material for a vehicle that is lightweight and excellent in moldability.

  Conventionally, as a molded ceiling for vehicles, a hard urethane or the like is used as a base material, glass fiber reinforcement layers are provided on both sides thereof, and a skin layer and a back layer are provided on the outside of both reinforcement layers, respectively ( Patent Document 1).

  In this case, as the glass fiber reinforcing layer, a glass mat coated (impregnated) with an adhesive made of a urethane resin (for example, an isocyanate resin) in order to obtain the reinforcement of the base material and the adhesive strength between the skin and the back surface. Etc. are provided in a sandwich on both sides of the substrate. As the skin layer, a nonwoven fabric, a tricot / slab urethane laminate skin, a woven fabric, a knitted fabric, a plastic sheet, or the like is used.

  As is generally known, the glass mat mentioned here is a bundle of glass filaments bundled in a large amount to form a fiber bundle of several mm (so-called roving), which is cut into a predetermined length to obtain a chopped strand. It is manufactured, dispersed in a mat shape, and formed into a mat shape using a binder.

  In the case of the urethane base ceiling as described above, the rigidity is generally secured by a glass mat that serves as a glass fiber reinforcing layer bonded to the base and both surfaces thereof. Furthermore, the stiffness is not simply the sum of the stiffness of the three, but a glass mat that cannot be stretched or contracted by external force is bonded to the front and back surfaces of the substrate with a certain thickness. By making a sandwich-like structure like the above and securing deformation resistance on both surfaces of the substrate (so-called gimbal cell), the overall rigidity is maintained.

  For forming these glass fiber reinforcing layers, for example, glass fiber chops (cut roving glass), glass fiber mats, and glass fiber cloths are provided on both sides of a core material made of polyurethane foam. There are known those provided with a back layer and a skin layer (see Patent Document 2).

  Moreover, what provided the glass fiber as glass paper instead of the glass fiber mat on both sides of a base material made of a polyurethane foam layer with a hot melt film adhesive is known (see Patent Document 3).

  The glass fiber reinforcement layer is a glass fiber reinforcement layer made of glass fiber filament glass paper, and a silane-based treatment agent consisting of a silane or a silane mixture mixed with a urethane emulsion is used as the glass paper treatment agent. The thing provided in the both sides of the core material which becomes is known (refer patent document 4).

JP 2001-301539 A JP 2002-046545 A Japanese Utility Model Publication No. 5-34278 WO2010 / 029861

  In the molded ceiling as described above, the weight occupied by the urethane base material and the glass fiber reinforcing layer is very large. However, it is difficult to reduce the weight of a urethane base material because of the demand as a core material, and among these, there is a great expectation for weight reduction of the glass fiber reinforcing layer.

  However, the molded ceiling as shown in Patent Document 1 only discloses a glass fiber reinforcement layer as a fiber reinforcement layer, and does not disclose the weight reduction of the glass fiber reinforcement layer.

  Patent Document 2 discloses that in order to reduce the weight of glass fiber, the base material is pre-impregnated with an isocyanate-based adhesive as an adhesive, and the glass fiber layer is pre-impregnated with an isocyanate-based adhesive as an adhesive. doing. Further, it is disclosed that an isocyanate-based adhesive has a good affinity with glass fibers and is excellent in reactivity, adhesiveness and workability.

In the glass fiber layer as shown in Patent Document 2, when the glass fiber reinforcing layer is made of chopped strand glass (hereinafter referred to as a glass mat), theoretically, even if the basis weight is about half of the current level, the strength is increased. It is expected that there may be no problem. However, in this glass mat, a large amount of glass filaments are bundled to form a fiber bundle of several mm, which is cut into a predetermined length to produce chopped strands, which are dispersed in a mat shape and matted using a binder. Since it is formed into a shape, it is difficult to make a mat with a completely uniform basis weight. For example, in the case of a nominal weight per unit area of 100 g / m ² , there are a lot of rough parts that only have a basis weight of about 50 g / m ² , and this tendency is further reduced as the basis weight of the glass mat is further lowered. Seems to be enlarged. Therefore, in the above-described molded ceiling, the bending strength at this rough portion is reduced to about half of the bending strength at the normal portion.

When such a rough part hits a place where the molding ceiling surface changes drastically, such as an overhead console part or an assist grip, it is stretched during the molding process to further increase the amount of bending required for the molding ceiling. The lower limit of strength will be interrupted. Therefore, in general glass mats, it is said that glass mats having a nominal value of 100 g / m ² or less cannot generally be used in consideration of variation in basis weight due to the manufacturing process.

  Thus, the glass mat has a limit in weight reduction.

  On the other hand, if it is set as the glass paper of glass fiber as shown to patent document 3, the malfunction of the above-mentioned glass mat can be eliminated and the possibility of being able to reduce in weight is provided.

  However, the idea of using glass paper as a glass fiber reinforcing layer has been considered for about 20 years ago as in Patent Document 3, but a molded ceiling using such glass paper as a fiber reinforcing layer is still practical. It is not converted.

  The reason is considered as follows. That is, when forming a molded ceiling with a conventional glass paper as shown in Patent Document 3 as a reinforcing layer on both sides of a urethane base and further provided with a skin layer and a back layer on the outside, it is almost displaced / deformed. It may be possible to mold the ceiling if it is a so-called plate-shaped ceiling with a small amount.

  However, in recent molding ceilings of vehicles, there are molding ceilings with large unevenness due to sunroofs, overhead consoles, etc., and molding ceilings with large depressions as a whole, and some are accompanied by significant deformation during molding. Yes.

  Therefore, when using glass fiber as a reinforcing material for molded ceilings, etc., each material (up to the skin or backside paper) stretches in order to follow the partial displacement and deformation during molding required from the shape of the molded ceiling. It is required to follow, but glass fiber reinforcements are not allowed to extend and deform from their role (reinforcement), so the fibers of each other are displaced at the time of molding (no misalignment occurs when the adhesive hardens after molding) Is following. Thus, the followability and bending strength with respect to the deformation | transformation at the time of shaping | molding are required.

  However, when molding is performed according to the shape of the molding ceiling which is greatly deformed in recent years, the fiber length of conventional glass paper is as short as 13 mm. This misalignment caused paper torn, making it unusable. For example, when a large amount of a melamine-based treatment agent is used and strengthened, a phenomenon that “cuts over a large range at the time of molding (the paper tears)” occurs because the fibers do not shift. Further, as in Patent Document 3, when a film of a hot melt adhesive is interposed, this film interferes with the relative displacement of the glass filament of the glass paper, the adhesive strength between the film and the glass paper, the film and the base material This results in insufficient bonding strength. Furthermore, the sound absorption performance is hindered by the film, and the advantages of the urethane-based molded ceiling are impaired. In addition, if a web hot melt (cobweb-like hot melt) is used to avoid it, the cost becomes very high and the handling becomes difficult and the productivity deteriorates.

  Therefore, as shown in Patent Document 4, the present inventor has developed a glass paper manufactured by a paper machine using a glass filament having a long fiber length of 30 mm or more. As shown in Patent Document 4, glass paper is used for the glass fiber reinforcement layer on the skin layer side, and glass mat is used for the glass fiber reinforcement layer on the back surface layer. A material having a sufficient bending strength was obtained with good bondability between the urethane foam layer of the material and the skin layer and the back paper layer.

  However, even in the case of Patent Document 4, if a molding depth is 80 mm or more at the time of molding and a molding angle is strict and deep, such as a molding part having a molding angle of 50 ° or more, a glass filament of glass paper As a result, an extremely thin portion and tearing become conspicuous, resulting in a product that cannot be used as a molded member, and there is room for improvement.

  For this reason, the present inventor has further studied the materials for glass paper and glass mat. As a result, even if the fiber length of the glass fiber is a long fiber of 30 mm or more, an extremely thin portion or breakage is conspicuous from the broken portion of the fiber, so that the glass fiber itself has no break, so-called continuance. The idea of whether it can be made into fiber was examined. Until now, continuous glass fiber is only used as a strand mat in which dozens of continuous single fiber fibers are bundled to form a fiber bundle of several millimeters (so-called roving), and these are formed into a sheet shape. there were.

  The continuous glass fiber strand mat in this state has a larger basis weight and weight than glass paper, and when it is formed into a molded ceiling with a deep molding such as 80 mm, a bundle of glass fibers is formed. Since it was thick, the joint surface with the urethane base material was in line group contact, the moldability was poor, and extremely thin portions and tears were conspicuous, and a product suitable for use could not be obtained.

  Therefore, the present inventor tried to form the continuous single yarn-like glass fiber itself into a lightweight sheet without bundling the continuous single yarn glass fiber itself, and obtained good results. Invented. That is, an object of the present invention is to provide a molded ceiling that can be reduced in weight by using glass fibers made of continuous single yarn and that does not cause defects such as cracks even when the molding depth is deep.

The invention of claim 1 comprises a base material layer made of a hard urethane foam,
A front-side glass fiber reinforcing layer and a back-side glass fiber reinforcing layer bonded to both front and back sides of the base material layer,
A skin layer bonded to the outside of the front glass fiber reinforced layer;
In a molded ceiling material for a vehicle comprising a back surface layer bonded to the outside of the back side glass fiber reinforcing layer,
At least one glass fiber reinforcement layer of the front side glass fiber reinforcement layer and the back side glass fiber reinforcement layer basically has many glass fiber filaments composed of continuous single yarns extending continuously in the longitudinal direction of the vehicle in the vehicle width direction. It consists of a glass fiber sheet film formed by juxtaposing and bonding with a binder,
The glass fiber sheet film is bonded to the base material layer with a urethane-based adhesive.

The invention according to claim 2 is the molded ceiling material for vehicles according to claim 1,
In the glass fiber sheet membrane, a plurality of glass fiber filaments curved in a zigzag shape are divided into a first group inclined in one direction with respect to the longitudinal direction of the vehicle and a second group inclined in the other direction, The glass fiber filaments of the first group and the second group are arranged in an X shape so as to cross each other in a laminated state.

The invention of claim 3 is the molded ceiling material for vehicle according to claim 1 or 2,
The diameter of each glass fiber filament composed of the continuous single yarn is 5 to 15 μm.

The invention of claim 4 is the molded ceiling material for a vehicle according to any one of claims 1 to 3,
Basis weight of the glass fiber sheet ^film, characterized in that it is a ^{20g / m 2 ~70g / m 2} .

  In invention of Claim 1, it is excellent in the followable | trackability at the time of shaping | molding, and while providing the required intensity | strength as a shaping | molding ceiling, a lightweight thing is obtained. In particular, the glass fiber sheet membrane of the present invention is not cut off in the middle of the molded ceiling, even in parts with large deformations such as overhead console parts. Compared to glass mats and glass paper made of strands, the film could be molded without being thinned or torn, and the bending strength was satisfactory.

  The said glass fiber sheet film should just be provided in at least one of a front side glass fiber reinforcement layer and a back side glass fiber reinforcement layer, and may be provided in both.

  Furthermore, if a glass fiber sheet film is produced using a silane-based treatment agent as a binder, the urethane-based adhesive (isocyanate-based adhesive) and the glass filament of the glass fiber sheet film are well entangled and bonded.

  In the invention of claim 2, since the zigzag-shaped glass fiber filaments arranged to be inclined in two directions with respect to the vehicle front-rear direction can extend in the front-rear and left-right directions at the time of molding, Therefore, a desired molded ceiling can be obtained.

  In the invention of claim 3, by setting the diameter of the glass filament made of continuous single yarn to 5 to 15 μm, a glass fiber sheet film of glass fiber made of continuous single yarn in which the binder is effectively infiltrated is obtained. .

In the invention of claim 4, the basis weight of the glass fiber sheet ^film, since 20g / ^{m 2} ~70g / m 2 emitted, it lighter.

FIG. 1 is a perspective view partially showing a molded ceiling of an automobile according to an embodiment of the present invention. FIG. 2 is a diagram for explaining a laminated state of the formed ceiling material used in FIG. 1. FIG. 3 is a glass fiber reinforcing sheet of the present embodiment, and is a diagram exaggeratingly showing the state of glass fibers made of continuous single yarn. FIG. 4 is a table showing a performance comparison between the embodiment of the present invention and a comparative example.

  Hereinafter, the best embodiment of the present invention will be described in detail with reference to the drawings. The following description of the preferred embodiments is merely exemplary in nature and is in no way intended to limit the invention, its application, or its application.

  In this embodiment, the present invention is applied to a molded ceiling of a vehicle, FIG. 1 is a partial view of the molded ceiling according to the embodiment of the present invention, and FIG. 2 is used in the embodiment of FIG. It is a figure explaining the lamination | stacking state of a shaping | molding ceiling material. FIG. 3 is a glass fiber reinforcing sheet of the present embodiment, and is a diagram exaggeratingly showing the state of glass fibers made of continuous single yarn. In FIG. 1, the left side is the rear side of the vehicle, and the right side is the front side of the vehicle.

  In FIG. 1, reference numeral 1 denotes a molded ceiling material for a vehicle as a molded interior material, and sun visor recesses 2 are formed on both the left and right sides of the front side of the molded ceiling material 1. A recess 3 is formed. Although not shown in the figure, the cross section of this portion is formed to be greatly recessed from a normal plane. Reference numeral 4 denotes assist grips provided on the left and right side portions of the molded ceiling material 1, 5 denotes a room lamp, and 6 denotes an inclined portion on which the assist grip 4 is provided. In the case where the concave portion 2, the concave portion 3, the inclined portion 6 or the like is formed to be deeply depressed, it is a portion where defects such as wrinkles and cracks are likely to occur during molding.

  A cross section of the molded ceiling material 1 is schematically shown in FIG. As shown in FIG. 2, the molded ceiling material 1 includes a back glass fiber reinforcing layer 14 on the back side (lower side in FIG. 2) of the base layer 11 made of foamed urethane, and the outside (the side opposite to the base layer 11). ) Located on the front side of the base material layer 11 (upper side in FIG. 2), the front glass fiber reinforcing layer 12 and further on the outer side (opposite side of the base material layer 11). This is a structure in which the positioned skin layer 13 is bonded and laminated.

  Each of the front glass fiber reinforcement layer 12 and the back glass fiber reinforcement layer 14 is made of a glass fiber sheet film 20. As shown in FIG. 3, the glass fiber sheet film 20 basically includes a binder 22 in which a large number of glass fiber filaments 21 made of continuous single yarns extending continuously in the vehicle front-rear direction are arranged in the vehicle width direction. It is formed by bonding.

  Specifically, each of the glass fiber filaments 21 made of continuous single yarn is not linear but curved in a zigzag shape (wave shape), and a plurality of the filaments have different inclination directions with respect to the longitudinal direction of the vehicle. For example, the glass fiber filaments 21 of the first glass fiber filament group are separated from the left side in the vehicle width direction from the front side to the rear side with respect to the longitudinal direction of the vehicle. On the other hand, the glass fiber filament 21 of the second glass fiber filament group is inclined from the right side in the vehicle width direction to the left side as it goes from the front side to the rear side in the longitudinal direction of the vehicle. Are arranged so as to be inclined. And in the glass fiber sheet film | membrane 20, the glass fiber filament 21 of these 1st and 2nd glass fiber filament groups is mutually crossed, and is arrange | positioned at X shape.

  In this case, the glass fiber filaments 21 of the first and second glass fiber filament groups are gathered and laminated so as to intersect each other, but the glass fiber filaments 21 of both glass fiber filament groups are divided little by little. It may be laminated.

  These glass fiber filament groups are joined with a silane-based binder to form a glass fiber sheet film 20 in a sheet shape.

  In this embodiment, both the front glass fiber reinforcing layer 12 and the back glass fiber reinforcing layer 14 are made of the glass fiber sheet film 20, but only one of them may be made of the glass fiber sheet film 20.

  The characteristics of the glass fiber sheet membrane 20 and the glass fiber filament 21 of the present invention will be described below.

The diameter of the glass fiber filament composed of the continuous single yarn of the present invention is preferably as thin as possible to reduce the weight, but if it is too thin, the single yarn may be broken and it becomes difficult to form, so it should be 5 to 15 μm. Is preferred. In addition, the diameter of a fiber is fundamentally varying, and it does not mean that all fall within the above numerical range, but means that the main one falls within the above numerical range. Since the basis weight of the glass fiber sheet membrane 20 of the present invention is small, the strength as the reinforcing layer is insufficient, and even if the basis weight is too much, it is contrary to the purpose of weight reduction just by becoming more than the required strength. ^{20g / m 2 ~70g / m 2} , particularly preferably a ^{25g / m 2 ~50g / m 2} .

  When manufacturing the glass fiber sheet film | membrane 20, a silane type processing agent is preferable as a binder. This silane-based treatment agent may be silane alone or a mixture of silane and urethane emulsion. As this urethane emulsion, it is preferable to use the same urethane adhesive used as an adhesive described later. The basis weight of the silane-based treatment agent varies depending on the diameter of the glass fiber filament made of continuous single yarn and the basis weight of the glass fiber sheet film 20, but it ensures an appropriate binding force of the filament and is a urethane applied during ceiling molding. In order to ensure compatibility with a system adhesive (sometimes an isocyanate adhesive), it is preferably about 10 to 20% by weight based on the basis weight of the glass filament.

In the present invention, if the amount of urethane-based resin (for example, isocyanate-based resin) as an adhesive applied to the glass fiber sheet film 20 is large, there is a fear that it will ooze out, and if it is small, the adhesive strength is insufficient. the amount ^{is, 10g / m 2 ~30g / m} 2, particularly preferably a ^{13g / m 2 ~25g / m 2} .

  Examples of the skin layer 13 include polyolefin, polyester, polyamide-based woven or non-woven fabric, tricot / slab urethane laminate skin, knitted fabric, plastic sheet, and vinyl leather. When using the molded interior material as the molded ceiling material 1, the urethane foam as the base material layer 11 may be in the form of a sheet, and the thickness thereof is 3 to 12 mm.

  The production method differs from the production / preparation of a conventional glass mat in terms of production / preparation of the glass fiber sheet film 20, but the prepared glass fiber sheet film 20 is used as a base material as the reinforcing layers 12 and 14, There is no significant difference in the point that it is laminated with the skin material and the back surface material. That is, the front side glass fiber reinforcing material sheet obtained by applying a urethane resin adhesive to the urethane foam base material layer 11, the glass fiber sheet film 20, and the back side glass fiber obtained by applying a urethane resin adhesive to the glass fiber sheet film 20. A reinforcing material sheet, a skin material, and a back material are prepared, a front glass fiber reinforcing sheet and a back glass fiber reinforcing material sheet are laminated on both sides of the base material layer 11, and then the outer skin of the front glass fiber reinforcing material sheet. In addition to laminating materials, a back material is laminated on the outside of the back glass fiber reinforcing material sheet, and then the laminate is placed in a heated mold and integrally molded by heating and pressing.

  Instead of the glass fiber sheet film side, apply a urethane resin adhesive (for example, spray coating) on the urethane foam side, and provide a glass fiber sheet film reinforcement layer so as to overlap the glass fiber sheet film. Also good.

  In addition, when the glass fiber sheet film 20 is manufactured from glass fiber filaments composed of continuous single yarns, if chemical fibers such as polyethylene resin are mixed, the moldability and rigidity can be improved. That is, at the time of molding of a molded ceiling or the like, the chemical fiber functions as a slipping agent and becomes slippery more than only the glass filaments, thereby improving the moldability. As a result, breakage of the glass fiber sheet film 20 during molding is effectively prevented. A chemical fiber such as polyethylene resin is excellent in compatibility with a urethane adhesive (particularly an isocyanate adhesive) that is applied to the glass fiber sheet film 20 to adhere the substrate and the glass fiber sheet film 20, so that the adhesion is stronger. Property is obtained and rigidity is improved. If the basis weight of the chemical fiber is small, there is no effect, and even if it is large, it is useless. The diameter and length of the chemical fiber may be set appropriately. However, the glass fiber sheet film can be easily processed when the diameter is the same as that of the glass filament. The length is preferably 20 to 100 mm, particularly preferably 30 to 75 mm.

  Next, the manufacturing method of the shaping | molding ceiling material 1 of embodiment is demonstrated. Prepare a thermoformable urethane foam sheet. Further, a glass fiber sheet film 20 is prepared. The manufacturing method of the glass fiber sheet membrane 20 is as follows.

  A glass fiber material such as E glass or C glass is heated and melted in a container, and a large number of filaments are drawn out from the container and wound around a yarn collection tube to make a glass fiber filament 21 made of continuous single yarn. A glass fiber binder 22 (silane coupling, epoxy emulsion, polyvinyl acetate emulsion, distilled water, etc.) is sprayed on the glass fiber filament 21 of the yarn collection tube. At this time, the yarn collection tube is rotated and moved back and forth to obtain the glass fiber sheet film 20 in which the glass fiber filaments 21 are zigzag (see FIG. 3). This manufacturing method is only one example, and another manufacturing method may be used.

  For example, a glass material such as E glass or C glass is heated and melted in a container, and a number of filaments are drawn out from the container to form glass fiber filaments 21. A glass fiber binder (silane coupling, epoxy emulsion, polyvinyl acetate emulsion, distilled water, etc.) is applied to the glass fiber filament 21. In this way, a large number of glass fiber filaments 21 with a binder are arranged side by side while being pulled out as a group of filaments, and are swung left and right to make a zigzag movement. Another filament group that performs a zigzag operation in the opposite direction to these filament groups is overlapped to produce a double filament group, which is cooled to produce a glass fiber sheet film.

  In the embodiment of the present invention, the glass fiber filament 21 composed of a continuous single yarn is produced in this manner. In the present invention, “continuous” means that the glass fiber filament is made of the above-described production method. When the single yarn is formed on the molded ceiling 1, it is continuous without being cut in the vehicle front-rear direction and is formed on the glass fiber sheet film 20.

  A glass fiber sheet film 20 is manufactured, and a back paper is prepared as a back material.

  Next, a process for manufacturing the molded ceiling 1 using these molding materials will be described. On both sides of the base material layer 11, a front glass fiber reinforcing sheet 12 made of a glass fiber sheet film 20 coated with an isocyanate adhesive and a back glass fiber made of a glass fiber sheet film 20 coated with an isocyanate adhesive. Laminating the reinforcing material sheet 14, then laminating the skin layer 13 on the outside of the front glass fiber reinforcing material sheet 12, and laminating the back material 15 on the outside of the back glass fiber reinforcing material sheet 14, The laminate is placed in a heated mold and integrally molded by heating and pressing.

  Next, the Example at the time of manufacturing the shaping | molding ceiling material as a shaping | molding interior material which concerns on this invention is described.

Example 1
In Example 1, a hard-formable urethane foam sheet (1200 mm × 1600 mm × thickness 6.5 mm) having open cells with a unit area weight of 180 g / m ² is prepared. Epidermis; 70 g / ^{m 2} of basis weight of the nonwoven fabric, the back surface; providing a nonwoven fabric and PP (polypropylene) Normal laminate made backsheet 30 g / ^{m 2} of the film. As a glass fiber sheet film for the front glass fiber reinforcing layer and the back glass fiber reinforcing layer, a continuous single fiber glass fiber filament (diameter: 9 μm) was used, and a silane-based treatment agent (an isocyanate was emulsified with 8: 2 in silane). A glass fiber reinforcing material sheet produced using a treating agent) with a basis weight of 50 g / m ² is prepared. An isocyanate-based adhesive is applied to the glass fiber reinforcing material sheet with a basis weight of 15 g / m ² .

  Each material prepared as described above is placed and laminated in the mold in the order of skin material-front side glass fiber reinforcing material sheet-foamed urethane foam sheet-back side glass fiber reinforcing material sheet-back surface material. While pressing in a mold, they are bonded together. After molding and bonding, the molded product was removed from the mold, and a molded ceiling having a width of 1200 mm × 1600 mm and a total thickness of 7.5 mm including all the materials forming the ceiling was manufactured.

(Example 2)
Example 2 differs from Example 1 in that the diameter of the continuous glass fiber filament is 6 μm and the basis weight of the glass fiber reinforcing material sheet is 62 g / m ² .

(Example 3)
Example 3 is different from Example 1 in that the diameter of the continuous glass fiber filament is 12 μm, and the basis weight of the glass fiber reinforcing material sheet is 38 g / m ² .

Example 4
In Example 4, the front-side glass fiber reinforcing layer is the same as that in Example 1, but the back-side glass fiber reinforcing layer is conventionally (disclosed in WO2010-029861) instead of the continuous single-fiber glass fiber filament. Glass paper) was used. That is, using a glass filament having a filament diameter of 11 μm and a length of 25 mm, a glass paper is produced using a silane-based treatment agent (treatment agent obtained by emulsifying silane with isocyanate at 8: 2), and is made of glass paper. A glass fiber reinforcing sheet produced with a basis weight of 27 g / m ² was prepared. An isocyanate-based adhesive was applied to the glass fiber reinforcing sheet with a basis weight of 15 g / m ² to obtain a back glass fiber reinforcing layer.

(Example 5)
In Example 5, the front glass fiber reinforcing layer is the same as that of Example 1, but a conventional glass mat was used for the back glass fiber reinforcing layer instead of the continuous single fiber glass fiber filament. As a glass mat, about 80 glass filaments having a diameter of about 10 to 15 μm are bundled to form a fiber bundle (so-called roving) of 0.8 to 1.5 mm by using a sizing agent. A chopped strand is produced by cutting into pieces and dispersed into a mat shape and formed into a mat shape using a binder. The weight per unit area is 100 g / m ^2, and the same shaped ceiling as in Example 1 is formed. did.

(Example 6)
In Example 6, when producing a glass fiber sheet film in Example 1, fibers of polyethylene resin were mixed with the glass fiber sheet film. The fiber of the polyethylene resin used was the same diameter as the glass filament and a length of 50 mm. The basis weight is 50 g / m ² as in Example 1, so that the basis weight of the glass fiber sheet film is 45 g / m ² and the basis weight of the fiber of the polyethylene resin is 5 g / m 2. ² .

(Comparative Example 1)
Comparative Example 1 was replaced with a glass fiber sheet membrane composed of the continuous single yarn glass fiber filament diameter of Example 1 as the front glass fiber reinforcing layer and the back glass fiber reinforcing layer, as can be seen in comparison with Example 1. In addition, conventional glass paper was used for both glass fiber reinforcement layers. That is, using a glass filament having a filament diameter of 11 μm and a length of 25 mm, a glass paper is produced using a silane-based treatment agent (treatment agent obtained by emulsifying silane with isocyanate at 8: 2), and is made of glass paper. A glass fiber reinforcing sheet produced with a basis weight of 27 g / m ² was prepared. An isocyanate adhesive was applied to the glass fiber reinforcing sheet with a basis weight of 15 g / m ² to obtain front and back glass fiber reinforcing layers.

(Comparative Example 2)
In Comparative Example 2, glass paper is used as the front and back glass fiber reinforcing layers as in Comparative Example 1, but the basis weight of the front and back glass fiber reinforcing layers is 52 g / m ^2. The bending ceiling was increased with respect to 1, and the same shaped ceiling as in Comparative Example 1 was formed.

(Comparative Example 3)
Comparative Example 3 is a glass fiber sheet membrane composed of the continuous single yarn glass fiber filament diameter of Example 1 as the front glass fiber reinforcing layer and the back glass fiber reinforcing layer so that the comparison with Example 1 can be seen. In addition, a conventional glass mat was used for both glass fiber reinforcement layers. As a glass mat, about 80 glass filaments having a diameter of about 10 to 15 μm are bundled to form a fiber bundle (so-called roving) of 0.8 to 1.5 mm by using a sizing agent. A chopped strand was produced by cutting into pieces, dispersed in a mat shape, and formed into a mat shape using a binder. A molded ceiling similar to that of Comparative Example 1 was formed with a basis weight of both glass fiber reinforcing layers: 100 g / m ² .

(Comparative Example 4)
Comparative Example 4 uses glass mats as the front and back glass fiber reinforcement layers as in Comparative Example 3, but the basis weight of the front and back glass fiber reinforcement layers is 230 g / m ^2. The bending ceiling was further increased with respect to 2, and the same shaped ceiling as in Comparative Example 2 was formed.

  Examples 1-6 and Comparative Examples 1-4 show the average value of 10 samples. Test results of Examples 1 to 6 and Comparative Examples 1 to 4 will be described with reference to FIG.

  In general, the required value as a molded ceiling is bending strength: about 10 N / 50 mm, bending elastic gradient: about 30 N / 50 mm / cm, but Examples 1-6 and Comparative Examples 1-4 are sufficiently satisfied. The value is obtained.

  However, recently, a so-called deep ceiling has been used in which parts such as an overhead console and a sun visor are greatly expanded. In such a molded ceiling, as described above, even if the bending strength satisfies a predetermined level, glass wrinkles are generated in a portion where the change in the molded ceiling surface such as an overhead console portion or an assist grip is severe, and it is severe. In some cases, the problem is that the base material at that location is cracked. Therefore, a test was conducted to confirm the situation where these problems occurred. Specifically, in Examples 1 to 6 and Comparative Examples 1 to 4, with 10 samples, it was visually observed how many samples had the above problems. In particular, 10 samples each having a depth of 50 mm and a thickness of 90 mm were molded and visually observed. The result is shown in FIG.

  In Examples 1 to 6, the glass fiber of the single yarn is continuous (continuous), and there is a glass fiber made of continuous single yarn even if there is a deep molded part such as 90 mm. It never happened. On the other hand, in Comparative Example 1, in the molded ceiling having a depth of 50 mm, two out of 10 samples (shown as 2/10 in FIG. 4, and the other examples are also displayed in the same manner) occur. When the depth was 90 mm, defects occurred in 7 out of 10 samples (7/10). In Comparative Example 2, when the depth was 50 mm, no defect occurred in 10 samples (indicated as “None”), but when the depth was 90 mm, 4 out of 10 samples (4 / A problem occurred in 10). In Comparative Example 3, when the depth is 50 mm, 6 (6/10) defects occurred in 10 samples, and when the depth was 90 mm, 9 out of 10 samples (9/10) A malfunction occurred. In Comparative Example 4, when the depth was 50 mm, no defect occurred in 10 samples, but when the depth was 90 mm, 1 defect (1/10) in 10 samples. Occurred.

  From these results, the following can be said. In Comparative Examples 1 to 4, when the glass ceiling is formed on the molded ceiling, the glass fiber distribution of the glass paper or the glass mat varies, and the glass fiber is small. The bending strength is weak at the portion (coarse portion) or the portion where the glass fiber is cut. Therefore, when the part where the bending strength is weak hits a place where the change of the molding ceiling surface, such as the overhead console part or the assist grip, is severe, it is stretched and further roughened during the molding process. The lower limit of the bending strength required for the ceiling is interrupted, resulting in defects such as wrinkles and cracks. In particular, when the basis weight of the glass fiber is small, the portion where the bending strength is weakened is conspicuous, and it seems that the above problems are often caused.

  The present invention is suitable for a molded ceiling material for a vehicle that is lightweight and excellent in moldability.

DESCRIPTION OF SYMBOLS 1 Vehicle molding material ceiling material 11 Base material layer 12 Front side glass fiber reinforcement layer 13 Outer skin layer 14 Back side glass fiber reinforcement layer 15 Back surface layer 20 Glass fiber sheet film | membrane 21 Glass fiber filament 22 Binder

Claims (4)

A base material layer made of hard urethane foam,
A front-side glass fiber reinforcing layer and a back-side glass fiber reinforcing layer bonded to both front and back sides of the base material layer,
A skin layer bonded to the outside of the front glass fiber reinforced layer;
In a molded ceiling material for a vehicle comprising a back surface layer bonded to the outside of the back side glass fiber reinforcing layer,
At least one glass fiber reinforcement layer of the front side glass fiber reinforcement layer and the back side glass fiber reinforcement layer basically has many glass fiber filaments composed of continuous single yarns extending continuously in the longitudinal direction of the vehicle in the vehicle width direction. It consists of a glass fiber sheet film formed by juxtaposing and bonding with a binder,
The molded ceiling material for vehicles, wherein the glass fiber sheet film is bonded to the base material layer with a urethane-based adhesive. The molded ceiling member for a vehicle according to claim 1,
In the glass fiber sheet membrane, a plurality of glass fiber filaments curved in a zigzag shape are divided into a first group inclined in one direction with respect to the longitudinal direction of the vehicle and a second group inclined in the other direction, A molded ceiling material for a vehicle, wherein the glass fiber filaments of the first group and the second group are arranged in an X shape so as to cross each other in a laminated state. In the molded ceiling material for vehicles according to claim 1 or 2,
A molded ceiling material for vehicles, wherein the diameter of each glass fiber filament composed of the continuous single yarn is 5 to 15 µm. The molded ceiling member for a vehicle according to any one of claims 1 to 3,
Basis weight of the glass fiber sheet ^film, automotive molded ceiling material, which is a ^{20g / m 2 ~70g / m 2} .

Images